ANNEX TO NASA-STD-8719.24 NASA PAYLOAD SAFETY

NASA TECHNICAL

STANDARD

ANNEX to

NASA-STD-8719.24

Revision B

National Aeronautics and Space Administration

Washington, DC 20546

Approved: 2022-03-30

Superseding: Annex To NASA-STD-

8719.24 Revision A with Change 2

ANNEX TO NASA-STD-8719.24

NASA PAYLOAD SAFETY REQUIREMENTS:

REQUIREMENTS TABLE

Measurement System Identification:

Metric (English)

Annex to NASA-STD-8719.24B

Page 2 of 455

DOCUMENT HISTORY LOG

Status

Document

Revision

Approval Date

Description

Baseline

2011-08-26

Initial Release

(JWL4)

Change

2012-01-26

- Page 3: Corrected PSWG Chair signature block;

- Pages 187 Vol 3, para13.1.1.1 and Vol 7, removed

revision from ST/SG/AC.10.1;

- Vol 7 page 404, bolded “hazardous materials”

definition header

(JWL4)

Change

2012-06-19

Throughout document: Corrected 18 typographical

errors (Administrative Change)

(JWL4)

Revision

2015-09-30

Added Attachment 5 to Volume 1 on Payload Safety

Introduction Briefing (PSIB) and related information that

is to be presented at the PSIB. Added NASA electronic

forms NF 1825, NASA ELV Payload Safety Hazard

Report Form; NF 1826, NASA ELV Payload Safety Post-

Tailoring Equivalent Level of Safety Request; and NF

1827, NASA ELV Payload Safety Waiver Request.

Added requirements addressing pyrovalves (Vol. 3,

Section12.1.2.6) and payload recovery missions

involving sample or payload returns. Added some

additional requirements for Composite Overwrapped

Pressure Vessels (COPVs) and a COPV Mechanical

Damage Control Plan (Vol. 3, Section 12.2.5). Revised

definition for “catastrophic.” Numerous improvements to

requirements to improved clarity and correctness.

(SH)

Change

2018-03-05

Typing errors and format issues are corrected. An

obsolete Air Force reference is removed. A NASA spec

for pyrovalves is added and revisions are made to

payload lifting requirements to reflect updates to NASA's

lifting standard and allow for non-load test slings to be

used verses tailoring the requirements. Wording for

clarity updated and a definition.

Change

2018-06-13

Updated the hyperlink

(http://kscsma.ksc.nasa.gov/ELVPayloadSafety) for the

NASA Expendable Launch Vehicle (ELV) Payloads

website throughout the document.

Revision

2022-03-30

Revision B incorporates Revision A w/Change 2.

Removed Expendable Launch Vehicle (ELV) from

document title changing title to NASA Payload Safety

Requirements. Revised Forward to remove ELV

reference and change signature block from T. Wilcutt to

W. DeLoach. General document revision include

editorial updates of applicable and reference

documents, terms and acronyms to ensure accuracy

and consistency with U.S. Air Force Space Command,

the United States Space Force Space Command,

Range Safety User Requirements 91-710 and NASA

program documentation, e.g., NPR 8715.1, NASA

Safety & Health Programs and NPR 8715.7, NASA

Payload Safety Program.

Annex to NASA-STD-8719.24B

Page 3 of 455

FOREWORD

This NASA technical standard provides uniform engineering and technical requirements for

processes, procedures, practices, and methods that have been endorsed as standard for NASA

programs and projects, including requirements for selection, application, and design criteria of an

item. This standard establishes technical safety requirements for unmanned orbital and unmanned

deep space payloads that fly onboard launch vehicles. The requirements contained in this Annex

to NASA-STD-8719.24 were developed jointly by NASA and United States Space Force (USSF)

Space Launch Delta (SLD) 30 and SLD 45 Safety representatives using 91-710, Range Safety

User Requirements, and NASA safety standards. The requirements of this document comply with

the requirements of 91-710, Range Safety User Requirements, and are acceptable to NASA and

the Space Force ranges. As such, they provide a streamlined starting point for the safety

requirements tailoring process. These requirements are provided in a matrix format that was

developed to facilitate project-specific tailoring of the safety requirements for each NASA payload

project.

This standard was developed by the NASA Office of Safety and Mission Assurance (OSMA).

Requests for information, corrections, or additions to this standard should be submitted to the

OSMA by email to Agency-SMA-Policy-[email protected] or via the “Email Feedback”

link at; https://standards.nasa.gov.

William Russ DeLoach Approval Date

Chief, Safety & Mission Assurance

Annex to NASA-STD-8719.24B

Page 4 of 455

Project Safety Requirements

Effective Date:

Project Safety Requirements

Revision: Basic

NASA PAYLOAD SAFETY

REQUIREMENTS

NASA PAYLOAD PROJECT

(NAME)

Project Contract No:

Contract Date:

NASA CENTER: (name)

Proprietary

The information contained in the document is technical in content and may be

proprietary as defined by the International Traffic in Arms Regulations (ITAR) or

by Export Administration Regulations (EAR) requirements. Contact the NASA

KSC Export Control Office, 321-867-9209, for an ITAR or EAR regulatory

determination. If not required delete this statement.

NASA Payload Safety Program

Office of Safety and Mission Assurance

National Aeronautics and Space Administration

Washington, D.C. 20546

Annex to NASA-STD-8719.24B

Page 5 of 455

Prepared by:

Name

Title

Organization

Date:

Concurrence:

Name

NASA Payload Project Manager

NASA Center:

Date:

Concurrence:

Name

NASA Payload S&MA Technical Authority

NASA Center:

Date:

Concurrence:

Name

USSF Space Launch Delta Range Safety Authority

Date:

Concurrence:

Name

Chairperson

NASA Payload Safety Working Group

NASA Center:

Date:

Annex to NASA-STD-8719.24B

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PREFACE

The Original Text column of the following requirements matrix contains the National Aeronautics and Space

Administration (NASA) payload safety requirements that are to be tailored for each NASA Payload project, as

required by NPR 8715.7, “NASA Payload Safety Program.” The NASA Payload safety requirements are the result

of a joint effort by NASA and the United States Space Force (USSF) Space Launch Delta (SLD) 30 and SLD 45

Range Safety representatives to establish an approved baseline from the USSF 91-710, “Range Safety User

Requirements,” and applicable NASA safety requirements and also address unique issues associated with NASA

payload safety design and operations. The NASA Payload safety requirements apply to all NASA Payload projects

launched from a USSF, NASA, or other range/launch site.

The NASA Payload safety requirements supplement NPR 8715.7 and satisfy USSF 91-710, when applied to NASA

launches from USSF launch ranges. As such, they provide a streamlined starting point for the safety requirements

tailoring process that is required for each NASA Payload project per NPR 8715.7.

The NASA Payload safety requirements (as tailored for each specific project) are mandatory for each NASA Payload

project and are to be applied to associated contracts and/or agreements. Additional requirements may be imposed by

other organizations, including other launch ranges, commercial payload processing facility operators, or launch

vehicle contractors. This document does not alter or otherwise modify the authority or roles and responsibilities

delineated by statute or policy applicable to the USSF, NASA, or other organizations participating in a NASA Payload

project. As outlined in USSF 91-710, the SLD Commanders have overall launch authority and responsibility for

public safety from USSF ranges. The Directors of NASA Wallops Flight Facility (WFF), and the Kennedy Space

Center (KSC), have authority and responsibility for launches originating from WFF and KSC respectively.

USSF 91-710 range safety requirements not applicable to NASA Payloads were eliminated from the following NASA

Payload safety requirements. Additionally, in some cases, entire volumes or chapters are not applicable and are not

included in the requirements matrix. This results in irregular numbering of paragraphs where certain paragraph(s)

were removed that were not applicable. The absence of these requirements does not alter USSF SLD 30 and SLD 45

Range Safety authority. The project may add back any USSF 91-710 requirements that are pertinent to their project

upon agreement by the project’s Payload Safety Working Group (PSWG) and SLD 30th and SLD 45th Range Safety

representatives.

Questions pertaining to the requirements in this document and applicable local safety requirements should be brought

to the attention of the payload project’s PSWG. Per NPR 8715.7, Payload Project Offices will contact the NASA

Payload Safety Manager as early as practical in the project’s Concept and Technology Development, Phase A, to

establish the project’s PSWG and initiate the payload safety review and approval process, which includes the

requirements tailoring process.

The NASA Payload Safety Manager is responsible for maintaining and keeping the NASA Payload safety

requirements current and coordinating all changes with the NASA Payload Safety Agency Team and the USSF SLD

30 and SLD 45 Range Safety Offices. The NASA Payload Safety Manager contact information and the NASA

Payload safety requirements tailoring matrix are available on the NASA Payload Safety Program website at:

https://kscsma.ksc.nasa.gov/PayloadSafety.

Note: This Preface provides background information that is applicable to all NASA Payload projects. It is not to be

tailored and shall remain as part of each final project-specific safety requirements document.

Annex to NASA-STD-8719.24B 
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TABLE OF CONTENTS 
VOLUME 1:  POLICIES AND PROCEDURE REQUIREMENTS ......................................... 14 
 INTRODUCTION .................................................................................................... 14 
  Objective ........................................................................................................................................... 14 
  Applicability ..................................................................................................................................... 14 
  Basis for the Requirements .............................................................................................................. 16 
 RESPONSIBILITIES AND AUTHORITIES ....................................................... 17 
  General .............................................................................................................................................. 17 
  Headquarters Space Systems Command Responsibilities .............................................................. 17 
  Space Launch Delta Responsibilities ............................................................................................... 17 
  Federal Aviation Administration Responsibilities .......................................................................... 18 
  Payload Project Responsibilities ...................................................................................................... 18 
 RANGE SAFETY POLICY .................................................................................... 20 
  General .............................................................................................................................................. 20 
  Prelaunch and Launch Operations ................................................................................................... 20 
  Launch Area Safety .......................................................................................................................... 20 
  Launch Complex Safety ................................................................................................................... 24 
 PSWG and RANGE SAFETY PROCESSES ....................................................... 25 
  PSWG, Range Safety and Payload Projects Interface Process ....................................................... 25 
  Equivalent Level of Safety (ELS) Determinations and Waivers .................................................... 25 
 SAFETY AUTHORIZATIONS, SAFETY APPROVALS, AND 
DOCUMENTATION ........................................................................................................................ 27 
  General .............................................................................................................................................. 27 
 INVESTIGATING AND REPORTING MISHAPS AND INCIDENTS .......... 28 
  Mishaps and Incidents Involving Space Force Personnel and Resources ...................................... 28 
  Non-Space Force Personnel and Resources on Space Force Property ........................................... 28 
  Reporting Space Launch System Anomalies ................................................................................... 28 
 CHANGES TO THIS PUBLICATION ................................................................. 29 
ATTACHMENT 1 POLICIES AND PROCEDUREs ................................................................. 30 
  NASA PAYLOAD SAFETY REQUIREMENTS TAILORING PROCESS ............................... 30 
ATTACHMENT 2 SAFETY PLAN REQUIREMENTS ............................................................ 35 
  Introduction ....................................................................................................................................... 35 
  System Safety Plan Tasks ................................................................................................................ 35 
ATTACHMENT 3 SUBMITTING NONCOMPLIANCE REQUESTS ................................... 48 
  Introduction ....................................................................................................................................... 48 
  Submitting Noncompliance Requests .............................................................................................. 49 

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ATTACHMENT 4 ACCEPTABLE RISK CRITERIA ............................................................... 51 
  INTRODUCTION ............................................................................................................................ 51 
ATTACHMENT 5 PAYLOAD SAFETY INTRODUCTION BRIEFING ............................... 52 
  Introduction ....................................................................................................................................... 52 
  Payload safety introduction briefing (PSIB) .................................................................................... 52 
VOLUME 3:  PAYLOADS AND GROUND SYSTEMS REQUIREMENTS .......................... 54 
 INTRODUCTION .................................................................................................... 54 
  General .............................................................................................................................................. 54 
  Organization of the Volume ............................................................................................................. 54 
 RESPONSIBILITIES AND AUTHORITIES ....................................................... 56 
  Payload Safety Working Group (PSWG) ........................................................................................ 56 
  Payload Project Responsibilities ...................................................................................................... 56 
 GENERAL DESIGN POLICY ............................................................................... 58 
  General .............................................................................................................................................. 58 
  Systems Without Specific Design Criteria ...................................................................................... 58 
 DOCUMENTATION REQUIREMENTS............................................................. 59 
  System Safety Plan and Hazard Analyses ....................................................................................... 59 
  Safety Data Package (SDP)/MISSILE SYSTEM PRELAUNCH SAFETY PACKAGE (MSPSP)
 .......................................................................................................................................................... 59 
  SDP Associated Test Plans and Test Results .................................................................................. 60 
  Nondestructive Examination Plans .................................................................................................. 60 
 Pad Safety Console Design ....................................................................................... 62 
 MATERIAL HANDLING EQUIPMENT, Cranes, Hoist AND PERSONNEL 
WORK PLATFORMS. ....................................................................... Error! Bookmark not defined. 
  Overview ........................................................................................................................................... 63 
  Material Handling Equipment (MHE) ............................................................................................. 63 
  Removable, Extendible, and/or Hinged Personnel Work Platforms ............................................... 74 
  Lifting Personnel with a Crane ........................................................................................................ 75 
  Flight Hardware Used to Lift Critical Loads and Clampbands. ...................................................... 76 
 ACOUSTIC HAZARDS .......................................................................................... 77 
  Acoustic Design Standards............................................................................................................... 77 
  Acoustic Data Requirements ............................................................................................................ 77 
 NON-IONIZING RADIATION SOURCES.......................................................... 78 
  ELECTROMAGNETIC RADIATION Emitters ............................................................................ 78 
  Laser Systems (Class 1M, 2M, 3B, and 4) ...................................................................................... 80 
 RADIOACTIVE (IONIZING) RADIATION SOURCES ................................... 85 
  Radioactive Source Design Standards and Controls ....................................................................... 85 
  Radioactive Sources Carried on Payloads ....................................................................................... 86 

Annex to NASA-STD-8719.24B 
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 HAZARDOUS MATERIALS ............................................................................... 89 
  Hazardous Materials Selection Criteria ........................................................................................... 89 
  Hazardous Materials Test Requirements ......................................................................................... 89 
  Hazardous Materials Environmental Requirements ........................................................................ 91 
  Hazardous Materials Data Requirements ........................................................................................ 91 
  Process Safety Management and Risk Management Plan .............................................................. 91 
 GROUND SUPPORT PRESSURE, VACUUM, AND HAZARDOUS 
STORAGE SYSTEMS ..................................................................................................................... 92 
  Ground Support Pressure, Vacuum, and Storage Systems Requirements ...................................... 92 
  Ground Support Pressure Systems Requirements ........................................................................... 92 
  Ground Support Pressure Systems Certification and Recertification ........................................... 130 
 FLIGHT HARDWARE PRESSURE SYSTEMS AND PRESSURIZED 
STRUCTURES ................................................................................................................................ 135 
  Flight Hardware Pressure System and Pressurized Structure General Requirements. ................. 135 
  Flight Hardware Pressure Vessel Design, Analysis, and Test Requirements ............................... 156 
  Flight Hardware Metallic Pressurized Structure Analysis and Test Requirements. ..................... 170 
  Flight Hardware Special Pressurized Equipment Design, Analysis, and Test Requirements ...... 173 
  Flight Hardware Pressure System Component Design and Test Requirements ........................... 178 
  Flight Hardware Pneumatic System Design Requirements .......................................................... 190 
  Flight Hardware Hydraulic System Design and Test Requirements ............................................ 193 
  Flight Hardware Hypergolic Propellant System Design and Test Requirements ........................ 195 
  Flight Hardware Cryogenic Systems Design and Test Requirements .......................................... 200 
12.10  Flight Hardware Pressure Systems Data Requirements ................................................................ 205 
 ORDNANCE SYSTEMS ..................................................................................... 207 
  Ordnance Hazard Classification ..................................................................................................... 207 
  Ordnance System General Requirements ...................................................................................... 207 
  Ordnance Electrical Circuits and Optical Circuits......................................................................... 208 
  Initiator Electrical Circuits ............................................................................................................. 212 
  Ordnance Safety Devices ............................................................................................................... 213 
  Ordnance Initiating Devices ........................................................................................................... 220 
  Explosive Transfer Systems and Receptor Ordnance ................................................................... 224 
  Ordnance Test Equipment .............................................................................................................. 225 
  Ordnance and Non-Explosive Initiator Data Requirements .......................................................... 226 
 ELECTRICAL AND ELECTRONIC EQUIPMENT ..................................... 228 
  Electrical and Electronic Ground Support Equipment and Flight Hardware General Design 
Requirements and Standards .......................................................................................................... 228 
  EGSE Design Requirements .......................................................................................................... 234 
  Electrical and Electronic Flight Hardware ..................................................................................... 239 
 MOTOR VEHICLES ........................................................................................... 245 
  General ............................................................................................................................................ 245 
  Motor Vehicles Other Than Lift Trucks ........................................................................................ 245 
  Lift Trucks ...................................................................................................................................... 246 

Annex to NASA-STD-8719.24B 
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 COMPUTER SYSTEMS AND SOFTWARE................................................... 248 
  General ............................................................................................................................................ 248 
  Determination of Safety Critical Computer System Functions ..................................................... 249 
  Hardware and Software Safety Design Requirements .................................................................. 251 
  Software Requirements .................................................................................................................. 254 
  Computer System and Software Data Requirements .................................................................... 257 
  Independent Verification and Validation (IV&V) Analysis Support ........................................... 258 
 WESTERN RANGE SEISMIC DESIGN .......................................................... 259 
  Applicability of Design and/or Anchorage or Restraint Requirements ........................................ 259 
  Basis for Design.............................................................................................................................. 259 
  WR Seismic Data Requirements .................................................................................................... 260 
  Earthquake Emergency Planning and Post Recovery Response ................................................... 260 
 SOLID ROCKET MOTORS, ROCKET MOTOR SEGMENTS, AND 
ROCKET MOTOR COMPONENTS .......................................................................................... 262 
  General ............................................................................................................................................ 262 
  Failure Modes, Effects, and Criticality Analysis (FMECA) and Operating & Support Hazards 
Analysis (O&SHA) ........................................................................................................................ 262 
  Lightning Effects Hazard Analysis ................................................................................................ 262 
  Solid Rocket Motor and Motor Segment Data Requirements ...................................................... 262 
ATTACHMENT 1 SAFETY DATA PACKAGE ....................................................................... 263 
  Introduction ..................................................................................................................................... 263 
  Preparation Instructions .................................................................................................................. 263 
  Modifications to the Safety DATA PACKAGE (SDP) ................................................................ 291 
VOLUME 6:  GROUND AND LAUNCH PERSONNEL, EQUIPMENT, SYSTEMS AND 
MATERIAL, GROUND OPERATIONS SAFETY REQUIREMENTS ................................ 292 
 INTRODUCTION .................................................................................................. 293 
  Applicability ................................................................................................................................... 293 
  Organization of the Volume ........................................................................................................... 293 
  Compliance Documents ................................................................................................................. 294 
 RESPONSIBILITIES AND AUTHORITIES ..................................................... 295 
  Payload Safety Working Group ..................................................................................................... 295 
  Payload Project Responsibilities .................................................................................................... 297 
 GROUND OPERATIONS POLICIES ................................................................ 301 
  Personnel Safety ............................................................................................................................. 301 
  Stopping Unsafe Operations .......................................................................................................... 301 
 DOCUMENTATION REQUIREMENTS........................................................... 302 
  Ground Operations Plans ............................................................................................................... 302 
  Test and Inspection Plans ............................................................................................................... 302 
  Safety and Emergency Plans .......................................................................................................... 303 
  Procedures ....................................................................................................................................... 303 
  Range User Training Plan .............................................................................................................. 304 

Annex to NASA-STD-8719.24B 
Page 11 of 455 
  Mishap Reporting ........................................................................................................................... 304 
  Safety for Return-to Earth Payloads or Sample Returns ............................................................... 305 
 GROUND OPERATIONS SAFETY REQUIREMENTS ................................. 308 
  Ground Operations Personnel Requirements ................................................................................ 308 
  Hazardous Ground Operations General Requirements ................................................................. 310 
  Personal Protective Equipment ...................................................................................................... 313 
  Fall Protection ................................................................................................................................. 314 
  Smoking Areas ............................................................................................................................... 315 
  Operating Restrictions Due to Adverse Weather .......................................................................... 316 
  Operating Restrictions Due to High Winds ................................................................................... 318 
  Facility Use ..................................................................................................................................... 319 
  Hazardous Operation Support Requirements ................................................................................ 320 
 MATERIAL HANDLING EQUIPMENT, CRANE, HOIST, PERSONNEL 
PLATFORM, POWERED INDUSTRIAL TRUCK, AND ELEVATOR OPERATIONS ... 322 
  Material Handling Equipment Operations ..................................................................................... 322 
  Crane and Hoist Operations ........................................................................................................... 328 
  Personnel Work Platform Operations ............................................................................................ 337 
  Powered Industrial Trucks ............................................................................................................. 338 
  Elevator Usage ................................................................................................................................ 339 
 ACOUSTIC HAZARD OPERATIONS ............................................................... 340 
  Acoustic Hazard Operating Standards ........................................................................................... 340 
  Acoustic Hazard Operations Personnel Protection Requirements ................................................ 340 
  Acoustic Operations ....................................................................................................................... 340 
 NON-IONIZING RADIATION OPERATIONS ................................................ 341 
  Non-Ionizing Radiation Operating Standards ............................................................................... 341 
  Radio Frequency Procedures.......................................................................................................... 341 
  EMFR Operations ........................................................................................................................... 341 
  Class 1M, 2M, 3B, and 4 Optical/Laser Operations ...................................................................... 343 
 RADIOACTIVE (IONIZING) RADIATION SOURCES OPERATIONS .... 346 
 HAZARDOUS MATERIALS OPERATIONS ................................................. 347 
  Hazardous Materials Operating Standards .................................................................................... 347 
  Hazardous Materials Operations Personal Protective Equipment (PPE) ...................................... 347 
  Hazardous Materials Procedures .................................................................................................... 347 
  Hazardous Materials Operations .................................................................................................... 347 
  Restrictions on the Use of Plastic Films, Foams, and Adhesive Tapes (PFAs) and other Static-
Producing and Flammable Materials ............................................................................................. 348 
  Hazardous Commodity Lockers..................................................................................................... 350 
  Disposal of Contaminated Liquid Propellant, Gas, or Other Regulated Wastes .......................... 350 
 GROUND SUPPORT AND FLIGHT HARDWARE PRESSURE SYSTEMS 
OPERATIONS ................................................................................................................................ 352 
  Pressure Systems Operating Standards .......................................................................................... 352 
  Pressure Systems Personnel Requirements ................................................................................... 352 

Annex to NASA-STD-8719.24B 
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  Pressure Systems Procedures ......................................................................................................... 355 
  Pressure Systems Test, Inspection, and Maintenance Requirements............................................ 356 
  Pressure Systems Operating Requirements ................................................................................... 358 
 RESERVED ........................................................................................................... 371 
 ORDNANCE OPERATIONS ............................................................................. 371 
  Ordnance Operations Procedure Requirements ............................................................................. 371 
  Ordnance Transportation, Receipt, and Storage ............................................................................ 371 
  Ordnance Systems Grounding ....................................................................................................... 374 
  Ordnance Operations ...................................................................................................................... 378 
  Explosive Ordnance Disposal ........................................................................................................ 384 
  Ordnance Facilities Operations ...................................................................................................... 384 
 ELECTRICAL SYSTEMS OPERATIONS ...................................................... 385 
  Electrical Systems Operating Standards and Definitions .............................................................. 385 
  Electrical Systems Operations Personnel and Special Insulated Equipment ................................ 389 
  Electrical Systems Procedures ....................................................................................................... 389 
  Electrical Equipment and Systems Test, Inspection, and Maintenance Requirements ................ 389 
  Electrical Systems Operating Requirements ................................................................................. 391 
  Battery Operations .......................................................................................................................... 393 
 MOTOR VEHICLE OPERATIONS ................................................................. 397 
  Motor Vehicle Operating Standards .............................................................................................. 397 
  Motor Vehicle Operating Requirements ........................................................................................ 397 
  Special-Purpose Trailers Used to Transport Critical or Hazardous Loads. .................................. 398 
 CONVOY OPERATIONS ................................................................................... 400 
  General ............................................................................................................................................ 400 
  Convoy Operations Procedures ...................................................................................................... 400 
  Convoy Operations Requirements ................................................................................................. 400 
 LAUNCH OPERATIONS ................................................................................... 402 
 SOLID ROCKET MOTORS AND ROCKET, ROCKET MOTOR 
SEGMENTS, AND ROCKET MOTOR OPERATIONS .......................................................... 402 
  Solid Rocket Motors and Rocket Motor Segments Operations General Requirements ............... 402 
  Solid Rocket Motor and Rocket Motor Segment Transportation ................................................. 402 
  Solid Rocket Motor and Rocket Motor Segment Inspections ....................................................... 403 
  Solid Rocket Motor and Rocket Motor Segment Processing and Handling ................................ 404 
ATTACHMENT 1 GROUND OPERATIONS PLAN ............................................................... 408 
  Introduction ..................................................................................................................................... 408 
  Preparation Instructions .................................................................................................................. 408 
ATTACHMENT 2 HAZARDOUS AND SAFETY CRITICAL PROCEDURES ................. 412 
  Introduction ..................................................................................................................................... 412 
  Preparation Instructions .................................................................................................................. 413 
  Classification of Hazardous Procedures ........................................................................................ 418 

Annex to NASA-STD-8719.24B

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Eastern and Western Range Operations/Areas Safety Plans ......................................................... 420

Launch Commit Criteria ................................................................................................................. 420

VOLUME 7: INDEX OF APPLICABLE AND REFERENCE DOCUMENTATION,

TERMS AND SUPPORTING INFORMATION ....................................................................... 421

Applicable Documents................................................................................................................................ 421

Reference Documents ................................................................................................................................. 427

Abbreviations and Acronyms ..................................................................................................................... 429

Definitions ................................................................................................................................................... 436

Annex to NASA-STD-8719.24B Payload Project Name Rev: Basic

I – Information/Title N/A – Not Applicable C – Compliant T – Tailored NC – Noncompliant

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VOLUME 1: POLICIES AND PROCEDURE REQUIREMENTS

STATUS

TAILORED

TEXT

RATIONALE/

COMMENTS

INTRODUCTION

Objective

The objective of this publication is to establish and enforce NASA payload project requirements to ensure the safety of the

public, launch area, payload processing facility, and launch complex personnel and resources and to ensure that all aspects of

prelaunch and launch operations adhere to applicable public laws. These safety requirements safeguard people and resources

(including flight hardware, ground support equipment (GSE) and facilities) from hazards associated with payloads that will

fly on unmanned Launch Vehicles (i.e. Payloads), including hazards associated with payload related GSE. This document is

a baseline and shall be tailored for each NASA payload project (mission). The contents of this publication are to be used in

conjunction with NASA Procedural Requirements (NPR) 8715.7, Payload Safety Program, by the payload project to develop

and process their payloads safely throughout the project’s life cycle. The requirements of this document comply with the

requirements of 91-710, Range Safety User Requirements, and are acceptable to NASA and the Space Force ranges. The

Payload Safety Working Group (PSWG) is the payload project’s primary interface for the safety review and approval process,

where all documentation required by this publication and safety concerns or issues start. The PSWG members represent their

respective organizations and are responsible for coordinating, as necessary, with their organization to ensure payload project

compliance with their organization’s safety policies, processes, and requirements whenever the payload is being processed on

their organizations property or in their jurisdiction. The PSWG shall include the NASA (or JPL) Payload Project System

Safety Engineer, the payload contractor safety representative(s), the NASA Kennedy Space Center (KSC) Launch Services

Division Safety Engineer (or equivalent) who typically chairs the PSWG, the launch vehicle contractor safety engineer, the

launch site range safety engineer, the payload processing facility safety engineer, and other invitees such as the mission’s

Launch Site Integration Manager (LSIM) and subject matter experts (see Volume 3, Paragraph 2.1) and payload or sample

recovery organization safety representative as needed. PSWG activities typically conclude with the signing of the Certificate

of Payload Safety Compliance. If there are any open action items, the payload project will provide the appropriate local safety

authorities and mission officials with updates and complete the Safety Verification Tracking Log (SVTL). NPR 8715.7, this

publication, and the PSWG safety review and approval process upholds and does not remove or alter the safety responsibility

and authority of any organization having safety authority jurisdiction where the payload project is processed. The paragraph

sections of this document follow the same paragraph sections of USSF 91-710. The mutual goal of NASA, the payload project,

and Range Safety shall be to conduct their missions safely, with a strong commitment to public safety.

Note: Range Safety is a member of the PSWG working as a PSWG member in the project’s safety review and approval

process. All correspondence (safety submittals, review comments, etc.) is processed and coordinated through the PSWG.

The phrase “PSWG and Range Safety” is used throughout this document not to imply that Range Safety is separate from

the PSWG but to emphasize Range Safety’s role, authority, and responsibility in public safety and launch site safety.

Select Status

Applicability

Annex to NASA-STD-8719.24B Payload Project Name Rev: Basic

I – Information/Title N/A – Not Applicable C – Compliant T – Tailored NC – Noncompliant

Page 15 of 455

VOLUME 1: POLICIES AND PROCEDURE REQUIREMENTS

STATUS

TAILORED

TEXT

RATIONALE/

COMMENTS

1.2.1. Payload Projects. The requirements, policies, processes, procedures, and approvals defined in this publication and

NPR 8715.7 shall be applicable to all NASA Payload projects. The requirements in this document apply to each payload

project and its design, fabrication, launch area testing, vehicle integration, launch processing, launch, ascent flight phase

through payload separation, and planned recovery; payload-provided upper stages; interface hardware that is flown as part of

a payload; and GSE (Ground Support Equipment) used to support payload-related operations. During the period from post

launch ascent flight phase through payload separation the requirements of this document apply only to the extent that a hazard

could credibly result in a mishap causing a fatal injury or loss of the flight termination system. This document does not address

in-flight spacecraft operational safety. This document applies to payload processing facilities and the launch site area and

does not apply to payload integration, operations and testing performed at NASA Centers, JPL and other contractor facilities

that take place prior to payload shipment to the launch site area. The mission success and any scientific objectives of the

payload are the responsibility of the Payload Project Office and are beyond the scope of this document. When conflicting

safety requirements are encountered, the most stringent shall be applied. When additional safety requirements are needed,

NPR 8715.7, USSF 91-710, and local safety requirements shall be applied as determined by the PSWG and Range Safety.

Select Status

1.2.2. Tailoring:

1.2.2.1. This document is a template for developing a specific payload project's safety requirements document. The tailored

edition shall be placed on contract, other agreement, or effected through the applicable range Universal Documentation

System. Requirements were identified to address the safe design and operational concerns encountered in a 'typical' spacecraft.

Every attempt was made to capture the intent of all original requirements from applicable baseline requirements (e.g., USSF

91-710). The contents of this publication provide additional clarification, remove non-applicable requirements, and reflect

current practices and procedures of Ranges, Launch Vehicle Contractors, Payload Processing Facility Contractors, etc. The

PSWG and Range Safety reserves the right to identify applicable requirements not addressed, and any oversights, omissions,

or inaccuracies during the tailoring process with the payload project office. See Attachment A1.1 of this volume, for further

tailoring instructions.

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1.2.2.2. Developing a tailored edition of this document. The tailored edition should look like this document with the following

exceptions:

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1.2.2.2.1. The tailored edition shall be constructed in the following manner:

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1.2.2.2.1.1. Insert a document heading/title that reads, "NASA Payload Safety Requirements" for Project Name, date of the

applicable contract/agreement/ etc.", centered at the top of each page.

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1.2.2.2.1.2. Date of tailored edition.

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1.2.2.2.1.3. The term "PROPRIETARY" shall be placed on page 1, centered directly over the ITAR/EAR regulatory

determination statement for each payload project.

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1.2.2.2.2. Remaining heading information shall be left justified.

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1.2.3. New Programs. This publication and NPR 8715.7 are applicable to all NASA Payload projects under all new programs.

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1.2.4. Previous Approvals. All new NASA Payload projects must comply with the requirements in this document. However,

similar previously approved projects, systems or operations and related noncompliances may be updated and submitted for

consideration by the PSWG in assessing the safety of the new payload project. Existing projects and noncompliance approvals

approved before the initial publication of this document shall be updated to reflect any changes since last approval and

resubmitted to the PSWG for PSWG and Range Safety assessment.

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Basis for the Requirements

This publication is based on, but not limited to, the responsibilities or standards contained in or applied by NPR 8715.7 Preface

and AFSPCMAN 91-710, Volume 1, Section 1.3.

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RESPONSIBILITIES AND AUTHORITIES

General

The roles, responsibilities, and authorities for ensuring safety for NASA Payload projects are provided in NPR 8715.7, USSF

91-710, and below. For NASA Payload safety roles, responsibilities and safety review and approval processes, see NPR

8715.7. For Space Force Range Safety roles, responsibilities, and safety review and approval processes, see USSF 91-710.

Headquarters Space Systems Command Responsibilities

The Headquarters, Space Systems Command (HQ SSC) operates the USSF ranges, including providing base support,

personnel, and other government assets. The SSC Commander (SSC/CC) is responsible for establishing range safety policy

for USSF ranges as outlined in Air Force Space Command Instruction (AFSPCI) 91-701, Range Safety Program Policy and

Requirements. HQ SSC is also responsible for establishing common range safety user requirements as outlined in this

publication for the SSC SLD 30 and SLD 45 to implement and enforce.

Space Launch Delta Responsibilities

2.3.1. Commanders, SLD 30 and SLD 45:

2.3.1.1. The SLD Commanders (SLD/CCs) have overall authority and responsibility for public safety at USSF ranges as

directed by the USSF/CC. This delegation is provided via the MAJCOM chain of command and AFI 91-202, as supplemented.

2.3.5. Range Safety Offices. Unless otherwise noted, the use of the term Range Safety in this publication refers to SLD

30/SE, SLD 45/SE, or other local range safety organization.

2.3.5.1. Enforcing safety requirements to ensure that public safety, launch area safety, and launch complex safety are provided

by and for all programs using the ranges.

2.3.5.3. Providing oversight, review, approval, and monitoring for all public safety and launch area safety concerns during

prelaunch operations at the launch complex and launch vehicle or SLD 30 and SLD 45 payload processing facilities.

2.3.5.5. Reviewing and approving flight plans, design, inspection, procedures, testing, and documentation of all hazardous

and safety critical launch vehicles, payloads, and ground support equipment, systems, subsystems, facilities, and material to

be used at the Eastern Range (ER) and Western Range (WR).

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Federal Aviation Administration Responsibilities

In accordance with 49 U.S.C., Subtitle IX, Commercial Space Transportation, Chapter 701, Commercial Space Launch

Activities, U.S.C. §§ 70101 - 70121, the FAA has responsibility for public safety of licensed launches. The Range Safety

requirements in this publication have been written with the intent of achieving commonality with the FAA requirements. The

FAA performed launch site safety assessments of the two United States Space Air Force Space Command (AFSPC) national

launch ranges and determined the level of safety obtained by the existing range safety process to be adequate. The FAA will

not require a license applicant to demonstrate the adequacy of the range services it proposes to use if the applicable launch site

safety assessment included those services and if those services remain adequate. SLD Commander discretion to accept higher

risk for the launch of government payloads does not apply to licensed launches without a Range User obtaining relief from

the FAA. (“Memorandum of Agreement between the Department of the Air Force and Federal Aviation Administration on

Safety for Space Transportation and Range Activities,” dated 16 January 2001).

FAA documents can be found on the FAA/AST web site at: http://www.faa.gov/about/office_org/headquarters_offices/ast/.

Payload Project Responsibilities

2.5.2. The payload Project Manager (PM) shall be responsible for payload project safety and for developing and maintaining

a safety management program encompassing all applicable safety requirements, identifying a qualified key system safety

person with authority for resolution of identified hazards and direct access to the PM, and establishing and funding a supporting

system safety organization/function with direct interfaces and access to other functional elements of the project. Once assigned

a project the PM shall notify the NASA Payload Safety Manager of the new project as early as possible, obtain a Payload

Project System Safety Engineer, help coordinate the establishment of the PSWG, and ensure compliance with their

responsibilities and the safety review and approval process listed in NPR 8715.7. The payload project shall provide a System

Safety Plan (SSP), detailing the safety program, for review and approval in accordance with Attachment A1.2 of this volume.

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2.5.3. Design, Test, and Inspection Requirements Payload projects shall be responsible for the design, inspection, and

testing of all hazardous and safety critical payload, project provided ground support equipment, systems, subsystems, facilities,

and materials to be used in accordance with the requirements of this publication and applicable local safety requirements.

Payload project requests to eliminate or reduce testing shall be justified with clear and convincing evidence presented to Range

Safety and the PSWG for approval. Payload project responsibilities include the following:

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2.5.3.1. Providing safe systems, equipment, facilities, and materials in accordance with this publication.

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2.5.3.2. Developing and obtaining PSWG and Range Safety review and approval for all required data and/or documents

necessary for their planned operations. The submittal, review, and approval of data are defined by this document and NPR

8715.7.

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2.5.3.5. Performing risk analyses and implementing design and mission plans consistent with acceptable risk to the general

public for deorbiting spacecraft in accordance with NASA-STD-8719.14 Process for Limiting Orbital Debris.

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2.5.3.6. Coordinating their safety programs with the PSWG in conjunction with Range Safety and any additional safety

authorities needed to ensure their activities meet national policy goals and provide for public, payload processing facility and

launch site safety and resource protection while minimizing impact on mission requirements.

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2.5.3.8. Verifying compliance with this publication. The use of subcontractors does not relieve the payload project of

responsibility. The payload project shall provide contractual direction and monitor subcontractor performance to verify

compliance.

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2.5.3.9. As applicable, when involved in joint projects, interfacing and integrating with other payload projects or associated

contractors in their safety programs.

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2.5.4 Radioactive Material Launches. Payload projects shall be responsible for notifying the NASA Nuclear Flight Safety

Officer (NFSO), the PSWG, and Range Safety and ensuring compliance with National Security Presidential Memorandum

(NSPM-20), dated 20 August 2019, Presidential Memorandum on Launch of Spacecraft Containing Space Nuclear

Systems. NSPM-20 has superseded Paragraph 9 of PD/NSC-25, dated 08 May 1996, Scientific or Technological

Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space, with

implementation through DAFMAN 91-110, Nuclear Safety Review and Launch Approval for Space or Missile Use of

Radioactive Material and Nuclear Systems and USSF 91-710, Range Safety User Requirements.

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2.5.5. Conduct of Operations. Payload projects shall be responsible for the conduct of operations as outlined below and in

Volume 6 and its attachments:

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2.5.5.1. Conducting operations in a safe manner.

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2.5.5.2. Plan and conduct hazardous and safety critical operations potentially affecting launch area personnel and/or public in

accordance with (IAW) SLD 30 or SLD 40 Safety approved procedures and IAW the current edition of the applicable

operations safety plan (OSP) for the launch complex, recovery site, facility, or area in use and for ordnance and propellant

operations and areas.

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2.5.5.3. Observing, evaluating, and enforcing compliance with safety requirements.

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2.5.7. Occupational Safety and Health:

2.5.7.1. Payload projects are fully responsible for the safety and health of their employees and shall comply with NPR 8715.1,

NASA Safety and Health Programs, NASA Agency health management policy and programs as defined in NPD 1800.2,

NASA Occupational Health Program, NPR 1800.1, NASA Occupational Health Program Procedures and the Occupational

Safety and Health Administration (OSHA) regulations/standards. Further, they have an inherent responsibility to protect any

government employees and property when such are involved in contractor operations or on contractor-leased facilities. Space

Force Range Safety shall assume no liability for payload project or contractor compliance or noncompliance with OSHA

requirements.

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2.5.8. Resource Safety. Payload projects are responsible for resource safety of their owned or leased facilities, equipment,

and flight hardware.

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RANGE SAFETY POLICY

General

3.1.1. Each Launch Vehicle shall have a risk management plan consistent with AFSPC range launch risk guidance. The

payload project shall demonstrate an acceptable level of mishap risk to the PSWG through the completion of the system safety

hazard analyses and risk assessments described in Attachment A1.2.

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Prelaunch and Launch Operations

3.2.1.1. Range Safety shall review, approve, and through Pad Safety, monitor, and impose safety holds, when necessary, on

all prelaunch and launch operations conducted on the ranges. These actions are required to ensure that the hazards associated

with propellants, ordnance, radioactive material, and other hazardous systems do not expose the public, launch area, or launch

complex to risks greater than those considered acceptable by public law and state documents. These documents include but

are not limited to PL 99-499 42 U.S.C. 11001-11050, Superfund Amendments and Reauthorization Act (SARA), Title III:

Emergency Planning and Community Right-to-Know Act (CPRCA); 29 CFR 1910.119, Process Safety Management of

Highly Hazardous Chemicals; 40 CFR 355, Emergency Planning and Notification; 40 CFR 68, Chemical Accident Prevention

Provisions, subpart G, Risk Management Plan; Executive Order 12856, Federal Compliance with Right-to-Know Laws and

Pollution Prevention Requirements; and, for the Western Range, California Occupational Safety and Health Administration

(CAL-OSHA).

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3.2.1.2. Range Safety shall conduct and oversee launch vehicle, payload, mission flight control, and Range Safety launch

support operations to ensure that risks to the public, launch area, and launch complex do not exceed acceptable limits consistent

with mission and national needs.

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Launch Area Safety

The following requirements are in addition to those specifically identified for launch area safety in 3.2.1 of this volume. (See

Attachment 4 of this volume and Volume 7 of this publication for the definitions of terms related to risk.)

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3.3.1. The ranges shall ensure that all personnel and USAF or third party resources located on any AFSPC range, including

Cape Canaveral Space Force Station (CCSFS) or Vandenberg Space Force Base (VSFB) or on any supporting site within the

ER or WR, are provided an acceptable degree of protection from the hazards associated with range operations.

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3.3.2. Table 3.2 shows nominal launch area and launch complex hazard consequence and probability categories correlated to

different levels of acceptability for prelaunch hazards not associated with launch or Range Safety launch commit criteria.

Numbers provided in Table 3.2 are guides only and are not necessarily hard limits. NASA safety risks assessment often do

not address specific monetary values or downtime. NASA safety risks focus more on credible scenarios that may result in

loss of life, personal injury, illness, mission loss, or system loss or damage.

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3.3.7. Range Safety shall evaluate all launch vehicle, payload, ground support, and facility systems used on the ranges to test,

checkout, assemble, handle, support, or launch space launch vehicles or payloads with regard to their hazard potential and

ensure they are designed to minimize risks to personnel and fall within acceptable exposure levels for launch area and launch

complex safety.

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Table 3.2. Acceptability Guidelines for Launch and Recovery Sites Hazard Consequences and Probability Categories

Hazard Severity

Potential Consequences

Probability*

Category

Injury/Illness/Environment

Equipment Loss ($)

Unit Downtime

Data Compromise

Catastrophic

Could result in one or more of the

following: death, permanent total

disability, irreversible significant

environmental impact.

>10,000,000

>4 Months

Data is never recoverable or primary

program objectives are lost.

Critical

Could result in one or more of the

following: permanent partial

disability, injuries or occupational

illness that may result in

hospitalization of at least three

personnel, reversible significant

environmental impact.

1,000,000

10,000,000

2 Weeks

4 Months

May cause repeat of test program.

III

Marginal

Could result in one or more of the

following: injury or occupational

illness resulting in one or more lost

workday(s), reversible moderate

environmental impact.

100,000

1,000,000

1 Day

2 Weeks

May cause repeat of test period.

Negligible

Could result in one or more of the

following: minor injury or

occupational illness not resulting

in a lost workday, minimal

moderate environmental impact.

< 100,000

< One Day

May cause repeat of data point, or

data may require minor manipulation.

Risk Priority: High-Unacceptable Serious – Waiver Required Medium - ELS Required Low – Operation Permitted

*Probability refers to the probability that the potential consequence will occur in the life cycle of the system (test/activity/operation).

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Table 3.2. ( Continued) Acceptability Guidelines for Pre-Launch Area and Launch Complex Hazard Consequences and Probability Categories

Use the following list to determine the appropriate Risk Level.

Probability

Description**

Probability Range

Specific Individual Item

Fleet or Inventory***

Frequent

3 x 10

-2

to 3 x 10

-1

Likely to occur repeatedly

Continuously experienced

Probable

3 x 10

-3

to 3 x 10

-2

Likely to occur several times

Will occur frequently

Occasional

3 x 10

-4

to 3 x 10

-3

Likely to occur sometime

Will occur several times

Remote

8 x 10

-5

to 3 x 10

-4

Unlikely to occur, but possible

Unlikely, but can reasonably be expected to occur

Improbable

1 x 10

-6

to 8 x 10

-5

Very unlikely to occur, but still possible

Unlikely to occur, but possible

**Definitions of descriptive words may need to be modified based on the quantity involved

*** The size of the fleet or inventory as well as the system life cycle shall be defined.

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Launch Complex Safety

The following requirements are in addition to those also specifically identified for launch complex safety in 3.2.1 and 3.3 of

this volume.

3.4.4. When hazards extend to range assets or the general public, the SLD Commander has the ultimate responsibility to

ensure proper safety through an appropriate level of oversight into payload project operations.

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PSWG and RANGE SAFETY PROCESSES

PSWG, Range Safety and Payload Projects Interface Process

4.1.1 The safety review and approval process are covered in the NPR 8715.7 and allows for Range Safety approval processes.

A Payload Safety Introduction Briefing (PSIB) is typically the first meeting of the PSWG followed by other meetings to

complete Safety Review I, II, and III in accordance with NPR 8715.7. The PSIB shall cover the listed information in

Attachment A1.5 of this Volume.

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Equivalent Level of Safety (ELS) Determinations and Waivers

4.6.1. General. Payload projects shall identify the need for any potential Equivalent Level of Safety (ELS) determination

and/or waiver regarding requirements in this publication to PSWG and Range Safety for resolution. Potential ELS

determinations or waivers shall be identified and presented to the PSWG and Range Safety approval authority at the earliest

possible time. Details and requirements for submitting noncompliance requests can be found in Attachment A1.3 of this

volume.

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4.6.2. ELS Determination. The phrase “ELS” means an approximately equal level of safety. An ELS may involve a change

to the level of expected risk that is not statistically or mathematically significant as determined by qualitative or quantitative

risk analysis. ELS determination made by NASA and AFSPC ranges have been referred to in the past as meets intent

certifications. ELS determinations are normally incorporated during the tailoring process.

4.6.3. Waivers:

4.6.3.1. The term “waiver” refers to a decision that allows a payload project to continue with a launch, including launch

process, even though the payload project does not satisfy a specific safety requirement and is not able to demonstrate an ELS.

A waiver applies where a failure to satisfy a safety requirement involves a statistically or mathematically significant increase

in expected risk as determined through quantitative or qualitative risk analysis, and the activity may or may not exceed the

public risk criteria.

4.6.3.2. It is the policy of the NASA and the ranges to avoid the use of waivers. Waivers to the requirements shall be granted

only in extremely unique or compelling circumstances and only when the mission objectives of the payload project cannot

otherwise be achieved. PSWG, Range Safety, and the payload project shall jointly endeavor to ensure that all requirements

of this publication are met as early in the design and operation process as possible to limit the number of required waivers to

an absolute minimum.

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4.6.3.3. Waivers shall always have the effectivity designated. A "get-well" plan shall be required except for those with lifetime

effectivity.

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4.6.3.4. The FAA shall be included in the waiver process for licensed programs at USSF ranges per the memorandum of

agreement between Headquarters USSF and FAA/AST on Resolving Requests for Relief from Common Launch Safety

Requirements.

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4.6.3.5. The SLD Commanders shall approve or disapprove all waivers affecting public safety as defined in AFSPCMAN 91-

710, Volume 1, Chapter 3, Table 3.1 and Table 3.2, for a specific mission based on national or mission needs. When the

specific mission risks are greater than an expected casualty (Ec) of 300 x 10

-6

, the SLD Commanders shall advise the 14

AF/CC. Refer to AFSPCI 91-701 for risk approval levels. The latest prescribed Space Force noncompliance request format

shall be used.

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4.6.3.6. The Chiefs of Safety or their designated representatives shall approve or disapprove all USSF waivers other than

those affecting public safety.

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4.6.4. Submittal. The payload project shall submit all waiver requests for review and approval separately. ELS

determinations shall normally be documented as part of the tailoring process. All approved waivers and ELS determinations

shall be included in the appropriate safety data package.

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4.6.5. Every applicable waiver shall be reviewed for validity prior to each launch or launch cycle. The payload project shall

present a synopsis of each applicable waiver with the rationale concerning its viability for review and approval by Range

Safety and the PSWG.

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SAFETY AUTHORIZATIONS, SAFETY APPROVALS, AND

DOCUMENTATION

General

The overall safety review and approval process for NASA Payloads is contained in NPR 8715.7.

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INVESTIGATING AND REPORTING MISHAPS AND INCIDENTS

Mishaps and Incidents Involving Space Force Personnel and Resources

6.1.1. NPR 8621.1, NASA Procedural Requirements for Mishap and Close Call Reporting, Investigating, and Recordkeeping,

applies to all NASA mishaps and close calls. For mishaps and incidents occurring on a Space Force range, AFI 91-204, Safety

Investigations and Reports, also applies and the ranges shall investigate and report all mishaps and incidents involving USAF

personnel and resources.

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Non-Space Force Personnel and Resources on Space Force Property

6.2.1. The AFSPC ranges shall not report or investigate non-Space Force mishaps under AFI 91-204 auspices. However,

Range Safety shall assist and participate in non-Space Force mishap investigations that affect or could affect public safety,

launch area safety, or Space Force resources and may assist in non-Space Force mishap investigations that affect or could

affect launch complex safety or non-Space Force third party resources.

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6.2.2. The PSWG and Range Safety shall be provided with the investigation results of any mishaps or incidents occurring on

the ranges.

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6.2.3. Regardless of the payload project or Range User, the SLD Commander may conduct formal investigations into any

mishap and incident on Space Force property that affects or could affect public safety, launch area safety, or launch complex

safety. However, the scope of such an investigation into contractor mishaps is limited to the protection of the public, other

Range Users, and Space Force personnel and resources.

Reporting Space Launch System Anomalies

6.3.1. Any anomaly with potential safety implications and close calls shall be reported in accordance with NPR 8621.1, NASA

Procedural Requirements for Mishap and Close Call Reporting Investigating, and Recordkeeping. Any anomaly with potential

safety implications occurring in a system during prelaunch processing, launch, flight, or post-launch processing shall be

promptly reported to the PSWG and Range Safety for review. Anomalies occurring during launch, flight, or post-launch shall

be promptly reported to Range Safety and local safety authorities. Payload projects shall notify the PSWG and Range Safety

office of all anomaly reviews/meetings prior to the review/meeting and shall provide copies of the briefings, reports, meeting

minutes, and actions identified and taken to address the anomalies.

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CHANGES TO THIS PUBLICATION

7.1. This publication shall be updated as needed to coincide with updates to USSF 91-710, Range Safety and NASA

requirements and to incorporate document improvements. The latest version with any changes shall be provided on the NASA

Payload Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety.

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7.2. Requests for changes to Annex to NASA-STD-8719.24 Revision B shall be submitted via a hot link on NASA Technical

Standards web page: https://standards.nasa.gov/standard/NASA/NASA-STD-871924-ANNEX.

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7.3. All changes to this publication shall first be coordinated jointly among the NASA Payload Safety Agency Team and the

Space Force Space Command Ranges (SLD 30 and SLD 45 Safety Offices). All affected NASA payload projects shall be

informed of any changes to this publication. The NASA Payload Safety Manager is responsible for keeping this document

current and incorporating changes.

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ATTACHMENT 1 POLICIES AND PROCEDURES

NASA PAYLOAD SAFETY REQUIREMENTS TAILORING PROCESS

A1.1.1. Scope. This attachment describes the rationale for tailoring, the tailoring process, and the requirements for

documenting tailored editions of the publication. This NASA Payload Safety Requirements tailoring matrix baseline

document may be found on the NASA Payload Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety.

A1.1.2. Applicability. The tailoring process is applicable to all NASA Payload projects.

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A1.1.3. Purpose. Tailoring provides a means for formulating a specific edition of this publication, incorporating only those

requirements that apply to a particular project. Additionally, tailoring allows for the project to propose whether or not they

will meet the requirements as written or achieve an ELS through an acceptable alternative. A tailored version of the publication

is denoted by the project’s name in the title. Departures from this policy shall be approved by the PSWG and Range Safety.

Tailoring refers to the process used of assessing the applicability of requirements and evaluating the project’s potential

implementation in order to generate a set of specific requirements for the project. The tailored edition shall be placed on the

payload project’s contract, grants, cooperative agreements, or other agreements.

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A1.1.4. Formation of a Payload Safety Working Group. A PSWG shall be formed to assist the project as needed in

tailoring per this publication.

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A1.1.5. Tailoring Rationale. Tailoring shall be accomplished based on the following rationale described below. Alternative

means of identifying deletions, changes, additions, and payload project information are allowable provided that they are

distinguishable from the original text and each other and are mutually agreed to by the payload project, PSWG, and Range

Safety.

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A1.1.6. Deletion of a Requirement:

A1.1.6.1. When a requirement is going to be complied with and is applicable to the project, a “C” shall remain in the STATUS

column of the tailored document. When a requirement is not applicable to a specific payload project, then a “N/A” shall be

placed in the STATUS column and rationale provided under the RATIONALE/COMMENTS column.

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A1.1.6.2. The original paragraph number and headings shall remain, but the non-applicable text shall be identified with the

abbreviation N/A in the STATUS column with rationale provided in RATIONALE/COMMENTS column.

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A1.1.7. Change to a Requirement: Equivalent Level of Safety

A1.1.7.1. Equivalent Level of Safety (ELS) determinations may be provided and approved by the PSWG and Range Safety

through the change process.

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A1.1.7.2. A change is allowed to tailor the requirement to a particular system as long as the intent of the requirement is met

and the ELS is maintained. An “NC” for noncompliance shall be placed in the tailored STATUS column and sufficient

rationale is provided in the RATIONALE/COMMENTS column to allow for PSWG and Range Safety assessment.

A1.1.7.3. The change shall be fully captured by showing the entire new paragraph with the change in the TAILORED TEXT

column of the tailored document. When the change is an ELS, the abbreviation “NC” shall be placed in the STATUS column

of the tailored document following the paragraph number. The new paragraph with the change shall be provided under the

TAILORED TEXT column with sufficient rationale provided under the RATIONALE/COMMENTS column for PSWG and

Range Safety assessment. If additional space is needed for the rationale (i.e. to show analysis or data, or to provide lengthy

rationale) then an addendum to the tailored document should be used referencing the paragraph number. ELS’ that are

requested after the final project specific tailored document has been completed and signed shall be requested using the NASA

Payload Safety Post Tailoring Equivalent Level of Safety (ELS) Request NASA Form NF 1826 found on the NASA Payload

Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety under the “Payload Safety Forms” button or an

equivalent form that contains all information required on NF 1826. When the change is merely an administrative change then

the abbreviation “T” shall be placed in the STATUS column of the tailored document after the paragraph number. The new

paragraph with the change shall be placed under the TAILORED TEXT column and rationale provided under the

RATIONALE/COMMENTS column. When the paragraph is not a requirement and is for information only the STATUS

column of the tailored shall be marked with an “I” and rationale provided if deemed necessary under the

RATIONALE/COMMENTS column.

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A1.1.7.4. The existing numbering system shall remain the same to the maximum extent possible.

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A1.1.7.5. Additional paragraphs may be added; however, using the remaining unaffected paragraph numbers is not allowed.

A1.1.7.6. All changes shall be captured in the TAILORED TEXT column of the project specific tailored document. All

changes shall be highlighted in bold. Deletions of text, including partial deletions, shall be shown with the original text marked

with strikethrough. Insertions of text, including partial insertions, shall be shown with the new text marked with underline.

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A1.1.8. Addition to a Requirement:

A1.1.8.1. An addition to a requirement is allowed when there are no existing requirements addressing new technology, when

unforeseen hazards are discovered, when federal or industry standards change, and for similar reasons.

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A1.1.8.2. An addition shall be added with new paragraph numbers in the section for which it is appropriate or in a new section

if no other section applies.

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A1.1.8.3. Additions shall be placed in the TAILORED TEXT column in the tailored document with a “T” placed in the

STATUS column and rationale provided under the RATIONALE/COMMENTS column. All changes shall be highlighted in

bold. Insertions/ additions of text, including partial insertions, shall be shown with the new text underlined.

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A1.1.9. Payload Project Information Only

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A1.1.9.1. Requirements having only an indirect effect on the payload project, but which are still required of the project as a

whole shall remain in the tailored publication as information only. Examples of such requirements include Pad Safety

responsibilities, other range contractor responsibilities, and payload project facilities manager responsibilities.

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A1.1.10. Waivers

A1.1.10.1. Waivers are not rationale for the deletion of requirements. The requirements shall remain in the tailored document

and the waiver process shall be used for the disposition of the requirement. When a requirement is not going to be met and

there is a resultant increase in risk as determined by the PSWG in conjunction with Range Safety then a waiver request must

be submitted. If the waiver is approved, then a “NC” is placed in the STATUS column of the tailored document. The waiver

title and number(s) shall be placed under the RATIONALE/COMMENTS column. The NF 1827 NASA Payload Safety

Waiver Request may be found on the NASA Payload Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety.

This form is used for all waivers. Additionally, if the waiver is impacting Space Force property and resources, then the LSRRR

(Launch Safety Requirements Relief Request) form shall be submitted, and the USSF 91-710, range safety user requirement

waiver process will be followed.

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A1.1.11. Risk-Cost Benefit Analysis:

A1.1.11.1. Technical issues regarding such items as applicable requirements, policy, criteria, or data may be evaluated on a

risk-cost benefit basis to determine if the risk is acceptable to waive the requirements.

A1.1.11.2. A risk-cost benefit analysis, based on the criteria defined in AFSPCMAN 91-710, Volume 1, Chapter 3, Table 3.1

and Chapter 3, Table 3.2 of this volume may be submitted to Range Safety.

A1.1.11.3. Based on risk-cost benefit analysis data, Range Safety and the Range User shall reach agreement on the disposition

of the requirement in question.

A1.1.11.4. If the application of a USSF 91-710 range safety user requirement, results in significant reduction in risk at a

significant cost benefit, it may be determined by Range Safety to be sufficient to impose the requirement; however, if the

benefit is insignificant and/or the cost is high, the requirement may be waived or determined to provide an ELS, all with

consideration for public safety.

A1.1.12. Preparation of a Project Specific Draft Tailored Edition of NASA Payload Safety Requirements document:

A1.1.12.1. The payload project shall produce a payload project mission specific draft edition of this document per NPR 8715.7

and this standard. The NASA Payload Safety Requirements tailoring matrix is found on the NASA Payload Safety Program

website at https://kscsma.ksc.nasa.gov/PayloadSafety.

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A1.1.12.2. The purpose of a draft project specific tailored matrix version is to eliminate all non-applicable requirements,

leaving only applicable requirements from which detailed tailoring can be performed and to allow for PSWG and Range Safety

review prior to finalizing.

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A1.1.12.3. The project specific draft shall be delivered to the PSWG as part of Safety Review I no later than 30 days prior to

the project’s mission PDR, in accordance with NPR 8715.7, Table 3-1. Overview of Deliverables for the Payload Safety

Process and Approvals.

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A1.1.13. Final Publication of the Project Specific NASA Payload Safety Requirements:

A1.1.13.1. The goal for final publication of the project specific tailored matrix is as soon as possible but should be no later

than 30 days prior to the project’s mission CDR or as scheduled by the PSWG (see NPR 8715.7 for deliverables schedule).

Tailoring can be an ongoing process and tailored documents should be considered living documents that may change

throughout the life of the project.

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A1.1.13.2. The tailoring process and delivery schedule is found in NPR 8715.7, Table 3-1. Overview of Deliverables for the

Payload Safety Process and Approvals.

A1.1.14. The tailored edition shall look like this NASA Payload Safety Requirements tailoring matrix with the

following exceptions:

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A1.1.14.1. The document title/heading on page 1 shall read, “NASA Payload Safety Requirements and the Payload Project

name. The “Payload Project Name” shall be centered at the top of each page.

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A1.1.14.2. The date of the applicable contract/CSOSA/agreement/etc. shall be shown under the title on page 1.

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A1.1.14.3. The date of the tailored edition shall be on the cover page of the document.

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A1.1.14.4. The information contained in the document is technical in content and may be proprietary as defined by the

International Traffic in Arms Regulations (ITAR) or by Export Administration Regulations (EAR) requirements. Each payload

project shall contact the NASA KSC Export Control Office, 321-867-9209, for an ITAR or EAR regulatory determination. If

not required delete this statement. The term "PROPRIETARY" shall be placed on page 1, centered directly over the

ITAR/EAR regulatory determination statement for each payload project.

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A1.1.14.5. All deleted information shall be marked as “N/A” under the STATUS column of the project’s tailored version of

this document.

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A1.1.15. Effectivity of Tailored Project Specific NASA Payload Safety Requirements document:

A1.1.15.1. Each project specific version of the NASA Payload Safety Requirements document shall contain a preface

paragraph detailing its effectivity.

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A1.1.15.2. At a minimum, the payload and the time period to which the project specific NASA Payload Safety Requirements

applies shall be addressed.

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A1.1.16. Assumptions:

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A1.1.16.1. Each project specific tailored version of the NASA Payload Safety Requirements tailoring matrix shall contain a

preface paragraph detailing the critical assumptions that were made in writing the tailored edition.

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A1.1.16.2. The nature of the assumptions shall be such that a change may invalidate the tailored document or require a change

or update. An example of such a critical assumption is that the design of any hazardous system does not change from that

presented before publication of the project specific tailored document.

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A1.1.16.3. The assumption(s) described in the tailored document shall include sufficient detail to categorize the scope of the

tailored requirement to the specific systems or subsystems affected by the proposed change. If two or more

systems/subsystems are affected by the tailored paragraph, then the assumption(s) shall state which of those

systems/subsystems is intended to be included in the scope of the tailoring. If there is a difference in the tailoring for the two

or more systems/subsystems, then the tailored paragraph shall be repeated with appropriate tailoring unique to each individual

system/subsystem.

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A1.1.17. Approvals:

A1.1.17.1. Once completed and finalized the project specific Payload Safety Requirements shall be approved and signed by

the Project Manager (PM), the preparer, the project’s NASA SMA Technical Authority, Range Safety Representative, PSWG

Chairperson and others as deemed necessary by the PSWG in accordance with NPR 8715.7 and this standard. Once signed

each significant addition, change, or deletion shall be approved in accordance with this document and NPR 8715.7. Changes

that are ELS that come up after the tailoring was completed shall be recorded on NF 1826 NASA Payload Safety Post-Tailoring

Equivalent Level of Safety (ELS) Request or an equivalent form that contains all information required on NF 1826. Waivers

(increased risk changes) shall be recorded on the NF 1827 NASA Payload Safety Waiver Request. If deemed necessary by

the Space Force, an Space Force Relief request will also be required. The NASA Payload Safety ELS and Waiver Requests

as well as the Space Force Range Safety Relief Request are found on the NASA Payload Safety Program website under Forms

at https://kscsma.ksc.nasa.gov/PayloadSafety.

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A1.1.17.2. Each complete, final project-specific tailored document affecting public safety shall be approved and signed by

the SW Commander.

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A1.1.17.3. Any revisions to the project-specific tailored version of the NASA Payload Safety Requirements document shall

be made in accordance with NPR 8715.7 and USSF 91-710 change processes.

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ATTACHMENT 2 SAFETY PLAN REQUIREMENTS

INTRODUCTION

A2.1.1. Purpose. This attachment establishes the minimum requirements for a payload project’s System Safety Plan (SSP).

The payload project SSP shall be consistent with MIL-STD-882, Standard Practice for System Safety, Task 101, System

Safety Program Plan. The payload project SSP shall include the key system safety roles, responsibilities, and interfaces of the

payload contractor, NASA, and other relevant organizations. The program includes the corresponding requirements for a

payload project SSP and identifies hazard analysis and risk assessment requirements.

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A2.1.2. Tailoring. Tailoring of this attachment and the requisite SSP is highly recommended. The tailoring process is defined

in Attachment A1.1 of this volume. When conflicting requirements or deficiencies are identified in safety requirements the

payload project shall submit notification, with proposed solutions or alternatives and supporting rationale, to the PSWG and

Range Safety for resolution.

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A2.1.3. Demonstration of an Acceptable Level of Mishap Risk. Payload projects shall demonstrate an acceptable level of

mishap risk to the PSWG and Range Safety through the completion of the system safety hazard analyses and risk assessments

described in this attachment.

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SYSTEM SAFETY PLAN TASKS

A2.2.1. To achieve the system safety objectives and obtain the PSWG and Range Safety approval, the following tasks shall

be completed by the payload project in the approximate order that they are listed and in conjunction with the milestones that

are identified.

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A2.2.1.1. Task 1: Establish a Payload Project System Safety Plan. By the time of the payload project's Payload Safety

Introduction Briefing, the payload project shall have established a Safety Program documented in the project’s SSP (see

A2.2.2) that meets the tailored requirements of this publication which includes the following:

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A2.2.1.2. Project Manager (PM). Establishing a safety management system. The payload Project Manager (PM) shall be

responsible for the following:

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A2.2.1.2.1. Establishing, controlling, incorporating, directing, and implementing the system safety plan policies.

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A2.2.1.2.2. Ensuring that mishap risk is identified and eliminated or controlled within established program risk acceptability

parameters. Decisions regarding resolution of identified hazards shall be based on assessment of the risk involved. To aid in

the achievement of the objectives of system safety, hazards shall be characterized as to hazard severity categories and hazard

probability levels, when possible. Since the priority for system safety is eliminating hazards by design, a risk assessment

procedure, considering only hazard severity, will generally suffice during the early design phase to minimize risk. When

hazards are not eliminated during the early design phase, a risk assessment procedure based upon the hazard probability, hazard

severity, as well as risk impact, shall be used to establish priorities for corrective action and resolution of identified hazards.

All catastrophic and critical hazards shall be documented on the NASA Form NF 1825 NASA Payload Safety Hazard Report

(see A2.2.1.8.1) or an equivalent form that contains all information required on NF 1825.

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A2.2.1.2.3. Establishing internal reporting systems and procedures for investigation and disposition of system related mishaps

and safety incidents, including close calls involving flight hardware and ground support equipment and reporting such matters

as required by NPR 8621.1. See Volume 6, 4.6.2 for the Accident Notification Plan. For all such situations at the payload

processing facility and launch site area, the local safety authority and the PSWG Chairperson shall be contacted immediately

after initial mishap response. The SW Commander and NASA may conduct formal investigations into any mishap and

incident that affects or could affect public safety, launch area safety, or launch complex safety. However, the scope of such

an investigation into contractor mishaps is limited to the protection of the public, other payload projects, and Space Force

personnel and resources.

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A2.2.1.2.4. Reviewing and approving the safety analyses, reports, and documentation required by this publication and

submitted to the PSWG for the PSWG and Range Safety to establish knowledge and acceptance of residual risks.

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A2.2.1.3. Payload Project System Safety Engineer. Establishing a Payload Project System Safety Engineer safety position

for each project in accordance with NPR 8715.7. The individual in this position shall be directly responsible to the payload

Project Manager for safety matters. At a minimum, the Payload Project System Safety Engineer shall be responsible for the

requirements in NPR 8715.7 and for the following:

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A1.2.2.1.3.1. Reviewing and approving all safety analyses, reports, and documentation required by this publication and

submitted to PSWG for PSWG and Range Safety review and approval.

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A1.2.2.1.3.2. Reviewing and approving all hazardous and safety critical test plans and procedures and verifying that all safety

requirements are incorporated.

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A1.2.2.1.3.3. Developing a planned approach for safety task accomplishment, providing qualified people to accomplish the

tasks, establishing the authority for implementing the safety tasks through all levels of management, and allocating appropriate

resources, both manning and funding, to ensure the safety tasks are completed.

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A1.2.2.1.3.4. Establishing a system safety organization or function and lines of communication within the project organization

and with associated organizations (government and contractor).

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A2.2.1.3.5. Establishing interfaces between system safety and other functional elements of the project, as well as between

other safety disciplines such as nuclear, range, explosive, chemical, and biological.

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A2.2.1.3.6. Designating the organizational unit responsible for executing each safety task.

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A2.2.1.3.7. Establishing the authority for resolution of identified hazards.

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A2.2.1.3.8. Establishing a single closed-loop hazard tracking system by development of a method or procedure to document

and track hazards and their controls and providing an audit trail of hazard mitigation.

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A2.2.1.3.9. Maintaining and making available to the PSWG and Range Safety Hazard Reports of all identified hazards.

Hazard Reports shall be documented on NF 1825 NASA Payload Safety Hazard Report Form and instructions found on the

NASA Payload Safety Program website https://kscsma.ksc.nasa.gov/PayloadSafety under “Payload Safety Forms” or an

equivalent form that contains all information required on NF 1825. The payload project shall track until closed all open hazards

using a Safety Verification Tracking Log (SVTL), of which an example is also found on the NASA Payload Safety Program

website, to track identified hazards to closure. Establishing the order of precedence for satisfying system safety requirements

and resolving identified hazards as follows:

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A2.2.1.3.9.1. Designing for Minimum Risk. From program inception, design to eliminate hazards. If an identified hazard

cannot be eliminated, reduce the associated risk to an acceptable level, as defined by PSWG and Range Safety, through design

selection.

A2.2.1.3.9.2. Incorporating Safety Devices. If identified hazards cannot be eliminated or their associated risk reduced through

design selection, that risk shall be reduced to a level acceptable to the PSWG and Range Safety through the use of fixed,

automatic, or other protective safety design features or devices. Provisions shall be made for periodic functional checks of

safety devices when applicable.

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A2.2.1.3.9.3. Providing Warning Devices. When neither design nor safety devices can effectively eliminate identified hazards

or reduce associated risk, devices shall be used to detect the condition and to produce a warning signal to alert personnel of

the hazard. Warning signals and their application shall be designed to minimize the probability of incorrect personnel reaction

to the signals and shall be standardized within like types of systems.

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A2.2.1.3.9.4. Developing Procedures and Training. Where it is impractical to eliminate hazards through design selection or

reduce the associated risk with safety and warning devices, procedures and training may be used when acceptable to the PSWG

and Range Safety. Procedures may include the use of personal protective equipment. Precautionary notations shall be

standardized as specified by the PSWG and Range Safety. Tasks and activities judged to be safety critical by the PSWG and

Range Safety require certification of personnel proficiency.

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A2.2.1.3.9.5. Defining system safety plan milestones and relate them to major program milestones, project element

responsibility, and required inputs and outputs.

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A2.2.1.3.9.6. Establishing System Safety Plan reviews and audits.

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A2.2.1.3.9.7. Conducting, documenting, and making the following documentation available to the PSWG and Range Safety

upon request:

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A2.2.1.3.9.7.1. The payload project system safety plan and supporting risk assessment data.

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A2.2.1.3.9.7.2. Associate contractor system safety plan and supporting risk assessment data.

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A2.2.1.3.9.7.3. Support contractor system safety plan and supporting risk assessment data.

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A2.2.1.3.9.7.4. Subcontractor system safety plan and supporting risk assessment data.

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A2.2.1.3.9.7.5. Providing support for the following:

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A2.2.1.3.9.7.5.1. Safety reviews and audits performed by representatives of the PSWG, Payload Safety Agency Team, or

others.

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A2.2.1.3.9.7.5.2. Presentations to government certifying activities such as phase safety reviews, munitions safety boards,

nuclear safety boards, NPR 8715.26, NASA Nuclear Flight Safety program review or flight safety review boards to the extent

specified by this publication. These may also include special reviews such as flight and article readiness reviews or pre-

construction briefings.

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A2.2.1.3.9.7.6. Safety reviews shall be held in accordance with NPR 8715.7 and are in association with the project’s schedule

per NPR 7120.5. Generally, the safety reviews shall address the following:

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A2.2.1.3.9.7.6.1. Program systems and operations overview.

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A2.2.1.3.9.7.6.2. Presentation of required documentation and hazard analyses.

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A2.2.1.3.9.7.6.3. Noncompliances to the project specific tailored requirements.

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A2.2.1.3.9.7.6.4. Open safety issues.

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A2.2.1.3.9.8. Establishing an incident alert and notification, investigation, and reporting process, to include notification of the

PSWG Chairperson and Range Safety.

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A2.2.1.3.9.9. Establishing a process to evaluate engineering change proposals (ECPs), specification change notices (SCNs),

software problem reports (SPRs), program or software trouble reports (PTRs, STRs) for their safety impact on the system, and

notify the PSWG and Range Safety if the level of risk of the system changes.

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A2.2.2. Task 2: Develop a System Safety Plan. The payload project shall develop and implement a PSWG and Range

Safety approved System Safety Plan (SSP) encompassing the total safety program for payload design, production, processing

and testing, vehicle integration, and launch through payload separation from the launch vehicle. For any planned return-to-

earth recovery or sample return missions see Volume 6, section 4.7. The SSP shall describe in detail tasks and activities of

system safety management and system safety engineering required to identify, evaluate, and eliminate or control hazards, to

reduce the associated risk to a level acceptable to the PSWG and Range Safety. The plan provides a formal basis of

understanding between the payload project and the PSWG and Range Safety on how the SSP will be conducted to meet the

requirements of NPR 8715.7 and this publication. The plan shall account for all required tasks and responsibilities on an item-

by-item basis. The payload project shall submit a draft SSP to the PSWG, including Range Safety for review at the Payload

Safety Introduction Briefing. A final SSP shall be submitted no later than 30 days prior to project’s mission PDR, or as

scheduled by the PSWG, for review and approval (see NPR 8715.7 for review and approval process). The SSP shall comply

with this document and include the following information:

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A2.2.2.1. System Safety Organization. The System Safety Organization section shall describe the following:

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A2.2.2.1.1. The location of the system safety and flight safety analysis organizations or functions within the overall project

organization, using charts to show the organizational and functional relationships and lines of communication.

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A2.2.2.1.2. The organizational relationship between other project functional elements having responsibility for tasks with

range safety impacts and the system safety management and engineering organization.

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A2.2.2.1.3. Review and approval authority of applicable tasks by key system safety personnel.

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A2.2.2.1.4. The responsibility and authority of key system safety personnel, other payload project organizational elements

involved in the range safety effort, contractors, and system safety groups.

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A2.2.2.1.5. A description of the methods by which safety personnel may raise issues of concern directly to the Project Manager

(PM) or the project manager's supervisor within the corporate organization.

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A2.2.2.1.6. Identification of the organizational unit responsible for executing each task.

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A2.2.2.1.7. Identification of the authority in regard to resolution of all identified hazards.

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A2.2.2.1.8. The staffing of the system safety organization for the duration of the program to include personnel loading and a

summary of the qualifications of key system safety personnel assigned to the effort, including those personnel identified with

approval authority for the payload project prepared documentation.

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A2.2.2.1.9. The process by which the payload project management decisions will be made, including such decisions as timely

notification of unacceptable risks, necessary action, incidents, or malfunctions, or request for noncompliances to safety

requirements or project waivers.

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A2.2.2.1.10. Details of how resolution and action relative to system safety will be accomplished at the project management

level possessing resolution authority.

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A2.2.2.2. System Safety Plan Milestones. The SSP shall:

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A2.2.2.2.1. Define system safety project milestones and relate them to major project milestones, program element

responsibility, and required inputs and outputs.

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A2.2.2.2.2. Provide and maintain a program schedule of safety tasks, including start and completion dates, reports, and

reviews.

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A2.2.2.2.3. Identify subsystem, component, or software safety activities as well as integrated system level activities such as

design analyses, tests, and demonstrations applicable to the SSP but specified in other engineering studies and development

efforts to preclude duplication.

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A2.2.2.3. System Safety Data. The SSP shall:

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A2.2.2.3.1. Identify deliverable data by title, number, and means of delivery such as hard copy or electronic submission.

Note: NPR 8715.7, this publication and MIL-STD-882 provide initial Data Item Descriptions and deliverables

identification. Electronic submittals are preferred, and secure websites shall be used to allow for PSWG and Range Safety

review.

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A2.2.2.3.2. Identify non-deliverable system safety data and describe the procedures for accessibility by the PSWG and Range

Safety and retention of data of historical value.

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A2.2.2.4. System Safety Interfaces. The SSP shall identify, in detail:

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A2.2.2.4.1. The interface between system safety and all other applicable safety disciplines such as USSF Range Safety, NASA

Range Safety, the NASA Nuclear Flight Safety Officer (NFSO), the NASA Center safety, local facility safety, explosive and

ordnance safety, chemical and biological safety, laser safety, and any others.

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A2.2.2.4.2. The interface between system safety, design and/or systems engineering, and all other support disciplines such as

maintainability, quality control, reliability, software development, human factors engineering, occupational health support

(health hazard assessments), and any others.

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A2.2.2.4.3. The interface between system safety and all system integration and test disciplines.

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A2.2.3. Task 3: Perform and Document a Preliminary Hazard Analysis. The payload project shall perform and document

a preliminary hazard analysis (PHA) to identify safety critical areas, to provide an initial assessment of hazards, and to identify

requisite hazard controls and follow-on actions. A preliminary hazard list shall be provided at the Payload Safety Introduction

Briefing (PSIB). The results of the PHA shall be submitted with the SDP I (preliminary MSPSP) for the project’s mission

PDR Safety Review 1 meeting in accordance with NPR 8715.7. Based on the best available data, including mishap data from

similar systems and other lessons learned, hazards associated with the proposed design or function shall be evaluated for

hazard severity, hazard probability, and operational constraint. Safety and health studies identifying provisions and

alternatives needed to eliminate hazards or reduce their associated risk to a level acceptable to the PSWG and Range Safety

shall be included. Hazards identified shall be documented on the NF1825 NASA Payload Safety Hazard Report found on the

NASA Payload Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety or an equivalent form that contains all

information required on NF 1825. At a minimum, the PHA shall consider the following for identification and evaluation of

hazards:

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A2.2.3.1. Hazardous components such as fuels, propellants, lasers, explosives, toxic substances, hazardous construction

materials, pressure systems, and other energy sources.

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A2.2.3.2. Safety related interface considerations among various elements of the system such as material compatibility,

electromagnetic interference, inadvertent activation, fire and explosive initiation and propagation, and hardware and software

controls. This shall include consideration of the potential contribution by software, including software developed by other

contractors and sources, to subsystem and system mishaps.

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A2.2.3.3. Safety design criteria to control safety-critical software commands and responses such as inadvertent command,

failure to command, untimely command or responses, inappropriate magnitude, or designated undesired events shall be

identified and appropriate action taken to incorporate them in the software and related hardware specifications.

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A2.2.3.4. Environmental constraints including the operating environments such as drop, shock, vibration, extreme

temperatures, humidity, noise, exposure to toxic substances, health hazards, fire, electrostatic discharge, lightning,

electromagnetic environmental effects, ionizing and non-ionizing radiation including laser radiation.

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A2.2.3.5. Operating, test, maintenance, built-in-tests, diagnostics, and emergency procedures (human factors engineering,

human error analysis of operator functions, tasks, and requirements; effect of factors such as equipment layout, lighting

requirements, potential exposures to toxic materials, effects of noise or radiation on human performance; explosive ordnance

render safe and emergency disposal procedures; life support requirements and their safety implications in manned systems,

crash safety, egress, rescue, survival, and salvage).

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A2.2.3.6. Those test unique hazards that will be a direct result of the test and evaluation of the article or vehicle.

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A2.2.3.7. Facilities, real property installed equipment, support equipment such as provisions for storage, assembly, checkout,

proof testing of hazardous systems and assemblies that may involve toxic, flammable, explosive, corrosive, or cryogenic

materials and wastes; radiation or noise emitters; electrical power sources.

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A2.2.3.8. Training and certification pertaining to hazardous and safety critical operations and maintenance of hazardous and

safety critical systems.

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A2.2.3.9. Safety related equipment, safeguards, and possible alternate approaches such as interlocks; system redundancy; fail-

safe design considerations using hardware or software controls; subsystem protection; fire detection and suppression systems;

personal protective equipment; heating, ventilation, and air-conditioning; and noise or radiation barriers.

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A2.2.3.10. Malfunctions to the system, subsystems, or software. Each malfunction shall be specified, the cause and resulting

sequence of events determined, the degree of hazard determined, and appropriate specification and/or design changes

developed.

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A2.2.4. Task 4: Perform and Document Subsystem, System, Facility, and Operating and Support Hazard Analyses:

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A2.2.4.1. Subsystem Hazard Analysis - The payload project shall perform and document a subsystem hazard analysis

(SSHA) to identify all components and equipment that could result in a hazard or whose design does not satisfy safety

requirements. The purpose of the SSHA is to verify subsystem compliance with safety requirements contained in subsystem

specifications and other applicable documents; identify previously unidentified hazards associated with the design of

subsystems including component failure modes, critical human error inputs, and hazards resulting from functional

relationships between components and equipment comprising each subsystem; and recommend actions necessary to eliminate

identified hazards or control their associated risk to acceptable levels. The SSHA shall include government furnished

equipment, non-developmental items, and software. Areas to consider are performance, performance degradation, functional

failures, timing errors, design errors or defects, or inadvertent functioning. The human shall be considered a component within

a subsystem, receiving both inputs, and initiating outputs, during the conduct of this analysis. The SSHA may indicate the

need for revised tailoring of some requirements of this publication depending on the level of risk identified or the discovery

of any previously unidentified hazards. Hazards identified shall be documented on the NF 1825 NASA Payload Safety Hazard

Report found on the NASA Payload Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety or an equivalent

form that contains all information required on NF 1825. The analysis shall include a determination of the following:

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A2.2.4.1.1. The modes of failure that could impact safety including reasonable human errors as well as single point and

common mode failures, and the effects on safety when failures occur in subsystem components.

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A2.2.4.1.2. The potential contribution of hardware and software, including that which is developed by other contractors and

sources, events, faults, and occurrences such as improper timing on the safety of the subsystem.

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A2.2.4.1.3. That the safety design criteria in the hardware, software, and facilities specifications have been satisfied.

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A2.2.4.1.4. A general assertion that the method of implementation of hardware, software, and facilities design requirements

and corrective actions has not impaired or decreased the safety of the subsystem nor has it introduced any new hazards or

risks.

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A2.2.4.1.5. The implementation of safety design requirements from top level specifications to detailed design specifications

for the subsystem. The implementation of safety design requirements developed as part of the PHA shall be analyzed to ensure

that it satisfies the intent of the requirements.

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A2.2.4.1.6. Test plan and procedure recommendations to integrate safety testing into the hardware and software test programs.

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A2.2.4.1.7. That system level hazards attributed to the subsystem are analyzed and control of the potential hazard is

implemented in the design.

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A2.2.4.1.8. SSHA Analysis Techniques. If no specific analysis techniques are directed or if the payload project recommends

that a different technique other than that specified by the PSWG and Range Safety should be used, the payload project shall

obtain approval of techniques to be used before performing the analysis.

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A2.2.4.1.9. SSHA Software:

A2.2.4.1.9.1. Software used to control safety critical computer system functions shall be developed in accordance with

Volume 3, Chapter 16 of this publication. Safety related software problems detected during or after software verification (and

prior to launch) shall be reported to the PSWG and Range Safety in time to support the ongoing phase of the software

development process.

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A2.2.4.1.9.2. Payload projects shall identify all safety critical computer system functions in accordance with Volume 3,

Chapter 16 and develop a SSHA for each.

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A2.2.4.1.9.3. Software shall be put under formal configuration control of a Software Configuration Control Board (SCCB) in

accordance with Volume 3, Chapter 16 as soon as a baseline is established. This will ensure that hardware/software changes

do not conflict with or introduce potential safety hazards due to hardware/software incompatibilities.

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A2.2.4.1.9.4. Safety-critical software, as defined per NASA-STD-8739.8, NASA Software Assurance and Software Safety

Standard, that have problems identified during or after software verification (and prior to launch) shall be reported to the

PSWG and Range Safety.

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A2.2.4.1.10. Updating the SSHA. The payload project shall update the SSHA as a result of any system design changes,

including software design changes that affect system safety.

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A2.2.4.1.11 SSHA Submittal. A draft SSHA shall be submitted with or included in Safety Data Package II (updated MSPSP)

no later than 30 days prior to project’s mission CDR and the finalized SSHA shall be submitted with or included in Safety

Data Package III (final MSPSP) (See Attachment V3.1 of Volume 3).

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A2.2.4.2. System Hazard Analysis. The payload project shall perform and document a system hazard analysis (SHA) to

identify hazards and make a general determination of the safety risk posture of the total system design, including software,

and specifically of the subsystem interfaces. The purpose of the SHA is to verify system compliance with safety requirements

contained in system specifications and other applicable documents; identify previously unidentified hazards associated with

the subsystem interfaces and system functional faults; assess the risk associated with the total system design, including

software, and specifically of the subsystem interfaces; and recommend actions necessary to eliminate identified hazards and/or

control their associated risk to acceptable levels. The SHA may indicate the need for revised tailoring of some requirements

of this publication depending on the level of risk identified or the discovery of any previously unidentified hazards. This

analysis shall include a review of subsystem interrelationships to determine the following:

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A2.2.4.2.1. Compliance with specified safety design criteria.

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A2.2.4.2.2. Possible independent, dependent, and simultaneous hazardous events including system failures; failures of safety

devices; common cause failures and events; and system interactions that could create a hazard or result in an increase in mishap

risk.

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A2.2.4.2.3. Degradation in the safety of a subsystem or the total system from normal operation of another subsystem.

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A2.2.4.2.4. Design changes that affect subsystems.

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A2.2.4.2.5. Effects of reasonable human errors.

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A2.2.4.2.6. Potential contribution of hardware and software, including that which is developed by other payload projects and

other sources or commercial off-the-shelf hardware or software, events, faults, and occurrences such as improper timing on

the safety of the system.

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A2.2.4.2.7. That the safety design criteria in the hardware, software, and facilities specifications have been satisfied.

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A2.2.4.2.8. That the method of implementation of the hardware, software, and facilities design requirements and corrective

actions has not impaired or degraded the safety of the system nor has introduced any new hazards.

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A2.2.4.2.9. SHA Analysis Techniques. If no specific analysis techniques are directed or if the payload project recommends

that a different technique than that specified by the PSWG and Range Safety should be used, the payload project shall obtain

approval of techniques to be used before performing the analysis. The SHA may be combined with and/or performed using

similar techniques to those used for the SSHA.

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A2.2.4.2.10. SHA Software:

A2.2.4.2.10.1. Software used to control safety critical computer system functions shall be developed in accordance with

Volume 3, Chapter 16 of this publication.

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A2.2.4.2.10.2. Payload projects shall identify all safety critical computer system functions in accordance with Volume 3,

Chapter 16 and develop a SHA for each.

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A2.2.4.2.10.3. Software shall be put under formal configuration control of a Software Configuration Control Board (SCCB)

in accordance with Volume 3, Chapter 16 as soon as a baseline is established. This will ensure that hardware/software changes

do not conflict with or introduce potential safety hazards due to hardware/software incompatibilities.

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A2.2.4.2.10.4. Problems identified that require the reaction of the software developer shall be reported to Range Safety in

time to support the ongoing phase of the software development process.

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A2.2.4.2.11. Updating the SHA. The payload project shall update the SHA as a result of any system design changes, including

software design changes that affect system safety.

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A2.2.4.2.12. SHA Submittal. A draft SHA shall be submitted with or in Safety Data Package II (updated MSPSP) no later

than 30 days prior to project’s mission CDR and the finalized SHA shall be submitted with or included in the Safety Data

Package III (final MSPSP) (See Volume 3, Attachment A1).

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A2.2.4.3. Operating and Support Hazard Analyses. The payload project shall perform and document an operating and

support hazard analysis (O&SHA) to examine procedurally controlled activities. The purpose of the O&SHA is to evaluate

activities for hazards or risks introduced into the system by operational and support procedures and to evaluate adequacy of

operational and support procedures used to eliminate, control, or abate identified hazards or risks. The O&SHA identifies and

evaluates hazards resulting from the implementation of operations or tasks performed by persons, considering the following

criteria: the planned system configuration and/or state at each phase of activity; the facility interfaces; the planned

environments or the ranges thereof; the supporting tools or other equipment, including software controlled automatic test

equipment, specified for use; operational and/or task sequence, concurrent task effects and limitations; biotechnological

factors, regulatory or contractually specified personnel safety and health requirements; and the potential for unplanned events

including hazards introduced by human errors. The human shall be considered an element of the total system, receiving both

inputs and initiating outputs during the conduct of this analysis. The O&SHA shall identify the safety and occupational health

requirements, or alternatives needed to eliminate, or control identified hazards or to reduce the associated risk to a level that

is acceptable under either regulatory or local specified criteria. The O&SHA may indicate the need for revised tailoring of

some requirements of this publication depending on the level of risk identified or the discovery of any previously unidentified

hazards. Hazards identified shall be documented on the NF 1825 NASA Payload Safety Hazard Report found on the NASA

Payload Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety or an equivalent form that contains all

information required on NF 1825. The analysis shall identify the following:

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A1.2.2.4.3.1. Activities that occur under hazardous conditions, their time periods, and the actions required to minimize risk

during these activities and time periods.

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A2.2.4.3.2. Changes needed in functional or design requirements for system hardware and software, facilities, tooling, or

support and test equipment to eliminate or control hazards or reduce associated risks.

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A2.2.4.3.3. Requirements for safety devices and equipment, including personnel safety and life support equipment.

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A2.2.4.3.4. Warnings, cautions, and special emergency procedures such as egress, rescue, escape, render safe, explosive

ordnance disposal, and back out, including those necessitated by failure of a computer software-controlled operation to produce

the expected and required safe result or indication.

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A2.2.4.3.5. Requirements for packaging, handling, storage, transportation, maintenance, and disposal of hazardous materials.

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A2.2.4.3.6. Requirements for safety training and personnel certification.

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A2.2.4.3.7. Effects of non-developmental hardware and software across the interface with other system components or

subsystems.

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A2.2.4.3.8. Potentially hazardous system states under operator control.

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A2.2.4.3.9. Assessment of Procedures. The O&SHA shall document system safety assessment of procedures involved in

system production, deployment, installation, assembly, test, operation, maintenance, servicing, transportation, storage,

modification, demilitarization, and disposal.

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A2.2.4.3.10. O&SHA Analysis Techniques. If no specific analysis techniques are directed or if the payload project

recommends that a different technique other than that specified by the PSWG and Range Safety should be used, the Range

User shall obtain approval of techniques to be used before performing the analysis.

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A2.2.4.3.11. Updating the O&SHA. The payload project shall update the O&SHA as a result of any system design or

operational changes.

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A2.2.4.3.12. O&SHA Submittal. A draft O&SHA shall be submitted as part of Safety Data Package III at least 90 days

prior to the payload shipment to the processing site and finalized as part of Safety Review III (See Attachment A2.1 of Volume

6).

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A2.2.5. Task 5: Perform and Document an Overall Payload Project Safety Assessment. The payload project shall

perform and document an overall Safety Assessment. The purpose of this task is to perform and document a comprehensive

evaluation of the mishap risk being assumed before payload processing or testing with considering all potential hazards. The

Safety Assessment shall be developed using data from the hazard analyses required in Task 4 (A2.2.4) and data packages

required by this publication and NPR 8715.7, and shall summarize the following information:

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A2.2.5.1. The safety criteria and methodology used to classify and rank hazards, plus any assumptions on which the criteria

or methodologies were based or derived including the definition of acceptable risk as specified by the PSWG and Range

Safety.

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A2.2.5.2. The results of analyses performed to identify hazards inherent in the system, including those hazards that still have

a residual risk and the actions that have been taken to reduce the associated risk to a level specified as acceptable by the PSWG

and Range Safety. See Table 3.2 of this volume.

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A2.2.5.3. The results of the safety program efforts, including a list of all significant hazards along with specific safety

recommendations or precautions required to ensure safety of personnel, property, or the environment. The list shall be

categorized as to whether or not the risks may be expected under normal or abnormal operating conditions.

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A2.2.5.4. Conclusion with the payload project safety manager and the payload Project Manager signed statement that all

identified hazards have been eliminated or their associated risks controlled to levels acceptable to the PSWG and Range Safety

and that the payload and its systems are ready to test and ready for payload processing.

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A2.2.5.5. Recommendations applicable to hazards at the interface of payload project systems with other systems, as required.

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A2.2.5.6. A formal request for approval to conduct operations at the payload processing facility and the range.

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ATTACHMENT 3 SUBMITTING NONCOMPLIANCE REQUESTS

INTRODUCTION

A3.1.1. Purpose. Equivalent levels of safety (ELS) and waivers are used when payload projects cannot meet the requirements

of this publication.

A3.1.2. Content. This attachment describes the noncompliance categories and the process for submitting ELSs and waivers.

A3.1.3. Applicability:

A3.1.3.1. The noncompliance process is applicable to all projects and is provided as the waiver process in NPR 8715.7 for

NASA waivers and for AF Range Safety noncompliances follow USSF 91-710. The PSWG will provide guidance on these

noncompliance and waiver processes.

A3.1.3.3. The flight plan approval process does not fall within the intent of this attachment except when it involves launch

vehicle and/or payload hardware.

A3.1.4. Grandfathering Criteria. Previously approved systems with or without granted ELSs and waivers are required to

be resubmitted for review and approval by the project specific PSWG and Range Safety.

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A3.1.5. Noncompliance Categories. Noncompliances shall be processed and approved by NASA in accordance with NPR

8715.7 and this publication. In addition, noncompliances impacting Space Force Range Safety responsibilities shall be

submitted to the PSWG to be processed and approved by the Space Force in accordance with the following:

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A3.1.5.1. Public Safety. Public safety noncompliance deals with safety requirements involving risks to the public, including

foreign countries, their personnel, and/or their resources.

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A3.1.5.2. Launch Area Safety. Launch area safety noncompliances deal with safety requirements involving risks that are

limited to personnel and/or resources on AFSPC ranges, including CCSFS and VSFB and may be extended to KSC. Launch

area safety involves multiple licensed users, government tenants, or USAF squadrons.

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A3.1.5.3. Launch Complex Safety. Launch complex safety noncompliances deal with safety requirements involving risk

that is limited to the personnel and/or resources under the control of a single licensed user, full time government tenant

organization, or USAF squadron/detachment (control authority). Launch complex safety is limited to risks confined to a

physical space for which the single control authority is responsible.

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A3.1.6. Effectivity of Noncompliances: Duration of the noncompliance (if approved) shall be stated on the noncompliance

request.

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A3.1.7. Conditions for Issuance of ELSs and Waivers:

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A3.1.7.1. Hazard Mitigation. All reasonable steps shall be taken to meet the intent of the publication requirements and

mitigate associated hazards to acceptable levels, including design and operational methods.

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A3.1.8. Risk-Cost Benefit Analysis: When required, a risk-cost benefit analysis, based on the criteria defined in AFSPCMAN

91-710, Volume 1, Chapter 3, Table 3.1 and Chapter 3, Table 3.2 of this volume, may be submitted to Range Safety.

SUBMITTING NONCOMPLIANCE REQUESTS

A3.2.1. Format. ELSs proposed during project specific NASA Payload Safety Requirements tailoring do not require the

submittal of NF 1826 NASA Payload Safety Post-Tailoring Equivalent Level of Safety (ELS) Request (See Attachment A1.1

of this Volume). Payload projects shall submit noncompliances to the PSWG in writing using the approved NASA

noncompliance forms, NF 1826 NASA Payload Safety Post-Tailoring Equivalent Level of Safety (ELS) Request, or an

equivalent form, that contains all information required on NF 1826, and NF 1827 NASA Payload Safety Waiver Request.

Additionally, the payload project shall submit the appropriate Space Force noncompliance relief request for all

noncompliances to USSF 91-710 impacting Space Force Ranges. These forms are found on the Payload Safety Program

website at https://kscsma.ksc.nasa.gov/PayloadSafety under the "Payload Safety Forms" button.

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A3.2.3. Process: The PSWG in conjunction with Range Safety can provide guidance in the noncompliance submittal process.

NASA noncompliance process is found in NPR 8715.7 and this publication. The Space Force noncompliance process is as

follows:

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A3.2.3.1. Requests for ELS s and waivers shall be submitted through the PSWG to the appropriate local safety authority.

ELSs or waivers impacting USSF Range Safety shall be submitted through the PSWG to the office of the appropriate Space

Wing Chief of Safety as early as they are known to be necessary.

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A3.2.3.2. Public safety ELSs and waivers such as those including flight plan approval, FTS design, and toxic propellant

storage normally require extensive risk analyses that can take one to two years to perform; therefore, these ELSs and waivers

shall be initiated during the planning phase and be closed out by Range Safety (ELSs) or the Space Wing Commander (waivers)

approval or design change before manufacture of the booster, spacecraft, FTS, or other system in question.

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A3.2.3.3. Launch area safety and launch complex safety ELSs and waivers normally require two weeks to two months to

process depending on the nature of the noncompliance and the requested effectivity.

A3.2.3.4. The Space Wing shall coordinate all noncompliance requests with affected agencies, as appropriate. A coordinated

review and resolution of requests for relief from common AF-FAA launch safety requirements shall be per procedures

developed between the AFSPC and the FAA. The Space Wing shall also coordinate all noncompliance requests with the

affected Range User.

A3.2.4. Approvals: The PSWG in conjunction with Range Safety can provide guidance on the noncompliance approval

process. NASA noncompliances shall be approved in accordance with NPR 8715.7. The Space Force s approvals are as

follows:

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A3.2.4.1. Programs launching from only the ER or WR require only the appropriate SLD30/SE or SLD45/SE approvals.

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A3.2.4.2. Programs launching from both ranges require approvals from SLD30/SE or SLD45/SE.

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A3.2.4.3. Waivers dealing with public safety shall be approved by the SLD Commanders.

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A3.2.4.4. Waivers other than public safety shall be approved by the Chiefs of Safety or their designated representatives.

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A3.2.4.5. ELSs shall be approved by appropriate SLD30/SE or SLD45/SE Chiefs of Safety or their designated representatives.

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ATTACHMENT 4 ACCEPTABLE RISK CRITERIA

INTRODUCTION

Per NPR 7120.5, NASA Space Flight Program and Project Management Processes and Requirements, the payload project will

implement the NASA continuous risk management process and develop a stand-alone Risk Management Plan that includes

the content required by NPR 8000.4, Risk Management Procedural Requirements. The payload project shall follow KSC’s

Safety and Mission Assurance Launch Services Division Risk Management System for risks impacting NASA KSC or KSC

contracted facilities and shall apply USSF 91-710 for risks impacting Space Force Ranges.

Note: See Volume 1 Chapter 3 of this document and NASA Payload Safety Hazard Report NF 1825 for additional guidance.

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ATTACHMENT 5 PAYLOAD SAFETY INTRODUCTION BRIEFING

INTRODUCTION

A5.1.1. Purpose. To identify the information to be presented at the Payload Safety Introduction Briefing (PSIB).

A5.1.2. Content. This attachment lists and describes the information to be presented at the PSIB.

PAYLOAD SAFETY INTRODUCTION BRIEFING (PSIB)

A5.2.1. The Payload Safety Introduction Briefing (PSIB) is normally the first formal meeting of the PSWG. PSIB presenters

typically include the payload project, PSWG Chairperson, Range Safety, Launch Site Integration Manager (or equivalent),

and other members of the PSWG as needed. The payload project is expected to provide the following information to a level

of detail that is based on information availability and is consistent with the complexity of the mission, the maturity of the

conceptual design, and the launch vehicle and launch site location.

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A5.2.1.1. Overview of the System Safety Plan as defined by the project's DRAFT System Safety Plan (see Volume 3,

paragraph 4.1.1.).

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A5.2.1.2. Identification of organizational roles and responsibilities.

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A5.2.1.3. Description of payload, instruments, and anticipated ground support equipment.

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A5.2.1.4. Description of the flight path in terms of azimuth and trajectory. Identification and description of planned return-

to-earth payload recovery or sample return activities and support if applicable.

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A5.2.1.5. Identification of potential mission-unique ground support equipment required for pad operations.

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A5.2.1.6. Identification and a preliminary assessment of potential hazards associated with payload and payload to launch

vehicle integration, multiple payloads from the same or other projects, and ground systems documented in a preliminary hazard

list.

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A5.2.1.7. Overview of the project's requirements tailoring process and planned activities for tailoring NASA-STD-8719.24

Annex, identifying any known critical concerns to be addressed during the tailoring process.

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A5.2.1.8. Identification of non-applicable chapters and sections using the NASA-STD-8719.24 Annex Table of Contents,

Volume 3 and Volume 6, as they relate to payload systems, instruments, operations and hazards known to date.

Note: A NASA-STD-8719.24 Annex Table of Contents Form is provided on Payload Safety Program website at

https://kscsma.ksc.nasa.gov/PayloadSafety under the “Forms” button.

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A5.2.1.9. A list of any known tailoring issues, previously approved noncompliances (i.e., waivers, ELS), and previously

approved alternative approaches.

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A5.2.1.10. Any potential hazardous failure modes, failure probability, and performance characteristics of the payload during

ground operations.

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A5.2.1.11. Identification of planned studies and analyses that support safety requirements, including scheduled completion.

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A5.2.1.12. Description of processing flow and anticipated schedule, integrated with major project milestones.

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A5.2.1.13. Identification of facility requirements, including launch complex, hazardous assembly and checkout areas, and

ordnance and propellant storage requirements.

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A5.2.1.14. Identification and discussion of potential contingency operations, for example, depressurization, propellant offload,

and accessibility after fairing installation.

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A5.2.1.15. Recommendations for future safety Technical Interchange Meetings, reviews, working groups, subject matter

expert support, resolution of unmet requirements, Design Reviews, and other topics as deemed necessary.

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A5.2.2. The PSWG Chairperson, in conjunction with Range Safety, presents an overview of the payload safety review process

including PSWG membership activities, safety review milestones, and deliverables. Additionally, the payload project is

reminded to follow NPR 8621.1 NASA Procedural Requirements for Mishap and Close Call Reporting, Investigating, and

Recordkeeping for mishaps, close calls and contingencies.

Note: Mishap and close call reporting, investigating, and record keeping as well as contingency preparedness and planning

fall under the NASA Program Manager for Mishap Investigations and the various programs and projects in accordance

with NPR 8621.1 and are not under the purview of the NASA Payload Safety Program.

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A5.2.3. The Launch Site Integration Manager (or equivalent), as the payload project’s liaison at the launch site, typically

provides an overview covering their coordination efforts and support for the payload at the processing facility.

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INTRODUCTION

General

1.1.1. All NASA Payload projects are subject to the requirements of this volume to ensure safety by design, testing, inspection,

and hazard analysis.

Organization of the Volume

1.2.1. Main Chapters. The main chapters of this volume include common requirements for all payloads. Appendices include

additional requirements to supplement the main chapters.

1.2.2. Open Text. The open text contains the actual mandatory performance-based requirements. The only tailoring expected

for these requirements would be the deletion of non-applicable requirements. For example, solid rocket motor performance

requirements would be deleted for payloads that do not use solid rocket motors.

1.2.3. Bordered Paragraphs:

1.2.3.1. Bordered paragraphs are non-mandatory and are used to identify some of the potential detailed technical solutions

that meet the performance requirements. In addition, the bordered paragraphs contain lessons learned from previous

applications of the performance requirement, where a certain design may have been found successful, or have been tried and

failed to meet the requirement. These technical solutions are provided for the following reasons:

1.2.3.1.1. To aid the tailoring process between the PSWG and payload projects in evaluating a potential system against all the

performance requirements.

1.2.3.1.2. To aid the PSWG and payload projects in implementing lessons learned.

1.2.3.1.3. To provide benchmarks that demonstrate what the PSWG in conjunction with Range Safety considers an acceptable

technical solution/ implementation of the performance requirement and to help convey the level of safety the performance

requirement is intended to achieve.

1.2.3.2. The technical solutions in the bordered paragraphs may be adopted into the tailored version of the requirements for a

specific program when the payload project intends to use that solution to meet the performance requirement. At this point,

they become mandatory requirements to obtain PSWG and Range Safety approval. This process is done to:

1.2.3.2.1. Provide an appropriate level of detail necessary for contractual efforts and to promote efficiency in the design

process.

1.2.3.2.2. Avoid contractual misunderstandings that experience has shown often occur if an appropriate level of detail is not

agreed to. The level of detail in the bordered paragraphs is necessary to avoid costly out-of-scope contractual changes and to

prevent inadvertently overlooking a critical technical requirement.

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1.2.3.3. The payload project always has the option to propose alternatives to the bordered paragraph solutions. Payload project

proposed solutions shall be evaluated against requirements in this manual. Payload project proposed alternative solutions shall

achieve an Equivalent Level of Safety and be approved by the PSWG and Range Safety. After meeting these two

requirements, the Range User proposed solutions become part of the tailored requirements for that specific program.

1.2.3.4. The PSWG and Range Safety shall determine whether payload project proposed detailed technical solutions meet the

intent of the requirements contained in this publication.

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RESPONSIBILITIES AND AUTHORITIES

Payload Safety Working Group (PSWG)

2.1.1. A unique PSWG is established for each NASA payload project. The PSWG consists of safety engineers and personnel

from the NASA payload project (NASA and contractor), launch services provider contractor organization (NASA Kennedy

Space Center Launch Services SMA for projects using NASA Launch Services Program), launch site range safety, the launch

services provider contractor organization, the payload processing facility safety representative, the payload or sample recovery

organization (as needed), subject matter experts and others as needed, and with participation from the Launch Site Integration

Manager (LSIM) as required. The PSWG proactively works with the project to identify potential hazards and safety issues

and advises on strategies for early abatement, mitigation, or resolution. The PSWG is responsible for the review and approval

of the safety deliverables required by this document. Specific responsibilities of the PSWG include review and approval of

documents such as project specific tailored NASA Payload Safety Requirements document, the Safety Data Packages

(SDPs)/Missile System Prelaunch Safety Packages (MSPSPs), System Safety Plans (SSPs), test plans, test reports, and other

documents as specified in this standard. PSWG activities typically conclude with the signing of the Certificate of Payload

Safety Compliance. If there are any open action items, the payload project will provide the appropriate local safety authorities

and mission officials with updates and complete the Safety Verification Tracking Log (SVTL). Test and operational

procedures are approved by the local safety authority responsible for ensuring safety in the area where the test or operation is

to take place.

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2.1.2. During the review and approval process, the PSWG in coordination with Range Safety and the payload project shall

ensure timely coordination with other authorities as appropriate. Other authorities include, but are not limited to, Radiation

Protection Officer (RPO)/Radiation Safety Officer (RSO), Occupational Health, Bioenvironmental Engineering, Civil

Engineering, Environmental Planning, Explosive Ordnance Disposal, and the Fire Department.

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Payload Project Responsibilities

Payload projects are responsible for establishing and maintaining a system safety plan in accordance with Volume 1,

Attachment A1.2 of this publication, and the design, inspection, and testing of all hazardous and safety critical payloads and

payload-related ground support equipment, systems, subsystems, and materials to be used at the payload processing facility

and launch site area in accordance with the requirements of this volume and NPR 8715.7. These responsibilities include the

following:

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2.2.1. Timely submission of an SSP.

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2.2.2. Timely submission of hazard analyses.

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2.2.3. Timely submission of all required SDPs/MSPSPs including Hazard Reports.

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2.2.4. Timely submission of all SDPs associated Test Plans and Test Reports.

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2.2.5. Coordinating with and supporting local safety authorities in carrying out tasks necessary for approval of design,

inspection, and testing.

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2.2.6. Timely submission of safety data deliverables per NPR 8715.7 and this document.

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GENERAL DESIGN POLICY

General

3.1.1. All systems shall be designed to tolerate a minimum number of credible failures, based on the degree of fault tolerance

required.

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3.1.2. The number of designed inhibits required to prevent an overall system failure or mishap is based on the failure or

mishap result. Specific inhibit requirements are addressed in the design criteria for each of the systems addressed in this

volume.

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It is the payload project’s responsibility (with support as needed from the launch services provider) to provide

relevant analysis or data to the PSWG to characterize system failure or mishap results when determining the proper

number of inhibits.

Systems Without Specific Design Criteria

Those systems that do not have specific design criteria or systems not addressed in this volume shall be designed to the

following general criteria:

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3.2.1. If a system failure may lead to a catastrophic hazard, the system shall have no less than three inhibits (dual failure

tolerant).

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3.2.2. If a system failure may lead to a critical hazard, the system shall have no less than two inhibits (single failure tolerant).

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3.2.3. If a system failure may lead to a marginal hazard, the system shall have a single inhibit (no failure tolerant).

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3.2.5. Systems shall be able to be brought to a safe state with the loss of an inhibit.

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3.2.6. Independent and Verifiable Inhibits.

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3.2.6.1. Each design inhibit shall be independent of any other inhibit (i.e., loss or removal of one inhibit shall not result in the

loss or removal of any other inhibit). Additionally, control of inhibits shall also be independent.

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3.2.6.2. Each design inhibit shall be verifiable after installation or through a process of pre-installation testing and

implementation of written procedures that ensure the integrity of the inhibit during and after installation.

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3.2.6.3 Two or more design inhibits that protect against a specific failure shall have design and/or implementation differences

between them to protect against a common cause failure of the inhibits. Inhibits are not considered independent if a single

failure can negate more than one inhibit.

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3.2.7. Design inhibits shall consist of electrical and/or mechanical hardware.

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3.2.8. Operator controls shall not be considered a design inhibit. Operator controls are considered a control of an inhibit. This

includes software controls.

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DOCUMENTATION REQUIREMENTS

System Safety Plan and Hazard Analyses

4.1.1. Documentation requirements and submittal timeframes are provided in NPR 8715.7 and this publication. A preliminary

System Safety Plan (SSP) shall be developed in accordance with Volume 1, Attachment A1.2 of this publication and shall be

provided at the Payload Safety Introduction Briefing (PSIB). Additionally, a preliminary hazard list, a preliminary list of

known tailoring issues, a Ground Operations Flow Overview, and a list of non-applicable chapters and sections from the Table

of Contents, Volume 3 and 6 sections (see Volume 1, Attachment A1.5) shall be provided at the PSIB.

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4.1.2. The final SSP shall be developed in accordance with Volume 1, Attachment A1.2 of this publication and submitted to

the PSWG no later than 30 days prior to the project’s mission PDR timeframe.

Note: When necessary, changes to the final SSP may be made in coordination with the PSWG and Range Safety.

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4.1.3. Preliminary Hazard analyses with Hazard Reports developed to date shall be developed and submitted to the PSWG

no later than 30 days prior to the project’s mission PDR timeframe for review and approval in accordance with Volume 1,

Attachment A1.2 of this publication.

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4.1.3.2. Final plan for resolution of all hazards identified in the hazard analyses shall be submitted to the PSWG no later than

90 days prior to payload shipment to the processing site for review and approval. All open hazard control verifications still

requiring verifications shall be listed on a Safety Verification Tracking Log or equivalent (see Payload Safety Program website

at https://kscsma.ksc.nasa.gov/PayloadSafety under “Payload Safety Forms”) until closed. After Safety Review III, Safety

Verification Tracking Logs (SVTLs) shall be updated at least weekly and provided with the related Hazard Reports to the

impacted local safety authorities.

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4.1.3.3. SSPs and hazard analyses shall comply with this publication and the intent of MIL-STD-882, Department of Defense

Standard Practice for System Safety, data requirements or commercial equivalent for commercial FAA-licensed programs.

Hazard Reports shall be prepared on NF 1825 NASA Payload Safety Hazard Report Form found on the Payload Safety

Program’s website at https://kscsma.ksc.nasa.gov/PayloadSafety under “Payload Safety Forms” or an equivalent form that

contains all information required on NF 1825.

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Safety Data Package (SDP)/MISSILE SYSTEM PRELAUNCH SAFETY PACKAGE

(MSPSP)

4.2.1. SDP Submittal, Review, and Approval Process:

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4.2.1.1. Payload projects shall submit an SDP for each project to the PSWG in accordance with NPR 8715.7 and this

publication.

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The NASA SDP is equivalent to the USSF 91-710 Missile System Prelaunch Safety Package (MSPSP).

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4.2.2. SDP Preparation. An SDP shall be developed in three phases, SDP I, SDP II, and SDP III corresponding to Safety

Review I, II, and III. The level of technical detail for each phase shall be commensurate with the level of project detail

available. SDPs shall be developed in accordance with Attachment A1 of this volume.

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SDP Associated Test Plans and Test Results

4.3.1. Test plans shall be identified and summarized in the SDP. Plans for any tests requested for review by the PSWG and

Range Safety shall be submitted to the PSWG before the intended use and allowing adequate time for review and approval.

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4.3.2. Test plans submitted for approval to the PSWG and Range Safety are required to be approved before test performance.

Test plans, test reports and test operating procedures for hazardous operations must be approved by the local safety authority

responsible for the area where the tests are to take place. Disapproved test plans shall be resubmitted.

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4.3.3. Test reports shall be submitted at least 45 calendar days before intended system use.

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4.3.4. PSWG, Range Safety, and appropriate local safety authorities shall review, comment, and approve test reports within

10 calendar days of receipt. Disapproved test reports shall be resubmitted. An approved test report is required before system

use.

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Nondestructive Examination Plans

4.4.1. Nondestructive examination (NDE) inspections for fracture control shall be performed in accordance with NASA-STD-

5009 Nondestructive Evaluation Requirements for Fracture Critical Metallic Components and meet the intent of MIL-HDBK-

6870 Inspection Program Requirements Nondestructive for Aircraft and Missile materials and Parts. Unless otherwise

specified in a separate part of this document that addresses a particular class of system or equipment, an NDE plan shall

include the following:

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4.4.1.1. NDE technique and acceptance criteria to be used on each single failure point (SFP) component or SFP weld after

initial proof and periodic load tests. NDE shall be performed in accordance with procedures and by qualified and certified

preapproved personnel in accordance with written practices meeting the requirements contained in American Society for

Nondestructive Testing (ASNT) SNT-TC-1A Recommended Practices for Personnel Qualifications and Certification in

Nondestructive Testing.

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4.4.1.2. Detailed engineering rationale for each technique and acceptance criteria.

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Detailed engineering rationale may include manufacturer stated requirements/recommendations or recognized industry

standards such as ANSI and ASME.

4.4.1.3. A determination of whether the equipment is dedicated to only one function or whether it is multipurpose.

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4.4.1.4. The environment and/or conditions under which the equipment will be used and stored.

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4.4.1.5. The existence of any SFP component and weld materials susceptible to stress corrosion.

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4.4.1.6. Corrosion protection and maintenance plans.

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4.4.2. Unless otherwise specified in a separate part of this document that addresses a particular class of system or equipment,

the NDE plan shall be submitted to the PSWG and Range Safety for review and approval as soon as developed and no later

than 30 days prior to the project Safety Review I meeting at project’s mission PDR, unless otherwise agreed to by the PSWG.

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PAD SAFETY CONSOLE DESIGN

Pad safety console design requirements are specified in AFSPCMAN 91-710, Volume 3, Chapter 5, Pad Safety Console.

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MATERIAL HANDLING EQUIPMENT, CRANES, HOIST AND PERSONNEL

WORK PLATFORMS.

Overview

6.1.1. This chapter is divided into three major types of equipment: Material Handling Equipment (MHE) , cranes and hoists,

and Personnel Work Platforms. If the payload project is providing a crane or hoist for payload processing use, then

AFSPCMAN 91-710, Section 6.2 shall be tailored into this document, as applicable.

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6.1.2. MHE is comprised of below-the-hook lifting devices (BTHLD), handling structures, support structures, slings, load

positioning (e.g., Hydra Set ®) and load indicating devices (LID), lifting assemblies, and rigging hardware. Slings, BTHLDs,

lifting assemblies, rigging hardware, and LIDs are governed by industry standards (e.g., Occupational Safety and Health

Administration [OSHA], ASME). Handling structures, support structures, and LPDs are governed by accepted engineering

practices and requirements of this Chapter. Data requirements are provided in Attachment 2 of this volume. These

requirements are applicable to new or modified MHE. The requirements are also applicable to permanent or short-term use

MHE and apply whether the equipment is owned, rented, or leased by the government, contractors, or commercial operators.

Periodic/recurring test and inspection requirements are found in Volume 6, 6.1.8.

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6.1.3 Periodic load test intervals may be extended by no more than 90 days from the original lifting device expiration date

due to programmatic or institutional needs, subject to the center LDEM, PSWG and Range approval. To extend the periodic

load test interval, the following conditions shall be met: a. The payload project provides documented rationale to the

LDEM, PSWG and Range Safety, and b. The LDEM, PSWG and Range Safety determines there is no increase in risk.

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Material Handling Equipment (MHE)

The design and initial test requirements for MHE used at the payload processing facility and launch site area for handling

(lifting, supporting, or manipulating) critical and non-critical hardware are included below.

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6.2.1. MHE General Requirements:

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6.2.1.1. MHE Requirements Validation:

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6.2.1.1.1. The Range User shall validate the requirements by providing a Compliance Check List in accordance with

Attachment 1, A1.3.

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6.2.1.1.2. The payload project certifies the design is in accordance with the requirements, provides documentation verifying

compliance through Safety Data Package submittal or reference documents, and maintains all MHE under a documented

configuration management system. Operation, testing, inspection, and maintenance of slings shall be in accordance with

manufacturer recommendations, this standard, NASA-STD-8719.9, and OSHA.

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6.2.1.1.3. Supporting data for leased and/or commercial-off-the-shelf (COTS) equipment shall include the following

information:

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6.2.1.1.3.1. COTS name, description, model number, and part number.

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6.2.1.1.3.2. Rated capacity (allowable working load).

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6.2.1.1.3.3. Certifications of compliance with industry consensus standards from a Nationally Recognized Testing Laboratory

(NRTL), manufacturer, or other qualified organization.

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6.2.1.1.3.4. MHE shall have documented traceability of material, manufacturer, and acceptance testing to required codes and

standards (e.g., OSHA, ASME).

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6.2.1.1.3.5. Applicable operating and maintenance (O&M) information, data, and/or manuals.

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6.2.1.2. MHE Single Fault Tolerance:

6.2.1.2.1. Critical MHE shall be designed without single failure points (SFPs).

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6.2.1.2.2. Exceptions shall be identified, justified, and submitted to the PSWG for Range Safety and PSWG approval.

Supporting data shall include the following information: (See also Attachment 1, A1.2.5.6 of this volume.)

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6.2.1.2.2.1. A list of all identified SFPs.

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6.2.1.2.2.2. Risk assessment.

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6.2.1.2.2.3. Risk mitigation considerations and inhibits.

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6.2.1.2.2.4. A map of SFP locations (for example, weld map, system components).

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6.2.1.2.2.5. Inspection and NDE requirements.

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6.2.1.2.3. SFP components and welds shall be accessible for nondestructive inspection, maintenance, and repair.

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6.2.1.3. MHE Inspection and Test Requirements:

6.2.1.3.1. MHE Test Weights and Load Test Devices:

6.2.1.3.1.1. Load tests shall be conducted with certified weights and/or certified weight fixtures.

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6.2.1.3.1.2. These weights shall be identified and permanently and clearly marked with the total weight and owner or agency

identification number.

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An example of marking requirements for test weights can be found in KSC-DE-512-SM, Ground Systems

Development Standard

6.2.1.3.1.3. Reinforcing steel (rebar) shall not be used for lift points.

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6.2.1.3.1.4. Calibrated load devices such as dynamometers may be used to test slings and other lifting devices except cranes

and hoists.

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6.2.1.3.1.5. Requirements for Fabrication of New Test Weights and Weight Fixtures.

6.2.1.3.1.5.1. Weight fixtures shall be designed, and load tested in accordance with requirements contained in 6.2.3.1.

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6.2.1.3.1.5.2. Weight fixtures shall be designed so that the loaded fixture center of gravity is centered below the crane hook

for all required weight combinations.

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6.2.1.3.1.5.3. Lifting lugs shall be provided if required to enable handling of empty test weight fixtures.

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Table 6.1. Attachment Point Preferences.

A single crane hook attachment points on the fixture (e.g., a screw operated pin) is preferable to multiple attachment

points that require use of slings.

6.2.1.3.1.5.4. Weight interlocking features shall be provided on both the weight fixture and the weights to help prevent sliding

of weights and to help even stacking.

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6.2.1.3.1.5.5. Weight lifting lugs shall be proof tested to 125% of the total weight before initial weight use.

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6.2.1.3.2. MHE Non Destructive Evaluation (NDE):

6.2.1.3.2.1. NDE plans shall be developed for MHE used to handle critical systems and equipment and MHE containing SFPs.

Surface inspections and volumetric inspections shall be performed on all MHE per PSWG and Range Safety approved NDE

plan after load tests.

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6.2.1.3.2.2. The NDE plan shall include detailed methodology, acceptance criteria, frequency of inspection, and a clear

schematic showing the exact location of the items to be inspected. For details of the NDE plan, see 4.4 of this volume.

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6.2.1.3.2.3. NDE shall be performed by qualified and certified personnel in accordance with written practices meeting the

requirements contained in American Society for Nondestructive Testing (ASNT) SNT-TC-1A Recommended Practice for

Personnel Qualifications and Certification in Nondestructive Testing.

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6.2.1.4. MHE Marking and Tagging Requirements:

6.2.1.4.1. Marking Requirements. All equipment (new and modified) shall be permanently marked in accordance with

applicable ASME B30 series standards, codes, and standards and have a permanently attached identification tag with the

following information:

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6.2.1.4.1.1. Manufacturer.

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6.2.1.4.1.2. Part number.

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6.2.1.4.1.3. Serial number.

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6.2.1.4.1.4. Date of manufacture or initial acceptance.

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6.2.1.4.1.5. Rated capacity.

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6.2.1.4.1.6. Weights of the top assembly and separate subassemblies.

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6.2.1.4.1.7. Weight of bridge and trolley (cranes only).

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6.2.1.4.2. Tagging Requirements:

6.2.1.4.2.1. Systems/equipment requiring periodic testing shall be tagged and test data included in its data package.

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6.2.1.4.2.2. The tags shall be of durable material, preferably corrosion resistant metal, properly secured with corrosion and

abrasion resistant wire or string, and marked (stamped or etched) with the following minimum information:

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6.2.1.4.2.2.1. Part number, serial number, or other unique identifier (reference designator).

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6.2.1.4.2.2.2. Date of most recent certification/test.

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6.2.1.4.2.2.3. Test load.

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6.2.1.4.2.2.4. Date of next load test or certification as applicable.

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6.2.1.4.2.2.5. Date of most recent NDE (if applicable).

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6.2.1.4.2.2.6. Date of next NDE (if applicable).

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6.2.1.4.2.2.7. A quality assurance or quality control indication certifying the data on the tag.

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6.2.1.4.2.3. The tags shall be accessible for inspection.

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6.2.1.4.2.4. If a lifting assembly is disassembled for testing or inspection, each component and subassembly shall be

individually tagged with the reference designator; for example, removal and separate storage of a shackle bolt from the shackle

after the proof load.

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Load-bearing components not traceable to a load test will invalidate the load test of the whole assembly.

Lifting equipment that has the necessary design features, maintenance/inspection, and test intervals to lift critical loads will be

marked conspicuously so that the operator and assurance personnel can distinguish that the equipment (unless a permanent

part of lifting device) is qualified for critical lifts.

6.2.1.4.2.4.1. The PSWG and Range Safety will accept the tethering of the shackle pin to the associated shackle as a method

of validating the proofed assembly. This is a substitute to tagging the pin individually. The methods above apply for shackle/

shackle pin verification as a proofed assembly. Tethering requirements in accordance with paragraph 5.2.6, are always

applicable in the prevention of a dropped object hazard.

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6.2.1.5. All MHE designs shall include a center-of-gravity analysis to ensure that the MHE/GSE/Flight Hardware does not

tip, fall, slide, or allow any sudden load shift.

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6.2.2. Slings:

A sling is a flexible lifting assembly used between the load and hoisting device hook, including one or multiple lengths of wire

rope, synthetic fiber materials, or steel chains made into forms for handling loads. Slings sometimes incorporating hooks and

associated attachment rigging hardware such as shackles, D-rings, turnbuckles, and eyebolts used to lift, lower, and position a

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load. Common types of slings include wire rope slings, synthetic round slings, metal mesh slings, synthetic web slings, and chain

slings. Rigging hardware are components used to lift, lower, and position a load and are typically used in combination with slings

and below-the-hook lifting devices (BTHLD). Common types include shackles, links, rings, swivels, turnbuckles, eyebolts, hoist

rings, wire rope clips, wedge sockets, and rigging blocks. Although slings and BTHLDs may use rigging hardware as part of

their assembly, each of these three, slings, BTHLDs, and rigging hardware, follow this standard, NASA-STD-8719.9, and OSHA

(slings only), and is addressed by a different ASME B30 series standard (i.e., ASME B30.9 for Slings, ASME B30.20 for

BTHLDs, and ASME B30.26 for Rigging Hardware). A “structural sling” is a rigid or semi-rigid fixture used between the actual

object being lifted and the lifting device like lifting beams or spreader bars. “Structural slings” are considered a BTHLD per

ASME B30 series standards (ASME B30.20) (See 6.2.3 below).

6.2.2.1. Sling Design Standards and Requirements:

6.2.2.1.1. Slings shall be designed and manufactured in accordance with, NASA-STD-8719.9, American Society of

Mechanical Engineers (ASME) B30.9, Slings, and 29 CFR 1910.184, Slings. Sling design shall maintain the minimum design

factors listed in Table 6-1.

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6.2.2.1.2. Carbon steel or wrought iron chain slings shall not be used.

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6.2.2.1.3. Wire rope slings shall be formed with swaged or zinc-poured sockets or spliced eyes.

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6.2.2.1.4. Wire rope clips or knots shall not be used to form wire rope slings.

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6.2.2.1.5. All synthetic slings shall be designed with an ultimate factor of safety of 5 or higher.

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6.2.2.1.6. Natural fiber rope or natural fiber web slings shall not be used.

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6.2.2.1.7. Rotation resistant rope shall not be used for fabricating slings.

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6.2.2.2. Sling Inspection and Test Requirements:

6.2.2.2.1. Before their first operational use at the payload processing facility and launch site area, and following modifications

or repairs, slings and rigging hardware shall be inspected and Proof Load tested to 200% of their rated load in accordance V3,

Table 6.1. NDE shall be performed in accordance with paragraph 6.2.1.3.2. MHE NDE.

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6.2.2.2.2 For slings used to support critical operations, volumetric and surface NDE testing shall be performed on all sling

assembly SFP components, such as pins, bolts, shackles, and links after the proof load test IAW the PSWG and Range Safety

approved NDE plan in accordance with paragraph 4.4 of this volume.

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Note: Slings and rigging hardware designated as non-load test slings or rigging hardware by the lifting device owner’s qualified person

and approved as such by the PSWG, Range Safety, and the payload Center’s LDEM in accordance with NASA-STD-8719.9 are exempt

from periodic testing (see 6.1.3). Slings, rigging hardware, and BTHLDs may be designated as non-load test slings/rigging

hardware/BTHLDs due to considerations such as usage, inspection and testing history, and potential for test-induced damage, subject

to PSWG, Range Safety, and payload Center’s LDEM approval. Non-load test slings/rigging hardware/BTHLDs are not subject to

periodic load testing requirements.

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Table 6-1: Slings, Rigging Hardware, and BTHLDs Design Minimum Requirements

Equipment

Design Load

Safety Factor

Proof Load

Test Factor

Periodic Load

Test Factors

Alloy Steel Chain Slings

2.0

1.0

Wire Rope Slings

2.0

1.0

Metal Mesh Slings

2.0

1.0

Synthetic Web Slings

2.0

1.0

Linear Fiber Slings

2.0

1.0

Structural Slings and

BTHLDs

Lesser of 3 times yield

or 5 times ultimate

1.25

1.0

Rigging Hardware

(Shackles, D-rings,

Turnbuckles, Eye

Bolts, Lifting Lugs,

Safety Hoist Rings, etc.)

2.0

1.0

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Table 6-1: Slings, Rigging Hardware, and BTHLDs Design Minimum Requirements (Continued)

1. Design factor based on ultimate material strength, except for structural slings.

2. Unless otherwise specified by design, due to material characteristics, geometry, design factors, etc., but in any case, at least 125 percent of the slings rated capacity.

3. Based on manufacturer’s rated load. Not applicable to non-load test slings, rigging hardware, or BTHLDs.

4. Proof load test shall be performed only by manufacturer or an equivalent entity approved by the PSWG, Range Safety, and the payload Center’s LDEM. If the sling is fabricated of components from

different sources (COTS or unique in-house manufactured parts) the manufacturer is the entity that fabricates the entire sling.

• Note 1: Equivalent entity is an organization capable of testing in accordance with the manufacturer’s procedure, and with sufficient knowledge and experience with design and properties of the

lifting device in question to understand when a test might be harmful or otherwise inappropriate for that lifting device, and knowledgeable of required points of inspection.

• Note 2: Periodic load test shall be accomplished within 1 year prior to use unless sling, rigging hardware, or BTHLD is designated as a non-load test sling, rigging hardware, or BTHLD. Safety

factor is defined as the ratio of a load that predicts a failure to a rated load. A 3:1 safety factor against the worst case failure mode that will result in local yielding is acceptable.

5. Shackles, D-rings, turnbuckles, eye bolts, lifting lugs , safety hoist rings, etc. are considered rigging hardware are typically used with slings and BTHLDs, and may be tested as part of the sling assembly,

individually, or both, as dictated by worst case stress and stability considerations per NASA-STD-8719.9, Lifting Standard

6.2.2.2.3 Synthetic round slings with internal cores shall be inspected prior to first use at the payload processing facility and

launch site area to detect damaged internal core (e.g., hand-over-hand tactile inspection; fiber-optic light transmission) that

may not be evident from visual inspection of the external surface.

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6.2.3. Below-the-Hook Lifting Devices (BTHLDs):

A BTHLD are all structural and mechanical lifting devices and equipment, except for slings, LPDs, and load cells,

used to connect a crane/hoist hook and a load being lifted, including lifting beams (and arms) and attachment

hardware such as bolts and pins (lifting assemblies). See 6.2.2 above for slings and rigging hardware requirements.

Standards for BTHLDs are covered by ASME B30.20, Below-the Hook Lifting Devices, but the device may contain

components such as slings, hooks, and rigging hardware addressed by other ASME B30 series standards (Safety

Standard for Cableways, Cranes, Derricks, Hoist, Hooks, Jacks, and Slings) or other standards.

6.2.3.1. BTHLD Design Standards and Requirements:

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6.2.3.1.1. BTHLDs shall be designed by a structural engineer and manufactured to the specified rated loads and load geometry

of Design Category B (with a minimum yield safety factor of 3) in accordance with ASME BTH-1, Design of Below-the-

Hook Lifting Devices, and ASME B30.20. A structural analysis that qualifies the unit for 125 percent initial Proof Load test,

and an NDE plan, shall be submitted to the PSWG, Range Safety, and the LDEM for review and approval. See Table 6-1 for

Proof Load Test Factors.

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6.2.3.1.2. Material used in the construction of BTHLDs shall exhibit a ductile failure mode (for example, ultimate strain not

less than 20 percent elongation). The intent is to have advanced warning of an upcoming failure via visually detectable

deformation of structural components.

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6.2.3.2. BTHLD Inspection and Test Requirements:

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6.2.3.2.1. Before their first operational use by the project at the payload processing facility and launch site area and following

modifications or repairs, BTHLDs shall be inspected and Proof Load tested to 125% of the rated load in accordance with

ASME B30.20 methodology and the PSWG and Range Safety approved NDE plan. The rated load shall not exceed 80% of

the actual test load. If the BTHLD contains components such as slings and shackles, then these components shall be Proof

Load tested individually to their respective proof load levels (200% of the rated load for slings and shackles) and the whole

assembly then Proof Load tested to 125% of the rated load.

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6.2.3.2.2. For BTHLDs used to support critical operations, volumetric and surface NDE shall be performed on all SFP

components and welds after the initial Proof Load test IAW a PSWG and Range Safety approved NDE plan. See paragraph

6.2.1.3.2. Material Handling Equipment Non Destructive Examination requirements.

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6.2.3.2.3. A BTHLD Periodic Load test shall be performed in accordance with V6, 6.1.8.2.

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6.2.3.2.4. BTHLDs are the structural, mechanical, and electrical components used to lift, support, and position a load.

Common BTHLDs include spreader bars, beam clamps, barrel lifters, and vacuum lifts and the associated slings, hooks, and

other rigging hardware. Some BTHLDs are referred to as structural slings. While slings and rigging may be part of a BTHLD,

they are not, by themselves, considered BTHLDs. With the exception of slings, load leveling devices, e.g., Hydra Sets, and

load cells, all structural and mechanical lifting devices and equipment used to connect a crane/hoist hook and a load being

lifted are BTHLDs, including lifting beams (and arms) and attachment hardware like bolts and pins. See 6.2.2 above for slings

and rigging hardware requirements.

6.2.3.2.5 When BTHLDs are composed of more than one lifting device or rigging hardware component, the components

shall be tested as an assembly, individually, or both, as dictated by worst case stress considerations. When testing as an

assembly, the load test value shall be based upon the rated load for the assembly.

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When BTHLDs are composed of more than one lifting device or rigging hardware component, the components

shall be tested as an assembly, individually, or both, as dictated by worst case stress considerations. When testing

as an assembly, the load test value shall be based upon the rated load for the assembly.

When testing as individual components, rigging hardware periodic test intervals may be in accordance with the

rigging hardware requirements of section 6.2.2.2, and individual BTHLDs and rigging hardware component load

test values may be based upon the component rated load within the assembly rather than the individual component

rated load.

6.2.4. Handling Structures:

Handling structures are those structures used to handle and manipulate hardware or equipment, such as spin

tables, equipment racks, and rotating devices.

6.2.4.1. Handling Structure Design Standards and Requirements:

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6.2.4.1.1. Handling structures shall be designed with a yield factor of safety of 3 based on rated loads.

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6.2.4.1.2. Handling structures whose failure would not result or propagate into a catastrophic event may be designed to a yield

factor of safety of 2 based on limit loads.

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6.2.4.1.3. Handling structures shall be designed to accommodate the worst case seismic load as specified by that location’s

building code and approving authorities. Handling structures at the WR shall be designed to accommodate the worst case

seismic load in accordance with Chapter 17.

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6.2.4.1.4. Material (including fittings and attachment hardware) used in the construction of handling structures shall exhibit

a ductile failure mode (ultimate strain not less than 20 percent elongation). The intent is to have advanced warning of an

upcoming failure via visually detectable plastic deformation of structural components. Exceptions may be considered with

PSWG and Range Safety approval, on a case-by-case basis.

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6.2.4.2. Handling Structure Inspection and Test Requirements:

6.2.4.2.1. Before their first operational use, all new, altered, modified or repaired handling structures shall be inspected in

accordance with applicable industry methodology and the PSWG and Range Safety approved NDE plan and load tested to

150 percent of the rated load.

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6.2.4.2.2. Handling structures designed to a factor of safety less than 3, but greater than or equal to 2, shall be initially inspected

and load tested to 125 percent of rated load.

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6.2.4.2.3. For handling structures used to support critical operations, volumetric and surface NDE shall be performed on all

SFP components and welds after the initial proof load test in accordance with PSWG and Range Safety approved NDE plan.

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6.2.5. Support Structures: Support structures are those structures used to support hardware or equipment, such as support

stands and fixed and portable launch support frames.

6.2.5.1. Support Structure Design Standards and Requirements:

6.2.5.1.1. Support structures shall be designed with a yield factor of safety of 3 based on rated loads.

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For large structures, requirements from American Institute of Steel Construction (AISC), American Society of

Civil Engineers (ASCE) 7 and pertinent building codes may also be considered.

6.2.5.1.2. Support structures whose failure would not result or propagate into a catastrophic event may be designed to a yield

factor of safety of 2 based on rated loads.

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6.2.5.1.3. Material (including fittings and attachment hardware) used in the construction of support structures shall exhibit a

ductile failure mode (for example, ultimate strain not less than 20 percent elongation). The intent is to have advanced warning

of an upcoming failure via visually detectable deformation of structural components. Exceptions may be considered with

PSWG and Range Safety approval, on a case-by-case basis.

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6.2.5.1.4. Support structures whose materials of construction do not meet the ductile material failure criteria above shall be

designed to an ultimate factor of safety of 5. Also, the design analysis shall include a fracture mechanics analysis to show a

service life cycle factor of safety of 100:1 and/or detailed NDE surface and/or volumetric requirements.

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6.2.5.1.5. Portable ground support equipment, such as equipment racks, shall be designed not to tip when fully loaded and/or

moved. For heavy moveable support and handling equipment, lifting lugs and forklift handling, such as fork tubes, shall be

incorporated to provide for safe handling.

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6.2.5.2. Support Structure Inspection and Test Requirements:

6.2.5.2.1. Before their first operational use, all new, altered, modified, or repaired support structures designed to a yield factor

of safety of at least 3 shall be inspected and Proof Load tested to 150 percent of rated load in accordance with applicable

industry methodology. A PSWG and Range Safety approved NDE plane shall be performed in accordance with paragraph 4.4

of this volume.

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6.2.5.2.2. Support structures designed to a factor of safety less than 3 but greater than or equal to 2 shall be inspected and

Proof Load tested to 125 percent of rated load. A PSWG and Range Safety approved NDE plane shall be performed in

accordance with paragraph 4.4 of this volume.

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6.2.5.2.3. Before every use, support structures shall be visually inspected in accordance with applicable industry methodology

and the PSWG approved NDE plan. Structures showing evidence of damage or rejectable criteria shall not be used in

operations.

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6.2.5.2.4. Support structures shall be periodically inspected, and rated load tested within four years of intended use in

accordance with applicable industry methodology and the PSWG and Range Safety approved NDE plan to the same load level

used in the initial testing.

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6.2.5.2.5. For support structures used to support critical loads or that create critical hazards, volumetric and surface NDE shall

be performed on all SFP components and welds after the initial proof load, inspected and load tested to the same level used in

initial testing within one year of intended use in accordance with applicable industry methodology and the PSWG and Range

Safety approved NDE plan.

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6.2.5.2.6. Support structures fabricated (including fittings and attachment hardware) of ductile materials at the operating

environmental conditions may be exempted by the PSWG, Range Safety or local safety authorities from periodic load testing

on a case-by-case basis.

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6.2.6. Load Positioning Device (LPD) and Load Measuring/Indicating Devices (LID) (e.g., Hydra Set ®)

Load positioning devices (LPD) are mechanical devices (e.g., Hydra Set ®), attached to a crane/hoist hook, and

used to make fine adjustments to the load position during lifting operations. Load indicating devices (LID) are

mechanical devices (e.g., load cells, dynamometers), attached to a crane/hoist hook, and used to measure the weight

of the load being lifted.

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6.2.6.1. LPD and LID Design Standards and Requirements. LPD and LID design allows use for a range of loads, with a

specification of not-to-exceed rating. These devices should be used within 20% to 80% range of their rated load capacity due

to lower accuracy in the extreme low and high ranges of the rated load.

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6.2.6.1.1. LPD and LID design shall ensure that positive control is maintained at all times, and no actions are initiated or

continued without the appropriate controls command being given.

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6.2.6.1.2. Failure of the LPD or LID shall not result in dropping or un-commanded movement of the suspended or supported

load.

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6.2.6.1.3. LPD shall be designed with a minimum ultimate factor of safety of 5.

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6.2.6.1.4. LIDs shall be designed in accordance with ASME B30.26, Rigging Hardware.

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6.2.6.1.5. A LPD and/or LID inspection plan, identifying all SFP and NDE requirements, methodology, and acceptance

criteria, shall be submitted to the PSWG and Range Safety for review and approval.

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6.2.6.1.6. Operator Training. Hydra-Set operators shall be trained and certified.

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6.2.6.2. LPD and LID Inspection and Test Requirements:

6.2.6.2.1. Before their first operational use, new, altered, repaired, or modified and LIDs shall be inspected and load tested

to 200 percent of rated load to verify controls and performance (for example, structural, mechanical, electrical). LPD and

LIDs shall be load tested by the manufacturer or if authorized, in accordance with the manufacturer instructions to prevent

system damage.

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6.2.6.2.2. NDE shall be performed during inspection and test per the NDE plan.

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6.2.6.2.3. For LPDs and LIDs used to support critical operations, volumetric and surface NDE shall be performed on all SFP

components and welds after the initial proof load test IAW the PSWG and/or SLD 30/SE and SLD 45/SE approved NDE plan.

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6.2.6.2.4. Before every use, LPDs and LIDs shall be visually inspected for proper function, loose hardware, excessive wear

and contamination, corrosion, cracks, or damage, and hydraulic system deterioration. Hydra-Sets or load cells showing

evidence of damage or rejectable criteria shall not be used in operations.

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6.2.6.2.5. LPDs and LIDs used to support critical lifts shall be inspected and load tested to 100 percent of the rated load within

1 year of intended use and calibrated in accordance with manufacturer instructions. Load testing to 100 percent shall be

performed in accordance with the manufacturer instructions to prevent system damage.

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6.2.6.2.6. LPDs and LIDs used to support critical lifts shall undergo operational tests in conjunction with proof and periodic

load tests and at least once per year. The LPD shall be operated to approximately the mid-stroke position with a test load of

50 to 100 percent of the LPD rated capacity. Using a dial indicator or equivalent, the load should not move up or down more

than .005 inches in 5 minutes. No hydraulic leaks, or structural damage or corrosion of the piston rod should be visible.

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6.2.7. Rigging Hardware. Rigging hardware consists of shackles, links, rings, swivels, turnbuckles, eyebolts, hoist rings, wire

rope clips, wedge sockets, rigging blocks, etc., and may be components of BTHLDs.

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6.2.7.1. Rigging Hardware Design Standards and Requirements. All rigging hardware shall be designed, manufactured,

handled, and stored in accordance with ASME B30.26. All hardware will be marked and identified accordingly.

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6.2.7.2. Rigging Hardware Inspection and Test Requirements.

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6.2.7.2.1. Before first use, all new, modified, or repaired rigging hardware shall be load tested to the proof loads specified in

ASME B30.26 prior to initial use.

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6.2.7.2.2. For rigging hardware used to support critical operations, volumetric and surface NDE shall be performed on all SFP

components and welds after the initial proof load test IAW the SLD 30/SE and SLD 45/SE approved NDE plan. Any rigging

hardware meeting removal criteria outlined in ASME B30.26 shall be removed from service.

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6.2.8. MHE Data Requirements. MHE initial and recurring data requirements shall be submitted in accordance with

Attachment 1 of this volume, A1.2.4.6.2 and A1.2.5.6. MHE periodic/recurring data requirements shall be submitted in

accordance with requirements in Volume 6.

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6.2.8.1. For MHE used in safety critical operations, provide initial proof load test plans and test results.

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6.2.8.2. Data Requirements Submission for Major Item MHE Designs. Unless otherwise agreed to by PSWG and Range

Safety or otherwise stated in this Chapter, all design engineering documents pertaining to major MHE items, such as cranes,

shall be submitted to the PSWG and Range Safety for review and approval 30 days prior to the following design review

meetings: introductory; conceptual (30%); preliminary (60%); critical (90%); and final (100%). All design engineering

drawings and specification packages shall have a space or block on the first drawing sheet reserved for the approval signature

of the Range Safety reviewing official. All Review Item Discrepancies (RID) shall be addressed at each design review and

resolved as soon as possible.

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Removable, Extendible, and/or Hinged Personnel Work Platforms

Requirements for the design, inspection, and test of personnel work platforms are included below.

6.4.1. Removable, Extendible, and/or Hinged Personnel Work Platform Design Requirements:

6.4.1.1. Safety factors for the design of platforms shall be consistent with those of the overall structures on which they are

permanently mounted. In no case shall the safety factors be less than that of the overall structure, the applicable national

consensus standard AISC, the Aluminum Association, or a yield factor of safety of 2, whichever is greater.

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6.4.1.2. Hinges, attaching points, and other high stress or abuse prone components and their interface hardware shall be

designed with a yield factor of safety of at least 3. Yield strength shall be less than or equal to 85 percent of ultimate strength

or the ultimate factor of safety shall be 5.

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6.4.1.3. The greater of (1) a minimum of 60 pounds per square foot or (2) 300 pounds per occupant shall be used for the

uniformly distributed live load.

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6.4.1.4. A minimum of 2,000 pounds shall be used for concentrated loading (point loading).

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6.4.1.5 Guardrail systems and toe boards shall be provided and designed in accordance with 29 CFR 1910 Subpart D , Walking

-Working Surfaces

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6.4.1.6. Personnel platforms shall have a means of positive mechanical restraint when in the open, raised, folded back, or use

position to prevent unintentional movement. Bolting shall not be acceptable. Latches, levers, tethered pins shall be used.

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6.4.1.7. Movable platform structures shall be grounded with the bonding conductor size in accordance with the NEC Article

250-102, Bonding Jumpers.

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6.4.2. Removable, Extendible, and Hinged Personnel Work Platform Marking Requirements.

6.4.2.1. All platforms shall be clearly marked with two-inch letters minimum indicating maximum load capacity.

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6.4.2.2. The following information shall be imprinted on a metal tag attached to the platform:

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6.4.2.2.1. Maximum distributed load.

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6.4.2.2.2. Maximum concentrated load (point load).

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6.4.3. Removable, Extendible, and/or Hinged Personnel Work Platform Inspection and Test Requirements. At a minimum,

the following tests shall be performed:

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6.4.3.1. All new, repaired, or modified platforms shall be load tested to 125 percent of their rated capacity before initial use.

After the proof load test, volumetric NDE testing shall be performed on all SPF components and welds in accordance with the

PSWG and Range Safety approved NDE plan. For repaired or modified platforms, volumetric NDE testing of all repaired or

modified SPF components and welds is required. Periodic inspection requirements for work platforms are found in Volume

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6.4.3.2. Visual inspection shall be performed annually on all hinges, attaching points, and other high stress or abuse prone

components on all platforms.

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6.4.4. Removable, Extendible, and/or Hinged Personnel Work Platform Data Requirements. Personnel work platform

data shall be submitted in accordance with Attachment 1, A1.2.5.8 of this volume.

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Lifting Personnel with a Crane

Personnel shall not ride the hook or load at any time. Conventional methods of reaching a worksite shall be utilized unless

they would be more hazardous or not possible.

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6.5.1 Man-Rated Baskets and personnel platforms used with cranes shall be designed, certified and load tested, and operated

in accordance with 29 CFR 1926.550, Cranes and Derricks, ASME B30.23, Personnel Lifting Systems and 29 CFR 1926.1427,

Operator Training, Certification, and Evaluation for all lifts of personnel. Manlifts and extensible boom platforms are also

discussed in 29 CFR 1910.67, Vehicle-mounted Elevating and Rotating Work Platforms

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Flight Hardware Used to Lift Critical Loads and Clampbands.

6.6.1. Flight Hardware Used to Lift Critical Loads Design Requirements. Lift fittings such as lugs and plates permanently

attached to flight hardware shall be designed so that the loss of one fitting and/or structure will not result in the dropping of

the load. If this requirement cannot be met, the minimum ultimate factor of safety shall be 1.5.

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Flight hardware used to lift critical loads includes clamp bands.

6.6.2. Flight and GSE Clampbands. Flight and GSE clampbands shall be designed with a minimum ultimate safety factor of

1.5 x limit load. Limit load shall include the effects of all expected lateral, compressive and tensile loads experienced by

clampbands during ground and flight environments.

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6.6.3. Flight Hardware Used to Lift Critical Loads and Clampband Initial Test Requirements. At a minimum, the

following tests shall be performed on permanently attached flight hardware lift fittings and clampbands prior to their first

operational use at the Ranges:

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6.6.3.1. Clampbands and lift fittings shall be load tested to 100 percent of limit load as an integral part of the lifting assembly

during structural load testing. All components shall be tested together as a system, if practical.

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6.6.3.2. After the load test, volumetric and surface NDE testing shall be performed on all clampbands, lift fitting SFP

components and SFP welds.

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6.6.4. Flight Hardware Used to Lift Critical Loads and Clampband Data Requirements. Data requirements for flight

hardware used to lift critical loads and clampbands shall be submitted in accordance with Volume 3, Attachment 1, A1.2.5.6.8.

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ACOUSTIC HAZARDS

Acoustic Design Standards

7.1.1. Equipment and systems shall be procured, designed and operated to ensure that personnel are not exposed to hazardous

continuous and impulsive noise levels that exceed the limits established by NPR 1800.1, Occupational Health Program

Procedures, latest revision, Hearing Conservation Section. In all cases, noise shall be at the lowest practical levels. Any work

area where environmental noise level is at or above 85 dB A-weighted or where the environmental impulse noise level is at

or above 140 dB C-weighted, regardless of duration of exposure of number of impulses, shall constitute a hazardous noise

area. NASA’s allowable noise exposure limit is the equivalent to an 85 dBA, 8-hour TWA exposure using a 3 dB exchange

rate as calculated by the following formula where L stands for exposure level and T stands for duration: T(min) = 480/2(L-

85)/3 . Exposures exceeding those calculated by the preceding formula levels shall be controlled, reduced, or eliminated

through a hierarchical combination of engineering controls, administrative controls, and hearing protection devices. Noise

dose shall include all impact/impulse noise measured up to and including 140 dB peak. The action level is 82 dBA, 8 hour

TWA, using a 3 dB exchange rate.

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7.1.2. “Buy Quiet and Quiet by Design” provisions are integral to the site selection and design of new or modified facilities

and equipment.

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7.1.3. Workspace noise shall be reduced to levels that permit necessary direct person-to-person and telephone communication.

Areas requiring occasional telephone use or occasional direct talk at distances up to 1.5 m (5 ft) shall not exceed 75 dBA.

Areas requiring frequent telephone use or direct talk at distances up to 1.5 m (5 ft) shall not exceed 65 dBA.

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7.1.4. Payload project shall coordinate with local authorities to ensure that potential acoustic hazards are evaluated by qualified

personnel.

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7.1.5. Caution alarms and audio warning signals shall be distinguishable by their intensity, duration and source, and be

compatible with the acoustical environment of the intended receiver as well as other personnel in the signal areas.

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Acoustic Data Requirements

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Acoustic data requirements shall be submitted in accordance with Attachment A1.2.4.12.2 of this volume.

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NON-IONIZING RADIATION SOURCES

ELECTROMAGNETIC RADIATION Emitters

The following requirements apply to electromagnetic radiation emitters unless exempted by AFI 48-109, Electromagnetic

Field Radiation (EMFR) Occupational and Environmental Health Program, any Wing Supplements/Instructions and local

authorities as identified by the PSWG in conjunction with Range Safety.

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The following general categories of RF and microwave radiation devices are typically exempt from review, unless

the results of a hazard analysis indicate that personnel and/or an integrated systems hazard exists, requiring

mitigation by design or operational controls:

- Devices with transmitter power of 7 watts or less and an antenna gain of unity (walkie-talkies, car phones,

cellular phones).

- RF/microwave radiation devices designed for and operated in a completely enclosed configuration where no

open-air transmission is possible.

- RF/microwave radiation devices designed to operate in a hard-lined, closed loop configuration where no open-

air transmission is possible.

8.1.1. Electromagnetic Field Radiation (EMFR) Emitter Design Standards:

8.1.1.1. EMFR emitters shall be designed to ensure that personnel are not exposed to hazardous energy levels in accordance

with ANSI/IEEE C95.1, Safety Levels with Respect to Human Exposure to Radio Frequency Electromagnetic Fields, 3 Khz.

to 300 Ghz, AFI 48-109, any Wing Supplements/Instructions and local guidance and requirements as identified by the PSWG

and Range Safety.

Note: Kennedy NASA Procedural Requirement KNPD 1860.1, KSC Radiation Protection Program provide local

requirements for KSC.

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8.1.1.2. Where total protection is not possible through the design process, clearance areas and access controls shall be

established.

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8.1.1.3. The payload project shall contact the local range and/or facility authorities with responsibility for EFMR safety and

deconflicting EMFR transmissions as identified by the PSWG in conjunction with Range Safety and provide EMFR system

design data as needed for the authorities to evaluate EMFR levels, determine the hazard potential for personnel, and ultimately

provide approval of the EMFR system.

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8.1.2. EMFR Emitter Design:

8.1.2.1. EMFR Emitter General Design Requirements:

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8.1.2.1.1. EMFR emitters shall be designed and located to allow test and checkout without presenting a hazard to personnel,

ordnance, or other electronic equipment. All systems shall be reviewed by PSWG, Range Safety, and the local Radiation

Protection Officer (RPO) or equivalent e.g., Radiation Safety Officer (RSO), and when required obtain the appropriate

approvals.

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8.1.2.1.2. Where necessary, safety devices shall be provided to protect operating personnel and exposed initiators during

ground operations

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Interlocks and interrupts are examples of safety devices that may be used to protect operating personnel and exposed

initiators during EMFR emitter ground operations.

8.1.2.1.4. Fail-safe systems shall be incorporated so that inadvertent operation of any hazardous EMFR emitting system is

prevented.

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8.1.2.2. Special Considerations for Electroexplosive and Critical Subsystem Exposure to Electro Magnetic Frequency

Radiation (EMFR):

8.1.2.2.1. Electroexplosive subsystems shall not be exposed to EMFR that is capable of firing the electroexplosive device

(EED) by pin-to-pin bridge wire heating or pin-to-case arcing.

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8.1.2.2.2. EMFR power at the EED shall not exceed 20 dB below the pin-to-pin direct current (DC) no-fire power of EED.

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8.1.2.2.3. EMFR shielding of pyrotechnics/explosives shall be IAW AIAA S-113A-2016, Criteria for Explosive Systems and

Devices on Space and Launch Vehicles, paragraph, 5.1.7.3 Electromagnetic Compatibility (EMC): The shielding for firing

circuits shall provide a minimum 20 dB safety margin between worst-case electrical noise and the electrical explosive device

demonstrated no-fire rating. Shielding for other circuits shall provide a minimum 6 dB safety margin between worst-case

electrical noise and the minimum activation power/no-damage rating.

To verify EMFR emitters, in proximity to Electro Explosive Devices (EED’s), or other ordnance subsystems, are below the

EED no-fire threshold, an analysis shall be performed in accordance with NASA-STD-8719.12, Safety Standard for

Explosives, Propellants, and Pyrotechnics, Appendix B; Hazards of Electromagnetic Radiation to EED’s, to determine safe

separation distances between EMFR Radio Frequency(RF) source emitters and EED’s and other exposed ordnance

subsystems.

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NASA-STD-7002, Payload Test Requirements, defines EMI test program requirements.

8.1.2.2.4. The effect of payload and launch system emitters on their own electroexplosive subsystem shall be evaluated by

analysis or electromagnetic compatibility (EMC) testing.

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8.1.3. EMFR Emitter Initial Test Requirements:

8.1.3.1. All EMFR emitters shall have their EMFR hazard area verified by the RPO/RSO or a designated representative before

the first operation and/or test.

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8.1.3.2. Safety features shall be tested, verified and documented before first operation/test.

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8.1.3.2.1. Test plans shall be submitted for review and approval to the appropriate local safety authority as identified by the

PSWG and Range Safety.

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8.1.3.2.2. Test results shall be submitted to local safety authorities as identified by the PSWG and Range Safety.

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8.1.4. EMFR Emitter Data Requirements:

8.1.4.2. EMFR Emitter Design and Test Data. The EMFR emitter design and test data requirements shall be submitted in

accordance with Attachment 1, A1.2.4.10.2.2 of this volume.

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Laser Systems (Class 1M, 2M, 3B, and 4)

8.2.1. Laser System Design Standards:

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8.2.1.1. Laser systems shall be designed to ensure that personnel are not exposed to hazardous emissions in accordance with

the requirements of ANSI Z136.1, Safe Use of Lasers, 21 CFR 1040, Performance Standards for Light Emitting Products,

AFI 48-139, Laser and Optical Radiation Protection Program and local guidance as defined by the appropriate local authorities

as identified by the PSWG and Range Safety.

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8.2.1.2. Where total protection against exposure is not possible through the design process, clearance areas and access controls

shall be established.

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8.2.1.3. The payload project shall contact the appropriate local authorities as identified by the PSWG in conjunction with

Range Safety and provide the laser system data for all Class 1M, 2M, 3B and 4 lasers and operations data for use in evaluation

and approval of the laser system. The appropriate local authorities shall evaluate laser levels and determine the hazard potential

for personnel.

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8.2.2. Laser System General Design Requirements. Requirements found in ANSI Z136.1 apply to Class 1M, 2M, 3B and

4 laser systems that may pose harm, unless exempted by AFI 48-139. The following requirements apply to all laser systems

unless exempted by the appropriate local authorities as identified by the PSWG in conjunction with Range Safety

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The following general categories of laser and LED devices, products and systems are typically exempt from

emitted laser radiation hazards:

- Class I and II laser devices and products, except for those that allow access to other classes of laser radiation

during servicing operations, provided that the laser product is maintained as a Class I or II laser product

through its useful life.

- Service Group 1 (SG1) fiber optic devices/systems.

- Laser Pointers (Class II), laser printers, laser copiers, image scanners, CD ROM players, and other devices,

such as those as defined and operated in KNPD 1860.1, KSC Radiation Protection Program.

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8.2.2.1. Control measures shall be designed into laser systems to reduce the possibility of human exposure to hazardous

laser radiation.

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Interlocks and interrupts are examples of safety devices that may be used to protect operating personnel and exposed initiators

from laser emissions.

8.2.2.2. Fail-safe systems shall be incorporated so that inadvertent operation of the laser system is prevented.

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8.2.2.3. Automatic, independent, redundant controls shall be provided to positively prohibit harmful radiation from areas

outside the intended operating area.

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8.2.2.3.1. Mechanical stops or barriers shall be used for Class 4 laser systems that may lead to a catastrophic hazard in the

event of a mishap.

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8.2.2.3.2. Electrical/software inhibits shall be used to shutter or shut down the laser before or when mechanical stops are

encountered.

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8.2.2.4. In addition to automatic controls, emergency laser shutdown or shuttering capability shall be provided.

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8.2.2.5. Emergency shutdown or shuttering shall be fail-safe or redundant.

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8.2.2.6. Laser platforms shall comply with the requirements for mechanical ground support equipment used to handle critical

hardware as described in Chapter 6 of this volume.

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8.2.2.7. Laser system mounts installed on moving or airborne vehicles shall be designed to compensate for the motion of the

vehicle.

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8.2.2.8. Heating effects on unprotected laser platforms shall be considered when siting and setting elevation and azimuth

stops.

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8.2.2.9. Hazardous materials used in laser systems shall meet the ground support requirements of Chapter 10 of this volume.

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8.2.2.10. Laser systems with pressurized subsystems such as cryogenic fluids shall meet the requirements of Chapter 11 of

this volume.

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8.2.2.11. Electrical ground systems used in laser systems shall meet the requirement of Chapter 14 of this volume.

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8.2.3. Laser System Test Requirements:

8.2.3.1. The payload project shall contact the appropriate local safety authority as identified by the PSWG in conjunction with

Range Safety and/or the RPO/RSO for hazard area verification before first operation and test.

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8.2.3.2. Safety features shall be verified before first operational use or test at the payload processing facility and launch site

area.

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8.2.3.3. Test plans and test results shall be submitted for review and approval to the appropriate local safety authorities as

identified by the PSWG and Range Safety.

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8.2.4. Laser System Data Requirements:

8.2.4.1. Laser system data requirements shall be submitted in accordance with Attachment 1, A1.2.4.10.3 of this volume.

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8.2.4.2. Hazard Evaluation Data. Analysis and supporting data outlining possible laser system failures for all phases of laser

system uses shall be submitted in accordance with Attachment 1, A1.2.4.10.3.7 of this volume.

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8.2.4.3. Biophysiological Data. Biophysiological data requirements shall be submitted in accordance with Attachment 1,

A1.2.4.10.3.8 of this volume.

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8.2.4.4. Test Plans and Test Results. Test plan and test results data requirements shall be submitted in accordance with 8.2.3.

Note: In addition to the hazards associated with exposure to the laser beam, non-beam hazards can result, and

ancillary systems require compliance to the applicable section(s) of this document. Examples of these hazards

include electrical, fire, explosion, laser generated air contaminants, ionizing and non-ionizing radiation,

compressed gases, laser dyes, and acoustic hazards.

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8.2.5. Engineering Controls. The following engineering controls are mandatory for Class 4 Lasers or laser systems and

should be applied to Class 3b Lasers or systems. Mandatory compliance to specific requirements may also be required by the

RPO/RSO or local health and safety authority, or as specified in the following paragraphs:

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8.2.5.1. Protective Housings shall be provided for all classes of lasers or laser systems, except as allowed by ANSI Z136.1

section 4.3.1.1. The protective housing may require interlocks and labels.

Note: In some circumstances such as research and development and manufacture/assembly of lasers, operation

of the laser or laser system without a protective cover may become necessary. In such cases, the appropriate local

safety authority and RPO/RSO shall determine the hazard and assure that controls are instituted appropriate to

the class of maximum accessible emission to assure safe operation. These controls may include, but not be limited

to:

(1) access restrictions

(2) eye protection

(3) area controls

(4) barriers, beam stops, shrouds, etc.

(5) administrative and procedural controls

(6) education and training.

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8.2.5.2 A master switch shall be operated by a key, or by coded access (computer code).

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8.2.5.2.1 The authority for access to the master switch shall be vested in the Area Radiation Officer (ARO)/Laser Safety

Officer (LSO) for the laser or laser device.

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8.2.5.2.2 The master switch shall be disabled (key removed or equivalent) when the laser or laser system is not intended to

be used.

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8.2.5.3 All energy sources associated with the laser or laser system shall be designed to comply with lockout/tagout

requirements required by OSHA.

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8.2.5.4 Viewing Portals, Collecting Optics and Display Screens

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8.2.5.4.1. All viewing portals and display screens included as an integral part of a Class 2, Class 3a, Class 3b, or Class 4 laser

or laser system shall incorporate a suitable means (filters, interlocks, attenuators) to maintain the laser radiation at the viewing

position at or below the applicable MPE for all conditions of operation and maintenance.

Note: Flammability and decomposition products of viewing portals and display screens are important in the

selection of material unless proper safeguards are in place to ensure personnel safety.

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8.2.5.4.2. All collecting optics, such as lenses, telescopes, microscopes, endoscopes, etc., intended for viewing use with a

Class 3b, or Class 4 laser or laser system shall incorporate a suitable means (filters, interlocks, attenuators) to maintain the

laser radiation at the viewing position at or below the applicable MPE for all conditions of operation and maintenance.

Note: Normal or prescription eyewear is not considered collecting optics.

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8.2.5.5 Remote interlock connector. The interlock connector facilitates electrical connections to an emergency master

disconnect interlock, or to a room, entry way, floor, or area interlock.

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8.2.5.5.1 When the terminals of the remote interlock connector are open circuited, the accessible radiation level shall not

exceed the appropriate MPE levels.

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8.2.5.6 Beam Stops or Attenuators shall be capable of preventing access to laser radiation in excess of the appropriate MPE

level when the laser or laser system output is not required.

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8.2.5.7 Laser Activation and Warning Systems

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8.2.5.7.1 An audible alarm, a warning light (visible through protective eyewear), or a verbal countdown command should be

used for Class 3b and shall be used for Class 4 lasers or laser systems during activation or startup.

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8.2.5.7.2 The audible warnings shall be distinctive and clearly identifiable sounds which are uniquely associated with the

emission of laser radiation.

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8.2.5.7.3 For Class 4 lasers or laser systems, the warning system shall be activated a sufficient time prior to emission of laser

radiation (emission delay) to allow appropriate action to be taken to avoid exposure to the laser radiation.

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8.2.5.8 Remote Firing and Monitoring

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8.2.5.8.1 Unless approved by the cognizant RPO/RSO Class 4 lasers and laser systems should be monitored and fired from

remote positions.

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8.2.5.8.1.1. The remote console should also include a laser activation warning system.

8.2.6 Use of Lasers in Navigable Airspace

8.2.6.1 Laser experiments or programs that involve the use of lasers or laser systems in laser experiments or programs (other

than Class 1 or Class 2) in navigable airspace shall ensure the safety of aircraft and the protection of people and property on

the ground.

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8.2.6.2 Early coordination with the appropriate local authorities as identified by the PSWG in conjunction with Range Safety

and Federal Aviation Administration shall occur in the planning stages to ensure proper control of any hazard to airborne

personnel or equipment. In accordance with NPR 1800.1, the Senior Environmental Health Officer shall be advised of

coordination with the FAA.

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RADIOACTIVE (IONIZING) RADIATION SOURCES

Radioactive Source Design Standards and Controls

9.1.1 Radioactive systems shall conform to the requirements specified in 10CFR, Energy, 49CFR, Transportation,

AFMAN 40-201, Radioactive Material (RAM) Management, and AFMAN 91-110, Nuclear Safety Review and Launch

Approval for Space or Missile Use of Radioactive Material and Nuclear Systems, NASA NPR 8715.1, Safety & Health

Programs and any payload processing facility requirements as specified by the PSWG and Range Safety.

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9.1.2 Radioactive sources shall be designed to prevent the release of radioactive material.

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9.1.3 Radioactive sources shall incorporate shielding in the design to ensure minimum exposure to personnel. Where total

protection from radiation exposure by use of shielding is not feasible, access controls shall be used.

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9.1.4 Radiation hazard warning signs and/or labels shall be fixed to the container or housing as directed by the Installation

Radiation Safety Officer (IRSO)

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9.1.5 High voltage sources shall be evaluated to determine their capability of producing X-rays.

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9.1.6 High voltage sources shall be properly shielded and shall use interlocks on cabinet doors to interrupt power when a door

is open.

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9.1.7 Control measures for flight systems shall be handled on a case-by-case basis.

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9.1.8 Range Users shall comply with requirements in Air Force Environmental Policy and the National Environmental

Policy Act and provide compliance documentation to the IRSO on the ER and/or the Radiation Safety Committee on the

WR.

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9.1.9 Application for USAF permits shall be submitted in accordance with AFMAN 40-201, Radioactive Material (RAM)

Management and any Wing Supplements/Instructions.

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9.1.10 The Nuclear Regulatory Commission (NRC) license holder or Range User shall submit 3 copies of the NRC license

with the USAF permit to the IRSO and SLD 30/SE and SLD 45/SE at least 90 calendar days before planned entry to the

range. Note: Licensing and permitting requirements and procedures are specified in 10 CFR, AFMAN 40-201, Radioactive

Material (RAM) Management and any Wing Supplements/Instructions.

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The USAF AFMAN 40-201, Radioactive Materials (RAM) Management has superseded AFI 40-201, Managing Radioactive

Materials in the USAF, and, AFI 40-201 45TH Space Wing Supplement Radioactive Material (RAM) Management has

superseded 45 SWI 40-201, Radiation Protection Program. KSC Requirements are provided in KNPR 1860.1, KSC Ionizing

Radiation Protection Program.

9.1.11. Radioactive sources shall be handled under the supervision of the designated Range User or the Radiation Protection

Officer named on the NRC license, state license, or USAF permit as described in AFMAN 40-201 Radioactive Materials

(RAM) Management.

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9.1.12. Written approval for use of radioactive materials on AFSPC ranges is provided by the Wing Radiation Safety

Committee. Range Users shall brief the Radiation Safety Committee on the hazards and procedures concerning the handling

of radioactive sources and shall comply with any unique requirements of AFMAN 40-201 Radioactive Materials (RAM)

Management., and any Wing Supplements or Instructions.

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9.1.13. The Safety Analysis Summary (SAS) and Radiation Protection Plan shall be submitted at least 180 calendar days

before launch.

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9.1.2. Additional ER and WR Design Controls:

9.1.2.1. Additional ER Design Controls:

9.1.2.1.1. Written approval for use of radioactive materials on CCSFS is provided by the SLD45/SE Radiation Safety

Committee (RSC). ER payload projects shall brief the RSC on the hazards and procedures concerning the handling of

radioactive sources and shall comply with any unique requirements of 45

Space Wing Supplement AFI 40-201.

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9.1.2.1.2. Radioactive sources shall be handled under the supervision of the payload project or the RPO/RSO named on the

Nuclear Regulatory Commission (NRC) license, state license or USAF permit.

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9.1.2.2. Additional WR Design Controls:

9.1.2.2.1. Written approval for use of radioactive materials on VSFB is provided by the SLD30/SE RADSAFCOM. WR

payload projects shall brief the RADSAFCOM on the hazards and procedures concerning the handling of radioactive sources

and shall comply with any unique requirements of SLD 30 Supplement 1 to AFMAN 91-110, Nuclear Safety Review and

Launch Approval for Space or Missile Use of Radioactive Material and Nuclear Systems.

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9.1.2.2.2. Radioactive sources shall be handled under the supervision of a designated payload project or the RPO/RSO named

on the NRC license, state license, or USAF permit as described in AFMAN 40-201.

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9.1.2.2.3. The final Safety Analysis Summary (SAS) and AFMAN 91-110, Nuclear Safety Review and Launch Approval for

Space or Missile Use of Radioactive Material and Nuclear Systems shall be submitted 180 days before each launch.

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Radioactive Sources Carried on Payloads

9.2.1. Radioactive Sources Carried on Payloads General Design Requirements - In addition to the design requirements

noted in 9.1.1, radioactive materials carried on payloads shall meet the following requirements:

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9.2.1.1. Radioactive materials carried aboard launch vehicles and payloads shall comply with AFMAN 91-110 public safety

launch risk constraints.

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9.2.1.2. Radioactive materials carried aboard payloads shall be compatible with and have no adverse safety effects on

ordnance items, propellants, high pressure systems, critical structural components, or flight termination systems.

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9.2.1.3. Radioactive materials carried aboard payloads shall be designed so that they may be installed as late in the countdown

as possible, particularly if personnel will be required to work within the system controlled radiation area (as defined in

AFMAN 40-201, and any Wing Supplements/Instructions)) while performing other tasks on payloads.

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9.2.2. Radioactive Sources Carried on Payloads Test Requirements:

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9.2.2.1. General. To launch radioactive materials, tests shall be performed to characterize the survivability of the radioactive

materials and any containment system, in the launch, abort, and destruct environments. The payload project shall also quantify

any release of radioactive materials from these environments and provide the information to the appropriate local safety

authority as identified by the PSWG and Range Safety.

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Abort and destruct environments may induce damaging effects due to reentry, ground impact, explosion and fragment impact,

fire, or mechanical crushing.

9.2.2.2. Test Plans, Test Analyses, and Test Results:

9.2.2.2.1. The appropriate local safety authority as identified by the PSWG and Range Safety shall approve test plans,

analyses, and results.

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9.2.2.2.2. The payload projects shall perform and document the results of radiation surveys of their radioactive sources before

coming to the payload processing facility and launch site area.

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9.2.2.2.3. The payload project shall coordinate and allow an initial radiation survey to be performed by the RPO/RSO the first

time the source arrives at the payload processing facility and launch site area. Follow-on surveys may be required by the

RPO/RSO and shall be coordinated and allowed.

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9.2.2.2.4. Safeguards, such as interlocks and leak tests, shall be tested and verified by the payload project before bringing a

radiation source to the ranges.

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9.2.3. Radioactive Sources Carried on Payloads Launch Approval Requirements:

9.2.3.1. A payload project contemplating launch of any radioactive source shall notify Range Safety and PSWG of any

intended launch of radioactive materials during the concept phase of the program and comply with AFMAN 91-110, and any

Wing Supplements/Instructions.

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9.2.3.2. Certification of compliance with an equivalent government agency safety review and launch approval process is

required for all payload projects.

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9.2.3.3. Radioactive Material Launches. Payload projects shall be responsible for notifying the NASA Nuclear Flight

Safety Officer (NFSO), the PSWG and Range Safety and ensuring compliance with National Security Presidential

Memorandum (NSPM-20), dated 20 August 2019, Presidential Memorandum on Launch of Spacecraft Containing Space

Nuclear Systems. NSPM-20 has superseded Paragraph 9 of PD/NSC-25, dated 08 May 1996, Scientific or Technological

Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space, with

implementation through DAFMAN 91-110, Nuclear Safety Review and Launch Approval for Space or Missile Use of

Radioactive Material and Nuclear Systems and USSF 91-710, Range Safety User Requirements.

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NSPM-20 establishes an Interagency Nuclear Safety Review Board (INSRB) for major sources. DoD, NASA, and FAA are all

members of that Board, and therefore may have insight in to related testing and analysis (e.g., launch abort data and evaluation;

failure mode, breakup, and blast data) of relevance to Range Safety.

9.2.4. Radioactive Sources Launch Approval Data Requirements. Radioactive sources launch approval data requirements

shall be submitted in accordance with Attachment 1, A1.2.4.11 of this volume.

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9.2.5. Radiation Producing Equipment and Devices Data Requirements. Radiation producing equipment and devices

data requirements shall be submitted in accordance with Attachment 1, A1.2.5.13 of this volume.

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HAZARDOUS MATERIALS

Hazardous Materials Selection Criteria

The requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive, flammable, or

explosive materials that may result in toxic, fire, or explosion hazards are described in this part. The requirements apply to all

of the chemicals included in, but not limited to, those specified in 29 CFR 1910.119, Process Safety Management of Highly

Hazardous Chemicals. These requirements also apply to explosives and pyrotechnics as defined in 29 CFR 1910.109,

Explosives and Blasting Agents.

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10.1.1. Hazardous Materials Flammability and Combustibility:

10.1.1.1. The least flammable material that meets design requirements while minimizing potential ignition sources and fire

propagation paths shall be used.

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10.1.1.2. Materials that will not burn readily upon ignition shall be used.

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10.1.2. Hazardous Materials Toxicity:

10.1.2.1. If more than one material satisfies the performance requirement, the least toxic material shall be used.

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10.1.2.2. Material that give off a toxic gas if ignited shall not be used if it is determined in a materials assessment that the

material could credibly come in contact with ignition or high heat source(s)

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10.1.3. Hazardous Materials Compatibility:

10.1.3.1. Materials, including leakage, shall not come in contact with a non-compatible material that can cause a hazard.

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10.1.3.2. Compatibility shall be determined on a case-by-case basis. If contact of material with a non-compatible material can

cause a critical or catastrophic hazard, the hazard shall be mitigated to a level acceptable to the PSWG and Range Safety.

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10.1.3.3. Non-Flight materials used in processing and testing of flight hardware shall not cause degradation of the flight

hardware.

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10.1.4. Hazardous Materials Electrostatic Buildup. Hazardous materials shall not retain a static charge that presents an

ignition source to ordnance or propellants or a shock hazard to personnel.

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Hazardous Materials Test Requirements

10.2.1. Materials Test Requirements and Databases. Material properties shall be determined by test processes defined in

this section or be selected from the PSWG and Range Safety approved material databases.

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Table 10-1. Potential Sources of Hazardous Material Information.

1) NASA Material and Process Technical Information System (MAPTIS) contains material codes and ratings for materials,

standard and commercial parts, and components. MAPTIS is accessible via the Internet at http://maptis.nasa.gov

2) Material selection from this or other approved NASA material data base, for example, KTI-5212, Material Selection List for

Plastic Films, Foams, and Adhesive Tapes.

10.2.1.1. Plastic materials that may pose a hazard because of compatibility or toxicity shall be tested in accordance with the

requirements described in NASA-STD-6001, Flammability, Offgassing and Compatibility Requirements and Test Procedures.

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10.2.1.2. Plastic materials that may pose a hazard because of flammability shall be tested in accordance with the requirements

described in NASA-STD-6001, Flammability, Offgassing, and Compatibility Requirements and Test Procedures.

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10.2.1.3. Plastic materials that may pose a hazard because of electrostatic discharge shall be tested in accordance with the

requirements described in KSC/MMA-1985-79, Standard Test Method for Evaluating Triboelectric Charge Generation and

Decay.

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10.2.1.4. Plastic materials that may pose a hazard because of hypergolic propellant ignition/breakthrough shall be tested in

accordance with the requirements described in KSC/MTB-175-88, Procedure for Casual Exposure of Materials to Hypergolic

Fluids, Exothermic Reaction Test Method.

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10.2.1.5. The results of these tests shall be submitted to the PSWG and Range Safety for review and approval, based on use.

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10.2.2. Other Hazardous Material Test Requirements:

10.2.2.1. Testing of materials whose hazardous properties are not well defined may be required by the PSWG and Range

Safety.

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10.2.2.2. Toxicity, reactivity, compatibility, flammability and/or combustibility testing requirements shall be determined on

a case-by-case basis by the PSWG and Range Safety.

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10.2.2.3. Testing shall consider the following material characteristics:

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10.2.2.3.1. Ability to build up a charge (triboelectric test).

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10.2.2.3.2. Ability of that charge to decay (triboelectric test).

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A material is considered to have good electrostatic dissipation properties if it can dissipate voltage down to 350 volts

in 5 seconds using the triboelectric test.

10.2.2.3.3. Flammability.

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10.2.2.3.4. Compatibility with other materials and liquids the material may come into contact with.

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Issues with material compatibility may result in operational restrictions.

10.2.2.4. Material restrictions may also arise from other limitations such as being humidity dependent (for charge dissipation)

or degradable in sunlight (ultraviolet).

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Hazardous Materials Environmental Requirements

10.3.1. The use of ozone-depleting chemicals and hazardous materials that result in the generation of regulated hazardous

waste shall be minimized to the greatest extent possible in accordance with federal and state regulations.

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10.3.2. Appropriate Environmental Planning organizations as determined by the PSWG and Range Safety shall review and

approve hazardous waste management and disposal procedures and plans.

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10.3.3. Payload project business plans shall comply with the range Hazardous Materials (HAZMAT) Plan.

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Hazardous Materials Data Requirements

10.4.1. Hazardous materials data requirements shall be submitted in accordance with Attachment 1, A1.2.4.13 of this

volume.

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Process Safety Management and Risk Management Plan

10.5.1. The payload project shall comply with 29 CFR 1910.119 and 40 CFR 68, AFMAN 91-203, Air Force Occupational

Safety, Fire and Health Standards, for Process Safety Management (PSM) and Risk Management Plan (RMP) and will be

identified in the System Safety Plan (SSP).

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10.5.2. PSWG shall confirm KSC representation on the SLD 45 Process Safety Management (PSM) team.

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GROUND SUPPORT PRESSURE, VACUUM, AND HAZARDOUS

STORAGE SYSTEMS

These requirements establish minimum safety design, fabrication, installation, testing, inspection, recertification, and data

requirements for fixed, portable, or mobile ground support hazardous pressure systems. Ground support systems include

aerospace ground equipment (AGE), ground support equipment (GSE), missile support systems, real property installed

equipment (RPIE), and industrial property.

Ground support hazardous pressure systems are defined as follows:

(1) pressurized systems used to store and transfer hazardous fluids such as cryogens, flammables, combustibles, and

hypergols.

(2) systems with operating pressures that exceed 150 psig.

(3) systems with stored energy levels exceeding 14,240 foot pounds.

(4) pressurized systems that are identified as Safety Critical by the PSWG and Range Safety.

Ground Support Pressure, Vacuum, and Storage Systems Requirements

11.1.1. Pressure and vacuum systems shall be designed, fabricated, inspected, tested, and installed in accordance with NASA-

STD-8719.17, and with accepted national industry standards such as ASME, American Petroleum Institute (API), Department

of Transportation (DOT), National Board Inspection Code (NBIC) NB-23, NFPA, UL, T.O. 00-25-223, Integrated Pressure

Systems and Components (Portable and Installed), and federal, state, and local environmental regulations. Ground-based

pressure vessels must be ASME code stamped and registered with the National Board of Boiler and Pressure Vessel Inspectors.

Vessels, cylinders, and tanks used for ground transportation must be DOT stamped in accordance with Title 49 of the Code

of Federal Regulations (49CFR) .

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11.1.1.1. Negative pressure protection shall be provided for vessels and systems not designed to withstand pressure below 1

atmosphere. This can be accomplished by the use of vacuum relief valves, check valves, ambient automatic pressure valves

or other suitable relief devices. Vacuum systems shall be designed in accordance with T.O. 00-25-223, Integrated Pressure

Systems and Components (Portable and Installed) and NASA-STD-8719.17. Safety relief devices shall be periodically retested

in accordance with NASA STD 8719.17 and NBIC NB-23.

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11.1.3. The requirements for operating hazardous pressure systems found in Volume 6 of this document shall be taken into

consideration in the design and testing of these systems.

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Ground Support Pressure Systems Requirements

11.2.1. Generic Ground Support Pressure System Requirements

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11.2.1.1. Generic Ground Support Pressure System Service Life. All pressure system components shall operate safely

and reliably during their intended period of service (service life). Components shall not fail at operating conditions in a time

period that is four times the service life of the components. In-service inspections, certification (for non-excluded PVS per

NASA STD 8719.17), normal preventive maintenance and calibration shall be performed to maintain the service life in

accordance with NASA-STD-8719.17, NASA Requirements for Ground-Based Pressure Vessels and Pressurized Systems

(PVS). The source documents for the service life are the ASME Boiler and Pressure Vessel Code (BPVC), API (American

Petroleum Institute), etc.

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11.2.1.1.2. Other components shall be designed to have a service life of not less than 5,000 cycles.

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Normal preventive maintenance and calibration may be performed to maintain the service life. The source

document for the service life is the ASME Boiler and Pressure Vessel Code.

11.2.1.2. Generic Ground Support Pressure System Safety Factor. Safety factor for pressure systems is the ratio of design

burst pressure over the maximum allowable working pressure (MAWP) or design pressure, whichever is greater. The safety

factor can also be expressed as the ratio of tensile strength over the maximum allowable stress for the material. ASME or

DOT codes are specified as compliance documents for various components such as pressure vessels and piping throughout

this part. Acceptable safety factors have already been incorporated into the specified code. If an ASME or DOT code is not

specified in this part as a compliance document for a component (applicable code does not exist), the minimum safety factor

for the component shall be 4 , or burst shall be 4 times MAWP.

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11.2.1.3. Generic Ground Support Pressure System Failure Tolerance

11.2.1.3.1. Ground support pressure systems shall be designed to ensure that no two failures can result in a catastrophic event

and no single failure (component fails to function or human operator error) can result in a critical event.

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11.2.1.3.2. Single-failure tolerant systems shall have at least two, PSWG and Range Safety approved, independent and

verifiable inhibits in place during all periods when the critical hazard exists. The structural failure of tubing, piping, welded

fittings, or pressure vessels are not to be considered single failure.

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11.2.1.3.3. Dual-failure tolerant systems shall have at least three, PSWG and Range Safety approved, independent and

verifiable inhibits in place during all periods when the catastrophic hazard exists.

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11.2.1.4. Generic Ground Support Pressure System Material Selection and Compatibility

11.2.1.4.1. Materials shall be compatible throughout their intended service life with the service fluids and the materials such

as supports, anchors, and clamps used in construction and installation of tankage, piping, and components as well as

nonmetallic items such as gaskets, seals, packing, seats, and lubricants.

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11.2.1.4.2. At a minimum, material compatibility shall be determined in regard to the following criteria: permeability,

flammability, ignition and combustion, functional and material degradation, contamination, toxicity, pressure and temperature

extremes, shock, oxidation, and corrosion.

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11.2.1.4.3. Brittle materials shall not be used for pressure system components. The nil-ductility transition temperature of

materials shall be below the service temperatures. PVS Minimum Design Metal Temperature (MDMT) shall be determined

in accordance with ASME BPVC and B31 piping code. Charpy impact and lateral expansion testing of base materials and

welds shall be performed as required in accordance with ASME BPVC and B31 piping code.

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Material Selection and Testing

Material properties should be selected in accordance with reputable government and industry sources such as

MAPTIS (Materials and Processing Technical Information Systems) or material test results when testing was done

in accordance with Range Safety approved testing methods. Reliable sources include the Department of

Transportation, Federal Aviation Administration, Office of Aviation Research (DOT/FAA/AR) Metallic Materials

Properties Development and Standardization (MMPDS) Handbook; Composite Materials Handbook (CMH)-

17;American Society for Testing Materials (ASTM) standards, and the Air Force Damage Tolerant Design

Handbook should be used to verify material is not crack sensitive.

11.2.1.4.4. Materials that could come in contact with fluid from a ruptured or leaky tank, pipe, or other components that store

or transfer hazardous fluids shall be compatible with the fluid so that they do not create a flammable, combustible, or toxic

hazard.

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11.2.1.4.5. Compatible materials selection shall be obtained from one of the following sources:

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11.2.1.4.5.1. Integrated Pressure Systems and Components (Portable and Installed) T.O. 00-25-223.

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11.2.1.4.5.2. Chemical Propulsion Information Agency (CPIA) 394, Hazards of Chemical Rockets and Propellants.

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11.2.1.4.5.3. NASA-STD-6016 B Standard Materials and Processes Requirements for Spacecraft

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11.2.1.4.5.4. NASA-STD-6001, Flammability, Offgassing, and Compatibility Requirements and Test Procedures

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11.2.1.4.5.5. The NASA Material and Process Technical Information System (MAPTIS). MAPTIS is accessible via the

Internet at http://maptis.nasa.gov

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11.2.1.4.5.6. KTI-5212, NASA/KSC Material Selection List for Plastic Films, Foams, and Adhesive Tapes.

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11.2.1.4.5.7. MSFC-STD-3029, NASA/MSFC Guidelines for the Selection of Metallic Materials for Stress Corrosion

Cracking Resistance in Sodium Chloride Environments.

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11.2.1.4.5.8. Other sources and documents approved by PSWG and Range Safety sources and documents.

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11.2.1.4.6. Compatibility Testing

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11.2.1.4.6.1. Materials shall be tested for compatibility if data does not exist.

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11.2.1.4.6.2. If compatibility testing is performed, the test plan shall be submitted to the PSWG for PSWG and Range Safety

review and approval.

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11.2.1.4.7. Compatibility Analysis. A compatibility analysis containing the following information shall be prepared:

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11.2.1.4.7.1. List of all materials used in system.

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11.2.1.4.7.2. Service fluid in contact with each material.

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11.2.1.4.7.3. Materials that may come in contact with leaking fluid.

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11.2.1.4.7.4. As requested, source document or test results showing material compatibility in regard to permeability,

flammability, ignition and combustion, functional and material degradation, contamination, toxicity, pressure and temperature

extremes, shock, oxidation, corrosion, and environmental conditions.

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11.2.1.4.8. Metallic components for pressure vessels, pipes, valves, and fittings shall be fabricated from low carbon stainless

steel or other alloys that provide adequate strength, corrosion resistance, and material compatibility. Materials specifications

shall be in accordance with ASME BPVC and B31 piping code. Material specifications for PVS used for ground transportation

shall be in accordance with 49 CFR.

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11.2.1.5. Generic Ground Support Pressure System Corrosion Control. Although corrosion control is primarily the

responsibility of the maintainer of the equipment, the designer is responsible for providing hardware that cannot present safety

problems caused by corrosion. As a minimum, the following potentially critical areas shall be evaluated and appropriately

protected:

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Table 11.1 Corrosion Control Guidance

A Range Safety approved corrosion control standard, such as NASA-STD-5008, Protective Coating Of Carbon

Steel, Stainless Steel, And Aluminum On Launch Structures, Facilities, And Ground Support Equipment, or NACE

RP0285-latest version, Corrosion Control of Underground Storage Tank Systems by Cathodic Protection (published

by the National Association of Corrosion Engineers), should be used as guidance for corrosion control. Corrosion

protection of fixed outdoor pressure systems includes supports, anchors, and clamps. Avoid use of 17-4PH stainless

steel wherever possible due to its susceptibility to stress corrosion cracking at low heat treatment levels. Any 17-

4PH stainless steel specified should be heat treated to condition H1025 or higher. Where 300-series stainless steels

are specified, type 303 should be avoided wherever possible due to susceptibility to stress corrosion cracking.

11.2.1.5.1. Carbon steel surfaces exposed to atmospheric corrosion shall be protected by the application of zinc coatings

(inorganic zinc or hot dip galvanizing) or equivalent means.

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11.2.1.5.2. Stainless steel surfaces exposed to rocket engine exhaust impingement or acid deposits from solid rocket motor

exhaust shall be coated with inhibitive poly amide epoxy primer and aliphatic polyurethane topcoat in accordance with NASA-

STD-5008, Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures.

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Nitrile, rubber-based, aluminum-pigmented coating (AR-7) is no longer recommended for coating stainless steel

surfaces because it has a high volatile organic compound content and is generally unavailable through commercial

suppliers.

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11.2.1.5.3. Exterior stainless steel surfaces of pressure systems with potential for exposure to hypergolic propellant shall be

coated with a compatible inhibitive coating applied in accordance with NASA-STD-5008 unless usage, storage, care, and

maintenance processes are in place to prevent any surface corrosion.

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Where exterior stainless steel surfaces of GSE pressure systems could be exposed to hydrazine, the surfaces could

be coated with inhibitive polyamide epoxy primer and aliphatic polyurethane topcoat that is hydrazine compatible

per NASA-STD-6001, Flammability, Offgassing, and Compatibility Requirements and Test Procedures, and

applied in accordance with NASA-STD-5008.

11.2.1.5.6. Dissimilar metals shall be protected through mutual isolation.

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11.2.1.6. Generic Ground Support Pressure System Contamination Control

11.2.1.6.1. To avoid a hazardous failure, adequate levels of contamination control shall be established by relating the

cleanliness requirements to the actual needs and nature of the system and components.

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KSC-C-123, Surface Cleanliness of Fluid Systems, Specifications for, or T.O. 42C-1-11, Cleaning, and Inspection

Procedures for Ballistic Missile Systems, should be used as guidance in relating cleanliness requirements to the

actual needs and nature of the system and components.

11.2.1.6.2. Materials and fluids used in the design shall be selected to reduce internally generated contamination caused by

rate of wear, friction, and fluid decomposition.

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11.2.1.6.3. Systems shall have acceptable contamination tolerance levels. The tolerance level of the system and/or

components shall be based on considerations of the overall functional requirements and service life.

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11.2.1.6.4. The system shall be designed to verify, through sampling, that the lines and components are clean after flushing

and purging of the system.

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11.2.1.6.5. Each component or section of a system shall be cleaned to the appropriate level before installation. Immediately

following cleaning, all components or sections of a system shall be protected to prevent contamination.

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11.2.1.6.6. Equipment designed to be cleaned or recleaned in place without significant disassembly shall be provided with

high point bleeds and low point drains to facilitate introduction and removal of cleaning fluid.

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11.2.1.6.7. Filters shall be installed immediately downstream of all interfaces where control of particulate matter is critical

and at other appropriate points as required to control particulate migration.

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11.2.1.6.8. Filter design shall permit easy servicing and ready accessibility.

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11.2.1.7. Generic Ground Support Pressure System Identification and Marking. All hazardous pressure system

components shall be identified as to function, content, applicable hazard, and, if applicable, direction of flow. The marking

and identification shall be accomplished by some means that cannot cause “stress concentration” or otherwise reduce the

integrity of the system. Minimum identification and marking requirements are as follows:

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11.2.1.7.1. Fixed Pressure Vessels.

11.2.1.7.1.1. Fixed pressure vessels shall be code stamped IAW the ASME Boiler and Pressure Vessel Code, Section VIII,

Division 1, Rules for Construction of Pressure Vessels, or ASME Boiler and Pressure Vessel Code, Section VIII, Division 2,

Alternative Rules – Rules for Construction of Pressure Vessels.

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11.2.1.7.1.2. The maximum pressure at which fixed pressure vessels shall be normally operated and the name of the working

fluid shall be painted in a conspicuous location on the vessel facing the roadway approach, if possible. This additional labeling

shall be legible at a distance of 50 feet under clear daytime conditions.

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11.2.1.7.2. Portable and mobile pressure vessels shall be marked in accordance with the applicable DOT specifications.

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11.2.1.7.3. Individual lengths or fabricated assemblies of pipe and tubing shall be identified with part number and/or contractor

tracking number, pipe or tube size, schedule number or wall thickness, test pressure, and the date of hydrostatic and/or

pneumatic test. Identification data shall be affixed to fabricated assemblies by means of an attached stainless steel band or

“dog tag” that has been stamped or electrochemically etched. When the tag does not contain the above identification data,

data shall be made available for review on site.

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11.2.1.7.4. Fixed ground support piping and tubing runs external to regulation and control panels and consoles shall be

identified and marked with commodity, maximum operating pressure (MOP) and flow direction along with applicable hazard

warnings and symbols identified and marked in accordance with ASME A13.1, Scheme for the Identification of Piping

Systems.

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11.2.1.7.5. Fixed ground support piping and tubing runs shall be identified in accordance with MIL-STD-101C, Color Code

for Pipelines and for Compressed Gas Cylinders or equivalent.

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11.2.1.7.6. Shutoff and metering valves, pressure relief valves, regulators, gauges, check valves, quick disconnect ground half

couplings, and filters shall have the manufacturer part number, unique serial number, and system reference designation for the

component (i.e., CV1, CV2), permanently attached to the body by stamping, engraving, or tagging when acceptable to the

PSWG and Range Safety. The following information shall be provided in the SDP (MSPSP):

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11.2.1.7.6.1. Manufacturer and/or contractor name.

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11.2.1.7.6.2. Manufacturer part number.

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11.2.1.7.6.3. Applicable design pressure rating.

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11.2.1.7.6.4. Service media.

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11.2.1.7.6.5. Month and year of most recent calibration for gauges and transducers.

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11.2.1.7.6.6. Flow direction arrow, if applicable.

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11.2.1.7.6.7. System reference designation for the component, such as CV1, CV2.

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11.2.1.7.6.8. Unique serial number.

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11.2.1.7.7. All manual pressure system regulation and control panels and consoles shall be clearly marked with a flow

schematic, operating parameters, and component identification.

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11.2.1.7.8. The system shall be designed or marked to prevent incorrect installation of filters.

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11.2.1.7.9. Flexible hoses shall be provided with an identification tag that is permanently and legibly marked with the

manufacturer part number, unique serial number, and system reference designation for the hose (i.e., FH1, FH2), and the

following shall be provided in the SDP:

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11.2.1.7.9.1. Manufacturer name.

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11.2.1.7.9.2. Manufacturer and/or contractor part number.

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11.2.1.7.9.3. Hose size, date of manufacture, and effective shelf/use life.

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11.2.1.7.9.4. Maximum allowable working pressure (MAWP) or manufacturer rated working pressure.

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11.2.1.7.9.5. Service media.

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11.2.1.7.9.6. Month and year of most recent hydrostatic test and test pressure.

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11.2.1.7.9.7. System reference designation for the hose, such as FH1, FH2.

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11.2.1.7.9.8. Unique serial number.

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11.2.1.7.10. Pressure relief devices shall be permanently and legibly marked in accordance with ASME BPVC. Pressure

relief valves which have been periodically set point tested in accordance with NASA-STD-8719.17 and NBIC NB-23 shall

have repair or test only nameplates permanently affixed and marked in accordance with NBIC NB-23 with the appropriate

"T/O" or "VR" stamp.

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11.2.1.8. Generic Ground Support Pressure System Bonding and Grounding.

Electrical bonds are classified according to the purpose for the bond: Class C for power return, Class H for shock hazard, Class

R for radio frequency, Class L for lightning, and Class S for electrostatic charge. There may be more than one purpose for

bonding a specific interface, and the bond shall meet the requirements of each applicable class maintaining all conductive

external parts and surfaces at ground potential at all times and in all anticipated conditions. At a minimum electrostatic charge

build-up must be addressed. NASA-STD-4003, Electrical Bonding for NASA Launch Vehicles, Spacecraft, Payloads, and

Flight Equipment, and NFPA 77, Recommended Practices on Static Electricity, shall be used for guidance. All pressure

systems shall be designed to ensure that all piping, tubing, external parts, shields, and surfaces are at ground potential at all

times. To control and dissipate the build-up of electrostatic charges, all pressure systems shall be properly bonded, grounded,

and constructed to provide the following:

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11.2.1.8.1. Any single joint measurement shall exhibit a DC resistance of 1.0 ohm or less.

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11.2.1.8.2. DC resistance from any point in the piping and tubing system to the nearest earth electrode ground plate shall be

1.0 ohm or less.

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11.2.1.8.3. A low-impedance path to earth shall be provided for electrical currents resulting from lightning discharges or

electrical power system faults to minimize abnormal voltage rises that might injure personnel or damage equipment.

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11.2.1.8.4. A discharge path shall be provided between distribution piping and tubing and earth to prevent the buildup of static

electricity.

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11.2.1.8.7. Flanged joints are acceptable if the flanges are stainless steel or the flanged areas in contact with the bolt heads

and washers are clean and bright. In addition, the bolts and nuts shall be equipped with serrated or spring washers to maintain

tightness.

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11.2.1.8.8. Tubing sections joined with fittings that seat metal-to-metal are considered adequately bonded.

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11.2.1.8.9. All mobile equipment shall be equipped for connection to bonding and grounding stations at fixed facility transfer

apron areas.

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11.2.1.8.10. Grounds shall be provided for propellant loading systems (flight propulsion systems or ground propellant tanks)

to allow for common grounding and bonding during propellant transfer operations. Loading systems include portable vessels

and units.

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11.2.1.8.11. The use of interconnecting dissimilar ground metals that could lead to increased resistance due to galvanic

corrosion over a relatively short time period shall be avoided.

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11.2.1.8.12. Nonmetallic plumbing installations shall be designed so that the static voltage, generated by fluid flow, will not

exceed 350 volts at any point outside the pipes, tubes, or hoses.

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11.2.1.8.13. The resistance of nonmetallic hoses shall not exceed 1.0 megohm per meter of length so as to dissipate charges

developing within the fluid or between fluid and the hose.

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11.2.1.9. Generic Ground Support Pressure System Physical Arrangement and Human Factors. Pressure systems shall

be designed to provide adequate accessibility, clearance, and operating safety.

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MIL-STD-1472 or the equivalent should be used as guidance in designing pressure system operating consoles.

11.2.1.9.1. Hypergolic propellant system design shall take into consideration the limitations imposed on individuals dressed

in Self-Contained Atmospheric Protective Ensemble (SCAPE) suits or Propellant Handlers Ensemble (PHE).

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11.2.1.9.2. All components and piping shall be located so they are readily accessible for maintenance, inspection, and

calibration. All piping shall be located to preclude a hazard to personnel (tripping or head injury).

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11.2.1.9.3. Tubing shall be located and protected so that damage cannot occur due to being stepped on, used as handholds, or

by manipulation of tools during maintenance.

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11.2.1.9.4. Pressure lines shall clear all structures, components, and other lines by not less than 1/4 inch under the most

adverse conditions of service to ensure that abrasive chafing does not occur.

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11.2.1.9.5. Piping, tubing, and other components shall be routed or located to provide protection from other operational

hazards, including moveable equipment. Where such exposure is unavoidable, safeguards that minimize the effects of such

exposure shall be incorporated in the design.

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11.2.1.9.6. Maximum spacing shall be provided between oxidizer and fuel lines to preclude mixing and combustion. A

minimum of 24 inches shall be provided.

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11.2.1.9.7. Pipes containing liquids shall not be attached or secured to electrical lines or conduit.

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11.2.1.9.8. A two-inch space shall be maintained between electrical conduits and pressure lines.

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11.2.1.9.9. Vent outlets shall be located far enough away from incompatible propellant systems and incompatible materials

to ensure that no contact is made during vent operations.

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11.2.1.9.10. System connections for incompatible propellants shall be keyed, sized, or located so that it is physically

impossible to interconnect them.

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11.2.1.9.11. Safety relief valves and burst diaphragms shall be located so that their discharge is directed away from personnel

and any safety critical equipment to prevent injury to personnel or damage to safety critical equipment. If this requirement

cannot be met, safety valves and burst diaphragms shall be equipped with deflection devices. Consideration shall be given to

minimizing the noise hazard of high pressure venting.

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11.2.1.9.12. Vent lines for flammable and combustible vapors, toxic gases, and gas streams that may be contaminated with

toxic vapors shall be extended away from work areas to prevent accidental ignition of vapors and/or injury to personnel.

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11.2.1.9.13. Pipe or flexible hose routing shall not block personnel egress routes.

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11.2.1.9.14. Pressure systems shall be designed so that the operator is not required to leave the operating control station to

monitor the hazard level of that system.

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11.2.1.9.15. Valves carrying hazardous liquids shall not be located overhead in the area of an operating station.

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11.2.1.9.16. Manually operated liquid valves shall be located to permit operation from the side or above to prevent spillage

of service fluid on the operator due to leak or failure of the valve seals.

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11.2.1.9.17. For systems with failure modes that could result in a time-critical emergency, provision shall be made for

automatic switching to a safe mode of operation. Caution and warning signals shall be provided for these time-critical

functions.

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11.2.1.9.18. Pressure systems shall be designed so that removal and replacement of tubing can be accomplished with minimal

removal of other system components.

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11.2.1.9.19. Systems shall be designed with accessibility to perform end-to-end static ground system checks.

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11.2.1.9.20. Pipes containing hazardous liquids shall be routed with a continuous downward slope to prevent the accumulation

of trapped liquid fluids and allow draining of the lines.

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11.2.1.9.21. Where possible, pipes carrying hazardous liquids shall be mounted so that the liquid cannot be trapped in internal

cavities when it is drained.

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11.2.1.9.22. High pressure lines and components shall be protected from damage due to leakage, servicing, or other

operational hazards created by other systems.

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11.2.1.9.24. Components shall be located, and lines routed to minimize the risk of ignition should a leak or rupture occur.

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11.2.1.9.25. Pressure lines shall not be installed inside conduit, large pipe, or tubing for protective support.

Exception: Lines may be enclosed in protective conduit, pipes, or tubing when routed under roadways, obstructions, and

through thick walls.

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11.2.1.9.26. System components such as a hand regulator and gauge that are closely related shall be arranged to allow

operation and surveillance from a common point.

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11.2.2. Ground Support Pressure System Hardware Design Requirements

11.2.2.1. Ground support pressure systems shall be designed IAW the ASME Boiler and Pressure Vessel Code, Section VIII,

Division 1, 2, or 3, ASME Code for Pressure Piping, B31, and all other applicable consensus standards and requirements

contained in paragraph section 11.2.2. Pressure systems test shall be performed IAW paragraph section 11.2.3. Ground

Support Pressure System Testing.

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11.2.2.2. Propellant systems shall be designed to ensure separation of fuels and oxidizers to prevent inadvertent mixing during

operations.

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11.2.2.3. All calibration adjustments shall be designed so that the setting, position, or adjustment cannot be inadvertently

altered.

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11.2.2.4.12. If DOT vessels are used in portable GSE, maintenance and operating procedures for periodic hydrostatic tests

shall be in accordance with DOT regulations.

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11.2.2.4.13. All pressure vessels shall be designed to allow for a minimum 10-percent ullage space at full-load conditions.

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11.2.2.5. Portable or Mobile Pressure Vessel

11.2.2.5.1. Mobile equipment for public and range highway use shall be designed, fabricated, inspected, tested, and

periodically retested and requalified IAW all requirements in 49 CFR. A copy of any DOT-approved exemptions shall be

provided to the appropriate local safety authority as identified by the PSWG and Range Safety.

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11.2.2.5.2. DOT pressure vessels shall be protected against overpressure in accordance with 49 CFR.

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11.2.2.5.3. DOT pressure vessels used and approved for use in a fixed ground-based system shall be provided overpressure

protection in accordance with ASME BPVC. DOT specification vessels in permanent or semi-permanent installations that do

not strictly comply with 49 CFR 171-180 shall be designated and certified as non-Code PVS and all requirements within

NASA-STD-8719.17 Sections 4.7.8 and 4.10.6 apply which includes ASME Equivalent Derating. The original cylinder

working pressure shall be de-rated for NASA use, based on equivalent stress ratio between DOT and ASME, to increase the

material FS to be FS =4 (or other appropriate FS applicable to the time and material of construction).

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11.2.2.6. Ground Support Pressure System Piping. At a minimum, all piping installations shall be designed in accordance

with ASME B31.3, Process Piping, in addition to the following:

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11.2.2.6.1. Pipe material shall be in accordance with ASTM A312 /A312M, Standard Specifications for Seamless and

Welding Austenitic Stainless Steel Pipes, and ANSI/ASME B36.10M, Welded and Seamless Wrought Steel Pipe or B36.19M,

Stainless Steel Pipe.

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Recommended pipe material is cold-drawn seamless, ASTM A312 grade TP304L or TP316L stainless steel.

11.2.2.6.2. Weld fittings such as tees, crosses, elbows, and reducers shall be of the butt-weld type in accordance with

ANSI/ASME B16.9, Factory Made Wrought Steel Butt Welding Fittings.

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Butt-weld fittings should be constructed of ASTM A403, grade WP-316L or WP-304Lwrought stainless steel.

11.2.2.6.3. Mechanical joints shall be made of forged ASTM A182 F340L or F316 butt-weld hubs, ASTM A182 F304 or

F316 clamp assemblies, and type 17-4PH Teflon-coated seal rings. Where system design dictates the use of industrial flanged-

type mechanical joints, they shall be in accordance with ANSI B16.5, Pipe Flanges and Flanged Fittings. Flange serrations

shall be of concentric design. Flange gaskets shall conform to ANSI/ASME B16.21, Nonmetallic Flat Gaskets for Pipe Flange,

and be compatible with the media.

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11.2.2.6.4. Threaded National Pipe (NPT) thread connectors shall not be used in hazardous pressure systems unless approved

by PSWG, Range Safety, and the Center Pressure Systems Manager.

Exception: With prior approval from PSWG and Range Safety, NPT connectors may be used for selected supply

components in some compressed nitrogen (GN

) or helium (GHe) gas pipeline metering and letdown stations. The

following guidelines will apply:

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11.2.2.6.4.1. Maximum Operating Pressure shall not exceed 6,000 psig.

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11.2.2.6.4.2. NPT connection size shall not exceed 1-inch nominal pipe size.

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11.2.2.6.4.3. Selected components are sample ports, vent/blowdown valves, pressure indicators, thermowells, and pressure

regulation sensors.

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11.2.2.6.4.4. NPT connectors used for connections that do not require repeated demating/mating shall have effective corrosion

control applied to the exposed threads to prevent external corrosion from weakening the high stress points.

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11.2.2.6.4.5. All of the selected components installed with NPT connections shall face away from high traffic areas and be

anchored or shielded to mitigate projectile risk if an NPT connector does fail.

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11.2.2.6.4.6. Signs shall be placed in the metering and letdown stations warning personnel not to step on or grab the pipe or

components protruding from the pipe due to use of NPT connectors in the pressure system.

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11.2.2.6.4.7. All connections that require periodic demating/mating for periodic maintenance purposes (such as relief valve

functional testing) shall use MS or equal straight thread connectors; NPT connectors shall not be used.

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11.2.2.6.4.8. Pressure reducing regulators and control valves shall not be installed in the pipeline using NPT (tapered thread)

fittings. Connections such as hub and seal ring connectors or flanged connections are recommended. Pipe hubs are specifically

designed for large, high-pressure connections.

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11.2.2.6.5. Socket welded flanges shall not be used in hazardous pressure system piping.

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11.2.2.6.6. All piping welds shall be of the full penetration butt-weld type.

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11.2.2.6.7. All piping and fitting butt welds used to fabricate hazardous pressure systems shall be 100 percent visually and

radiographically inspected. Accept/reject criteria shall be in accordance with ASME B31.3, Table 341.3.2A or Table

K341.3.2A for pressure systems equal to or greater than 6,000 psi.

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11.2.2.6.8. Cryogenic piping systems shall provide for thermal expansion and contraction without imposing excessive loads

on the system.

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Offset bends and loops rather than bellows should be used for this purpose wherever possible.

11.2.2.6.10. All piping shall be located so that it is not hazardous to working personnel.

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11.2.2.6.11. Cryogenic Pipe Weld Inspection

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11.2.2.6.11.1. All inner pipe welds shall be 100 percent radiographically inspected.

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11.2.2.6.11.2. The accept/reject criteria shall be in accordance with Table 341.3.2A of ASME B31.3, or Table K341.3.2A for

pressures equal to or above 6000 psi.

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11.2.2.7. Ground Support Pressure System Tubing. Tubing connections can be of a butt-weld type or by use of precision

37-degree fittings.

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If welded, pneumatic distribution tubing should be annealed seamless, stainless steel type 304/316 or 304L/316L.

11.2.2.7.1. If 37-degree flared end fittings are used, they shall be designed in accordance with precision type AN, MS, or

KSC-GP-425, Fluid Fitting Engineering Standards, standards.

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The material used to join 37-degree flared end fittings should be type 316 stainless steel.

11.2.2.7.2. If butt-weld fittings are used to join tubing, they shall be designed in accordance with KSC-GP-425 or equivalent.

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The material should be type 304L or 316L stainless steel.

11.2.2.7.3. All tubing and butt-weld fitting welds shall be 100 percent visually and radiographically inspected. The accept

and reject criteria shall be in accordance with Table 341.3.2 of ASME B31.3.

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11.2.2.7.4. Tubing used with AN or MS fittings shall be flared per SAE AS4330, Design Standard - Standard Dimensions for

Flared Tubing, and tubing used with KSC-GP-425 fittings shall be flared per KSC-GP-425. “Crush” washers are prohibited.

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11.2.2.7.5. Since flared tubing is not designed for service above 6,000 psig, PSWG, Range Safety, and the Center Pressure

Systems Manager approved super pressure tubing shall be used for service above 6,000 psig.

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11.2.2.7.6. Fabrication and installation of tubing using KSC-GP-425 fittings shall be in accordance with KSC-SPEC-Z-0008,

Fabrication and Installation of Flared Tube Assemblies and Installation of Fittings and Fitting Assemblies.

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11.2.2.7.7. Tube fittings with NPT connectors shall not be used in hazardous pressure systems.

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11.2.2.7.8. The number of mechanical joints in tubing systems shall be kept to a minimum.

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Table 11.4 Steel Types for Pressure System Tubing

All pressure gauge material that normally contacts the service fluid should be type 316 stainless steel.

Exception: Bourdon-tube bleed screws may be constructed of any 300-series stainless steel.

11.2.2.7.9. Tubing shall be seamless, stainless steel per ASTM A269, Seamless and Welded Austenitic Stainless Steel Tubing.

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11.2.2.8. Ground Support Pressure System Regulators

11.2.2.8.1. Regulators shall be sized to accurately control the pressure to be used in the system.

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11.2.2.8.2. Manually operated regulators shall be selected so that over torqueing the regulator cannot damage soft seats to the

extent that seat failure occurs.

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11.2.2.8.3. Regulators shall be designed so that a functional failure cannot create a hazard to personnel.

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11.2.2.8.4. Dome loaded pressure regulators shall be designed to withstand a differential pressure across the diaphragm and/or

piston equal to the maximum rated inlet pressure without damage. A means of venting the dome loading circuit shall be

provided.

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11.2.2.8.5. Pressure regulator actuators shall be capable of shutting off the fluid when the system is at the maximum possible

flow and pressure.

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11.2.2.8.6. A regulator shall not be used as a safety critical component or be required to function to prevent a failure that

might injure personnel.

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11.2.2.8.7. For each stage of regulation, the ratio of upstream-to-downstream pressure shall not exceed 10:1 for optimum

control.

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11.2.2.8.8. Regulators shall be selected so their working pressure falls within the center 50 percent of the total pressure range

if it is susceptible to inaccuracies or creep at either end of the pressure range.

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11.2.2.8.9. Regulator designs using uncontained seats shall not be used.

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11.2.2.8.10. The use of a sheathed flexible actuator such as push-pull wires and torque wires for regulator control is prohibited.

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11.2.2.8.11. Remote readout pressure transducers are required to monitor hazardous operations from a remote location.

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11.2.2.9. Ground Support Pressure System Valves

11.2.2.9.1. Both manual and automatic valve actuators shall be operable under maximum design flow and pressure for

complete opening and closing the respective valve.

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11.2.2.9.2. Remotely operated valves shall be designed to be fail-safe if pneumatic or electric control power is lost.

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11.2.2.9.3. Designs using uncontained seats shall not be used.

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11.2.2.9.4. Use of metal-to-metal seats without prior PSWG, Range Safety, and Center Pressure Systems Manager

concurrence is prohibited.

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Metal-to-metal seats are not suited for frequent mate/demate activities, as the seats are subject to scratching and

damage when demated, which leads to increased leakage. They are suitable for permanent or rarely demated

connections.

11.2.2.9.5. Inlet and outlet isolation valves (shutoff valves) and appropriate intermediate vent valves shall be provided for

shutdown and maintenance.

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11.2.2.9.6. Valve stem travel shall be limited by a positive stop at each extreme position.

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11.2.2.9.7. The application or removal of force to the stem positioning device shall not cause disassembly of the pressure

containing structure of the valve.

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11.2.2.9.8. Manually operated valves shall be designed so that over torqueing the valve stem cannot damage soft seats to the

extent that seat failure occurs.

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11.2.2.9.9. Inlet and outlet isolation valves shall be capable of isolating the maximum allowable working pressure in both

directions without seat failure.

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11.2.2.9.10. Fast opening valves that can produce high velocity kinetic effects or heating effects due to rapid pressurization

shall not be used.

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11.2.2.9.11. Systems shall have shutoff valves located as close to the supply vessel as practical and be readily accessible.

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11.2.2.9.12. Remotely controlled valves shall provide for remote monitoring of open and closed positions.

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11.2.2.9.13. Local or remote stem position indicators shall sense the position of the stem directly, not the position of the

actuating device.

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11.2.2.9.14. For remotely controlled valves, positive indication of actual valve position shall be displayed at the control

station. Indication of valve stem position or flow measurement is an acceptable indication. Indication of a remote command

being initiated is not a positive indication of valve position.

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11.2.2.9.15. Valves used in flared tubing system applications shall be designed for panel or other rigid mounting.

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11.2.2.9.16. All pressure system valves that are required to be in a closed or open position during system operation shall be

protected against inadvertent actuation by physical means.

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Examples of physical means to protect against inadvertent actuation are mechanical stops, lock wires, or access

control.

11.2.2.9.17. Valves that are not intended to be reversible shall be designed or marked so that they cannot be connected in a

reverse mode.

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11.2.2.9.17.1. Check valves shall be provided where back flow of fluids would create a hazard.

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11.2.2.9.17.2. Check valves shall be the spring-loaded type with soft seats.

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11.2.2.9.18. The use of sheathed flexible actuators, such as push/pull wires and cables, for valve control is prohibited.

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11.2.2.9.19. All electrical control circuits for remote activation shall be shielded or otherwise protected from hazardous stray

energy.

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11.2.2.9.20. Balanced manual valves that use external balancing ports or vents open to the atmosphere shall not be used.

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11.2.2.9.21. Remotely operated flow control valves shall be operated pneumatically, electrically, or hydraulically and shall

be capable of fail-safe operation to either the open or closed position. Determination of fail-safe mode (the open or closed

position) shall depend on the system characteristics.

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11.2.2.10. Ground Support Pressure System Vents, Drains, Low Points, Bleeds, Test Ports, and Sampling Ports. All

pressure and propellant systems shall have a low-point drain capability unless prohibited by the DOT, as well as a high-point

bleed capability with easy accessibility.

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11.2.2.10.1. Pressure and propellant systems shall be designed so that commodities cannot be trapped in any part of the system

without vent capability.

Exception: Loosening of fittings to vent trapped pressure is allowed when the fluid under pressure is non-

hazardous and only for the purpose of calibrating or replacing pressure gauges or transducers that are provided

with an upstream isolation valve where the total trapped volume does not exceed 1.5 cubic inches.

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11.2.2.10.2. Vent system outlets shall be in a location normally inaccessible to personnel and shall be conspicuously identified.

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11.2.2.10.3. Vent outlets shall be protected against rain intrusion and entry of birds, insects, and animals.

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11.2.2.10.4. Oxidizer and fuel vent outlets to the atmosphere shall be separated sufficiently to prevent mixing of vented

fluids/gases.

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11.2.2.10.5. All vent outlets shall be designed to preclude accumulation of vented fluid in dangerous concentrations in areas

frequented by unprotected personnel or motor vehicles.

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11.2.2.10.6. Vent line supports shall be designed to withstand reaction loads due to the actuation of safety relief devices in

accordance with ASME B31.3, paragraph 322.6.2.

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11.2.2.10.7. Each line venting into a multiple-use vent system shall be protected against back pressurization by a check valve

if the upstream system cannot withstand the back pressure or where contamination of the upstream system cannot be tolerated.

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11.2.2.10.8. Incompatible fluids shall not be discharged into the same vent or drain system.

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11.2.2.10.9. Fuel and oxidizer vent systems shall be equipped with a means of purging the system with an inert gas to prevent

explosive mixtures.

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11.2.2.10.10. Vent systems shall be sized to provide minimum back pressures consistent with required venting flow rates. In

no case shall back pressures interfere with proper operation of relief devices. The calculated capacity of any pressure relief

system may be determined by analyzing the total system resistance to flow. This analysis shall take into consideration the flow

resistance of the piping and piping components including the exit nozzle on the vessels, elbows, tees, reducers, and valves.

The calculation shall be made using accepted engineering practices for determining fluid flow through piping systems. This

calculated relieving capacity shall be multiplied by a factor of 0.90 or less to allow for uncertainties inherent in this method.

The aggregate capacity of the open flow paths, or vents, shall be sufficient to prevent overpressure in excess of those specified

in ASME BPVC Division 1, UG-125(c). When the MAWP is 15 psi (105 kPa) or less, in no case shall the pressure be allowed

to rise more than 21% above the MAWP.

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11.2.2.10.11. Personnel and critical equipment shall be protected from potential venting hazards.

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11.2.2.10.12. Bleed ports shall be located so that they can be operated with minimal removal of other components and permit

the attachment of a hose to direct the bleed-off material into a container, away from the positions of the operators.

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11.2.2.10.13. Test points shall be provided on pressure systems so that disassembly for test is not required.

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11.2.2.10.14. Test points shall be easily accessible for attachment of ground test equipment.

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11.2.2.10.15. A sampling port shall be provided upstream and downstream of each regulator in any pneumatic branch line

that interfaces with a hypergolic propellant system to permit periodic sampling and analysis of the medium for contamination.

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11.2.2.10.16. Sample ports shall be provided at cryogenic system low points.

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11.2.2.10.17. A single pressure gauge shall be provided at some point downstream either in the pneumatic system or the

propellant system to indicate the pressure in the propellant system.

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11.2.2.10.18. Gauge calibration ports shall be designed to limit potential impingement of contaminated gas on personnel.

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11.2.2.10.20. Normal discharge of the protective purge gas from a hazard proofed-enclosure outlet shall be to an unclassified

location, or to a Division 2 or Zone 2 location if the equipment does not create ignition capable particles during normal

operation.

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11.2.2.11. Ground Support Pressure System Indicating Devices

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11.2.2.11.1. All pressure gauges shall conform to the requirements of ASME B40.1, Gauges, Pressure Indicating Dial Type.

Exception: Pressure gauges that are part of a cylinder regulator assembly such as those used with cutting,

welding, or other industrial equipment are exempt from these requirements as are gauges associated with

pneumatic controllers, positioners, and other standard process control equipment.

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11.2.2.11.2. A pressure indicating device shall be connected downstream of each pressure regulator, on each storage system,

and on any section of the system where pressure can be trapped.

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11.2.2.11.3. Gauges shall be sized to accurately display the pressure to be used in the system.

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11.2.2.11.4. All pressure gauges shall be equipped with a full diameter pressure release back that shall be sized for maximum

flow without case rupture.

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11.2.2.11.5. Gauges shall be securely attached to a panel or other rigid mounting.

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11.2.2.11.6. If pressure gauge isolation valves are used, they shall be designed so that they can be secured in the open position.

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Lock wiring is an acceptable means of securing pressure gauge isolation valves in the open position.

11.2.2.11.7. Gauge installations shall be designed to have a minimum of one-inch clearance to allow unrestricted venting in

the event the gauge vents. Personnel and equipment shall be protected from the vent area.

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11.2.2.11.8. Gauges shall be selected so that the normal operating pressure falls between 25 percent and 75 percent of the

scale range, except for gauges used in applications that require a wide range of operating pressure, which shall not exceed 95

percent of scale range of the gauge.

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11.2.2.11.9. Remote readout pressure transducers shall be used when it is necessary to monitor hazardous operations from a

remote location.

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11.2.2.11.10. Pressure gauges shall be of one-piece, solid-front, metal-case construction, using an optically clear shatterproof

window made of high-impact, non-cracking plastic, heat-treated glass, or laminated glass.

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11.2.2.11.11. Liquid system liquid sensors suitable for indicating the presence or absence of liquid shall be provided.

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Metals that could come in contact with the service medium should be compatible, such as type 304 or 316 stainless

steel.

11.2.2.11.12. Liquid system liquid level indicators that contain welded portions (typically magnetic float type) shall be

constructed of stainless steel.

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Low carbon stainless steels such as type 304L or 316L should be used for welded parts.

11.2.2.11.13. For liquid systems, the use of glass-faced or radiation source emitting liquid level indicators is prohibited. Other

prohibited types include capacitance, conductive, and pressure/density types due to historical operational failures and

continuous maintenance problems.

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11.2.2.11.14. Liquid system sight glasses used for liquid level indicators shall be protected from physical damage.

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11.2.2.11.15. As required, pressure gauges shall allow for precision cleaning and verification of cleanliness by particle

analysis and non-volatile residue analysis; for example, a bourdon tube tip bleeder or equivalent.

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11.2.2.11.16. Each pressure-indicating device shall be provided with an isolation valve and a test connection (test port)

between the isolation valve and the pressure-indicating device. Trapped volume between the isolation valve and the pressure-

indicating device shall not exceed 1 inch

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11.2.2.11.17. The operating range-of-pressure transducers used for monitoring pressures during hazardous operations shall

not be less than 1.2 and not more than 2.0 times the system MOP.

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11.2.2.12. Ground Support Pressure System Flexible Hoses - Flexible hoses shall be used only when required for hookup

of portable equipment or to provide for movement between interconnecting fluid lines when no other feasible means is

available.

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11.2.2.12.1. Unless otherwise specified, each flexible hose assembly shall be hydrostatically tested to a minimum 1.5 times

the hose's MAWP at the time of manufacture/fabrication and retested if they are modified or repaired. The hose shall not be

damaged or deformed nor leak when subjected to its required pressure.

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11.2.2.12.2. Flexible hoses shall consist of a flexible inner pressure carrier tube (compatible with the service fluid) constructed

of [typically poly-tetrafluoroethylene (PTFE) for hypergolic fluid] or corrugated metal (typically 300-series stainless steel)

material reinforced by one or more layers of 300-series stainless steel wire and/or fabric braid.

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In applications where stringent permeability and leakage requirements apply, hoses with a metal inner pressure carrier tube

should be used. Where these hoses are used in a highly corrosive environment, consideration should be given to the use of

Hastalloy C-22 in accordance with ASTM B575 for the inner pressure carrier tube and C-276 material for the reinforcing braid.

11.2.2.12.3. Flexible hoses shall be provided with 300-series stainless steel end fittings of the coupling nut, 37-degree flared

type or with fittings to mate with the appropriately sized ASME B16.5 flange or KC159 hub. Other end fittings may be used

for unique applications, with prior PSWG and Range Safety approval.

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11.2.2.12.4. Flexible hoses shall not be interchanged among incompatible service media. Permeation is not totally negated

by any cleaning process. Hoses shall be dedicated to a service media.

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11.2.2.12.5. Flexible hoses that could subject personnel to injury or cause damage or loss of safety critical or mission essential

hardware, to a whipping hazard in the event of end connection failure, shall meet the following restraint requirements:

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11.2.2.12.5.1. Flexible hoses shall be restrained at each end by an approved stainless resistant device and securely attached

across each union or splice at intervals not to exceed 6 feet. Flexible hose installations that are 6 feet long or longer shall be

configured so that restraint is provided on both the hose and adjacent structure at no greater than 6-foot intervals and at each

end to prevent personnel injury in the event of a flexible hose rupture or breakaway.

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11.2.2.12.5.2. Hose end restraints shall be securely attached to the structure in a manner that does not interfere with the hose

flexibility.

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11.2.2.12.5.3. Flexible hose restraint devices shall be capable of withstanding not less than 1.5 times the open line pressure

force. See Table 11.2 below.

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11.2.2.12.5.4. The design safety factor for restraint devices shall not be less than 3 on material yield strength.

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11.2.2.12.5.5. Temporary flexible hose installations may be weighted with 50-pound sandbags, lead ingots, or other suitable

weights at intervals not to exceed 6 feet.

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11.2.2.12.5.6. Hose clamp-type restraining devices shall not be used.

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11.2.2.12.6. Flexible hose installation shall be designed to avoid abrasive contact with adjacent structures or moving parts.

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11.2.2.12.7. Flexible hose assemblies shall not be installed in a manner that will place a mechanical load on the hose or hose

fittings to an extent that will degrade hose strength or cause the hose fitting to loosen.

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11.2.2.12.8. Flexible hose shall not be supported by rigid lines or components if excessive loads from flexible hose motion

can occur.

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11.2.2.12.9. Flexible hose between two components may have excessive motion restrained where necessary but shall never

be rigidly supported by a tight rigid clamp around the flexible hose.

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11.2.2.12.10. Flexible hoses shall not be exposed to temperatures that exceed the rated temperature of the hose.

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Table 11.2 Open Line Force Calculation Factor

11.2.2.12.8. Flexible hose shall not be supported by rigid lines or components if excessive loads from flexible hose motion

can occur.

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Diameter Opening (inch)

Calculated Force Factor for Each psi of Source

Pressure (psi)

1/8

0.18506

1/4

0.28320

3/8

0.38140

1/2

0.47960

5/8

0.57770

3/4

0.67590

7/8

0.77410

1.0

0.87230

To calculate the force acting on line opening, select the applicable diameter opening

and multiply the right-hand column by the source pressure (psi).

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11.2.2.12.9. Flexible hose between two components may have excessive motion restrained where necessary but shall never

be rigidly supported by a tight rigid clamp around the flexible hose.

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11.2.2.12.10. Flexible hoses shall not be exposed to temperatures that exceed the rated temperature of the hose.

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11.2.2.12.11. Flexible hoses that are permitted to pass close to a heat source shall be protected with a fireproof boot metal

baffle.

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11.2.2.12.12. Designs using convoluted, unlined bellows, or flexible metal hoses shall be analyzed to verify premature failure

caused by flow-induced vibration is precluded.

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11.2.2.12.13. Acoustic coupling that can intensify the stresses caused by flow-induced vibration shall be avoided by ensuring

that normal fluid flow requirements do not exceed a velocity of Mach 0.2.

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A guidance document for performing the flow-induced vibration analysis is MSFC-SPEC-3746, Flow-Induced

Vibration Assessment Requirements for Metal Bellows and Flex hoses.

11.2.2.12.14. The bend radius of flexible hoses shall be designed to be no less than the safe minimum bend radius

recommended in authoritative specifications for the particular hose and in no case less than five times the outside diameter of

the hose.

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11.2.2.12.15. A means of plugging or capping flexible hoses shall be provided when the hose is not in use.

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11.2.2.12.16. Ground Support Cryogenic System Flexible Hoses:

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11.2.2.12.16.1. Flexible hoses shall be used only when required to isolate vibration and piping movement and for hookup of

portable and mobile equipment.

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11.2.2.12.16.2. Flexible hoses shall be of the single-wall, double-wall, or double-wall vacuum-jacketed type.

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11.2.2.12.16.3. All convoluted portions of flexible hoses shall be covered with stainless steel wire braid.

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11.2.2.12.17 Flexible hoses whose rupture would cause unacceptable hazard to personnel or risk to mission shall be retested

at the flexible hose MAWP no less frequently than every 5 years. A flexible hose that is permanently installed by welding or

brazing does not require retesting IAW NASA STD-8719.17 section 4.10.4

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11.2.2.12.18 A flexible hose exhibiting major defects as classified in SAE ARP 1658B, shall be removed from service IAW

NASA STD-8719.17 section 4.10.4.7

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11.2.2.13. Ground Support Pressure System Relief Devices

11.2.2.13.1. All fixed pressure vessels shall be protected against overpressure by means of at least one conventional safety

relief valve or pilot-operated pressure relief valve in accordance with ASME Boiler and Pressure Vessel Code, Section VIII,

Division 1. Rupture disks alone shall not be used to protect against overpressure.

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11.2.2.13.2. A rupture disc may be installed between the pressure relief valve and the vessel provided that the limitations of

ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, Paragraphs UG-127(a)(3)(b) and UG 127(a)(3)(c) are met.

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11.2.2.13.3. Particular care shall be taken to monitor and/or vent the space between the rupture disc and the relief valve as

required. The space between a rupture disc and a relief valve shall be designed to allow annual testing for leakage and/or

contamination.

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11.2.2.13.4. All rupture discs installed in hazardous fluid systems shall be replaced every two years.

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A non-fragmenting rupture disc should be used when a rupture disc is used between a pressure vessel and a relief

valve to prevent contamination or damage to the relief valve.

11.2.2.13.5. Installation of the pressure relief devices shall be in accordance with ASME Boiler and Pressure Vessel Code,

Section VIII, Division 1.

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1.2.2.13.6. The flow capacity for all relief devices shall be certified in accordance with ASME Boiler and Pressure Vessel

Code, Section VIII, Division 1, Paragraphs UG-130 through UG-134.

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11.2.2.13.7. The total required relieving capacity of pressure relief devices shall be determined in accordance with ASME

BPVC, Section VIII, Division 1, API 520, API 521, and/or CGA (S-1.1, S-1.2, S-1.3, 341, E-4 etc.) requirements as applicable

for all relevant failure scenarios. The required relieving capacity shall be provided by a single valve where possible.

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11.2.2.13.8. Pressure relief devices shall be set to operate at a pressure not to exceed the MAWP of the vessel or the design

pressure of a system. See ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, Paragraph UG-134. If multiple

relief devices are required see UG-134 for the requirements.

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11.2.2.13.9. The relieving capacity of the safety relief valve shall be equal to or greater than the maximum calculated required

flow capacity to prevent PVS overpressure 10% above MAWP (or piping system design pressure) for normal operating

contingency failure scenarios (i.e. full open failure of upstream pressure reducing devices, heat exchanger/vessel block outlets,

cooling water failure, overfilling, loss of automated controls, power failure, etc...), and no more than 21% above MAWP for

fire scenarios. See ASME BPVC Div. 1, UG-125 and API 520. If multiple relief devices are required see UG-125 for the

requirements.

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11.2.2.13.10. Pressure relief valves shall be set to operate at a pressure not to exceed 110 percent of the system MOP or that

allowed by ASME B31.3, whichever is less.

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11.2.2.13.11. Negative pressure protection shall be provided for vessels not designed to withstand pressures below one

atmosphere if the pressure vessel feed system or operational use renders it susceptible to negative gauge pressure.

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Negative pressure protection may be accomplished by the use of check valves or negative pressure relief devices.

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11.2.2.13.12. Pressure vessel relief devices shall be located so that other components cannot render them inoperative except

as specified in ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, Paragraphs UG-135(d)(1), UG-135(d)(2),

and Appendix M, Installation and Operations, Paragraphs M-5, and M-6. When a full-area stop valve is allowed in accordance

with ASME Boiler and Pressure Vessel Code, the valve type shall have provisions for being locked in the open or closed

position.

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Safety wiring is an acceptable means of locking shutoff valves in the open or closed position.

11.2.2.13.13. The shutoff valve associated with the relief device shall have permanent marking clearly identifying its position

(OPEN or CLOSED).

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The body and other pressure containing parts for pressure relief devices should be 300-series stainless steel.

Exception: DOT cylinders or trailer relief devices may contain parts of brass or bronze.

11.2.2.13.14. A pressure relief valve shall be installed downstream of the last GSE regulator before flight hardware interface

and before entering a container and/or black box purge system.

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11.2.2.13.15. All relief valves and piping shall be structurally restrained to eliminate any thrust effects from transferring

moment forces to the vessel nozzles or lines.

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11.2.2.13.16. The effects of the discharge from relief devices shall be assessed and analyzed to ensure that operation of the

device cannot be hazardous to personnel or equipment. Items to be analyzed are thrust loads, noise, impingement of high

velocity gas or entrained particles, toxicity, oxygen enrichment, flammability, and oxygen deprivation.

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11.2.2.13.17. All relief devices shall be vented separately unless the following can be positively demonstrated:

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11.2.2.13.17.1. The creation of a hazardous mixture of gases in the vent system and the migration of hazardous gases into an

unplanned environment is impossible.

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11.2.2.13.17.2. The capacity of the vent system is adequate to prevent a pressure rise more than 20 percent above MOP or

exceed 10 percent of the set pressure of the valve in accordance with ASME Boiler and Pressure Vessel Code, Section VIII,

Division 1, Appendix M, Paragraph M-8. The analysis shall assume that all relief valves connected to the vent system are

open and flowing full capacity.

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11.2.2.13.17.3. Relief devices vented to a common header shall be pressure balanced bellows type or appropriate pilot

operated type relief valves for which set pressure is unaffected by the vent header superimposed back pressure. Conventional

relief valves shall only be used if an analysis of failure scenarios confirm that multiple devices are not needed for any failure

scenario.

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11.2.2.13.18. Both the inlet and discharge sides of a relief valve shall be hydrostatically or pneumatically tested. When the

discharge side has a lower pressure rating than the inlet side, they are to be hydrostatically or pneumatically tested

independently. Prior approval of the plan for pneumatic testing shall be obtained from the PSWG, Range Safety, and Center

Pressure Systems Manager.

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11.2.2.13.19. Pressure relief valves shall be tested for proper setting before installation and annually thereafter.

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11.2.2.13.20. Pressure relief devices shall be marked in accordance with ASME Boiler and Pressure Vessel Code, Section

VIII, Division 1, Paragraphs UG-129, UG-130, UG-131, and UG-132 as applicable.

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11.2.2.13.21. A pressure relief valve shall be installed as close as is practical downstream of each pressure reducing device

(regulator, orifice) or downstream of any source of pressure such as compressors, gas rechargers, and tube bank trailer

whenever any portion of the downstream system cannot withstand the full upstream pressure. The criteria for “withstand” is

that the upstream pressure shall not exceed the MAWP of any pressure vessel or component downstream of the regulator or

pressure source.

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11.2.2.13.22. A three-way valve with dual relief valve is required where continuous operation of the system is needed during

relief valve calibration.

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11.2.2.13.23. Pressure system relief devices shall have no intervening stop valves between piping being protected and the

relief devices or between the relief device and the point of discharge except as allowed by ASME B31.3, Paragraph 322.6.1.

When a full-area stop valve is allowed in accordance with the ASME code, the valve shall have provisions for being locked

in the open or closed position. The valve shall have permanent marking clearly identifying its position (OPEN or CLOSED).

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11.2.2.13.24. Pressure relief valve set point testing shall be performed in accordance with NASA-STD-8719.17 and NBIC

NB-23. Set point testing shall only be performed by organizations that possess current National Board Certificate of

Authorization for the repair of pressure relief valves (VR Stamp) or Test Only Certificate (T/O Stamp).

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Mandatory

Safety wiring is an acceptable means of locking shutoff valves in the open or closed position.

11.2.2.14. Ground Support Pressure System Supports, Anchors, Clamps, and Other Restraints

11.2.2.14.1. All piping supports, anchors, hangers, and other restraints shall conform to the requirements of ASME B31.3,

Paragraph 321.

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11.2.2.14.2. Line Restraints.

11.2.2.14.2.1. Where line restraint is required, anchors, guides, pivots, or restraints shall be fabricated or purchased and

assembled in such a form as to secure the desired points of piping in relatively fixed positions.

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11.2.2.14.2.2. Line restraints shall permit the line to expand and contract freely in opposite directions away from the anchored

or guided point.

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11.2.2.14.2.3. Line restraints shall be designed to withstand the thrust, torsional forces, and load conditions of operation.

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11.2.2.14.2.4. Line restraints shall contain the line in case of line failure.

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11.2.2.14.2.5. The support shall be capable of withstanding no less than two times the available force as a result of thrust

generated from component failure under pressure.

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11.2.2.14.3. All relief valves and attached vent piping shall be designed to withstand any thrust caused by venting fluids.

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11.2.2.14.4. All rigid tubing assemblies shall be supported by rigid structures using cushioned steel clamps or suitable multiple

tube, block-type clamps.

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11.2.2.14.5. Tubing supports within consoles or modules shall be spaced according to the maximum spacing listed in Table

11.3.

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11.2.2.14.6. Tubing supports between consoles and modules shall be spaced according to the maximum spacing listed in

Table 11.4.

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11.2.2.14.7. Components within a system shall be supported by a firm structure and not the connecting tubing or piping unless

it can be shown by analysis that the tubing or piping can safely support the component with a safety factor of 3 against yield.

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11.2.2.14.8. Hazardous pressure system piping shall be installed with sufficient flexibility to prevent static or dynamic flow-

induced loads and thermal expansion or contraction from causing excessive stresses to be induced in the system, excessive

bending moments at joints, or undesirable forces or moments at points of connection to equipment or at anchorage or guide

points.

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11.2.2.14.7. Components within a system shall be supported by a firm structure and not the connecting tubing or piping unless

it can be shown by analysis that the tubing or piping can safely support the component with a safety factor of 3 against yield.

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11.2.2.14.8. Hazardous pressure system piping shall be installed with sufficient flexibility to prevent static or dynamic flow-

induced loads and thermal expansion or contraction from causing excessive stresses to be induced in the system, excessive

bending moments at joints, or undesirable forces or moments at points of connection to equipment or at anchorage or guide

points.

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11.2.2.15. Reserved

11.2.2.16. Ground Support Pressure System Pumps

11.2.2.16.1. The Standards of the Hydraulic Institute should be used as a guide in selecting a safe pump.

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11.2.2.16.2. Gear pumps shall not be used for high pressure applications involving flammable and/or hazardous fluids.

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11.2.2.16.3. The inlet pressure of hydraulic pumps shall be controlled to prevent cavitation effects in the pump passage or

outlets.

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11.2.2.16.4. Hydraulic pumps required to provide emergency power shall not be used for any other function.

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11.2.2.16.5. Hydraulic pressure systems shall have regulators with a pressure relieving or self-bleeding feature.

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Table 11.3. Spacing for Tubing Supports Within Consoles or Modules.

Nominal Tubing Diameter (inches)

Maximum Distance Between Tubing Support

(inches)

1/8 through 3/8

1/2 through 3/4

1 and over

Table 11.4. Spacing for Tubing Supports between Consoles or Modules.

Nominal Tubing Diameter (inches)

Maximum Distance Between Tubing Support

(feet)

1/8 through 3/8

1/2 through 3/4

1 through 2

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11.2.2.16.6. Pumps used in hypergolic propellant systems shall be of the centrifugal type specifically designed for pumping

hypergolic propellants.

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11.2.2.17. Ground Support Hydraulic System Hardware

11.2.2.17.1. General Ground Support Hydraulic System Design

11.2.2.17.1.1. For all power-generating components, pump pulsations shall be controlled to a level that does not adversely

affect system tubing, components, and support installation.

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11.2.2.17.1.2. When two or more hydraulic actuators are mechanically tied together, only one lock valve shall be used to

hydraulically lock all the actuators.

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11.2.2.17.1.3. The ambient operating temperature for hydraulic systems shall not exceed 275

F for systems using petroleum-

based fluids.

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11.2.2.17.1.4. Fluids for systems operating at temperatures higher than 275

F shall be fire resistant or fireproof for the intended

service.

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11.2.2.17.1.5. Where system leakage can expose hydraulic fluid to potential ignition sources, fire resistant or flameproof

hydraulic fluid shall be used.

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11.2.2.17.1.6. All hydraulic piping installations shall be designed, installed, and tested in accordance with ASME B31.3.

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11.2.2.17.1.7. Pressure snubbers shall be used with all hydraulic pressure transmitters, hydraulic pressure switches, and

hydraulic pressure gauges. Exception: Pneumatic pressure gauges are excluded from this requirement.

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11.2.2.17.1.8. A gauge indicating accumulator gas pressure shall never be used to indicate equivalent hydraulic pressure.

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11.2.2.17.1.9. Pressure system relief devices shall have no intervening stop valves between piping being protected and the

relief devices or between the relief device and the point of discharge, except as allowed per ASME B31.3.

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11.2.2.17.1.10. When a full-area stop valve is allowed in accordance with the ASME Boiler and Pressure Vessel Code, the

valve type shall have provisions for being secured in the open or closed position.

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11.2.2.17.1.11. The shutoff valve shall have permanent marking clearly identifying its position (OPEN or CLOSED).

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11.2.2.17.1.12. Thermal expansion relief valves shall be installed as necessary to prevent system damage from thermal

expansion of hydraulic fluid.

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11.2.2.17.1.13. The liquid thermal expansion relief valve setting shall not exceed 120 percent of the system design pressure

in accordance with ASME B31.3 paragraph 322.6.3 (b).

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11.2.2.17.2. Ground Support Hydraulic System Accumulators and Reservoirs

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11.2.2.17.2.1. Accumulators and reservoirs that are pressurized with gas (within the scope of ASME BPVC VIII Div. 1 U-1)

shall be designed, constructed, tested, certified, and code stamped in accordance with ASME Boiler and Pressure Vessel Code,

Section VIII, Division 1 or Division 2 and registered with the National Board.

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11.2.2.17.2.2. Hydraulic system reservoirs shall be provided with a fluid level indicator. If a sight glass is used for a liquid

level indicator, it shall be properly protected from physical damage.

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11.2.2.17.2.3. Only inert gases shall be used in pressurization accumulators in systems operating at pressures in excess of 200

psig or temperatures over 160

F unless adequate fire and explosion resistance is demonstrated.

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11.2.2.17.2.4. For a gas-pressurized reservoir, the gas pressure shall be controlled by an externally nonadjustable pressure

regulating device to control the gas pressure in the reservoir.

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11.2.2.17.2.5. Hydraulic systems having reservoir filling caps shall include design provisions that will automatically vent the

reservoir opening.

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11.2.2.18. Ground Support Hypergolic Propellant System Hardware. The minimum design requirements for all mobile,

or portable equipment used to handle hypergolic propellants (Nitrogen Tetroxide [N

], Hydrazine [N

,] Unsymmetrical

Dimethylhydrazine [UDMH], Aerozine 50 [A-50], Monomethyl hydrazine [MMH]) shall comply with NASA-STD-5005

Standard for The Design and Fabrication of Ground Support Equipment and the requirements described below.

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11.2.2.18.3. Components used in any fuel or oxidizer system shall not be interchanged after exposure to the respective media.

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11.2.2.18.5. Bi-propellant propellant systems shall have the capability of loading and off-loading fuel and oxidizer systems

one at a time.

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11.2.2.18.6. The minimum design requirements for controlling the migration of liquid or gas hypergolic propellant into an

associated pneumatic system are as follows:

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11.2.2.18.6.1. Each pneumatic branch line that interfaces with a hypergolic propellant system shall be single failure tolerant

to permit positive shutoff of the pneumatic supply and prevent back flow through the branch. A pressure gauge shall be

provided at some point downstream either in the pneumatic system or the hypergols system of each check valve to indicate

the pressure in the hypergolic propellant system.

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A hand-operated, shutoff valve upstream of a regulator and a spring-loaded, poppet-type check valve to permit

positive shutoff of the pneumatic supply and prevent back flow through the branch is an acceptable solution.

11.2.2.18.6.2. Each pneumatic branch supply shall interface with only one type of hypergolic propellant (fuel or oxidizer).

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11.2.2.18.6.3. Downstream of the pneumatic pressure regulator, the pneumatic system shall be identified and marked as a

hypergolic propellant system.

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11.2.2.18.6.4. Hypergolic propellant system GSE shall be designed to interface with facility scrubber or incinerator.

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11.2.2.18.6.5. Interfaces with scrubber and incinerator designs and qualification tests shall be reviewed and approved by the

appropriate local safety authorities as identified by the PSWG and Range Safety.

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11.2.2.18.6.6. Each line venting into a multiple-use vent system shall be protected against back pressurization by means of a

check valve if the upstream system cannot withstand the back pressure or where contamination of the upstream system cannot

be tolerated.

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11.2.2.18.7. Copper, bronze, or other alloys that might form copper oxides shall be avoided in hydrazine areas. If used, they

shall be positively protected by distance, sealing in a compatible material, or use of a splash guard.

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11.2.2.18.8. GSE used to handle propellant systems shall be designed to ensure that all incompatible fuels and oxidizers are

separated so that operations during the prelaunch phase cannot cause inadvertent mixing of the propellants.

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11.2.2.18.9. Downstream of the pneumatic pressure regulator, including the regulator seat, the pneumatic system shall be

constructed of materials that are compatible with all of the hypergolic propellants serviced by the pneumatic supply.

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11.2.2.18.10. The area in close proximity to the hardware containing and/or transporting hydrazine-based fuels shall be

maintained free of surface corrosion and its associated oxidation byproducts.

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11.2.2.18.11. All hypergolic fuel and oxidizer transportation and storage containers shall have the capability to be grounded.

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11.2.2.18.12. Flexible non-metallic Carbon-filled, Teflon-lined flexible hoses blister when used for N

, MMH, for N

service shall be replaced after 2 years of cumulative exposure to any of these fluids. For guidance, see KSC-STD-Z-0006,

Design of Hypergolic Propellants Ground Support Equipment.

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11.2.2.19. Ground Support Cryogenic System Hardware. The minimum design requirements for all mobile, and portable

equipment used to handle liquid oxygen (LO

or LOX), or liquid hydrogen (LH

), liquid helium (LHe), liquid nitrogen (LN

liquefied natural gas (LNG) and their respective vent gases are as follows:

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The inner shell and piping in the annular space should be type 304 or 316 (304L or 316L, if welded) stainless steel.

The outer shell and supports may be stainless steel or carbon steel.

11.2.2.19.1. Cryogenic systems shall be insulated with compatible material or be vacuum-jacketed to avoid liquefaction of

air. Drip pans or other equivalent means shall be provided under flanges when there exists the possibility of leaking liquefied

air.

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11.2.2.19.2. Cryogenic fuel and oxidizer systems shall have the capability of loading and off-loading one commodity at a

time.

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11.2.2.19.3. Vacuum-jacketed systems shall be capable of having the vacuum verified.

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11.2.2.19.4. Purge gas for LH

and cold gaseous hydrogen (GH

) lines shall be gaseous helium (GHe). Neither GN

nor LN

shall be introduced into any LH

line that interfaces with a liquid storage tank cold port.

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11.2.2.19.5. Cryogenic systems shall be designed to ensure the separation of fuels and oxidizers and to prevent inadvertent

mixing.

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11.2.2.19.6. Precautions shall be taken to prevent cross mixing of media through common purge lines by use of check valves

to prevent back flow from a system into a purge distribution manifold.

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11.2.2.19.7. Cross connection of GN

and GH

systems is prohibited.

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11.2.2.19.8. All permanently installed cryogenic vessels shall consist of an inner and an outer shell.

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11.2.2.19.9. The annular space between the inner and outer shell shall be insulated and may be vacuum-jacketed or purged.

Exception: LH

and LHe vessels shall be vacuum-jacketed.

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11.2.2.19.10. The inner pressure vessel shall be designed, constructed, examined, tested, certified, registered with the National

Board, and code stamped on the exterior of the vessel in compliance with ASME Boiler and Pressure Vessel Code, Section

VIII, Division 1 or Division 2.

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An additional nameplate marked “DUPLICATE” may be attached to the support structure.

11.2.2.19.12. The outer vessel shall be designed for 15.0 psia external pressure.

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11.2.2.19.13. For nonvacuum-jacketed vessels, the annular space shall be protected by means of a vacuum breaker.

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11.2.2.19.14. Local and remote readout liquid level indicators shall be provided for LH

and storage vessels.

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11.2.2.19.15. At a minimum, local readout capability shall be provided for all other cryogenic storage vessels.

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11.2.2.19.16. Cryogenic piping systems shall provide for thermal expansion and contraction without imposing excessive loads

on the system.

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11.2.2.19.17. Cryogenic systems shall be designed to ensure icing does not render any valve or system component inoperable.

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11.2.2.19.18. Cryogenic valves with extended stems shall be installed with the actuator approximately vertical above the

valve.

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11.2.2.19.19. GH

and liquefied natural gas (LNG) shall be vented to the atmosphere through a burner system.

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11.2.2.19.20. GH

and liquefied natural gas (LNG) burner design and testing requirements shall be approved by the

appropriate local safety authority as identified by the PSWG and Range Safety.

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11.2.2.19.21. Pressure vessels shall be designed with an opening for inspection purposes.

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11.2.2.19.22. All inner vessel pressure retaining welds including shell, head nozzle, and nozzle-to-head and shell welds shall

be 100 percent inspected by radiographic and/or ultrasonic volumetric NDE.

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11.2.2.19.23. All inner vessel attachment welds for items such as supports, lugs, and pads shall be 100 percent inspected by

liquid penetrant, ultrasonic, magnetic particle, eddy current, and/or radiographic surface NDE.

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11.2.2.19.24. Welded attachments to the inner vessel such as stiffening rings or supports shall be continuously welded.

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11.2.2.19.25. All attachments to the inner shell shall be positioned so that no attachment weld overlaps any Category A or B

weld as defined in ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, Paragraph UW-3.

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11.2.2.19.26. Cryogenic systems shall be provided with readily accessible low-point drain capability to allow draining of

tanks and piping systems. Small volumes contained in valves, filters, and other containers that will boil-off in a short period

of time do not require low-point drain capability.

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11.2.2.19.27. Vacuum-jacketed or other types of thermal insulation shall be based on system heat leak rate and failure mode

and effect determination.

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11.2.2.19.28. Guidelines for oxygen systems design, material selection, operations, storage, and transportation can be found

in ASTM Manual MNL36, Safe Use of Oxygen and Oxygen Systems: Handbook for Design, Operation, and Maintenance.

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11.2.2.19.29. For failure modes that could result in a time-critical emergency condition, provisions shall be made for automatic

switching to a safe mode of operation. Caution and warning signals shall be provided for these time-critical functions.

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11.2.2.19.30. Flight propulsion systems and/or propellant tanks and their associated propellant loading system (including

portable vessels and units) shall be designed such that propellant transfer operations are commonly bonded and grounded.

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11.2.2.19.31. Titanium and titanium alloys shall not be used where there is possible exposure to gaseous oxygen (cryogenic

boil-off) or liquid oxygen.

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11.2.2.20. Ground Support Cryogenic Piping System Joints, Connections, and Fittings

11.2.2.20.1. Cryogenic piping design shall be in accordance with ASME B31.3, Process Piping.

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11.2.2.20.2. Joints in piping systems shall be of the butt-weld, flanged, bayonet, or hub type in accordance with KSC-GP-

425, KC159/KC163, or the commercial equivalent.

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11.2.2.20.3. Butt-welded joint designs shall meet the requirements of ASME B31.3.

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11.2.2.20.4. Flanged joints shall be either weld neck or lap joint, raised face type conforming to ASME B16.5 and shall be

constructed of forged ASTM A182 304L or 316L material. The use of slip-on flanges shall be avoided.

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The preferred materials for welded pipe fittings are 304L or 316L stainless steel.

11.2.2.20.5. Flange faces or lap-joint stub end faces shall be concentrically serrated conforming to Manufacturers

Standardization Society of the Valve and Fittings Industry Standard Practice, MSS-SP-6, Standard Finishes for Contact Faces

of Pipe Flanges and Connecting End Flanges of Valves and Fittings.

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11.2.2.20.6. LH

vent system flanged joints shall be metal-to-metal and welded in accordance with applicable ASME B31.3,

Process Piping requirements.

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11.2.2.20.7. Flange bolting and studs shall conform to ASME B18.2.1, Square and Hex Bolts and Screw Inch Series

recommended dimensions with rolled threads conforming to ASME B1.1, Unified Inch Screw Threads.

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11.2.2.20.8. Bolt materials shall be per ASTM A193 or ASTM A320.

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11.2.2.20.9. Nuts for flange bolting and studs shall be ASTM A194, conforming to ASME B18.2.2, Square and Hex Nuts

(Inch Series), heavy hex type and shall use ASME B1.1 thread.

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Type 304 or 316 stainless steel are the preferred materials for nuts, bolts, and studs used for flange bolting.

11.2.2.20.10. Pipe fittings such as tees, elbows, crosses, reducers, and lap joint stub ends shall be full penetration butt weld

type only, conforming to ASME B16.9 and ASTM A403.

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ASTM A403 grade WP304L or WP316L wrought stainless steel is the preferred materials for pipe fittings.

11.2.2.20.11. Bayonet fittings shall be used on vacuum-jacketed lines where butt welding is not practical, and a mechanical

joint is required.

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11.2.2.20.12. Metal-to-metal couplings shall be the butt-welded types. The gaskets (not reusable) shall be constructed of

stainless steel only. The V-band clamps shall be constructed of stress-corrosion-resistant material.

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11.2.2.20.13. Vacuum-jacketed pipe shall not use bellows in the inner pipe. Allowance for differential expansion between

inner and outer pipe shall be provided by bellows in the outer pipe.

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11.2.3. Ground Support Pressure System Testing

11.2.3.1. Testing Ground Support Pressure Systems Before Assembly

11.2.3.1.2. Fluid system components such as piping, tubing, flexible hoses, valves, filters, fittings, and pressure regulators

(not including pressure gauges, transducers, and pressure relief devices) shall be pressure tested in accordance with methods

and criteria contained in ASME B31.3.

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11.2.3.1.3. Pressure vessels designed to meet DOT specifications shall undergo qualification and hydrostatic testing in

accordance with 49 CFR and DOT requirements.

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11.2.3.1.4. Hydrostatic or pneumatic testing shall demonstrate that there is no distortion, damage, or leakage of components

at the appropriate test level pressure.

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11.2.3.1.5. The following inspections shall be performed after hydrostatic testing:

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11.2.3.1.5.1. Mechanical components such as valves, regulators, piping, and fittings shall be inspected for distortion or other

evidence of physical damage. Damaged components shall be rejected.

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11.2.3.1.5.2. A component functional and leak test shall be performed at the MAWP of the component.

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11.2.3.1.6. Pressure relief devices, gauges and transducers shall be calibrated before installation and yearly thereafter.

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11.2.3.1.7. For pressure gauges, transducers, or rupture discs and other components not covered by ASME B31.3, pneumatic

testing to 1.25 times maximum operating pressure (MOP/MEOP) (not to exceed MAWP), in lieu of hydrostatic testing, is

permissible if hydrostatic testing is impractical, impossible, or jeopardizes the integrity of the component or system.

Pneumatic testing to 1.1 times design pressure for components covered by ASME B31.3 in lieu of hydrostatic testing, is

permissible if hydrostatic testing is impractical, impossible, or jeopardizes the integrity of the component or system. Prior

approval for pneumatic proof testing at the ranges shall be obtained from SLD 30/SE and SLD 45/SE.

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11.2.3.1.8. Certain critical system components may require further testing (helium mass spectrometer) in accordance with

ASME Boiler and Pressure Vessel Code, Section V, Nondestructive Examination, Article 10, Leak Testing.

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11.2.3.1.9. All valves used for hypergolic propellant systems shall be tested for both external and internal leakage at MAWP

using an inert gas (helium/nitrogen) consisting of at least 10 percent helium. The use of argon as a testing medium is

prohibited.

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11.2.3.1.9.1. No external leakage is allowed (bubble-tight).

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11.2.3.1.9.2. Internal leakage of valves shall not exceed limits specified in the valve performance specification.

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11.2.3.1.9.3. Where no valve specification exists, the leak rate shall not exceed 1x10-6 cc/sec at standard temperature and

pressure.

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11.2.3.2. Testing Ground Support Pressure Systems After Assembly

11.2.3.2.1. Ground Support Pressure System Hydrostatic Tests

11.2.3.2.1.1. All newly assembled pressure systems shall be hydrostatically tested to 1.5 times system design pressure before

use. When the design temperature is greater than the test temperature the minimum test pressure shall be adjusted in

accordance with ASME B31.3 par. 345.4.2(b). Where this is not possible adequate rational and data supporting the adequacy

of component testing and alternate means of testing the assembled system shall be submitted for review and approval by the

PSWG, Range Safety, and the Center Pressure Systems Manager. Pneumatic testing at 1.1 times the system design pressure

is acceptable in lieu of hydrostatic testing at 1.5 times the design pressure. Prior approval of the plan for pneumatic testing

shall be obtained from the PSWG, Range Safety, and the Center Pressure Systems Manager.

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11.2.3.2.1.2. All cryogenic systems shall be hydrostatically tested to at least 1.25 times system MOP using an inert cryogenic

fluid at or below the expected lowest temperature.

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11.2.3.2.1.3. Cryogenic systems that cannot be chilled and hydrostatically tested with an inert fluid at or below the lowest

expected temperature shall require a cold shock demonstration test, a hazard analysis, and a fracture mechanics safe-life

analysis. The test and analysis methodology is subject to review and approval by the PSWG, Range Safety, and the Center

Pressure Systems Manager.

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11.2.3.2.1.4. The hydrostatic test or cold shock/soak test (for at least 1 hour) shall demonstrate that the system or components

shall sustain test pressure level and temperature gradient without distortion, damage, or leakage.

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11.2.3.2.1.5. The following inspections shall be performed on vacuum-jacketed systems:

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11.2.3.2.1.5.1. An examination for cold spots on vacuum jackets. Cold spots in the outer line shall not be more than 5

colder than the surrounding area, except in cases where system heat-leak requirements permit colder temperatures, such as

around low-point drain valves, relief valves, or other areas where a direct thermal path is available.

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11.2.3.2.1.5.2. Vacuum readings for all vacuum volumes shall be taken and recorded. These readings shall be taken before,

during, and after the test.

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11.2.3.2.1.5.3. The vacuum readings after the hydrostatic or cold shock/soak using a cryogenic fluid shall be taken when the

system returns to ambient temperature.

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11.2.3.2.2. Ground Support Pressure System Leak Tests

11.2.3.2.2.1. For systems with a hazardous fluid, after hydrostatic testing and before the introduction of propellant, a

pneumatic leak test of completely assembled systems shall be conducted at the system MOP using an inert gas

(helium/nitrogen) consisting of at least 10 percent helium. The use of argon as a testing medium is prohibited.

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11.2.3.2.2.2. After successful completion of the hydrostatic test using a cryogenic fluid, a pneumatic leak test of the complete

system shall be performed at the system MOP using helium or a mixture of nitrogen with a minimum of 25 percent helium.

There shall be no leakage into the vacuum volume in excess of 1.0E-06 cc/sec. The sensitivity of the instrumentation used to

measure leak rate shall be a minimum of 1.0E-09 std cm3/sec/div in accordance with Article 10 of the ASME Boiler and

Pressure Vessel Code.

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11.2.3.2.2.3. All newly assembled pressure systems, except systems designed, fabricated, inspected, and tested in accordance

with DOT requirements, shall be leak tested at the system MOP before first use at the payload processing facility and launch

site area.

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11.2.3.2.2.4. This test shall be conducted at the payload processing facility and launch site area unless prior approval from

the PSWG and Range Safety has been obtained.

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11.2.3.2.2.5. Minimum test requirements:

11.2.3.2.2.5.1. The gas used during the leak test shall be the same as the system fluid media except that for hazardous gas

systems, a system compatible, non-hazardous gas may be used that has a density as near as possible to the system fluid; for

example, helium should be used to leak test a gaseous hydrogen system.

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11.2.3.2.2.5.2. Mechanical connections, gasketed joints, seals, valve bonnets, and weld seams shall pass a mass spectrometer

helium leak check or shall be visually bubble tight for a minimum of 1 minute when leak tested with MIL-PRF-25567, Leak

Detection Compound, Oxygen Systems, Type 1 or equivalent leak test solution.

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Alternate methods of leak testing may be approved on a case-by-case basis.

11.2.3.2.2.5.3. Non-hazardous liquid systems may be leak tested using the normal system service.

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11.2.3.2.3. Ground Support Pressure System Validation and Functional Tests

11.2.3.2.3.1. All newly assembled pressure systems shall have a system validation test and a functional test of each component

at system MOP before first operational use at the payload processing facility and launch site area.

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11.2.3.2.3.2. These tests shall be conducted at the payload processing facility and launch site area unless prior approval from

the PSWG and Range Safety has been obtained.

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11.2.3.2.3.3. Minimum test requirements:

11.2.3.2.3.3.1. Tests shall demonstrate the functional capability of all components such as valves, regulators, orifices, pumps,

flexible hose connections, and gauges.

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11.2.3.2.3.3.2. All operational sequences for the system shall be executed including emergency shutdown and safing

procedures.

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11.2.3.2.3.3.3. All shutoff and block valves shall be leak checked downstream to verify their shutoff capability in the closed

position.

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11.2.3.2.3.3.4. The intended service fluid shall be used as the test fluid where practical. PSWG and Range Safety approved

inert service fluid may be used in place of the service fluid if the intent of the test (equivalent effect on the system) is

demonstrated.

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11.2.3.2.3.3.5. Systems shall be tested to verify bonding and grounding.

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11.2.3.3. Ground Support Pressure System Periodic Testing and Maintenance

11.2.3.3.1. Uninstalled flexible hoses shall be hydrostatically proof tested to 1.5 times their MAWP within one year before

use, or pneumatically tested to 1.1 times MAWP once every two years unless otherwise approved by the PSWG or Range

Safety. Installed flexible hoses in functional use shall be hydrostatically tested to 1.5 times their MAWP once a year.

Exception: This requirement does not apply to flexible hoses that are permanently installed, located, and operated in an environment

that does not exceed the rated temperature, pressure, and shelf life of the hose.

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11.2.3.3.2. Prior to project use and at least annually, all flexible hoses shall be visually inspected over their entire length.

Those with damaged fittings, broken braid, kinks, flattened areas, or other evidence of degradation shall be removed from

service. A flexible hose exhibiting major defects as classified in SAE ARP 1658, shall be removed from service.

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11.2.3.3.3. Pressure gauges and transducers shall be calibrated within one year before use. Pressure gauges and transducers

in functional use shall be calibrated once a year.

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11.2.3.3.4. Pressure relief valves shall be tested for proper setting and operation once a year. Pressure relief valve set point

testing shall be performed in accordance with NASA-STD-8719.17 and NBIC NB-23. Set point testing shall only be

performed by organizations that poses current National Board Certificate of Authorization for the repair of pressure relief

valves (VR Stamp) or Test Only Certificate (T/O Stamp).

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11.2.3.4. Testing Modified and Repaired Ground Support Pressure Systems

11.2.3.4.1. After repairs and/or modifications to existing tankage, piping, and other system components, tests shall be

performed to the same standards, codes, and requirements for which a new system would be designed, fabricated, and tested.

Minor refurbishment, such as replacement of gaskets, seals, and valve seats that does not affect structural integrity, does not

require a requalification test.

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11.2.3.4.2. Any pressure system component covered by ASME B31.3, including piping, tubing, fittings, or welds, that has

been repaired, modified, or possibly damaged, having been hydrostatically or pneumatically tested, shall be retested

hydrostatically to 1.5 time MAWP or pneumatically to 1.1 times MAWP before reuse. Any pressure system component that

may be damaged during testing, including pressure gauges, transducers, or rupture discs and other components shall be retested

hydrostatically to 1.5 times MOP (not to exceed MAWP) before reuse. Pneumatic testing requires prior approval by the

PSWG, Range Safety, and the Center Pressure Systems Manager.

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11.2.3.4.3. After hydrostatic testing, modified or repaired systems shall be leak tested at the system MOP before placing them

back in service. This test shall be conducted at the payload processing facility and launch site area unless prior approval has

been obtained from the PSWG and Range Safety.

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11.2.3.4.4. After hydrostatic testing, modified or repaired systems shall be functionally tested at the system MOP before reuse.

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11.2.3.4.5. All system mechanical joints affected in the disconnection, connection, or replacement of components shall be

leak tested at the system MOP before being placed back in service.

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11.2.3.4.6. Gaskets shall not be reused.

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11.2.4. Ground Support Pressure System Analysis and Documentation Requirements

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11.2.4.1. Ground Support Pressure System Hazard Analysis

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11.2.4.1.1. As applicable, a hazard analysis shall be performed on all hazardous systems hardware and software in accordance

with a jointly tailored SSP. (See Volume 1, Attachment 2.)

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11.2.4.1.2. At a minimum, the hazard analysis shall include the analysis requirements in AFI 10-2501, Air Force Emergency

Management Program, and AFMAN 91-203, Air Force Occupational Safety, Fire and Health Standards, for toxic, reactive,

flammable, and explosive fluids and 29 CFR 1910.119 for highly hazardous chemicals, as applicable. Additional hazard

analysis may be required by the PSWG and Range Safety regarding emergency planning and response of hazardous materials.

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11.2.4.2. Engineering Assessment, Data, and Analysis Requirements

11.2.4.2.1. An engineering assessment and analysis IAW NASA STD 8719.17 shall be performed before the start of the first

recertification period.

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11.2.4.2.2. The engineering assessment of the design, fabrication, material, service, inspection, and testing shall be evaluated

against the latest codes, standards, regulations, and requirements identified in this volume.

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11.2.4.2.3. Discrepancies with the latest requirements shall be resolved by repair, modification, analysis, inspection, or test.

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11.2.4.2.4. Design, Fabrication, and Installation Deficiencies. At a minimum, the following potential design, fabrication, and

installation type deficiencies shall be assessed:

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11.2.4.2.4.1. Design deficiencies such as design notches, weld joint design, and reinforcements.

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11.2.4.2.4.2. Material deficiencies such as laminations, laps, seams, cracks, hardness variations, and notch brittleness.

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11.2.4.2.4.3. Welding deficiencies such as cracks, incomplete fusion, lack of penetration, overlap, undercut, arc strikes,

porosity, slag inclusions, weld spatter, residual stresses, and distortion.

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11.2.4.2.4.4. Installation deficiencies such as fit up, alignment, attachments, and supports.

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11.2.4.2.4.5. Operation and Maintenance Deficiencies. At a minimum, the following potential operation and maintenance

deficiencies shall be assessed:

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11.2.4.2.4.5.1. Refurbishment damage.

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11.2.4.2.4.5.2. Modification and/or repair deficiencies.

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11.2.4.2.4.5.3. Operation beyond allowable limits or improper sequence.

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11.2.4.2.4.5.4. Maintenance deficiencies.

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11.2.4.3. Inservice Operating, Maintenance, and Inspection Plan. The payload project responsible for the design of

hazardous pressure systems shall prepare an in-service operating, maintenance, and inspection plan. This plan shall be referred

to as the Inservice Inspection (ISI) Plan. The ISI Plan shall be IAW NASA-STD-8719.17 section 4.8.3 and shall address and

provide the following:

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Table 11.9. In-service Operating, Maintenance, and Inspection Plan Guidance.

Guidance for preparing an ISI Plan can be found in ASME Post Construction Committee (PCC)-3, Inspection Planning Using

Risk-Based Methods.

Petroleum storage systems designed, operated, and maintained in accordance with OSHA and/or other identified standards

are not generally considered hazardous and thus do not require ISI plans. Compressed air (shop air) systems designed,

operated, and maintained in accordance with 29 CFR.169 also do not require an ISI Plan.

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11.2.4.3.1. Credible damage mechanisms that may cause service-related failures of the system during its service life shall be

analyzed.

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11.2.4.3.2. Methods such as “eliminated,” “controlled by design,” “controlled by procedure,” or “controlled by corrosion

protection” used to eliminate and control these failure mechanisms shall be identified.

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Failure mechanisms to be evaluated include corrosion, stress, fatigue, creep, design fabrication, installation,

operation, and maintenance deficiencies.

11.2.4.3.3. Using the results of the above failure mechanism analysis, the following minimum requirements for an operating,

maintenance, and inspection plan shall be defined:

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11.2.4.3.3.1. Operating plans shall address operating constraints such as maximum pressure, MAWP, MOP, minimum and

maximum temperature, vibration, and maximum cycles.

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11.2.4.3.3.2. Maintenance plans shall address corrosion protection, maintenance schedule, soft-good replacement program,

refurbishment, calibration, and other maintenance requirements.

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Hazardous pressure systems intended for one-time use can usually be exempted from the cited maintenance plan

requirements. Typically, a Launch Site Requirements Relief Request (LSRRR) provides the basis for this

exemption.

11.2.4.3.3.3. Inspection plans shall identify the type and frequency of inspections such as visual, surface, and volumetric NDE

required for each vessel and system to detect the types of failure mechanisms identified in 11.2.4.3.1 above.

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11.2.4.3.3.4. Hazardous pressure systems shall be maintained and periodically inspected in accordance with the ISI Plan.

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11.2.4.3.3.5. Unacceptable findings from the performance of periodic inspections shall be resolved with the PSWG, Range

Safety, and the Center Pressure Systems Manager participation.

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11.2.4.4. Ground Support Pressure System Data Requirements. The minimum data required to certify compliance with

the design, analysis, and test requirements of ground support pressure systems are listed below. The data required shall be

incorporated into the Safety Data Package (MSPSP) or submitted as a separate package when appropriate. Certification data

shall be placed in a certification file to be maintained by the hazardous pressure system operator. The PSWG, Range Safety,

and the Center Pressure Systems Manager shall review and approve this data before first operational use of new, modified, or

repaired hazardous pressure systems at the payload processing facility and launch site area.

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11.2.4.4.1. Ground Support Pressure System General Data Requirements. The following general ground support

equipment data shall be submitted as part of the MSPSP.

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11.2.4.4.1.1. Hazard analysis of hazardous pressure systems in accordance with the SSP (Volume 1, Attachment 2).

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11.2.4.4.1.2. A compliance checklist of all design, test, analysis, and data submittal requirements in this volume.

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11.2.4.4.1.3. The material compatibility analysis in accordance with the 11.2.1.4 of this chapter.

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11.2.4.4.1.4. Inservice operating, maintenance, and inspection plan in accordance with 11.2.4.3 of this chapter.

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11.2.4.4.1.5. Physical and chemical properties and general characteristics of propellants, test fluids, and gases data.

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11.2.4.4.1.6. For hazardous propellants, fluids, and gases, data shall be submitted in accordance with 3.10.4 and Attachment

1, A1.2.4.7.1.3 of this volume.

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11.2.4.4.2. Ground Support Pressure System Design Data Requirements. Ground support pressure systems design data

shall be submitted in accordance with Attachment 1, A1.2.5.9 of this volume.

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11.2.4.4.3. Ground Support Pressure System Component Design Data Requirements. Ground support pressure systems

component design data shall be submitted in accordance with Attachment 1, A1.2.5.9.3 of this volume.

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11.2.4.4.4. Ground Support Pressure System Test Procedures and Reports

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11.2.4.4.4.1. All test plans, test procedures and test reports required in Chapter 11 of this volume shall be submitted to the

PSWG, in conjunction with Range Safety and the Center Pressure Systems Manager for review and approval.

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11.2.4.4.4.2. A list and synopsis of all hazardous pressure system operational procedures to be performed at the payload

processing facility and launch site areas shall be provided to the appropriate local safety authority responsible for the procedure

review at the location where the operations are to take place.

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Ground Support Pressure Systems Certification and Recertification

11.3.1. Ground Support Pressure Systems Recertification Test Requirements. Testing requirements for recertification

of components and systems are as follows:

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11.3.1.1. Vessels and packaging designed to 49 CFR specifications shall be retested to DOT requirements.

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11.3.1.2. All ground support pressure systems, except DOT vessels shall be pressure tested in accordance with ASME Boiler

and Pressure Vessel Code, Section VIII, Division 1, or Division 2, as applicable to the year of construction of the vessel.

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11.3.1.3. All piping and tubing system components shall be pressure tested in accordance with methods and criteria contained

in ASME B31.3.

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11.3.1.4. Cryogenic systems shall be retested in accordance with 11.2.3.2 of this volume.

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11.3.1.5. 100 percent visual inspection of all joints and connections shall be performed before and after hydrostatic or

pneumatic pressure tests. Parts that indicate a change in volume, permanent deformation, leakages, or cracks shall be rejected.

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11.3.1.6. 100 percent visual inspection of the external surfaces of a vessel and system and 100 percent of the internal surfaces

for vessels shall be performed before and after hydrostatic or pneumatic pressure tests.

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11.3.1.6.1. Any sign of corrosion, dents, or other damages shall be identified and annotated on permanently maintained

recertification documents.

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11.3.1.6.2. For corroded areas, the corrosion shall be removed.

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11.3.1.6.3. Using ultrasonic testing (UT), the entire surface area affected by corrosion shall be measured and the remaining

wall thickness determined.

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11.3.1.6.4. Wall areas that are below the minimum required thickness and other unacceptable findings shall be fixed before

placing the system back into service.

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11.3.1.6.5. The susceptibility effects of corrosion such as cracking, delamination, or intergranular attack should be addressed.

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11.3.1.7. All weld joints on vessels and systems with pressure greater than 500 psig or containing a hazardous fluid shall be

100 percent volumetrically and surface NDE inspected.

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11.3.1.7.1. Radiographic examination shall be used to the maximum extent possible.

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11.3.1.7.2. UT shall be used if radiographic testing (RT) is determined to be ineffective.

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11.3.1.7.3. NDE surface and volumetric testing shall be performed after the hydrostatic/pneumatic pressure test.

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11.3.1.8. All components and systems shall be leak checked in accordance with paragraph 11.2.3.2.2., Ground Support

Pressure System Leak Tests and functionally tested in accordance with 11.2.3.2.3., Ground Support Pressure System

Validation and Functional Tests.

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11.3.1.9. Leaks shall be repaired and components that do not function properly shall be repaired or replaced before starting

the subsequent recertification period.

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11.3.2. Ground Support Pressure Systems General Recertification Requirements. Requirements for performing

recertification are found in NASA-STD-8719.17 and the following:

11.3.2.1. The recertification period for vessels and systems shall comply with local requirements and shall not exceed the

shortest period resulting from or determined by the following criteria:

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11.3.2.1.1. The shortest service life shall be determined based on the system and components design performance parameters,

operational requirements, and inspection and test results. PVS shall be recertified on or before one-half the documented initial

service life or one-half the recertified remaining life and not to exceed 20 years IAW NASA STD 8719.17, 4.11.2.3 and

4.8.2.7.

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11.3.2.1.2. Twenty years for systems and for vessels that can be 100 percent inspected both internally and externally.

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11.3.2.1.3. Ten years for systems and for vessels that cannot be 100 percent inspected internally but can be 100 percent

inspected externally.

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11.3.2.1.4. Five years for systems and for vessels that cannot be 100 percent inspected either internally or externally.

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11.3.2.1.5. Manufacturer recommendations.

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11.3.2.1.6. Recertification of cryogenic vessels shall be accomplished at a minimum of every 20 years with an internal

inspection every 10 years.

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11.3.2.3. Portable or mobile vessels used for transportation and/or storage of pressurized or hazardous commodities shall be

designed, maintained, and recertified in accordance with 49 CFR or applicable codes.

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11.3.2.4. Inspections and maintenance shall be performed on hazardous pressure systems and integrated portable or mobile

vessels in accordance with local requirements and a system inspection and maintenance plan developed by the system operator

approved by the PSWG, Range Safety and the Center Pressure Systems Manager.

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11.3.2.5. The hazardous pressure system operator shall retain all documentation generated as a result of the recertification

effort and place a copy of this documentation in the system certification and recertification file located at the ranges.

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11.3.3. Ground Support Pressure Systems Certification

11.3.3.1. Ground Support Pressure Systems Certification Files General Requirements

11.3.3.1.1. Certification files shall be maintained and updated in an appropriate configuration management system acceptable

to the responsible pressure systems manager. These files shall be available at the payload processing facility and launch site

area and accessible for PSWG and Range Safety review. Vessels and systems, including mobile and portable systems, that

do not have current certification files shall be deactivated and removed from service.

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11.3.3.1.2. Certification files shall be updated within 90 calendar days of completion of periodic inspections and tests.

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11.3.3.1.3. Updated information shall include any changes to the current certification files and the following:

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11.3.3.1.3.1. Temperature, pressurization history, and pressurizing fluid for both the tests and operations.

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11.3.3.1.3.2. Results of any inspection conducted, including the name of the inspector, inspection dates, inspection techniques

used, location and character of defects, defect origin, and defect cause.

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11.3.3.1.3.3. Maintenance and corrective actions performed from the time of manufacture throughout operational life,

including refurbishment.

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11.3.3.1.3.4. Sketches and photographs to show areas of structural damage and extent of repairs.

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11.3.3.1.3.5. Certification and recertification tests performed, including test conditions and results.

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11.3.3.2. Ground Support Pressure System Certification Data

11.3.3.2.1. The certification file for each hazardous pressure system shall contain all the data required to justify system

certification IAW NASA-STD-8719.17.

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11.3.3.2.2. The data shall include, but not be limited to, the following:

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11.3.3.2.2.1. Design calculations for stress, fatigue, and other items that verify compliance with applicable code requirements

such as ASME, ANSI, and DOT.

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11.3.3.2.2.3. In-process fabrication and construction inspection plans and results.

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11.3.3.2.2.4. Pressure vessel manufacturer data reports (ASME Form U-1 or Form U-1A).

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11.3.3.2.2.5. Specification drawings and documents for all components.

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11.3.3.2.2.6. If available, maintenance manuals for all components.

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11.3.3.2.2.7. If available, component operating manual.

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11.3.3.2.2.8. As required, a cross-sectional assembly drawing of the component to assess the safety aspects of the internal

elements.

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11.3.3.2.2.9. System operating and maintenance plans and procedures.

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11.3.3.2.2.10. Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance

Qualifications (WPQ) in accordance with ASME BPVC, B31 piping codes and Section IX.

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11.3.3.2.2.11. Unique qualification and acceptance test plans and test reports.

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11.3.3.2.2.12. Certification documentation showing that vessels are designed, fabricated, and tested in accordance with ASME

Boiler and Pressure Vessel Code, Section VIII, Division 1/Division 2 or 49 CFR.

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11.3.3.2.2.13. Certification that all components, including pipe and tube fittings have successfully passed a hydrostatic or

pneumatic pressure test.

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11.3.3.2.2.14. A controlled pressure system drawing (Piping and Instrumentation Diagram or a schematic) and component

sheets that reflect the current system configuration.

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11.3.3.2.2.15. All system Non-Destructive Examination reports.

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11.3.4. Ground Support Pressure System Analyses. An engineering analysis shall be performed as follows:

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11.3.4.1. A stress analysis of all vessels and piping shall be available for evaluation or performed to verify that stresses are

within allowable limits of current codes, standards, and regulations as identified in this volume and NASA-STD-8719.17.

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11.3.4.2. The number of stress cycles experienced by the vessel during the certification period shall be determined.

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11.3.4.3. Using fracture mechanics analysis, the cyclic limits for vessels with pressures greater than 2,500 psig, burst-before-

leak failure mode, or corrosive and/or toxic fluids shall be determined.

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11.3.4.4. The safe-life analysis shall be performed under the assumption of pre-existing cracks. This does not imply that

cracks are allowed. All unacceptable indications shall be repaired. The safe-life analysis shall be conducted in accordance

with the following requirements:

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11.3.4.4.1. The analysis shall show that the vessel will service at least 4 times the cycles expected during the recertification

period.

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11.3.4.4.2. The analysis shall calculate and evaluate the results from the worst combination of crack sizes (for guidance refer

to NASA-STD-5009 Nondestructive Evaluation Requirements for Fracture-Critical Metallic Components and locations such

as boss transition area, heat affected area, weld joint, and membrane section within the vessel.

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11.3.4.4.3. The appropriate stress component in the vessel shall be used in the analysis.

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11.3.4.4.4. The initial flaw size used in the safe-life analysis shall be based on either the hydrostatic test pressure or the

detection limits of the appropriate NDE techniques. Flaw shapes (a/2c) ranging from 0.1 to 0.5 shall be considered.

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Refer to NASA-STD-5009 and ASME Section VIII for guidance.

11.3.4.4.5. Calculated cycles to failure shall be based on the maximum and minimum operating pressure.

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11.3.4.4.6. A linear elastic fracture mechanic parameter (stress-intensity factors) shall be used to determine critical crack

sizes. The most conservative deformation mode shall be used to determine the appropriate stress-intensity factors (fracture

toughness) as appropriate for the parent, weld, and joint materials.

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11.3.4.4.7. Fracture mechanics shall only be used to predict the subcritical crack propagation life before unstable crack growth.

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11.3.4.4.8. The safe-life analysis results shall be reduced by a factor of 4 in conjunction with assuming the most conservative

bounds on material properties and crack growth data for the vessel environment.

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11.3.4.4.9. Failure mode determination shall be in accordance with API-579/ASME-FFS-1, Fitness for Service, or equivalent

standard and shall consider operations in hazardous area classification zones as defined by Volume 6, Chapter 14, Section

14.1.2.

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11.3.4.4.10. Vessels subject to stress corrosion (sustained stress) shall show that the corresponding applied stress intensity

during operation is less than the threshold stress intensity in the intended environment.

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11.3.4.4.11. Corrosion allowance and the remaining wall shall be determined based on MIL-HDBK-729, Corrosion and

Corrosion Prevention Metals.

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FLIGHT HARDWARE PRESSURE SYSTEMS AND PRESSURIZED

STRUCTURES

This chapter establishes minimum design, fabrication, installation, testing, inspection, certification, and data requirements

for flight aerospace vehicle equipment (AVE) and pressurized systems, pressure vessels, and pressurized structures.

Flight Hardware Pressure System and Pressurized Structure General Requirements.

Hazardous flight hardware pressure systems are defined as follows:

(1) Flight systems containing hazardous fluids such as cryogens, flammables, combustibles, and toxics.

(2) Systems used to transfer hazardous fluids such as cryogens, flammables, combustibles, and hypergols.

(3) Systems with operating pressures that exceed 100 psig.

(4) Systems with stored energy levels exceeding 14,240 foot pounds; and

(5) Systems that are identified by Payload Safety Working Group (PSWG) as safety critical.

12.1.1. Flight Hardware Pressure System and Pressurized Structure General Design Requirements

12.1.1.1. The structural design of all pressure vessels and pressurized structures shall use industry or government standard

processes and procedures for manufacture and repair.

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12.1.1.2. The design shall provide for access, inspection, service, repair, refurbishment, and pre-launch servicing as

required.

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The Payload Project System Safety Engineer must ensure that all of the requirements in this chapter and

document are well understood and incorporated by the spacecraft design engineers or tailored appropriately.

12.1.1.3. For all reusable pressure vessels and pressurized structures, the design shall permit hardware to be maintained in

and refurbished to a flightworthy condition. To be considered flightworthy, repaired, or refurbished hardware items shall pass

all the applicable acceptance tests and inspections required for new flight hardware.

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12.1.1.4. Repaired, refurbished, or hardware transferred from another payload project shall meet the same conditions of

flightworthiness as new hardware. To be considered flight worthy, repaired, refurbished, or hardware transferred from another

payload project, items shall pass all the applicable qualification, acceptance tests and inspections required for new flight

hardware.

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12.1.2. Flight Hardware Pressure System and Pressurized Structure Failure Tolerance

12.1.2.1. Payload/Spacecraft hazardous pressure systems shall be designed to be single fault tolerant against inadvertent

actuations (including leakage) or component failure that could result in a critical hazard during prelaunch operations.

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12.1.2.2. Payload/Spacecraft hazardous pressure systems shall be designed to be dual fault tolerant against inadvertent

actuations (including leakage) or component failure that could result in a catastrophic hazard during prelaunch operations.

Exception: Structural failure (i.e., rupture or leakage) of tubing, piping, vessels, components featuring machined parent metal

or all-welded construction (e.g. valves, regulators, transducers, heat exchangers, etc.), and normally closed pyrovalves with

machined parent metal shear sections shall not be considered credible single-barrier failures provided they meet the applicable

requirements of this volume. Normally closed pyrovalves used in propellant/pressurization systems without additional barriers

to leakage shall be considered hazardous ordnance devices per Chapter 13 of this volume and shall meet the tubing and fitting

requirements of this volume.

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12.1.3. Flight Hardware Pressure System Offloading

12.1.3.1. For contingency safing operations, hazardous pressure systems shall be designed so that depressurization and drain

fittings are accessible and do not create a personnel or equipment hazard for offloading hazardous fluids at the launch complex.

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12.1.3.2. System design and accessibility shall permit the offload of propellant and pressure systems at any point after

pressurization or loading, including the ability to offload all systems at the launch pad and/or vehicle integration facilities.

This shall occur without de-mating of the spacecraft from the launch vehicle or any other disassembly of vehicle systems

unless approved by the appropriate authorities as identified by the PSWG and Range Safety.

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System design and contingency planning shall permit for safe movement of the payload. Planning shall address

the worst-case scenario.

Accessibility through payload fairing door(s) is the desired approach. Verification/validation of the design for

accessibility is best achieved through a high fidelity modeling or mock-up of hardware, including required GSE,

tooling, PPE, etc., or by demonstrating similarity to accepted design and processes.

Early coordination with the launch vehicle supplier is necessary to establish required payload fairing door size

and placement, operational support, and ability to perform contingency support in hazardous and/or explosive

environments. Also, see 12.1.10.1.

12.1.3.3. If the payload project and the local safety authority decide that depressurizing and/or offloading the pressure systems

of a spacecraft is necessary, spacecraft offload procedures shall be approved by the local safety authority prior to use, in

accordance with Volume 6 section 4.4 and attachment 2 of this publication or as required by the local safety authority.

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12.1.3.4. Flight hardware propellant systems shall be designed to permit propellant loading or offloading without the need for

internal or external power to re-configure propulsion system components.

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12.1.4. Flight Hardware Pressure System Operations. The requirements for operating hazardous pressure systems found

in Volume 6 of this publication shall be taken into consideration in the design and testing of these systems in addition to the

general requirements identified in 12.5 of this chapter.

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12.1.5. Flight Hardware Pressure System and Pressurized Structure Analyses

12.1.5.1. Flight Hardware Pressure System and Pressurized Structure Hazard Analysis

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12.1.5.1.1. A hazard analysis shall be performed on all hazardous systems hardware and software (if applicable) in accordance

with a PSWG approved SSP (Volume 1, Attachment 2).

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12.1.5.1.2. Hazards related to the test, integration, and planned and contingency operations of these systems in payload

processing facility and launch site area shall be analyzed.

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12.1.5.2. Flight Hardware Pressure System and Pressurized Structure Functional Analysis

12.1.5.2.1. A detailed system functional analysis shall be performed to determine that the operation, interaction, or sequencing

of components shall not lead to damage to the launch vehicle, payload, or associated ground support equipment.

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This requirement is generally satisfied in the subsystem/system hazard analysis.

12.1.5.2.2. The analysis shall identify all possible malfunctions or personnel errors in the operation of any component that

may create conditions leading to an unacceptable risk to personnel or equipment.

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12.1.5.2.3. The analysis shall also evaluate any credible secondary or subsequent occurrence, failure, or component

malfunction that, initiated by a primary failure, could result in personnel injury.

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12.1.5.2.4. Items identified by the hazard analyses shall be designated safety critical and shall require the following

considerations:

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12.1.5.2.4.1. Hazard identification and proposed corrective action.

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12.1.5.2.4.2. Design action.

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12.1.5.2.4.3. Safety procedures and operating requirements.

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12.1.5.2.4.4. Safety supervision.

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12.1.5.2.5. Systems analysis data shall show that:

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12.1.5.2.5.1. The system provides the capability of maintaining all pressure levels in a safe condition in the event of the

interruption of any process or control sequence at any time during test or countdown.

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12.1.5.2.5.2. Redundant pressure relief devices have mutually independent pressure escape routes.

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12.1.5.2.5.3. In systems where pressure regulator failure may result in a critical hazard to personnel or hardware safety

systems, regulation is redundant and, where passive redundant systems are specified, includes automatic switchover.

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12.1.5.2.5.4. When the hazardous effects of safety critical failures or malfunctions are prevented through the use of redundant

components or systems, all such redundant components or systems shall be operational before the initiation of irreversible

portions of safety critical operations or events.

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12.1.5.3. Flight Hardware Pressure System and Pressurized Structure Stress Analysis

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12.1.5.3.1. General Requirements

12.1.5.3.1.1. A detailed and comprehensive stress analysis of each pressure vessel and pressurized structure shall be conducted

under the assumption of no crack-like flaws in the structure.

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12.1.5.3.1.2. The analysis shall determine stresses resulting from the combined effects of internal pressure, ground or flight

loads, and thermal gradients.

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12.1.5.3.1.3. Both membrane stresses and bending stresses resulting from internal pressure and external loads shall be

calculated to account for the effects of geometrical discontinuities, design configuration, and structural support attachments.

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12.1.5.3.1.4. Loads shall be combined by using the appropriate design limit or ultimate safety factors on the individual loads

and comparing the results to material allowable loads.

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12.1.5.3.1.5. Safety factors shall be as determined in 12.2.

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12.1.5.3.1.6. Safety factors on external (support) loads shall be as assigned to the primary structure supporting the pressurized

system.

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12.1.5.3.2. Metallic Pressure Vessels and Pressurized Structures Stress Analysis

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12.1.5.3.2.1. For metallic pressure vessels and pressurized structures, classical solutions are acceptable if the design

geometries and loading conditions are simple and the results are sufficiently accurate (as determined by PSWG and Range

Safety) to warrant their application.

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12.1.5.3.2.2. Finite element or other equivalent structural analysis techniques shall be used to calculate the stresses, strains,

and displacements for complex geometries and loading conditions.

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12.1.5.3.2.3. As necessary, local structural models shall be constructed to augment the overall structural model in areas of

rapidly varying stresses.

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12.1.5.3.2.4. Minimum material gauge as specified in the design drawings shall be used in calculating stresses.

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12.1.5.3.2.5. The allowable material strengths shall reflect the effects of temperature, thermal cycling and gradients,

processing variables, and time associated with the design environments.

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12.1.5.3.2.6. Minimum margins of safety associated with the parent materials, weldments, and heat-affected zones shall be

calculated and tabulated for all pressure vessels and pressurized structures along with their locations and stress levels.

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12.1.5.3.2.7. The margins of safety shall be positive against the strength and stiffness requirements of 12.1.7 and 12.1.8.

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12.1.5.3.3. Composite Hardware Stress Analysis

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12.1.5.3.3.1. Composite overwrapped pressure vessels (COPVs) constructed with a metallic liner and a carbon fiber polymer

overwrap material, shall be analyzed in accordance with ANSI/American Institute of Aeronautics and Astronautics (AIAA)

S-081B-2018, Space Systems - Composite Overwrapped Pressure Vessels (COPVs). All other metallic lined COPV’s using

a composite overwrap material or a non-metallic lined pressure vessel manufactured of a composite material shall be analyzed

in accordance with BPVC-X-2019 ASME Boiler and Pressure Vessel Code Section X Fiber-Reinforced Plastic Pressure.

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12.1.5.3.3.2. Interlamination normal and shear stresses as well as in-plane stress components shall be calculated.

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12.1.5.3.3.3. Effects of ply orientation, stacking sequence, and geometrical discontinuities shall be accounted for.

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12.1.5.4. Flight Hardware Pressure System and Pressurized Structure Fatigue Analysis. When conventional fatigue

analysis is used to demonstrate the fatigue-life of an unflawed pressure vessel or pressurized structure, nominal values of

fatigue-life characteristics including stress-life (S-N) and strain-life (Se - N) data of the structural materials shall be used.

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12.1.5.4.1. These data shall be taken from reliable sources or other sources approved by the payload project and the PSWG.

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Fatigue-life characteristics data are available from reliable sources such as MIL-HDBK-5.

12.1.5.4.2. The analysis shall account for the spectra of expected operating loads, pressure, and environments.

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12.1.5.4.3. Fatigue damage cumulative technique (such as Miner's rule) is an acceptable method for handling variable

amplitude fatigue cyclic loadings.

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12.1.5.5. Flight Hardware Pressure System and Pressurized Structure Safe-Life Analysis

12.1.5.5.1. When crack growth safe-life analysis is used to demonstrate the safe-life of a pressure vessel or a pressurized

structure, undetected flaws shall be assumed to be in the critical locations and in the most unfavorable orientation with respect

to the applied stress and material properties.

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12.1.5.5.2. The size of the flaws (cracks) shall be based on the appropriate NDE techniques and flaw detection capabilities.

Proof test logic shall not be used to determine the initial flaw size for fracture analysis.

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12.1.5.5.3. The crack growth safe-life analysis shall be based on fracture mechanics methodology that has been submitted to

the PSWG for PSWG and Range Safety review and approval.

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12.1.5.5.4. Nominal values of fracture toughness and fatigue crack growth rate data associated with each alloy, temper,

product form, and thermal and chemical environments shall be used in the safe-life analysis.

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12.1.5.5.5. Pressure vessels or pressurized structures that experience sustained stresses shall also show that the corresponding

maximum stress intensity factor (K

max

) during sustained load in operation is less than the stress-corrosion cracking threshold

ISCC

) data in the appropriate environment, K

max

< K

ISCC

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12.1.5.5.6. A crack growth software package accepted by the PSWG and Range Safety shall be used to conduct the safe-life

analysis.

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12.1.5.5.7. Aspect ratio (a/2c) changes shall be accounted for in the analysis.

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12.1.5.5.8. Retardation effects on crack growth rates from variable amplitude loading shall not be considered without approval

by the payload project.

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12.1.5.5.9. Tensile residual stresses shall be included in the analysis.

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12.1.5.5.10. The safe-life analysis shall be included in the stress analysis report. In particular, loading spectra, environments,

assumed initial flaw sizes, crack-growth models, fatigue crack growth rate, and fracture data shall be delineated. A summary

of significant results shall be clearly presented.

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12.1.6. Flight Hardware Pressure Vessel and Pressurized Structure Loads, Pressures, and Environments

12.1.6.1. The entire anticipated load-pressure-temperature history and associated environments throughout the service life

shall be determined in accordance with specified mission requirements.

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12.1.6.2. At a minimum, the following factors and their statistical variations shall be considered:

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12.1.6.2.1. The environmentally induced loads and pressures.

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12.1.6.2.2. The environments acting simultaneously with these loads and pressures with their proper relationships.

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12.1.6.2.3. The frequency of application of these loads, pressures, environments, and their levels and duration.

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12.1.7. Flight Hardware Pressure Vessel and Pressurized Structure Strength Requirements

12.1.7.1. All pressure vessels and pressurized structures shall possess sufficient strength to withstand limit loads and

maximum operating pressure (MOP) in the expected operating environments throughout their respective service lives without

experiencing detrimental deformation.

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12.1.7.2. All pressure vessels and pressurized structures shall also withstand ultimate loads and design burst pressure in the

expected operating environments without experiencing rupture or collapse.

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12.1.7.3. Pressure vessels and pressurized structures shall be capable of withstanding ultimate external loads and ultimate

external pressure (destabilizing) without collapse or rupture when internally pressurized to the minimum anticipated operating

pressure.

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12.1.7.4. All pressure vessels and pressurized structures shall sustain proof pressure without incurring gross yielding or

detrimental deformation and shall sustain design burst pressure without rupture.

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12.1.7.5. When proof tests are conducted at temperatures other than design temperatures, the change in material properties at

the proof temperature shall be accounted for in determining proof pressure.

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12.1.7.6. Pressurized structures subject to instability modes of failure shall not collapse under ultimate loads nor degrade the

functioning of any system due to elastic buckling deformation under limit loads.

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12.1.7.7. Evaluation of buckling strength shall consider the combined action of primary and secondary stresses and their

effects on general instability, local or panel instability, and crippling.

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12.1.7.8. Design loads for buckling shall be ultimate loads, except that any load component that tends to alleviate buckling

shall not be increased by the ultimate design safety factor.

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12.1.7.9. Destabilizing pressures shall be increased by the ultimate design factor, but internal stabilizing pressures shall not

be increased unless they reduce structural capability.

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12.1.7.10. The margin of safety shall be positive and shall be determined by analysis or test at design ultimate and design

limit levels, when appropriate, at the temperatures expected for all critical conditions.

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12.1.8. Flight Hardware Pressure Vessel and Pressurized Structure Stiffness Requirements

12.1.8.1. Pressure vessels and pressurized structures shall possess adequate stiffness to preclude detrimental deformation at

limit loads and pressures in the expected operating environments throughout their respective service lives.

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12.1.8.2. The stiffness properties of pressure vessels and pressurized structures shall be such as to prevent all detrimental

instabilities of coupled vibration modes, minimize detrimental effects of the loads and dynamics response that are associated

with structural flexibility, and avoid adverse contact with other vehicle systems.

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12.1.9. Flight Hardware Pressure Vessel and Pressurized Structure Thermal Requirements

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12.1.9.1. Thermal effects, including heating rates, temperatures, thermal gradient, thermal stresses and deformations, and

changes in the physical and mechanical properties of the material of construction shall be considered in the design of all

pressure vessels and pressurized structures.

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12.1.9.2. These effects shall be based on temperature extremes that simulate those predicted for the operating environment

plus a design margin as specified in NASA-STD-7002 Payload Test Requirements, Space and Missile Systems Center (SMC)

Standard, SMC-S-016, Test Requirements for Launch, Upper-stage, and Space Vehicles, or equivalent.

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12.1.10. Physical Arrangement of Flight Hardware Pressure Systems and System Components

12.1.10.1. Flight Hardware Pressure System and System Component General Requirements

12.1.10.1.1. The design of hypergolic propellant systems shall take into consideration limitations imposed on individuals

dressed in SCAPE or other approved propellant handling ensembles during fill and drain operations.

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12.1.10.1.2. Sufficient clearances are needed for the insertion of assembly tools.

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12.1.10.1.3. Redundant pressure components and systems shall be separated from main systems to decrease the chance of

total system failure in case of damage, fire, or malfunction.

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12.1.10.1.4. Pressure systems shall be shielded from other systems to protect against hazards caused by proximity to

combustible gases, heat sources, and electrical equipment.

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12.1.10.1.5. Any failure in any such adjacent system shall not result in combustion, explosion, or release of pressure fluids.

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12.1.10.1.6. Safety critical pressure systems shall be designed so that special tools are not required for removal and

replacement of components unless it can be shown that the use of special tools does not create additional hazards and the

special tools will be made available throughout testing, ground processing and launch.

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12.1.10.2. Flight Hardware Pressure System Components and Fittings

12.1.10.2.1. Components shall be designed so that, during the assembly of parts, sufficient clearance exists to permit assembly

of the components without damage to seals, O-rings, or backup rings where they pass over threaded parts or sharp corners.

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12.1.10.2.2. All incompatible propellant system connections shall be designed to be physically impossible to interconnect.

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Incompatible propellant system connections should be keyed, sized, or located so that it is physically impossible to

interconnect them.

12.1.10.2.3. Quick Disconnect Couplings

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The quick disconnect assembly consists of both the ground-half and air-half couplings.

12.1.10.2.3.1. All quick disconnect couplings shall be designed with a factor of safety of not less than 2.5.

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12.1.10.2.3.2. Quick disconnect coupling bodies and appropriate parts shall be constructed of 304, 304L, 316, or 316L series

stainless steel. All parts that contact the fluid shall be compatible with the fluid.

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12.1.10.2.3.3. The quick disconnect ground-half coupling shall withstand being dropped from a height of six feet on to a metal

deck/grating or concrete floor without leaking or becoming disassembled.

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12.1.10.2.3.4. When uncoupled, the quick disconnect shall seal the air-half and ground-half couplings and shall not permit

external leakage. Both halves of the coupling shall seal under both low and high pressure. In cryogenic systems only, quick

disconnects used in vent coupling assemblies shall allow gaseous cryogenic flow through the coupling whether connected or

disconnected.

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12.1.10.2.3.5. When coupled, the quick disconnect shall permit fluid flow in either direction.

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12.1.10.2.3.6. The quick disconnect shall not permit external leakage during any phase of coupling or uncoupling.

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12.1.10.2.3.7. The quick disconnect shall be designed so that coupling and uncoupling can be performed with simple motions.

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12.1.10.2.3.8. The quick disconnect coupling shall contain a positive locking device that will automatically lock the

connection of the coupling halves. It shall be possible by visual inspection to determine that the quick disconnect is completely

coupled and locked. The quick disconnect shall not have any partially coupled unlocked position in which the coupling can

remain stable and permit fluid flow.

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12.1.10.2.3.9. Special care shall be taken in the quick disconnect design to ensure that the possibility of inadvertent uncoupling

and/or coupling external leakage due to side and axial loads is minimized.

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12.1.10.2.3.10. The quick disconnect shall be designed to couple/uncouple without imparting adverse loads on fluid lines that

could cause flight hardware damage.

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12.1.10.2.3.11. Quick disconnects shall be designed to ensure that all incompatible fuel and oxidizer couplings cannot be

inadvertently connected, causing mixing of propellants.

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12.1.10.2.3.12. All quick disconnect ground half couplings shall be identified in accordance with the requirements of

11.2.1.7.6 of this volume.

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12.1.10.2.4. Pressure fluid tanks shall be shielded or isolated from combustion apparatus or other heat sources.

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12.1.10.3. Flight Hardware Pressure System Tubing and Piping

12.1.10.3.1. In general, tubing and piping shall be located so that damage cannot occur due to being stepped on, used as

handholds, or by manipulation of tools during installation.

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12.1.10.3.2. Straight tubing and piping runs shall be avoided between two rigid connection points.

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12.1.10.3.3. Where such straight runs are necessary, provisions shall be made for expansion joints, motion of the units, or

similar compensation to ensure that no excessive strain is applied to the tubing and fittings.

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12.1.10.3.4. Line bends shall be used to ease stresses induced in tubing by alignment tolerances and vibration.

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12.1.10.4. Flight Hardware Pressure System Flexible Hose Requirements

12.1.10.4.1. Flight pressure system Flexible hose shall be designed, qualified and acceptance tested in accordance with

ANSI/AIAA S-080-2018 Space Systems – Metallic Pressure Vessels, Pressurized Structures, and Pressure Components.

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12.1.10.4.2. Flexible hoses shall be used only when required to provide movement between interconnecting fluid lines when

no other means are available.

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12.1.10.4.3. Flexible hose systems shall be designed to prevent kinking, avoid abrasive chafing from the restraining device,

and avoid abrasive contact with adjacent structure or moving parts that may cause reduction in strength.

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12.1.10.4.4. Flexible hoses shall not be supported by rigid lines or components if excessive loads from flexible hose motion

can occur.

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12.1.10.4.5. Flexible hose assemblies shall not be installed in a manner that will place a mechanical load on the hose or hose

fittings to an extent that will degrade hose strength or cause the hose fitting to loosen.

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12.1.10.4.6. Flexible hoses shall be designed such that the bend radius is not less than the minimum bend radius recommended

in authoritative specifications for the particular hose.

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12.1.10.4.7. Flexible hoses shall not be exposed to internal temperatures that exceed the rated temperature of the hose.

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12.1.10.4.8. Flexible hoses shall not be permitted to pass close to a heat source unless approved by the PSWG and Range

Safety and sufficiently protected from the heat source.

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12.1.10.4.9. All flexible hoses that are not lined shall be subjected to a flow-induced vibration analysis, performed in

accordance with MSFC-SPEC-3746, Flow-Induced Vibration Assessment Requirements for Metal Bellows and Flexible

hoses.

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MSFC-SPEC-3746 provides guidance for performing flow-induced vibration analysis.

12.1.10.4.10. Flexible hoses shall consist of a flexible inner pressure carrier tube (compatible with the service fluid)

constructed of elastomeric (typically polytetrafluoroethylene [PTFE]) for hypergolic fluid) or corrugated metal (typically 300

series stainless steel) material reinforced by one or more layers of 300 series stainless steel wire and/or fabric braid.

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In applications where stringent permeability and leakage requirements apply, hoses with a metal inner pressure

carrier tube should be used. If these hoses will be used in a highly corrosive environment, consideration should be

given to the use of Hastalloy C-22 in accordance with ASTM B575 for the inner pressure carrier tube and C-276

material for the reinforcing braid.

12.1.10.4.11. Flexible hose restraining devices shall be designed and demonstrated to contain a force not less than 1.5 times

the open line pressure force (see Table 12.1).

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12.1.10.4.11.1. The restraint design safety factor shall not be less than 3 on material yield strength.

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12.1.10.4.11.2. Hose clamp-type restraining devices shall not be used.

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12.1.10.4.12. Flexible hose installations shall be designed to produce no stress or strain in the hard lines or components.

Stresses induced because of dimensional changes caused by pressure or temperature variations or torque forces induced in the

flexible hose shall be included in the analysis.

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12.1.10.4.13. Flexible hose assemblies that exhibit operational use anomalies conditions shall be identified, documented, and

tracked IAW paragraph 12.1.18.3. Flight Hardware Pressure System and Pressurized Structure Inspection and Maintenance.

Flexible hoses exhibiting major defects as classified in SAE ARP 1658, shall be removed from service.

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Table 12.1. Open Line Force Calculation Factor

Diameter Opening (inch)

Calculated Force Factor for Each psi of Source

Pressure (psi)

1/8

0.18506

1/4

0.28320

3/8

0.38140

1/2

0.47960

5/8

0.57770

3/4

0.67590

7/8

0.77410

0.87230

To calculate the force acting on line opening, select the applicable diameter opening

and multiply he right-hand column by the source pressure (psi)

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12.1.10.5. Flight Hardware Pressure System Valves, Vents, Vent Lines, and Drains

12.1.10.5.1. Manually operated valves shall be located to permit operation from the side or above to prevent spillage of

“hazardous” service fluid on the operator due to leak or failure of the valve seals.

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12.1.10.5.2. For remotely controlled non-pyrotechnically actuated valves, positive indication of actual valve position shall

be displayed at the control station.

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Indication of valve stem position or flow measurement is an acceptable indication. Indication of an electrical

control circuit actuation is not a positive indication of valve position.

12.1.10.5.3. Vent lines for flammable and combustible vapors shall be extended away from work areas to prevent accidental

ignition of vapors and/or injury to personnel.

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12.1.10.5.4. Vent outlets shall be located far enough away from incompatible propellants systems and incompatible materials

to ensure no contact is made during vent operations.

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12.1.10.5.5. Safety valves and burst diaphragms shall be located so that their operation cannot cause injury to personnel

standing close by or damage to the installation or equipment, or they shall be equipped with deflection devices to protect

personnel and equipment.

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12.1.10.5.6. Lines, drains, and vents shall be separated or shielded from other high-energy systems; for example, heat, high

voltage, combustible gases, and chemicals.

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12.1.10.5.7. Drain and vent lines shall not be connected to any other lines in any way that could generate a hazardous mixture

in the drain/vent line or allow feedback of hazardous substances to the components being drained or vented.

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12.1.10.5.8. Systems containing liquid explosives, flammable liquids, or explosive waste shall be designed so that a complete

offload/drainage of the system is achievable by gravity or pneumatics.

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12.1.10.5.9. For systems designed for gravity drainage, the pipe/tube slope shall be not less than 1/4 inch per foot at any

point. Drain lines designed for positive pressure purges do not have a slope requirement.

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12.1.10.5.10. The drain system shall include a sump or basin where the fluid can safely collect. This sump or basin shall be

designed so that it can be easily cleaned, and drainage easily removed.

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12.1.10.6. Flight Hardware Pressure System Test Points

12.1.10.6.1. If required, test points shall be provided so that disassembly for test is not required.

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12.1.10.6.2. The test points shall be easily accessible for attachment of ground test equipment.

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12.1.10.6.3. Common-plug test connectors for pressure and return sections shall be designed to require positive removal of

the pressure connection before unsealing the return connections.

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12.1.10.6.4. Individual pressure and return test connectors shall be designed to positively prevent inadvertent cross-

connections.

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12.1.11. Flight Hardware Pressure System and Pressurized Structure Supports and Clamps

12.1.11.1. All rigid pipe and tubing assemblies shall be supported by a firm structure to restrain destructive vibration, shock,

and acceleration.

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12.1.11.2. Components within a system shall be supported by a firm structure and not the connecting tubing or piping unless

it can be shown by analysis that the tubing or piping can safely support the component.

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12.1.11.3. Pipe and tube accessories such as supports, anchors, and braces shall be compatible with hypergolic propellant

vapors when installed in a hypergolic propellant system.

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12.1.11.4. All threaded parts in safety critical components shall be securely locked to resist uncoupling forces by acceptable

safe design methods.

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Safety wiring and self-locking nuts are examples of acceptable safe design.

12.1.11.5. Torque for threaded parts in safety critical components shall be specified and documented.

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12.1.11.6. Friction-type locking devices shall be avoided in safety critical applications.

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12.1.11.7. Star washers and jam nuts shall not be used as locking devices.

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12.1.11.8. The design of internally threaded bosses shall preclude the possibility of damage to the component or the boss

threads because of screwing universal fittings to excessive depths in the bosses.

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12.1.11.9. Retainers or snap rings shall not be used in pressure systems where failure of the ring would allow connection

failures or blow-outs caused by internal pressure.

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12.1.11.10. Snubbers shall be used with all bourdon-type pressure transmitters, pressure switches, and pressure gauges, except

air pressure gauges.

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12.1.12. Flight Hardware Pressure System Bonding and Grounding

12.1.12.1. Hazardous pressure systems shall be designed so that the flight system being loaded or unloaded, and the ground

support loading system can be commonly grounded and bonded during transfer operations. When the flight system and the

ground system are connected, maximum DC resistance from any flight system tubing or tanks to the nearest earth electrode

plate shall be 1.0 ohm or less. See 11.2.1.8.

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12.1.12.2. Propellant system components and lines shall be grounded to metallic structures.

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12.1.12.3. All hazardous pressure systems shall be electrically bonded to the flight vehicle to minimize the DC resistance

between the hazardous pressure system and the flight vehicle.

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12.1.13. Flight Hardware Pressure System and Pressurized Structure Material Compatibility and Selection

12.1.13.1. Material Compatibility

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12.1.13.1.1. Materials shall be compatible throughout their intended service life with the service fluids and the materials used

in the construction and installation of tankage, piping, and components as well as with nonmetallic items such as gaskets,

seals, packing, seats, and lubricants.

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12.1.13.1.2. At a minimum, material compatibility shall be determined in regard to flammability, ignition and combustion,

toxicity, and corrosion.

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12.1.13.1.3. Materials that could come in contact with fluid from a ruptured or leaky tank, pipe, or other components that

contain hazardous fluids shall be nonflammable and non-combustible.

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12.1.13.1.4. Compatible materials selection shall be obtained from one of the following sources:

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12.1.13.1.4.1. T.O. 00-25-223.

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12.1.13.1.4.2. CPIA (Chemical Propulsion Information Agency) 394.

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12.1.13.1.4.3. NASA-STD-6016, Standard Materials and Processes Requirements for Spacecraft.

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12.1.13.1.4.4. NASA-STD-6001, Flammability, Offgassing, and Compatibility Requirements and Test Procedures

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12.1.13.1.4.5. The NASA Material and Process Technical Information System (MAPTIS). MAPTIS is accessible via the

Internet at http://maptis.nasa.gov

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12.1.13.1.4.6. KTI-5212, NASA/KSC Material Selection List for Plastic Films, Foams, and Adhesive Tapes.

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12.1.13.1.4.7. MSFC-STD-3029, NASA/MSFC Guidelines for the Selection of Metallic Materials for Stress Corrosion

Cracking Resistance in Sodium Chloride Environments.

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12.1.13.1.4.8. Other sources and documents approved by the PSWG and Range Safety.

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12.1.13.1.5. Compatibility Testing. When compatibility data cannot be obtained from a PSWG and Range Safety approved

source, compatibility tests shall be performed. Test procedures, pass/fail criteria, and test results shall be submitted to the

PSWG for PSWG and Range Safety review and approval.

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12.1.13.1.6. Compatibility Analysis. The payload project shall prepare a compatibility analysis containing the following

information:

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12.1.13.1.6.1. List of all materials used in system.

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12.1.13.1.6.2. Service fluid in contact with each material.

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12.1.13.1.6.3. Source document or test results showing material compatibility in regard to flammability, toxicity, corrosion,

and ignition and combustion.

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12.1.13.2. Material Selection

12.1.13.2.1. Material "A" allowable values shall be used for pressure vessels and pressurized structures where failure of a

single load path would result in loss of structural integrity.

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12.1.13.2.2. For redundant pressurized structures where failure of a structural element would result in a safe redistribution of

applied loads to other load-carrying members, material "B" allowables may be used.

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12.1.13.2.3. The fracture toughness shall be as high as practical within the context of structural efficiency and fracture

resistance.

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12.1.13.2.4. For pressure vessels and pressurized structures to be analyzed with linear elastic fracture mechanics, fracture

properties shall be accounted for in material selection. These properties include fracture toughness; threshold values of stress

intensity under sustained loading; sub-critical crack-growth characteristics under sustained and cyclic loadings; the effects of

fabrication and joining processes; the effects of cleaning agents, dye penetrants, coatings, and proof test fluids; and the effects

of inspection couplants or materials, temperature, load spectra, and other environmental conditions.

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12.1.13.2.5. Materials that have a low K

ISCC

in the expected operating environments shall not be used in pressure vessels and

pressurized structures unless adequate protection from the operating environments can be demonstrated by tests and reviewed

and approved by the PSWG and Range Safety.

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12.1.13.2.6. If the material has a K

ISCC

less than 60 percent of the plane-strain fracture toughness, K

under the conditions

of its application, it shall be mandatory to show, by a “worst case” fracture mechanics analysis, that the low K

ISCC

factor will

not precipitate premature structural failure.

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12.1.14. Flight Hardware Pressure System Contamination and Cleanliness Requirements

12.1.14.1. Adequate levels of contamination control shall be established by relating the cleanliness requirements to the actual

needs and nature of the system and components.

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12.1.14.2. General contamination control requirements are as follows:

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12.1.14.2.1. Components and systems shall be protected from contaminants by filtration, sealed modules, clean fluids, and

clean environment during assembly, storage installation, and use.

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12.1.14.2.2. Systems shall be designed to allow verification that the lines and components are clean after flushing and purging

the system.

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12.1.14.2.3. Systems shall be designed to ensure that contaminants or waste fluids can be flushed and purged after fill and

drain operations.

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12.1.15. Flight Hardware Pressure System Components Service Life and Safe-Life

12.1.15.1. All hazardous pressure system components shall be designed for safe endurance against hazardous failure modes

for not less than 400 percent of the total number of expected prelaunch cycles.

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12.1.15.2. The safe-life for pressure vessels and pressurized structures shall be established assuming the existence of pre-

existing initial flaws or cracks in the vessel and shall cover the maximum expected operating loads and environments. The

safe-life shall be at least four times the specified life for those pressure vessels not accessible for periodic inspection and

repair.

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12.1.15.3. For those pressure vessels and pressurized structures that are readily accessible for periodic inspection and repair,

the safe-life, as determined by analysis and test, shall be at least four times the interval between scheduled inspection and/or

refurbishment.

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12.1.15.4. All pressure vessels and pressurized structures that require periodic refurbishment to meet safe-life requirements

shall be recertified after each refurbishment by the same techniques and procedures used in the initial certification, unless an

alternative recertification plan has been approved by the payload project and the PSWG and Range Safety.

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12.1.16. Flight Hardware Metallic Materials

12.1.16.1. Selection. Metallic materials shall be selected on the basis of proven environmental compatibility, material

strengths, fracture properties, fatigue-life, and crack growth characteristics consistent with the overall program requirements.

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12.1.16.2. Evaluation. Metallic material evaluation shall be conducted based on the following considerations:

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12.1.16.2.1. The metallic materials selected for design shall be evaluated with respect to material processing, fabrication

methods, manufacturing operations, refurbishment procedures and processes, and other pertinent factors that affect the

resulting strength and fracture properties of the material in the fabricated as well as the refurbished configurations.

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12.1.16.2.2. The evaluation shall ascertain that the mechanical properties, strengths, and fracture properties used in design

and analyses shall be realized in the actual hardware and that these properties are compatible with the fluid contents and the

expected operating environments.

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12.1.16.2.3. Materials that are susceptible to stress-corrosion cracking or hydrogen embrittlement shall be evaluated by

performing sustained threshold stress intensity tests when applicable data are not available

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12.1.16.3. Characterization. Metallic material characterization shall be based on the following considerations:

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12.1.16.3.1. The allowable mechanical properties, strength and fracture properties of all metallic materials selected for

pressure vessels and pressurized structures shall be characterized in sufficient detail to permit reliable and high confidence

predictions of their structural performance in the expected operating environments unless these properties are available from

reliable or other sources approved by the payload project, PSWG and Range Safety.

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Strength and fracture properties of metallic materials selected for pressure vessels and pressurized structures are

available from references such as DOT/FAA/AR-MMPDS, ASTM Standards, the Air Force Damage Tolerant

Design Handbook, military specifications, and the Aerospace Structural Metals Handbook.

12.1.16.3.2. Where material properties are not available, they shall be determined by test methods approved by the payload

project, and the PSWG and Range Safety.

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12.1.16.3.3. The characterization shall produce the following strength and fracture properties for the parent metals,

weldments, and heat-affected zones as a function of the fluid contents, loading spectra, and the expected operating

environments, including proof test environments, as appropriate:

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12.1.16.3.3.1. Tensile yield strength, Fy, and ultimate tensile strength, Fu.

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12.1.16.3.3.2. Fracture toughness, K

, K

ISCC

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12.1.16.3.3.3. Sustained-stress crack-growth data, da/dt versus K

max

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12.1.16.3.3.4. Fatigue crack growth data, da/dn versus K

and load ratio, R.

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12.1.16.3.4. Proven test procedures shall be used for determining material fracture properties as required. These procedures

shall conform to recognized standards.

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Recognized standards include those developed by the ASTM.

12.1.16.3.5. The test specimens and procedures used shall provide valid test data for the intended application.

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12.1.16.3.6. Sufficient tests shall be conducted so that meaningful nominal values of fracture toughness, fatigue data and

crack growth rate data corresponding to each alloy system, temper, product form, thermal and chemical environments, and

loading spectra can be established to evaluate compliance with safe-life requirements.

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12.1.16.3.7. If the conventional fatigue analysis is to be performed, the stress-life (S-N) or the strain-life (Se-N) fatigue data

shall be generated in accordance with the standard test methods developed by ASTM.

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12.1.16.4. Fabrication and Process Control

12.1.16.4.1. Proven processes and procedures for fabrication and repair shall be used to preclude damage or material

degradation during material processing, manufacturing operations, and refurbishment.

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12.1.16.4.2. In particular, the melt process, thermal treatment, welding process, forming, joining, machining, drilling,

grinding, repair and rewelding operations, and other operations shall be within the state-of-the-art and have been used on

currently approved hardware.

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12.1.16.4.3. The fracture toughness, mechanical and physical properties of the parent materials, weldments and heat-affected

zones shall be within established design limits after exposure to the intended fabrication processes.

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12.1.16.4.4. The machining, forming, joining, welding, dimensional stability during thermal treatments, and through-

thickness hardening characteristics of the material shall be compatible with the fabrication processes to be encountered.

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12.1.16.4.5. Fracture control requirements and precautions shall be defined in applicable drawings and process specifications.

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12.1.16.4.6. Detailed fabrication instructions and controls shall be provided to ensure proper implementation of the fracture

control requirements.

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12.1.16.4.7. Special precautions shall be exercised throughout the manufacturing operations to guard against processing

damage or other structural degradation. In addition, procurement requirements and controls shall be implemented to ensure

that suppliers and subcontractors use fracture control procedures and precautions consistent with the fabrication and inspection

processes intended for use during actual hardware fabrication.

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12.1.17. Flight Hardware Pressure Vessel and Pressurized Structure Quality Assurance Program Requirements

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12.1.17.1. A quality assurance (QA) program shall be established to ensure that the necessary NDE and acceptance tests are

effectively performed to verify that the product meets the requirements of this publication. The QA program shall be based

on a comprehensive study of the product and engineering requirements, drawings, material specifications, process

specifications, workmanship standards, design review records, stress analysis, failure mode analysis, safe-life analysis, and

the results from development and qualification tests.

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12.1.17.2. The program shall ensure that materials, parts, subassemblies, assemblies, and all completed and refurbished

hardware conform to applicable drawings and process specifications; that no damage or degradation has occurred during

material processing, fabrication, inspection, acceptance tests, shipping, storage, operational use and refurbishment; and that

defects that could cause failure are detected or evaluated and corrected.

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12.1.17.3. QA program Inspection Plan. At a minimum, the following considerations shall be included in structuring the

quality assurance program:

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12.1.17.3.1. An inspection master plan shall be established before the start of fabrication.

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12.1.17.3.2. The plan shall specify appropriate inspection points and inspection techniques for use throughout the program,

beginning with material procurement and continuing through fabrication, assembly, acceptance proof test, operation, and

refurbishment, as appropriate.

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12.1.17.3.3. In establishing inspection points and inspection techniques, consideration shall be given to the material

characteristics, fabrication processes, design concepts, structural configuration, and accessibility for inspection and detection

of discontinuities or flaws.

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12.1.17.3.4. For metallic hardware, the flaw geometries shall encompass defects commonly encountered, including surface

crack at the open surface, corner crack, or through-the-thickness crack at the edge of fastener hole, and surface crack at the

root of intersecting prismatic structural elements.

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12.1.17.3.5. Acceptance and rejection standards shall be established for each phase of inspection and for each type of

inspection technique.

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12.1.17.3.6. For COPVs and other composite hardware, laminate defects, such as delamination, fiber breakage, surface cuts,

porosity, air bubbles, cracks, dents, and abrasions, shall be considered.

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12.1.17.3.7. All inspections shall be performed by inspectors qualified and certified in inspection techniques according to the

American Society for Nondestructive Testing recommended practices (SNT-TC-1A) or PSWG and Range Safety approved

equivalent.

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12.1.17.3.8. For COPVs, inspectors shall also be certified to American Society for Nondestructive Testing (ASNT) Level II

(or PSWG and Range Safety approved equivalent) and shall be familiar with laminate production processes and composite

shell defects. Inspectors shall be certified to inspect specific types of COPVs using specific inspection techniques in

accordance with ASNT standards.

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12.1.17.4. Inspection Techniques. At a minimum, the following considerations shall be included in determining the

appropriate inspection techniques:

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12.1.17.4.1. The selected NDE inspection techniques shall have the capability to determine the size, geometry, location, and

orientation of suspect discontinuities; a flaw or defect; to obtain, where multiple flaws exist, the location of each with respect

to the other and the distance between them; and to differentiate among defect shapes, from tight cracks to spherical voids.

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12.1.17.4.2. Two or more NDE methods shall be used for a part or assembly that cannot be adequately examined by only one

method.

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12.1.17.4.3. The flaw detection capability of each selected NDE technique shall be based on past experience on similar

hardware.

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12.1.17.4.4. Where this experience is not available or is not sufficiently extensive to provide reliable results, the capability,

under production or operational inspection conditions, shall be determined experimentally and demonstrated by tests approved

by the payload project on representative material product form, thickness, and design configuration.

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12.1.17.4.5. The flaw detection capability shall be expressed in terms of detectable crack length, crack depth, and crack area.

For COPVs, the detection of laminate defects, such as delamination, fiber breakage, and air bubbles, shall also be addressed.

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12.1.17.4.6. The selected NDE should be capable of detecting allowable initial flaw size corresponding to a 90 percent

probability of detection at a 95 percent confidence level.

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12.1.17.4.7. The most appropriate NDE technique(s) for detecting commonly encountered flaw types shall be used for all

metallic pressure vessels, COPVs, pressurized structures, and other hardware based on their flaw detection capabilities.

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12.1.17.5. Inspection Data. At a minimum, inspection data shall be dispositioned as follows:

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12.1.17.5.1. Inspection data in the form of flaw histories shall be maintained throughout the life of the pressure vessel or

pressurized structure. The inspection data shall be stored in the system certification file.

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12.1.17.5.2. These data shall be periodically reviewed and assessed to evaluate trends and anomalies associated with the

inspection procedures, equipment and personnel, material characteristics, fabrication processes, design concept, and structural

configuration.

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12.1.17.5.3. The result of this assessment shall form the basis of any required corrective action.

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12.1.17.5.4. For suspect COPVs, the payload project shall ensure a Material Review Board (MRB) is initiated to evaluate the

NDE results and recommend disposition. The MRB shall consist of the procuring agency (Range User), the COPV

manufacturer, and Range Safety. Findings of the MRB shall be briefed to the payload project and the PSWG and Range

Safety. The MRB shall use NDE comparison, past experience, additional NDE, and other qualitative and quantitative methods

to recommend the acceptability of a suspect vessel. Data collected from the MRB process shall be input into the inspection

database and system certification file.

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12.1.17.6. Acceptance Proof Test

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12.1.17.6.1. All pressure vessels, pressurized structures, and pressure components shall be proof pressure tested in accordance

with the requirements of 12.2 through 12.5, as applicable, to verify that the hardware has sufficient structural integrity to

sustain the subsequent service loads, pressure, temperatures, and environments.

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12.1.17.6.2. For pressure vessels, pressurized structures, and other pressurized components, the temperature shall be

consistent with the critical use temperature; or, as an alternative, tests may be conducted at an alternate temperature if the test

pressures are suitably adjusted to account for temperature effects on strength and fracture toughness.

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12.1.17.6.3. Proof test fluids shall be compatible with the structural materials in the pressure vessels and pressurized

structures.

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12.1.17.6.4. Proof test fluids shall not pose a hazard to test personnel.

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12.1.17.6.5. If such compatibility data is not available, required testing shall be conducted to demonstrate that the proposed

test fluid does not deteriorate the test article.

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12.1.17.6.6. Accept/reject criteria shall be formulated before the acceptance proof test.

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12.1.17.6.7. Every pressure vessel and pressurized structure shall not leak, rupture, or experience gross yielding during

acceptance testing.

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12.1.18. Flight Hardware Pressure System and Pressurized Structure Operations and Maintenance

12.1.18.1. Flight Hardware Pressure System and Pressurized Structure Safe Operating Limits

12.1.18.1.1. Safe operating limits shall be established for each pressure vessel and each pressurized structure based on the

appropriate analysis and testing used in its design and qualification in accordance with 12.2, 12.3, and 12.4.

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12.1.18.1.2. These safe operating limits shall be summarized in a format that provides rapid visibility of the important

structural characteristics and capability.

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12.1.18.2. Flight Hardware Pressure System and Pressurized Structure Operating Procedures

12.1.18.2.1. Operating procedures shall be established for each pressure vessel and pressurized structure.

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12.1.18.2.2. These procedures shall be compatible with the safety requirements and personnel control requirements at the

facility where the operations are conducted.

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12.1.18.2.3. Step-by-step directions shall be written with sufficient detail to allow a qualified technician or mechanic to

accomplish the operations.

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12.1.18.2.4. Schematics that identify the location and pressure limits of relief valves and burst discs shall be provided when

applicable, and procedures to ensure compatibility of the pressurizing system with the structural capability of the pressurized

hardware shall be established.

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12.1.18.2.5. Before initiating or performing a procedure involving hazardous operations with pressure systems, practice runs

shall be conducted on non-pressurized systems until the operating procedures are well rehearsed.

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12.1.18.2.6. Initial tests shall then be conducted at pressure levels not to exceed 50 percent of the normal operating pressures

until operating characteristics can be established and stabilized.

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12.1.18.2.7. Only qualified and trained personnel shall be assigned to work on or with high pressure systems.

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12.1.18.2.8. Warning signs with the hazard(s) identified shall be posted at the operations facility before pressurization.

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12.1.18.3. Flight Hardware Pressure System and Pressurized Structure Inspection and Maintenance

12.1.18.3.1. The results of the appropriate stress and safe-life analyses shall be used in conjunction with the appropriate

results from the structural development and qualification tests to develop a quantitative approach to inspection and repair.

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12.1.18.3.2. Allowable damage limits shall be established for each pressure vessel and pressurized structure so that the

required inspection interval and repair schedule can be established to maintain hardware to the requirements of this volume.

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12.1.18.3.3. NDE technique(s) and inspection procedures to reliably detect characteristic discontinuities, defects and

determine flaw size under the condition of use shall be developed for use in the field and at payload processing facilities.

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12.1.18.3.4. Procedures shall be established for recording, tracking, and analyzing operational data as it is accumulated to

identify critical areas requiring corrective actions.

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12.1.18.3.5. Analyses shall include prediction of remaining life and reassessment of required inspection intervals.

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12.1.18.4. Flight Hardware Pressure System and Pressurized Structure Repair and Refurbishment

12.1.18.4.1. When inspections reveal structural damage or defects exceeding the permissible levels, the damaged hardware

shall be repaired, refurbished, or replaced, as appropriate.

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12.1.18.4.2. All repaired or refurbished hardware shall be recertified after each repair and refurbishment by the applicable

acceptance test procedure for new hardware to verify their structural integrity and to establish their suitability for continued

service.

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12.1.18.5. Flight Hardware Pressure System and Pressurized Structure Storage Requirements

12.1.18.5.1. When pressure vessels and pressurized structures are prepared for transportation or storage, they shall be

protected against exposure to adverse environments that could cause corrosion or other forms of material degradation.

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12.1.18.5.2. Pressure vessels and pressurized structures shall be protected against mechanical degradation resulting from

scratches, dents, or accidental dropping of the hardware.

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12.1.18.5.3. Induced stresses due to storage fixture constraints shall be minimized by suitable storage fixture design.

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12.1.18.5.4. In the event storage requirements are violated, recertification shall be required before acceptance for use.

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12.1.18.6. Flight Hardware Pressure System and Pressurized Structure Reactivation

12.1.18.6.1. Pressure vessels and pressurized structures that are reactivated for use after an extensive period in either an

unknown, unprotected, or unregulated storage environment shall be recertified to ascertain their structural integrity and

suitability for continued service before commitment to flight.

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12.1.18.6.2. Recertification tests for pressurized hardware shall be in accordance with the appropriate Recertification Test

Requirement. (See 12.2.2.8.)

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12.1.19. Flight Hardware Pressure System and Pressurized Structure Documentation Requirements

12.1.19.1. Inspection, maintenance, and operation records shall be kept and maintained throughout the life of each pressure

vessel and each pressurized structure.

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12.1.19.2. At a minimum, the records shall contain the following information:

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12.1.19.2.1. Temperature, pressurization history, and pressurizing fluid for both tests and operations.

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12.1.19.2.2. Number of pressurizations experienced as well as number allowed in safe-life analysis.

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12.1.19.2.3. Results of any inspection conducted, including the inspector, inspection dates, inspection techniques employed,

location and character of defects, defect origin, and cause.

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12.1.19.2.4. Storage condition.

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12.1.19.2.5. Maintenance and corrective actions performed from manufacturing to operational use, including refurbishment.

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12.1.19.2.6. Sketches and photographs to show areas of structural damage and extent of repairs.

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12.1.19.2.7. Acceptance and recertification tests performed, including test conditions and results.

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12.1.19.2.8. Analyses supporting the repair or modification that may influence future use capability.

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Flight Hardware Pressure Vessel Design, Analysis, and Test Requirements

12.2.1. Flight Hardware Metallic Pressure Vessel General Design, Analysis, and Verification Requirements. Three

approaches for the design, analysis and verification of metallic pressure vessels can be selected as shown in Figure 12.1.

Selection of the approach to be used depends on the desired efficiency of design coupled with the level of analysis and

verification testing required.

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12.2.1.1. Approach A. Approach A in Figure 12.1 shows the steps required for verification of a metallic pressure vessel

designed with a burst factor equal to 1.5 or greater.

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12.2.1.1.1. Based on the results of the failure mode determination, one of two distinct verification paths shall be satisfied:

(Path 1) Leak-before-burst (LBB) with leakage of the contents not creating a condition that could lead to a mishap (such as

toxic gas venting or pressurization of a compartment not capable of the pressure increase) or (Path 2) Brittle fracture failure

mode or hazardous LBB in which, if allowed to leak, the leak would cause a hazard.

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12.2.1.1.2. The verification requirements for Path 1 are delineated in 12.2.2 and the verification requirements for Path 2 in

12.2.3.

12.2.1.2. Approach B. Approach B, Figure 12.1 shows the steps required for verification of flight hardware metallic pressure

vessels designed using the ASME Boiler and Pressure Vessel Code in accordance with paragraph 12.2.4., or with 49 CFR

DOT Pressure Vessel Codes.

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12.2.1.3. Approach C. Approach C, Figure 12.1 – Approach C specifies the design, qualification, and acceptance test

requirements of flight hardware metallic PVS shall be in accordance with ANSI/AIAA S-080A-2018, Space Systems –

Metallic Pressure Vessels, Pressurized Structures, and Pressure Components.

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VOLUME 3: PAYLOADS AND GROUND SYSTEMS REQUIREMENTS

STATUS

TAILORED

TEXT

RATIONALE/

COMMENTS

Figure 12.1. Pressure Vessel Design Verification Approach

12.2.2. Path 1. Flight Hardware Metallic Pressure Vessels with Non-Hazardous LBB Failure Mode

12.2.2.1. The LBB failure mode shall be demonstrated analytically or by test showing that an initial surface flaw with a shape

(a/2c) ranging from 0.05 to 0.5 will propagate through the vessel thickness to become a through-the-thickness crack with a

length less than or equal to 10 times the vessel thickness and still be stable at MOP/MEOP.

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12.2.2.2. Fracture mechanics shall be used if the failure mode is determined by analysis.

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12.2.2.3. A pressure vessel that contains non-hazardous fluid and exhibits LBB failure mode is considered a non-hazardous

LBB pressure vessel.

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12.2.2.4. Flight Hardware Metallic Pressure Vessels with Non-Hazardous LBB Failure Mode Factor of Safety

Requirements

12.2.2.4.1. Metallic pressure vessels that satisfy the non-hazardous LBB failure mode criterion may be designed

conventionally, wherein the design factors of safety and proof test factors are selected on the basis of successful past

experience.

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12.2.2.4.2. Unless otherwise specified, the minimum burst factor shall be 1.5.

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12.2.2.5. Flight Hardware Metallic Pressure Vessels with Non-Hazardous LBB Failure Mode Fatigue-Life

Demonstration

12.2.2.5.1. After completion of the stress analysis conducted in accordance with the requirements of 12.1.5.3, conventional

fatigue-life analysis shall be performed, as appropriate, on the unflawed structure to ascertain that the pressure vessel, acted

upon by the spectra of operating loads, pressures, and environments meets the life requirements.

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12.2.2.5.2. A life factor of 4 shall be used in the analysis.

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12.2.2.5.3. Testing of unflawed specimens to demonstrate fatigue-life of a specific pressure vessel together with stress analysis

is an acceptable alternative to fatigue test of the vessel.

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12.2.2.5.4. Fatigue-life requirements are considered demonstrated when the unflawed specimens that represent critical areas

such as membrane section, weld joints, heat-affected zone, and boss transition section successfully sustain the limit loads and

MEOP/MOP in the expected operating environments for the specified test duration without rupture.

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12.2.2.5.5. The required test duration is 4 times the specified service life.

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12.2.2.6. Flight Hardware Metallic Pressure Vessels with Non-Hazardous LBB Failure Mode Qualification Test

Requirements

12.2.2.6.1. Qualification tests shall be conducted on flight quality hardware to demonstrate structural adequacy of the design.

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12.2.2.6.2. The test fixtures, support structures, and methods of environmental application shall not induce erroneous test

conditions.

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12.2.2.6.3. The types of instrumentation and their locations in qualification tests shall be based on the results of the stress

analysis of 12.1.5.3.

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12.2.2.6.4. The instrumentation shall provide sufficient data to ensure proper application of the accept/reject criteria, which

shall be established before test.

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12.2.2.6.5. The sequences, combinations, levels, and duration of loads, pressure, and environments shall demonstrate that

design requirements have been met.

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12.2.2.6.6. Qualification testing shall include random vibration testing and pressure testing. The following delineates the

required tests:

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12.2.2.6.6.1. Random Vibration Testing. Random vibration qualification testing shall be performed in accordance with the

requirements of NASA-STD-7001, Payload Vibroacoustic Test Criteria, SMC-S-016 or equivalent unless it can be shown that

the vibration requirement is enveloped by other qualification testing performed.

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12.2.2.6.6.2. Pressure Testing. Required qualification pressure testing levels are shown in Table 12.2. Requirements for

application of external loads in combination with internal pressures during testing shall be evaluated based on the relative

magnitude and/or destabilizing effect of stresses due to the external load. If limit-combined tensile stresses are enveloped by

test pressure stresses, the application of external loads shall not be required. If the application of external loads is required,

the load shall be cycled to limit for 4 times the predicted number of operating cycles of the most severe design condition (for

example, destabilizing load with constant minimum internal pressure or maximum additive load with a constant maximum

expected operating pressure). Qualification test procedures shall be approved by the payload project, the PSWG, the

appropriate launch or test range approval authority, and other necessary approval authorities as identified by the PSWG and

Range Safety.

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Table 12.2. Qualification Pressure Test Requirements.

Test Item

No Yield After

No Burst at (1)

Vessel # 1(2)

Burst Factor x MOP

Vessel # 2

Cycle at 1.5 x MOP for 2x predicted number of service life.

(50 cycles minimum)

Cycle at 1.0 x MOP for 4x predicted number of service life.

(50 cycles minimum)

Burst Factor x MOP

(1) Unless otherwise specified, after demonstrating no burst at the design burst pressure test level, increase pressure to actual

burst of vessel. Record actual burst pressure.

(2) Test may be deleted at discretion of the payload project.

12.2.2.7. Flight Hardware Metallic Pressure Vessels with Non-Hazardous LBB Failure Mode Acceptance Test

Requirements. Every pressurized system element shall be proof tested to verify that the materials, manufacturing processes,

and workmanship meet design specifications and that the hardware is suitable for flight.

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12.2.2.7.1. Acceptance tests shall be conducted on every pressure system element before commitment to flight. Accept/reject

criteria shall be formulated before tests.

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12.2.2.7.2. The test fixtures and support structures shall be designed to permit application of all test loads without jeopardizing

the flightworthiness of the test article.

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12.2.2.7.3. At a minimum, the following are required as part of the acceptance process:

12.2.2.7.3.1. Nondestructive Inspection. A complete inspection by the selected nondestructive inspection (NDE) technique(s)

shall be performed before the proof pressure test to establish the initial condition of the hardware.

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12.2.2.7.3.2. Proof Pressure Test. Every pressure vessel shall be proof pressure tested to verify that the item has sufficient

structural integrity to sustain the subsequent service loads, pressure, temperatures, and environments. The proof test fixture

shall simulate the structural response or reaction loads of the flight mounting configuration when vessel mounting induces

axial or radial restrictions on the pressure driven expansion of the vessel. Test temperature shall be consistent with the critical

use temperature, or the test pressure shall be adjusted to account for temperature effects on material properties. The minimum

proof pressure shall be:

P = ((1 + Burst Factor)/2) x MOP for a burst factor less than 2.0, or

P = 1.5 x MOP for a burst factor equal or greater than 2.0.

The minimum hold time at proof pressure shall be 5 minutes.

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12.2.2.8. Flight Hardware Metallic Pressure Vessels with Non-Hazardous LBB Failure Mode Recertification Test

Requirements. All refurbished pressure system elements shall be recertified after each refurbishment by the acceptance test

requirements for new hardware to verify their structural integrity and to establish their suitability for continued service before

commitment to flight. Pressure vessels that have exceeded the approved storage environment (temperature, humidity, time,

and others) shall also be recertified by the acceptance test requirements for new hardware.

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12.2.2.9. Special Provisions. For one-of-a-kind applications, a proof test of each flight unit to a minimum of 1.5 times MOP

and a conventional fatigue analysis showing a minimum of 10 design lifetimes may be used in lieu of the required pressure

testing as defined in 12.2.2.6. The implementation of this option needs prior approval by the payload project, the PSWG, and

any other necessary approval authorities identified by the PSWG and Range Safety.

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12.2.3. Path 2. Flight Hardware Metallic Pressure Vessels with Brittle Fracture or Hazardous LBB Failure Mode

12.2.3.1. Flight Hardware Metallic Pressure Vessels with Brittle Fracture or Hazardous LBB Failure Mode Factor of

Safety Requirements

12.2.3.1.1. Safe-life design methodology based on fracture mechanics techniques shall be used to establish the appropriate

design factor of safety and the associated proof factor for metallic pressure vessels that exhibit brittle fracture or hazardous

LBB failure mode.

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12.2.3.1.2. The loading spectra, material strengths, fracture toughness, and flaw growth rates of the parent material and

weldments, test program requirements, stress levels, and the compatibility of the structural materials with the thermal and

chemical environments expected in service shall be taken into consideration.

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12.2.3.1.3. Nominal values of fracture toughness and flaw growth rate data corresponding to each alloy system, temper, and

product form shall be used along with a life factor of 4 on specified service life in establishing the design factor of safety and

the associated proof factor.

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12.2.3.1.4. Unless otherwise specified, the minimum burst factor shall be 1.5.

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12.2.3.2. Flight Hardware Metallic Pressure Vessels with Brittle Fracture or Hazardous LBB Failure Mode Safe-Life

Demonstration Requirements

12.2.3.2.1. After completion of the stress analysis conducted in accordance with the requirements of 12.1.5.3, a safe-life

analysis of each pressure vessel covering the maximum expected operating loads and environments shall be performed under

the assumption of preexisting initial flaws or cracks in the vessel.

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12.2.3.2.2. The analysis shall show that the metallic pressure vessel with flaws placed in the most unfavorable orientation

with respect to the applied stress and material properties, of sizes defined by the acceptance proof test or NDE and acted upon

by the spectra of expected operating loads and environments, meets the safe-life requirements of 12.1.15.

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12.2.3.2.3. Nominal values of fracture toughness and flaw growth rate data associated with each alloy system, temper, product

form, thermal and chemical environments, and loading spectra shall be used along with a life factor of 4 on specified service

life in all safe-life analyses.

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12.2.3.2.4. Pressure vessels that experience sustained stress shall also show that the corresponding applied stress intensity

) during operation is less than K

ISCC

in the appropriate environment.

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12.2.3.2.5. Testing of metallic pressure vessels under fracture control in lieu of safe-life analysis is an acceptable alternative,

provided that, in addition to following a quality assurance program (12.1.17) for each flight article, a qualification test program

is implemented on pre-flawed specimen’s representative of the structure design.

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12.2.3.2.6. These flaws shall not be less than the minimum detectable flaw sizes established by the selected NDE method(s).

Proof test logic shall not be used to determine minimum flaw size.

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12.2.3.2.7. Safe-life requirements of 12.1.15 are considered demonstrated when the pre-flawed test specimens successfully

sustain the limit loads and pressure cycles in the expected operating environments without rupture.

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12.2.3.2.8. A life factor of 4 on specified service life shall be applied in the safe-life demonstration testing.

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12.2.3.2.9. A report that documents the fracture mechanics safe-life analysis or safe-life testing shall be prepared to delineate

the following:

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12.2.3.2.9.1. Fracture mechanics data (fracture toughness and fatigue crack growth rates).

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12.2.3.2.9.2. Loading spectrum and environments.

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12.2.3.2.9.3. Initial flaw sizes.

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12.2.3.2.9.4. Analysis assumptions and rationales.

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12.2.3.2.9.5. Calculation methodology.

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12.2.3.2.9.6. Summary of significant results.

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12.2.3.2.9.7. References.

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12.2.3.2.10. This report shall be closely coordinated with the stress analysis report and shall be periodically revised and

updated during the life of the program.

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12.2.3.3. Flight Hardware Metallic Pressure Vessels with Brittle Fracture or Hazardous LBB Failure Mode Qualification Test

Requirements. Qualification testing shall meet requirements of 12.2.2.6.

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12.2.3.4. Flight Hardware Metallic Pressure Vessels with Brittle Fracture or Hazardous LBB Failure Mode Acceptance Test

Requirements. Acceptance test requirements for pressure vessels that exhibit brittle fracture, or hazardous LBB failure mode

are identical to those with ductile fracture failure mode as defined in 12.2.2.7 except that the test level shall be that defined by

the fracture mechanics analysis. Surface and volume NDE shall be performed before and after proof test on the weld joints

as a minimum. Cryo-proof acceptance test procedures may be required to adequately verify initial flaw size. The pressure

vessel shall not rupture or leak at the acceptance test pressure.

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12.2.3.5. Flight Hardware Metallic Pressure Vessels with Brittle Fracture or Hazardous LBB Failure Mode Recertification

Test Requirements. Recertification testing shall meet the requirements of 12.2.2.8.

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12.2.3.6. Flight Hardware Metallic Pressure Vessels with Brittle Fracture or Hazardous LBB Failure Mode Special

Provisions. For one-of-a-kind applications, a proof test of each flight unit to a minimum of 1.5 times MOP and a conventional

fatigue analysis showing a minimum of 10 design lifetimes may be used in lieu of the required pressure testing as defined in

12.2.2.6 for qualification. The implementation of this option needs prior approval by the PSWG and Range Safety.

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12.2.4. Approach B, Flight Hardware Metallic Pressure Vessels Designed Using ASME Boiler and Pressure Vessel

Code. Metallic pressure vessels may be designed and manufactured per the rules of the ASME Boiler and Pressure Vessel

Code, Section VIII, Divisions 1 or 2.

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12.2.4.1. Flight Hardware Metallic Pressure Vessels Designed Using ASME Boiler and Pressure Vessel Code Qualification

Test Requirements. Qualification testing shall meet the requirements of 12.2.2.6.

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12.2.4.2. Flight Hardware Metallic Pressure Vessels Designed Using ASME Boiler and Pressure Vessel Code

Acceptance Test Requirements

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12.2.4.2.1. A proof test shall be performed as specified in ASME Boiler and Pressure Vessel Code.

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12.2.4.2.2. NDE shall be performed in accordance with the ASME Code and RT and/or UT as appropriate to quantify defects

in all full penetration welds after the proof test.

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12.2.5. Flight Hardware Composite Overwrapped Pressure Vessels. Flight Hardware Composite Overwrapped Pressure

Vessels (COPV). Flight Hardware COPV's shall be designed, qualified, and acceptance tested using Approach A, Approach

B, or Approach C as shown in Figure 12.1.

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12.2.5.1. Approach A. Flight COPVs designed using Approach A in Figure 12.1 shall have a design burst pressure equal to

1.5 or greater. The COPV failure mode shall be demonstrated by applicable fracture mechanics analysis, test, or similarity,

as approved by the PSWG and Range Safety.

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12.2.5.1.1. Manufacturers of COPVs using non-metallic liners or new composite over wrap materials (other than carbon,

aramid, or glass fibers in epoxy resins) and their customers shall conduct the necessary development test program that is

acceptable to the PSWG and Range Safety to substantiate a level of safety that is comparable to conventional metal-lined

COPVs.

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12.2.5.1.2. Based on the results of the failure mode determination, one of two distinct Paths shall be satisfied:

1) (Path 1) LBB, in which leakage of the contents will not create a hazard, or

2) (Path 2) Brittle fracture failure mode or hazardous LBB, in which, if allowed to leak, the leak would cause a hazard

(such as release of toxic gas, damage to nearby safety critical components, or over-pressurization of a closed

compartment).

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12.2.5.1.3. The verification requirements for path 1 (LBB) are delineated in 12.2.6 and the verification requirements for path

2 (brittle fracture/hazardous LBB) are delineated in 12.2.7.

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12.2.5.1.4. Failure mode and safe-life testing using coupons or subscale vessels shall not be used unless approved by the

PSWG and Range Safety.

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12.2.5.1.5. COPVs with metal liners, evaluated by similarity (in other words, comparison with a vessel that has already been

tested and documented having similar fiber, epoxy, matrix design, and geometry) may not require a demonstration test, if

approved by the PSWG and Range Safety.

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12.2.5.1.6. For COPVs subjected to sustained load conditions, stress rupture life shall be considered. The operating strain in

the fiber shall be below 50 percent of the ultimate fiber strain at burst during ground pressurization, storage, integration, and

flight operations. Operating strain may exceed 50 percent of the ultimate fiber strain during transportation proof or other proof

testing when personnel are not present.

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12.2.5.2. Approach B. Approach B, in Figure 12-1, shows the steps required for verification of a COPV designed using

ASME Boiler and Pressure Vessel Code, Section X, or DOT Title 49 Exemptions with a burst factor equal to 3.0 or greater.

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12.2.5.3. Approach C. Approach C specifies that COPV’s, constructed with a metal liner and a carbon fiber/polymer matrix

overwrap, shall be designed, qualified and acceptance tested in accordance with ANSI/AIAA S-081B-2018.

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12.2.5.4. Damage Control Plan (DCP). Damage control plan(s) shall be developed to identify and mitigate credible sources

of mechanical and other forms of damage to the COPV during manufacturing and throughout service life. The DCP shall be

developed in accordance with ANSI/AIAA S-081B-2018, section 5.3, and shall include the use of protective covers. The DCP

may include additional protections, as necessary, such as damage indicators.

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12.2.5.4.1. Damage Control Test (DCT). The ability of the DCP to mitigate credible sources of damage to the COPV during

manufacturing and throughout the service life shall be verified by test. DCT procedures shall be developed and performed in

accordance with ANSI/AIAA S-081B-2018, section 10.3.

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12.2.5.4.2. The DCP and DCT procedures shall be submitted to Range Safety for review and approval prior to implementation

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12.2.5.5. COPV Prelaunch Inspection and Pressure Test Requirements

12.2.5.5.1. Before the first pressurization of a COPV at a NASA facility, a NASA contracted commercial payload processing

facility, or at the launch site, compliance with the Mechanical Damage Control Plan (DCP) shall be verified. A trained COPV

inspector certified in accordance with ANSI/AIAA S-081B requirements and Section 12.1.17.3 shall perform the inspection.

If this inspection is not possible at the launch base (in other words, the COPV is not accessible), then it shall be conducted the

last time the vessel is accessible for inspection.

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12.2.5.5.2. An inspection of the vessel shall be conducted to determine if there is any evidence of visible damage or evidence

of damage to the composite shell.

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12.2.5.4.3. After arrival at the prelaunch processing facility and completion of the inspection with no evidence of damage to

the COPV, but prior to propellant loading or pressurization, COPVs shall be pressure tested to 100% of the maximum ground

operating pressure. The minimum hold time for this pressure test shall be 5 minutes. This pressurization shall be conducted

remotely, or a blast shield shall be used to protect personnel. Personnel will not approach the COPV for a minimum of 10

minutes following the pressurization.

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12.2.6. COPVs with Non-Hazardous LBB Failure Mode

12.2.6.1. General

12.2.6.1.1. The failure mode designation for COPVs shall be based on the liner and the composite overwrap.

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12.2.6.1.2. For metal-lined COPVs, the LBB failure mode shall be demonstrated by applicable fracture mechanics analysis

and/or test or similarity, as approved by the PSWG and Range Safety. The effects of the liner sizing operation on the fracture

mechanics characteristics of the metal liner shall be accounted for in the LBB evaluation. For non-metallic lined COPVs, the

LBB failure mode shall be demonstrated by test.

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12.2.6.1.3. The demonstration of the LBB failure mode by test of a COPV shall include a pre-flawed liner (flaw size

determined by analysis of the liner material and flaw detection capabilities of the selected NDE techniques). Surface cracks

shall be put into the liner at locations and orientations that are most critical to the LBB response. An inert fluid shall be used

to pressurize the COPV. Pressure cycles shall be applied to the COPV with the upper pressure limit equal to the MOP. The

LBB failure mode shall be demonstrated if one or more of the cracks leak pressure from the COPV at MOP before catastrophic

failure occurs.

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12.2.6.2. COPVs with Non-Hazardous LBB Failure Mode Factor of Safety Requirements. Nonmetallic pressure vessels

that satisfy the non-hazardous LBB failure mode criterion may be designed conventionally, wherein the design factors of

safety and proof test factors are selected on the basis of successful past experience. The minimum burst factor shall be 1.5.

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12.2.6.3. COPVs with Non-Hazardous LBB Failure Mode Fatigue-Life Demonstration

12.2.6.3.1. After completion of the stress analysis, a fatigue-life demonstration shall be performed for the liner, bosses, and

composite shell of an unflawed COPV. Fatigue-life shall be demonstrated either by test or analysis, as approved by the PSWG

and Range Safety. The test or analysis shall account for the spectra of expected loads, pressures, and environments.

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12.2.6.3.2. The minimum fatigue life for COPVs shall be 4 times the service life. The planned number of cycles for the

COPV service life shall account for any cycles to be performed at the payload processing facility and launch site area, a launch

base pressure test at 1.0 times the ground MOP, in addition to cycles at the manufacturer’s facility.

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12.2.6.4. COPVs with Non-Hazardous LBB Failure Mode Qualification Test Requirements. Qualification testing shall meet

the requirements of 12.2.2.6.

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12.2.6.5. COPVs with Non-Hazardous LBB Failure Mode Acceptance Test Requirements. Acceptance testing shall be

in accordance with 12.2.2.7 and the additional requirements of 12.2.6.5.1 through 12.2.6.5.3 below.

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12.2.6.5.1. Nondestructive Inspection. In accordance with 12.2.2.7.3.1, every COPV shall be subjected to visual and other

nondestructive inspection before and after proof testing. All inspections shall be conducted by specially trained COPV

inspectors certified in accordance with ANSI/AIAA S-081B requirement and Section 12.1.17.3.

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12.2.6.5.2. Proof Pressure Test. Every COPV shall be proof pressure tested in accordance with 12.2.2.7.3.2.

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12.2.6.5.3. Liner Inspection. Following completion of the autofrettage cycle and the proof pressure test, every COPV shall

be inspected internally for liner buckling, debonding, or other gross internal defects.

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12.2.6.5.4. Prelaunch Inspection and Pressure Test. Before a COPV is used in operations an inspection and pressure test shall

be conducted in accordance with 12.2.5.3.

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12.2.6.6. COPVs with Non-Hazardous LBB Failure Mode Recertification Test Requirements. Recertification testing shall

meet the requirements of 12.2.2.8.

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12.2.7. Flight Hardware COPVs with Brittle Fracture or Hazardous LBB Failure Mode. The requirements described

below are applicable only to flight hardware COPVs that exhibit brittle fracture or hazardous LBB failure modes.

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12.2.7.1. COPVs with Brittle Fracture or Hazardous LBB Failure Mode Factor of Safety Requirements. The minimum burst

factor shall be 1.5.

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12.2.7.2. COPVs with Brittle Fracture or Hazardous LBB Failure Mode Safe-Life Demonstration Requirements

12.2.7.2.1. In addition to performing a stress analysis as specified in 12.1.5.3, a safe-life demonstration of each pressure

vessel, covering the maximum expected operating loads and environments, shall be performed assuming pre-existing initial

flaws or cracks in the vessel. For metal-lined COPVs, safe-life shall be demonstrated either by test, analysis, similarity, or

any combination thereof. For non-metallic lined COPVs, the safe-life shall be demonstrated by test, similarity, or both.

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12.2.7.2.2. Specifically, the analysis shall show that the metal-lined COPV (with liner flaws placed in the most unfavorable

orientation with respect to the applied stress and material properties, of sizes defined by the NDE flaw detection capabilities,

and acted upon by the spectra of expected operating loads) shall meet the safe-life requirements specified by 12.1.15.

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12.2.7.2.3. For metallic liners, the nominal values of fracture toughness and flaw growth rate data associated with each alloy

system, temper, product form, thermal and chemical environments, and loading spectra shall be used in all safe-life analyses.

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12.2.7.2.4. Metal-lined COPVs that experience sustained stress shall also show that the corresponding stress intensity factor

) applied to the metal liner during the operation is less than K

ISCC

in the appropriate environment. For all liner materials

for which data do not exist, the sustained load crack behavior of the liner material shall be determined by test for all fluids that

are introduced into the COPV under pressure.

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12.2.7.2.5. Testing of metal-lined COPVs under fracture control is an acceptable alternative to safe-life analysis, provided

that, in addition to following a quality assurance program (12.1.17) for each flight article, a qualification test program is

implemented on pre-flawed specimen’s representative of the structure design. For non-metallic lined COPVs, safe-life

demonstrations shall be performed by test.

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12.2.7.2.6. These flaws shall not be less than the minimum detectable flaw sizes established by the selected NDE method(s).

Proof test logic shall not be used to determine minimum flaw size.

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12.2.7.2.7. Safe-life requirements of 12.1.15 are considered demonstrated when the pre-flawed test specimens successfully

sustain the limit loads and pressure cycles in the expected operating environments without rupture.

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12.2.7.2.8. The safe-life shall be 4 times the service life for all safe-life demonstrations. The planned number of cycles for

the COPV service life shall account for any cycles to be performed at the payload processing facility and launch site area in

addition to a launch base pressure test at 1.1 times the ground MOP and cycles at the manufacturer’s facility.

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12.2.7.2.9. A report that documents the fracture mechanics safe-life analysis (for metal liners only) or safe-life testing shall

be prepared to delineate the following:

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12.2.7.2.9.1. Fracture mechanics data for metal liners, including fracture toughness and fatigue crack growth on launch

vehicles.

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12.2.7.2.9.2. Loading spectrum and environments.

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12.2.7.2.9.3. Initial flaw sizes.

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12.2.7.2.9.4. Analysis assumptions and rationales.

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12.2.7.2.9.5. Calculation methodology.

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12.2.7.2.9.6. Summary of significant results.

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12.2.7.2.9.7. References.

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12.2.7.2.10. This report shall be closely coordinated with the stress analysis report and shall be periodically revised and

updated during the life of the program.

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12.2.7.3. COPVs with Brittle Fracture or Hazardous LBB Failure Mode Fatigue-Life Demonstration. For fatigue-life

demonstration requirements, see 12.2.2.6.

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12.2.7.4. COPVs with Brittle Fracture or Hazardous LBB Failure Mode Qualification Test Requirements. Qualification

testing shall meet the requirements of 12.2.2.6.

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12.2.7.5. COPVs with Brittle Fracture or Hazardous LBB Failure Mode Acceptance Test Requirements. Acceptance

testing shall be in accordance with 12.2.2.7 and the additional requirements of 12.2.7.5.1 through 12.2.7.5.3 below.

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12.2.7.5.1. Nondestructive Inspection. In accordance with 12.2.2.7.3.1, every COPV shall be subjected to visual and other

nondestructive inspection prior to proof testing. In addition, following completion of the proof test, every COPV shall be

inspected internally for liner buckling, debonding, or other gross internal defects. All inspections shall be conducted by

specially trained COPV inspectors certified in accordance with ANSI/AIAA S-081B requirement and Section 12.1.17.3. If

this inspection is not possible at the payload processing launch site area (i.e., the COPV is not accessible), then it shall be

conducted the last time the COPV is accessible for inspection.

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12.2.7.5.2. Proof Pressure Test. Every COPV shall be proof pressure tested in accordance with 12.2.2.7.3.2.

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12.2.7.5.3. Prelaunch Inspection and Pressure Test. Before a COPV is used in prelaunch operations at the payload processing

facility or launch area, a prelaunch inspection and pressure test shall be conducted in accordance with 12.2.5.3.

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12.2.7.6. COPVs with Brittle Fracture or Hazardous LBB Failure Mode Recertification Test Requirements. Recertification

testing shall meet the requirements of 12.2.2.8.

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12.2.8. COPV Data Requirements. The following data and documentation shall be provided for flight COPVs in addition

to the data required in section 12.10 for all flight pressure systems and vessels.

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12.2.8.1. COPV Design Data.

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12.2.8.1.1. Design specifications.

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12.2.8.1.2. Design drawings.

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12.2.8.1.3. Design calculations.

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12.2.8.1.4. Material manufacturer's specification sheets for resin, fiber reinforcement, promoters, catalyst, and other

components used in laminate construction.

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12.2.8.1.5. Properly certified documentation for parts of the vessel fabricated by other fabricators.

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12.2.8.1.6. Process specifications, giving the fabrication procedures used to fabricate both the prototype vessel(s) and all

production vessels.

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12.2.8.2. COPV Validation Data. A summary of the design, analysis, and development test data that validates the design

burst pressure, failure mode (LBB or brittle fracture), and material (liner and over wrap) compatibility with propellants and

other service fluids.

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12.2.8.3. COPV Test Data

12.2.8.3.1. Qualification test report.

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12.2.8.3.2. Quality control and production test reports.

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12.2.8.3.3. Acceptance test report.

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12.2.8.3.4. Prelaunch inspection and pressure test reports.

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12.2.8.3.5. In-service inspection and recertification test reports for reusable flight COPVs.

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12.2.8.4. Other Required COPV Documentation

12.2.8.4.1. Ground processing plans and procedures for the launch sites, including all operations and activities involving to

the COPV.

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12.2.8.4.2. A risk assessment of the COPV during ground processing.

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12.2.8.4.3. A description and the analysis of the protection system(s) used to prevent impact damage.

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12.2.8.4.4. Description of the protective coating/covers or splash shields used to guard against contact with incompatible

commodities.

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12.2.8.4.5. History of pressure cycles (rate, magnitude, and duration) along with the design limitations.

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12.2.8.4.6. Data to verify design limits have not been exceeded for specified storage and transport environmental conditions.

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12.2.8.4.7. Reports of inspections or observations that identified COPV exposure to abnormal conditions, such as impacts,

chemical exposure, excessive environmental loads (such as vibration, acceleration, temperature).

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12.2.8.4.8. Mechanical Damage Control Plan (MDCP) shall be created and implemented that assures the COPV will not fail

due to mechanical damage during manufacturing, testing, shipping, installation, or flight.

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12.2.8.4.8.1. MDCP shall identify all credible mechanical damage threats starting from the point of manufacture to the end-

of-service life.

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12.2.8.4.8.2. Mechanical damage mitigation plans and procedures, and inspection points, shall be defined.

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12.2.8.4.8.3. Comprehensive operating/handling/shipping procedures shall be prepared and included in the MDCP to ensure

the COPV does not receive critical mechanical damage.

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12.2.8.4.8.4. One or more of the following approaches shall be selected to satisfy the appropriate safety authorities that a

mechanically damaged COPV will meet the minimum burst factor requirement.

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12.2.8.4.8.4.1. Protective Covers. Covers may be used to isolate and protect the COPV. This approach requires that the cover

be tested to demonstrate that the worst-case credible mechanical damage threat results in 5 ft-lb or less energy imparted to the

COPV. If the energy imparted to the COPV is greater than 5 ft-lbs., then an impacted dedicated test article vessel must be

pressure tested to demonstrate that the burst factor requirement of Section 12.2.2.6 of this chapter.

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12.2.8.4.8.4.2. Damage Indicators. Indicators may be used to clearly show whether a COPV has received critical damage.

This approach requires that the indicators be tested to demonstrate that they can sense and indicate a mechanical damage event

over the range of 5 ft-lbs. to the maximum credible threat level. If the indicator’s minimum sensing energy is above 5 ft-lbs.,

then a dedicated test article COPV must be impacted at that energy level and pressure tested to demonstrate that the burst

factor requirement of Section 12.2.2.6 of this chapter is met.

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12.2.8.4.8.4.3. Worst-Case Threat Damage Tolerance Testing. A dedicated test article COPV may be tested to demonstrate

it can withstand 1.25 x the worst-case credible mechanical damage and still meet the burst factor requirement of Section

12.2.2.6 of this chapter.

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12.2.8.4.8.4.4. Visual Mechanical Damage Threshold Testing. A dedicated test article COPV may be tested to demonstrate

that the mechanical damage threshold energy creates a visually detectable damage indication that will survive the pressure test

for the burst factor requirement of Section 12.2.2.6 of this chapter. This approach requires the COPV to be accessible for

100% visual inspection after the threat exposure and prior to pressurization.

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Flight Hardware Metallic Pressurized Structure Analysis and Test Requirements.

12.3.1. Flight Hardware Metallic Pressurized Structure General Requirements. For pressurized structures made of metallic

materials such as the fuel tanks of a launch or an upper-stage vehicle, the design approach may be based on successful past

experience when appropriate. However, the analysis and verification requirements specified in this part shall be met.

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12.3.2. Flight Hardware Metallic Pressurized Structures with Non-Hazardous LBB Failure Mode.

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12.3.2.1. Flight Hardware Metallic Pressurized Structure Factor of Safety Requirements. Unless otherwise specified, metallic

pressurized structures that satisfy the LBB failure mode may be designed with a minimum ultimate safety factor of 1.25 for

unmanned systems and 1.40 for manned systems.

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12.3.2.2. Flight Hardware Metallic Pressurized Structure Fatigue-Life Demonstration. In addition to the stress analysis

conducted IAW section 12.1.5.3, a conventional fatigue-life analysis shall be performed, as appropriate, on the unflawed

structure to ascertain that the pressure vessel, acted upon by the spectra of operating loads, pressures, and environments meet

the life requirements. A life factor of 4 shall be used in the analysis.

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12.3.2.3. Flight Hardware Metallic Pressurized Structure Qualification Test Requirements.

12.3.2.3.1. Qualification tests shall be conducted on flight quality hardware to demonstrate structural adequacy of the design.

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12.3.2.3.2. Because of the potential test facility size limitation, the qualification testing may be conducted at the component

level provided that the boundary conditions are correctly simulated.

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12.3.2.3.3. The test fixtures, support structures, and methods of environmental application shall not induce erroneous test

conditions.

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12.3.2.3.4. The sequences, combinations, levels, and duration of loads, pressure and environments shall demonstrate that

design requirements have been met.

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12.3.2.3.5. Qualification testing shall include pressure cycle testing and burst testing. The following delineates the required

tests:

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12.3.2.3.5.1. Pressure Cycle Testing.

12.3.2.3.5.1.1. Requirements for application of external loads in combination with internal pressure during testing shall be

evaluated based on the relative magnitude and on the destabilizing effect of stresses due to the external loads.

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12.3.2.3.5.1.2. If limit-combined tensile stresses are enveloped by the MOP stress, the application of an external load is not

required.

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12.3.2.3.5.1.3. Unless otherwise specified, the peak pressure shall be equal to the MOP during each pressure cycle, and the

number of cycles shall be 4 times the predicted number of operating cycles or 50 MOP cycles, whichever is greater.

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12.3.2.3.5.2. Burst Testing.

12.3.2.3.5.2.1. After the pressure cycle testing, the test article shall be pressurized (pneumatically or hydrostatically, as

applicable and safe) to the design burst pressure, while simultaneously applying the ultimate external loads, if appropriate.

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12.3.2.3.5.2.2. The design burst pressure shall be maintained for a sufficient period of time to ensure that the proper pressure

is achieved.

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12.3.2.4. Flight Hardware Metallic Pressurized Structure Acceptance Test Requirements. Every pressurized structure shall be

proof tested to verify that the materials, manufacturing processes, and workmanship meet design specifications and that the

hardware is suitable for flight. Acceptance testing shall meet the requirements of section 12.2.2.7. Exception: If personnel are

exposed to the structure when pressurized above 50% of MOP, the minimum proof factor shall be 2.5. If personnel are not

exposed to the structure when pressurized, the proof pressure factor shall be 1.1 times MOP.

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12.3.2.5. Flight Hardware Metallic Pressurized Structure Recertification Test Requirements. Recertification testing shall meet

the requirements of paragraph 12.2.2.8.

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12.3.3. Flight Hardware Metallic Pressurized Structures with Hazardous LBB or Brittle Failure Mode.

12.3.3.1. Flight Hardware Metallic Pressurized Structures with Hazardous LBB or Brittle Failure Mode Factor of Safety

Requirements. Unless otherwise specified, metallic pressurized structures that satisfy the LBB failure mode may be designed

with a minimum ultimate safety factor of 1.25 for unmanned systems and 1.40 for manned systems.

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12.3.3.2. Flight Hardware Metallic Pressurized Structures with Hazardous LBB or Brittle Failure Mode Safe-Life

Demonstration.

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12.3.3.2.1. Safe-life analysis of each pressurized structure shall be performed under the assumption of pre-existing initial

flaws or cracks in the structure as specified in section 12.1.5.5.

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12.3.3.2.2. In particular, the analysis shall show that the pressurized structure with flaws placed in the most unfavorable

orientation with respect to the applied stress and material properties, of sizes defined by the acceptance proof test or NDE and

acted upon by the spectra of expected operating loads, pressure, and environments meets the safe-life requirements of section

12.1.15.

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12.3.3.2.3. Nominal values of fracture toughness and flaw growth rate data associated with each alloy system, temper, product

form, thermal and chemical environments, and loading spectra shall be used along with a life factor of 4 on specified service

life in all safe-life analysis.

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12.3.3.2.4. Safe-life testing in lieu of safe-life analysis is an acceptable alternative, provided that, in addition to following a

quality assurance program (see section 12.1.17) for each flight article, a qualification test program is implemented on pre-

flawed specimen’s representative of the structural design.

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12.3.3.2.5. These flaws shall not be smaller than the minimum detectable flaw sizes established by the selected NDE

method(s). Proof test logic shall not be used to determine minimum flaw size.

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12.3.3.2.6. Safe-life requirements of section 12.1.15 are considered demonstrated when the pre-flawed test specimens

successfully sustain the limit loads and pressure cycles in the expected operating environments.

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12.3.3.2.7. A life factor of 4 on specified pressure cycles in the service life shall be applied in the safe-life demonstration

testing.

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12.3.3.3. Flight Hardware Metallic Pressurized Structures with Hazardous LBB or Brittle Failure Mode Qualification Test

Requirements. Qualification testing shall include pressure cycle testing and burst testing. The following delineates the required

tests:

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12.3.3.3.1. Pressure Cycle Testing.

12.3.3.3.1.1. Requirements for application of external loads in combination with internal pressure during testing shall be

evaluated based on the relative magnitude and on the destabilizing effect of stresses due to the external loads.

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12.3.3.3.1.2. If limit-combined tensile stresses are enveloped by the MOP stress, the application of external load is not

required.

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12.3.3.3.1.3. Unless otherwise specified, the peak pressure shall be equal to the MOP during each pressure cycle, and the

number of cycles shall be 4 times the predicted number of operating cycles or 50 MOP cycles, whichever is greater.

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12.3.3.3.1.4. If the application of external loads is required, the load shall be cycled 4 times the predicted number of operating

cycles of the most severe design condition; for example, destabilizing load with constant minimum internal pressure or

maximum additive load with MOP.

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12.3.3.3.2. Burst Testing.

12.3.3.3.2.1. After the pressure cycle testing, the test article shall be pressurized (pneumatically or hydrostatically, as

applicable and safe) to the design burst pressure while simultaneously applying the ultimate external loads, if appropriate.

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12.3.3.3.2.2. The design burst pressure shall be maintained for a period of time sufficient to ensure that the proper pressure is

achieved.

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12.3.3.3.2.3. Unless otherwise specified, the minimum design burst pressure shall be 1.25 times MOP for unmanned systems,

and 1.4 times for manned systems.

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12.3.3.4. Flight Hardware Metallic Pressurized Structures with Hazardous LBB or Brittle Failure mode Acceptance Test

Requirements.

12.3.3.4.1. The acceptance test requirements for pressurized structures that exhibit brittle fracture failure mode, or hazardous

LBB failure mode are identical to those with non-hazardous LBB failure mode as defined in section 12.3.2 except that the

selected NDE techniques shall be capable of detecting flaws or cracks smaller than the allowable initial flaw size as determined

by safe-life analysis.

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12.3.3.4.2. Surface and volumetric NDE shall be performed on welds before and after proof testing if personnel are exposed

to the structure when pressurized above 50% of MOP. If personnel will not be exposed to pressures greater than 50%, surface

and volumetric NDE shall be performed on welds after the proof test.

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12.3.3.5. Flight Hardware Metallic Pressurized Structures with Hazardous LBB or Brittle Failure Mode Recertification Test

Requirements. Recertification testing shall meet the requirements of paragraph 12.2.2.8.

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Flight Hardware Special Pressurized Equipment Design, Analysis, and Test Requirements

The detailed design, analysis, and test requirements for cryostats (or dewars), heat pipes, and sealed containers, which are

classified as special pressurized equipment, are described below.

12.4.1. Flight Hardware Cryostats or Dewars with LBB Failure Mode

12.4.1.1. Flight Hardware Cryostats or Dewars with LBB Failure Mode General Requirements. Pressure containers of

the cryostat or Dewar shall be demonstrated to exhibit LBB failure mode in accordance with the following criteria:

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12.4.1.1.1. The LBB failure mode shall be demonstrated analytically or by test showing that an initial surface flaw with a

shape (a/2c) ranging from 0.05 to 0.5 will propagate through the vessel thickness to become a through-the-thickness crack

with a length 10 times the vessel thickness and still remain stable at MOP.

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12.4.1.1.2. Fracture mechanics shall be used if the failure mode is determined by analysis.

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12.4.1.1.3. A pressure vessel that contains non-hazardous fluid and exhibits LBB failure mode is considered as a non-

hazardous LBB pressure vessel.

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12.4.1.2. Flight Hardware Cryostats or Dewars with LBB Failure Mode Factor of Safety Requirements. Unless

otherwise specified, the minimum burst factor for the pressure container of a cryostat shall be 1.5.

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12.4.1.3. Flight Hardware Cryostats or Dewars with LBB Failure Mode Qualification. Qualification tests shall be

conducted on flight quality hardware to demonstrate structural adequacy of the design. The following tests are required:

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12.4.1.3.1. Random Vibration Testing. Random vibration testing shall be performed on cryostats per the requirements of

SMC-S-016.

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12.4.1.3.2. Pressure Testing. The cryostat (Dewar) shall be pressurized to the design burst pressure that is 1.5 times MOP of

the pressure container. The design burst pressure shall be maintained for a period of time sufficient to ensure that the proper

pressure was achieved.

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12.4.1.4. Flight Hardware Cryostats or Dewars with LBB Failure Mode Acceptance Test Requirements

12.4.1.4.1. Acceptance tests should be conducted on every cryostat (or Dewar) before being committed to flight.

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12.4.1.4.2. The following tests are required:

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12.4.1.4.2.1. Proof-Pressure Test. Cryostats shall be proof-pressure tested to 1.25 times the MOP of the pressure container.

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12.4.1.4.2.2. Nondestructive Examination. Surface and volumetric selected NDE techniques shall be performed after the

proof-pressure test.

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12.4.1.5. Flight Hardware Cryostats or Dewars with LBB Failure Mode Recertification Test Requirements. Recertification

testing shall meet the requirements of 12.2.2.8.

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12.4.1.6. Flight Hardware Cryostats or Dewars with LBB Failure Mode Special Requirements. Outer shells (vacuum

jackets) shall have pressure relief capability to preclude rupture in the event of pressure container leakage. If pressure

containers do not vent external to the cryostats (or dewars) but instead vent into the volume contained by outer shells, the relief

devices of outer shells shall be capable of safely venting at a rate to release full flow without outer shells rupturing. Relief

devices shall be redundant and individually capable of full flow. Furthermore, pressure relief devices shall be certified to

operate at the required condition of use without frozen moisture or fluid preventing proper operation.

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12.4.2. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode

12.4.2.1. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode Factor of Safety Requirements

12.4.2.1.1. Safe-life design methodology based on fracture mechanics techniques shall be used to establish the appropriate

design factor of safety and the associated proof factor for metallic pressure vessels that exhibit brittle fracture or hazardous

leak-before-burst failure mode.

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12.4.2.1.2. The loading spectra, material strengths, fracture toughness, and flaw growth rates of the parent material and

weldments, test program requirements, stress levels, and the compatibility of the structural materials with the thermal and

chemical environments expected in service shall be taken into consideration.

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12.4.2.1.3. Nominal values of fracture toughness and flaw growth rate data corresponding to each alloy system, temper, and

product form shall be used along with a life factor of 4 on specified service life in establishing the design factor of safety and

the associated proof factor.

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12.4.2.1.4. Unless otherwise specified, the minimum burst factor shall be 1.5.

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12.4.2.2. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode Safe-Life Demonstration

Requirements

12.4.2.2.1. After completion of the stress analysis conducted in accordance with the requirements of 12.1.15.3, safe-life

analysis of each pressure container covering the maximum expected operating loads and environments, shall be performed

under the assumption of pre-existing initial flaws or cracks in the vessel.

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12.4.2.2.2. In particular, the analysis shall show that the metallic cryostat with flaws placed in the most unfavorable orientation

with respect to the applied stress and material properties, of sizes defined by the acceptance proof test or NDE and acted upon

by the spectra of expected operating loads and environments, meet the safe-life requirements of 12.1.15.

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12.4.2.2.3. Nominal values of fracture toughness and flaw growth rate data associated with each alloy system, temper, product

form, thermal and chemical environments, and loading spectra shall be used along with a life factor of 4 on specified service

life in all safe-life analyses.

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12.4.2.2.4. Cryostats that experience sustained stress shall also show that the corresponding applied stress intensity (K

) during

operation is less than K

ISCC

in the appropriate environment.

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12.4.2.2.5. Testing of metallic cryostats under fracture control in lieu of safe-life analysis is an acceptable alternative, provided

that, in addition to following a quality assurance program (12.1.17.) for each flight article, a qualification test program is

implemented on pre-flawed specimen’s representative of the structure design.

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12.4.2.2.6. These flaws shall not smaller than the minimum detectable flaw sizes established by the acceptance proof test or

the selected NDE method(s). Proof test logic shall not be used to determine minimum flaw size.

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12.4.2.2.7. Safe-life requirements of 12.1.15 are considered demonstrated when the pre-flawed test specimens successfully

sustain the limit loads and pressure cycles in the expected operating environments without rupture.

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12.4.2.2.8. A life factor of 4 on specified service life shall be applied in the safe-life demonstration testing.

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12.4.2.2.9. A report that documents the fracture mechanics safe-life analysis or safe-life testing shall be prepared to delineate

the following:

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12.4.2.2.9.1. Fracture mechanics data (fracture toughness and fatigue crack growth rates).

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12.4.2.2.9.2. Loading spectrum and environments.

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12.4.2.2.9.3. Initial Flaw sizes.

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12.4.2.2.9.4. Analysis assumptions and rationales.

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12.4.2.2.9.5. Calculation methodology.

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12.4.2.2.9.6. Summary of significant results.

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12.4.2.2.9.7. References:

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12.4.2.2.10. This report shall be closely coordinated with the stress analysis report and shall be periodically revised and

updated during the life of the program.

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12.4.2.3. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode Qualification Test Requirements.

Qualification testing shall meet the requirements of 12.2.2.6.

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12.4.2.4. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode Acceptance Test Requirements

12.4.2.4.1. The acceptance test requirements for cryostats that exhibit brittle fracture, or hazardous LBB failure mode are

identical to those for metallic pressure vessels with ductile fracture failure mode as defined in 12.2.2.7 except that test level

shall be that defined by the fracture mechanics analysis whenever possible.

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12.4.2.4.2. At a minimum, surface and volumetric NDE technique shall be performed on all weld joints before and after the

proof test.

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12.4.2.4.3. Cryo-proof acceptance test procedures may be required to adequately verify initial flaw size.

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12.4.2.4.4. The pressure container shall not rupture or leak at the acceptance test pressure.

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12.4.2.5. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode Recertification Test Requirements.

Recertification testing shall meet the requirements of 12.2.2.8.

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12.4.2.6. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode Special Provisions

12.4.2.6.1. For one-of-a-kind applications, a proof test of each flight unit to a minimum of 1.5 times MOP and a conventional

fatigue analysis showing a minimum of 10 design lifetimes may be used in lieu of the required pressure testing as defined in

12.2.4 or 12.2.3.3, as applicable, for qualification.

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12.4.2.6.2. Outer shells (vacuum jackets) shall have pressure relief capability to preclude rupture in the event of pressure

container leakage. If pressure containers do not vent external to the cryostats or dewars, but instead vent into the volume

contained by outer shells, the relief devices of outer shells shall be capable of venting at a rate to release full flow without the

outer shall rupturing. Pressure relief devices shall be certified to operate at the required condition of use.

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12.4.2.6.3. The implementation of this option needs prior approval by the payload project and the PSWG and Range Safety.

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12.4.3. Flight Hardware Heat Pipe Requirements

12.4.3.1. Flight Hardware Heat Pipe Factor of Safety

12.4.3.1.1. Unless otherwise specified, the minimum burst factors for heat pipes with a diameter greater than 1.5 inches shall

be 2.5.

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12.4.3.1.2. For heat pipes with a diameter less than or equal to 1.5 inches, the minimum burst factor shall be 4.0.

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12.4.3.2. Flight Hardware Heat Pipe Qualification Test Requirements. Pressure testing shall be conducted to demonstrate

no failure at the design burst pressure.

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12.4.3.3. Flight Hardware Heat Pipe Acceptance Test Requirements

12.4.3.3.1. All fusion joints or full penetration welds on the heat pipes that contain hazardous fluids shall be inspected using

acceptable surface and volumetric NDE techniques.

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12.4.3.3.2. A proof pressure test shall be conducted to a minimum level of 1.5 times MOP on all heat pipes.

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12.4.3.4. Flight Hardware Heat Pipe Recertification Test Requirements. Recertification testing shall meet the requirements

of 12.2.2.8.

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12.4.3.5. Flight Hardware Heat Pipe Special Requirements. The heat pipe material shall satisfy the material compatibility

requirements defined in 12.1.16 for the contained fluid at both the proof test temperature and operational temperature.

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12.4.4. Flight Hardware Sealed Containers

12.4.4.1. Sealed Containers with Non-Hazardous LBB Failure Mode. The LBB failure mode shall be demonstrated as

defined in 12.2.2.

Exception: Those containers made of aluminum, stainless steel, or titanium sheets that are acceptable as LBB

designs do not have to demonstrate LBB failure mode.

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12.4.4.1.1. Sealed Containers with Non-Hazardous LBB Failure Mode Factor of Safety. Unless otherwise specified, the

minimum burst factor shall be 1.5.

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12.4.4.1.2. Sealed Containers with Non-Hazardous LBB Failure Mode Qualification Test Requirements

12.4.4.1.2.1. Sealed containers containing non-electronic equipment shall only be subjected to pressure testing.

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12.4.4.1.2.2. For sealed containers containing safety-related electronic equipment, other qualification tests including

functional, thermal vacuum, thermal cycling, random vibration, and pyro shock shall be conducted per SMC-S-016 or

equivalent.

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12.4.4.1.3. Sealed Containers with Non-Hazardous LBB Failure Mode Acceptance Test Requirements. Sealed

containers shall be proof-pressure tested to a minimum level of 1.25 times maximum design pressure differential.

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12.4.4.1.4. Sealed Containers with Non-Hazardous LBB Failure Mode Recertification Test Requirements

12.4.4.1.4.1. All refurbished sealed containers shall be recertified after each refurbishment by the acceptance test requirements

for new hardware to verify their structural integrity and to establish their suitability for continued service before commitment

to flight.

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12.4.4.1.4.2. Sealed containers that have exceeded the approved storage environment (temperature, humidity, time, and

others) shall also be recertified by the acceptance test requirements for new hardware.

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12.4.4.2. Sealed Containers with Brittle Fracture or Hazardous LBB Failure Mode

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12.4.4.2.1. Sealed containers that exhibit a brittle fracture failure mode or contain hazardous fluid, or both, shall meet the

requirements of 12.2.3.

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12.4.4.2.2. For sealed containers containing safety-related electronic equipment, qualification tests including functional,

thermal vacuum, thermal cycling, and pyro shock shall be conducted in addition to random vibration and pressure testing.

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Flight Hardware Pressure System Component Design and Test Requirements

The requirements for the design and testing of flight hardware pressure system components are described below. Included

are hydraulic, pneumatic, hypergolic, and cryogenic fluid and propellant system components.

12.5.1. Flight Hardware Pneumatic and Hydraulic Pressure System Components

12.5.1.1. Factor of Safety Requirements. Flight hardware pneumatic and hydraulic pressure system components shall be

designed to the minimum factors shown in Table 12.3.

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12.5.1.2. Flight Hardware Pneumatic and Hydraulic Pressure System Component General Selection and Design

Requirements

12.5.1.2.1. Components shall be selected to ensure that misconnections or reverse installations within the subsystem are not

possible. Color codes, labels, and directional arrows shall be used to identify hazards and direction of flow.

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Table 12.3. Pressure Components Safety Factors

Component

Proof

Design Burst

Lines and fittings diameter < 1.5 inches (38 mm)

1.5

4.0

Lines and fittings diameter > 1.5 inches (38 mm)

1.5

2.5

Fluid Return Sections

1.5

3.0

Fluid Return Hose

1.5

5.0

Other Pressure Components

1.5

2.5

1) Components subject to low or negative pressure shall be evaluated at 2.5 times

maximum external pressure expected during service life.

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12.5.1.2.2. The maximum fluid temperature shall be estimated early in design as part of data for selection of safety critical

components, such as system fluid, pressurizing gas, oil coolers, and gaskets.

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12.5.1.2.3. Components that are capable of safe actuation under pressure equal to the maximum relief valve setting in the

circuit in which they are installed shall be specified.

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12.5.1.2.4. Pumps, valves and regulators, hoses, and all such prefabricated components of a pressure system shall have proven

pressure service ratings equal to or higher than the limit load (MOP) and rated life of the system.

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12.5.1.2.5. The Standards of the Hydraulic Institute shall be used in evaluating safety in pump selection.

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12.5.1.2.6. Where leakage or fracture is hazardous to personnel or critical equipment, valves shall be selected so that failure

occurs at the outlet threads of valves before the inlet threads or body of the valve fails under pressure.

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12.5.1.2.7. Pressure regulators shall be selected to operate in the center 50 percent of their total pressure range and avoid creep

and inaccuracies at either end of the full operating range.

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12.5.1.2.8. In all cases, flareless tube fittings shall be properly preset before pressure application.

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12.5.1.2.9. Where system leakage can expose hydraulic fluid to potential ignition sources or is adjacent to a potential fire zone

and the possibility of flame propagation exists, fire-resistant or flame-proof hydraulic fluid shall be used.

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12.5.1.3. Flight Hardware Oxygen System Components

12.5.1.3.1. For oxygen systems of 3,000 psi or higher, valves and other components that are slow opening and closing types

shall be selected to minimize the potential for ignition of contaminants.

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12.5.1.3.2. Oxygen systems shall require electrical grounding to eliminate the possibility of the buildup of static electrical

charges.

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12.5.1.3.3. Oxygen system components, design, and material selection shall conform to ASTM MNL 36.

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12.5.1.4. Flight Hardware Pneumatic and Hydraulic System Manual Valves and Regulators

12.5.1.4.1. Manually operated valves and regulators shall be selected so that over-torqueing of the valve stem of the regulator

adjustment cannot damage soft seats to the extent that failure of the seat will result.

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12.5.1.4.2. Valve designs that use uncontained seals are unacceptable and shall not be selected.

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12.5.1.5. Flight Hardware Pneumatic and Hydraulic System Warning Devices and Safety Critical Components

12.5.1.5.1. Warning devices that are activated by hazardous over or under pressure shall be selected whenever necessary.

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12.5.1.5.2. The warning device shall either activate automatic response mechanisms or shall notify operational personnel of

impending hazards.

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12.5.1.5.3. Warning devices to indicate hazardous over or under pressures to operating personnel shall be specified.

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12.5.1.5.4. These warning devices shall actuate at predetermined pressure levels designed to allow time for corrective action.

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12.5.1.5.5. Safety critical actuation of pneumatic systems shall not be adversely affected by any back pressure resulting from

concurrent operations of any other parts of the system under any set of conditions.

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12.5.1.5.6. Components that can be isolated and contain residual pressure shall be equipped with gage reading and bleed

valves for pressure safety checks.

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12.5.1.5.7. Bleed valves shall be directed away from operating personnel.

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12.5.1.5.8. Fittings or caps for bleeding pressure are not acceptable.

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12.5.1.5.9. Pressurized reservoirs that are designed for gas/fluid separation with provisions to entrap gas that may be hazardous

to the system or safety critical actuation and prevent its recirculation in the system shall be specified. Specific instructions

shall be posted adjacent to the filling point for proper bleeding when servicing.

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12.5.1.5.10. Compressed gas emergency systems shall be bled directly to the atmosphere away from the vicinity of personnel

rather than to reservoir.

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12.5.1.5.11. If the gas is combustible, safety critical components shall be utilized and methods for reducing the potential for

accidental ignition or explosion shall be assessed, controlled as required, and verified and documented through a hazard

analysis.

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12.5.1.5.12. Where necessary to prevent a hazardous sequence of operations and provide a fail-safe capability at all times,

interlocks shall be specified. For example, the OPEN position of remotely controlled valves that can hazardously pressurize

lines leading to remotely controlled (or automatic) disconnect couplings shall be interlocked to preclude the OPEN valve

position coincident with the disconnected condition of the couplings.

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12.5.1.5.13. Pressure systems that combine several safety critical functions shall have sufficient controls for isolating failed

functions for the purpose of safely operating the remaining functions.

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12.5.1.5.14. All pressure systems shall have pressure indicating devices to monitor critical flows and pressures marked to

show safe upper and lower limits of system pressure.

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12.5.1.5.15. The pressure indicators shall be located to be readily visible to the operating crew.

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12.5.1.5.16. All systems shall be protected for pressure above 500 psi in all areas where damage can occur during servicing

or other operational hazards.

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12.5.1.5.17. Pressure lines and components of 500 psi or higher that are adjacent to safety critical equipment shall be shielded

to protect such equipment in the event of leakage or burst of the pressure system.

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12.5.1.5.18. Automatic disengagement or bypass shall be provided for pneumatic systems that provide for manual takeover

in the event of a hazardous situation.

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12.5.1.5.19. Positive indication of disengagement shall be provided.

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12.5.1.5.20. Safety critical pneumatic actuators shall have positive mechanical stops at the extremes of safe motion.

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12.5.1.5.21. Adjustable orifice restrictor valves shall not be used in safety critical pneumatic systems.

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12.5.1.6. Flight Hardware System Pneumatic Components

12.5.1.6.1. Pneumatic components (other than tanks) for safety critical systems shall exhibit safe endurance against hazardous

failure modes for not less than 400 percent of the total number of expected cycles including system tests.

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12.5.1.6.2. The configuration of pneumatic components shall permit bleeding of entrapped moisture, lubricants, particulate

material, or other foreign matter hazardous to the system.

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12.5.1.6.3. Compressors that are designed to sustain not less than 2.5 times delivery pressure after allowance for loss of

strength of the materials equivalent to not less than that caused by 1,000 hours aging at 275

F shall be selected.

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12.5.1.7. Flight Hardware Pneumatic and Hydraulic System Design Loads

12.5.1.7.1. Installation of all lines and components to withstand all expected acceleration and shock loads shall be specified.

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Shock isolation mounts may be used if necessary, to eliminate destructive vibration and interference collisions.

12.5.1.7.2. The mounting of components, including valves, on structures having sufficient strength to withstand torque and

dynamic loads and not supported by the tubing shall be specified.

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12.5.1.7.3. Light-weight components that do not require adjustment after installation (for example, check valves) may be

supported by the tubing, provided that a tube clamp is installed on each such tube near the component.

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12.5.1.7.4. Tubing shall be supported by cushioned steel tube clamps or by multiple-block type clamps that are suitably spaced

to restrain destructive vibration.

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12.5.1.8. Flight Hardware Pneumatic and Hydraulic System Electrical and Electronic Devices

12.5.1.8.1. Electrical components for use in potentially ignitable atmospheres shall be demonstrated to be incapable of causing

an explosion in the intended application.

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12.5.1.8.2. Electrically energized hydraulic components shall not propagate radio-frequency energy that is hazardous to other

subsystems in the total system or interfere in the operation of safety critical electronic equipment. (See MIL-STD-464, Systems

Electromagnetic Environmental Effects Requirements.)

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12.5.1.8.3. Pressure system components and lines shall be electrically grounded to metallic structures.

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12.5.1.8.4. All solenoids shall be capable of safely withstanding a test voltage of not less than 1500 V rms at 60 cps for 1

minute between terminals and case at the maximum operating temperature of the solenoid in the functional envelope.

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12.5.1.8.5. Electric motor-driven pumps used in safety critical systems shall not be used for ground test purposes unless the

motor is rated for reliable, continuous, and safe operation. Otherwise, the test parameters may perturb reliability calculations.

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12.5.1.9. Flight Hardware Pneumatic and Hydraulic System Pressure Relief Devices

12.5.1.9.1. Pressure relief devices shall be specified on all systems having a pressure source that can exceed the MAWP of

the system or where the malfunction/failure of any component can cause the MAWP to be exceeded.

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12.5.1.9.2. Relief devices are required downstream of all regulating valves and orifice restrictors unless the downstream

system is designed to accept full source pressure.

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12.5.1.9.3. On space systems, where operational or weight limitations preclude the use of relief valves and systems operate

in an environment not hazardous to personnel, they can be omitted if (1) the ground or support system contains such devices

and they cannot be isolated from the airborne system during the pressurization cycle, and (2) the space vehicle cannot provide

its own protection.

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12.5.1.9.3.1. Where a ground system is specifically designed to service an unmanned flight vehicle, pressure relief protection

may be provided within the ground equipment, if no capability exists to isolate the pressure relief protection from the flight

vehicle during the pressurization cycle.

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12.5.1.9.4. Where safety factors of less than 2.0 are used in the design of flight hardware pressure vessels, a means for

automatic relief, depressurization, and pressure verification of safety critical vessels in the event of launch abort shall be

provided. Spacecraft (payload) pressure vessels may be designed without automatic relief (other means of safe relief shall be

provided) if a safety analysis validates that a rupture will not damage the safety systems.

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12.5.1.9.5. Whenever any pressure volume can be confined and/or isolated by system valving, an automatic pressure relief

device shall be provided.

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12.5.1.9.6. Pressure relief devices shall vent toxic or inert gases to safe areas, away from the vicinity of personnel. Scrubbers

or vapor disposal systems shall also be used at a safe distance from personnel.

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Pop-valves, rupture disks, blow-out plugs, armoring, and construction to contain the greatest possible overpressure

that may develop are examples of corrective measures for system safety.

12.5.1.9.7. Shut-off valves for maintenance purposes on the inlet side of pressurized relief valves are permissible if a means

for monitoring and bleeding trapped pressure is provided and the requirements of ASME Boiler and Pressure Vessel (BPVC)

Code for unfired pressure vessels, Section VIII Appendix M, Paragraph M-5 are met. It is mandatory that the valve be locked

open when the system is re-pressurized.

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12.5.1.9.8. Hydrostatic testing systems for vessels that are not designed to sustain negative internal pressure shall be equipped

with fail-safe devices for relief of hazardous negative pressure during the period of fluid removal.

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Check valves and valve interlocks are examples of devices that can be used for this purpose.

12.5.1.9.9. Vessels that can be collapsed by a negative pressure shall have negative pressure relief and/or prevention devices

for safety during storage and transportation.

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12.5.1.9.10. Pressurized reservoirs shall be designed so that all ullage volumes are connected to a relief valve that shall protect

the reservoir and power pump from hazardous overpressure or back pressure of the system.

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12.5.1.9.11. The air pressure control for pressurized reservoirs shall be an externally nonadjustable, pressure regulating device.

If this unit also contains a reservoir pressure relief valve, it shall be designed so that no failure in the unit permits over-

pressurization of the reservoir.

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12.5.1.10. Flight Hardware Pneumatic and Hydraulic System Contamination. Contamination shall be prevented from

entering or developing in safety and safety critical flight hardware pneumatic or hydraulic system components. Safety and

safety critical systems shall be designed to include provisions for detection, filtration, and removal of contaminants.

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1. The following contamination-related considerations should be addressed in the design of pressurized systems. Contamination includes

solid, liquid, and gaseous material.

a. Contamination should be prevented from entering or developing within the system.

b. The system should be designed to include provisions to detect contamination.

c. The system should be designed to include provisions for removal of contamination and provisions for initial purge with fluid or gas

that cannot degrade future system performance. The system should be designed to be tolerant of contamination.

2. All pressurizing fluids entering safety critical system should be filtered through a 10 micron filter, or finer, before entering the system.

3. All pressure systems should have fluid filters in the system, designed and located to reduce the flow of contaminant particles to a safe

minimum.

4. All of the circulating fluid in the system should be filtered downstream from the pressure pump or immediately upstream from safety

critical actuators.

5. Entrance of contamination at test points or vents should be minimized by downstream filters.

6. The bypass fluid or case drain flow on variable displacement pumps should be filtered.

7. When the clogging of small orifices could cause a hazardous malfunction or failure of the system, they should be protected by a filter

element designed to prevent clogging of the orifice. Note that this includes servo valves.

8. Filters or screens should not be used in suction lines of power pumps or hand pumps of safety critical systems.

9. Air filters should be specified for hydraulic reservoir air pressurization circuits and located to protect the pressure regulating

equipment from contamination.

10. Dry compressed air should be specified for hydraulic reservoir pressurization.

11. A moisture removal unit should be specified to protect the pressure regulation lines and equipment.

12. Unpressurized Reservoirs. Unpressurized hydraulic reservoirs should have filters and desiccant units at the breather opening to

preclude introduction of moisture and contaminants into the reservoir.

12.5.1.11. Flight Hardware Pneumatic and Hydraulic System Bleed Ports

12.5.1.11.1. Where necessary, bleed ports shall be provided to remove accumulations of residue or contaminants.

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12.5.1.11.2. High point bleed ports shall be provided where necessary for removal of trapped gases.

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12.5.1.11.3. The bleed valve shall be directed away from operating personnel and possible ignition sources.

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12.5.1.11.4. Components, cavities, or lines that can be isolated shall be equipped with bleed valves that can be used to release

retained pressure, or they shall indicate that continued pressure exists in the system.

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12.5.1.11.5. Bleed valves used for reducing pressure on systems containing hazardous fluids shall be routed to a safe disposal

area.

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12.5.1.11.6. Auxiliary Bleed Ports

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12.5.1.11.6.1. Auxiliary bleed ports shall be provided where necessary to allow bleed off for safety purposes.

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12.5.1.11.6.2. Bleeder valves shall be located so that they can be operated without removal of other components and shall

permit the attachment of a hose to direct the bleed-off fluid into a container.

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12.5.1.11.7. Reservoir filler caps shall include design provisions that shall automatically bleed the reservoir on opening so

that possible ullage pressure cannot impart hazardous kinetic energy to either the filler caps, the fluid in the reservoir, or the

system.

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12.5.1.12. Flight Hardware Pneumatic and Hydraulic System Control Devices

12.5.1.12.1. Safety critical pressure systems incorporating two or more directional control valves shall be designed to preclude

the possibility of inadvertently directing the flow or pressure from one valve into the flow path or pressure path intended for

another valve, with any combination of valve settings possible in the total system.

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12.5.1.12.2. Control devices shall be designed to prevent overtravel or under travel that may contribute to a hazardous

condition or damage to the valve.

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12.5.1.12.3. All pressure and volume controls shall have stops, or equivalent, to prevent settings outside their nominal safe

working ranges.

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12.5.1.12.4. Control components that have integral manually operated levers and stops shall be capable of withstanding the

following limit torques in Table 12.4.

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Table 12.4. Limit Torque Requirements

12.5.1.13. Flight Hardware Pneumatic and Hydraulic System Manually Operated Levers

12.5.1.13.1. Components that have integrated manually operated levers shall provide levers and stops capable of withstanding

the limit torques specified by MIL-STD-1472.

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12.5.1.13.2. Levers and stops shall be provided on remote controls capable of withstanding a limit torque of 1,800 inch-

pounds.

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12.5.1.13.3. Because jamming is possible, sheathed flexible actuators shall not be used for valve controls in safety critical

pressure systems (for example, push-pull wires and torque wires that are sheathed are not acceptable).

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12.5.1.14. Flight Hardware Pneumatic and Hydraulic System Accumulators

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Lever Radius

Design Torque

Less than 3 inches

50 x R inch-pound

3 to 6 inches

75 x R inch-pound

Over 6 inches

150 x R inch-pound

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12.5.1.14.1. Accumulators shall be designed in accordance with the pressure vessel standards for ground systems and located

for minimal probability of mechanical damage and for minimum escalation of material damage or personnel injury in the

event of a major failure such as tank rupture.

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12.5.1.14.2. Accumulator gas pressure gauges shall not be used to indicate system pressure for operational or maintenance

purposes.

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12.5.1.14.3. Gas type and pressure level shall be posted on, or immediately adjacent to, the accumulator.

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12.5.1.15. Flight Hardware Pneumatic and Hydraulic System Flexible Hose. Flexible hose requirements are specified in

12.1.10.4.

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12.5.1.16. Flight Hardware Pneumatic and Hydraulic System Qualification Test Requirements. Qualification tests are

not required on lines and fittings. Internal/external pressure testing shall be conducted on all other pressure components to

demonstrate no failure at the design burst pressure. Seamless lines, tubing, and pipe are exempt.

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12.5.1.17. Flight Hardware Pneumatic and Hydraulic System Acceptance Test Requirements

12.5.1.17.1. Testing Flight Hardware Pneumatic and Hydraulic Components Before Assembly

12.5.1.17.1.1. All pressurized components such as valves, pipe, tubing, and pipe and tube fittings shall be hydrostatically

proof tested to a minimum of 1.5 times the component MAWP for a minimum of 5 minutes.

Note: In the event that component testing before assembly is not feasible, components may be hydrostatically tested after assembly into

a subsystem or system to 1.5 times the system MOP. This approach shall be approved by PSWG and Range Safety.

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12.5.1.17.1.2. Proof testing shall demonstrate that the components sustain proof pressure levels without distortion, damage,

or leakage.

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12.5.1.17.1.3. Both the inlet and discharge sides of a relief valve shall be proof tested. When the discharge side has a lower

pressure rating than the inlet, they are to be proof tested independently.

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12.5.1.17.1.4. The following inspections shall be performed after proof testing:

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12.5.1.17.1.4.1. Mechanical components such as valves and regulators shall be inspected for external deformation,

deterioration, or damage.

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12.5.1.17.1.4.2. Damaged, distorted, or deteriorated parts shall be rejected and replaced and the test repeated.

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12.5.1.17.1.5. Functional and leak tests shall be performed at the component MAWP after the proof test.

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12.5.1.17.1.6. Pneumatic pressure system components shall undergo sufficient qualification and acceptance testing to

demonstrate that the system and components meet design and safety requirements when subjected to prelaunch and launch

environments such as vibration, shock, acceleration, and temperature.

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12.5.1.17.1.7. Test plans and test reports shall be submitted to the PSWG and made available to the PSWG and Range Safety.

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12.5.1.17.1.8. Pressure relief valves shall be tested for proper setting and flow capacity before installation and first use on the

ranges.

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12.5.1.17.1.9. Pressure gauges and transducers shall be hydrostatically tested to a minimum of 1.5 times the system

MOP/MEOP.

Note: Depending upon the manufacturer or model of the pressure transducer, it may not be possible to hydrostatically

test it to a minimum 1.5 times MOP without causing a shift in the transducer. This is dependent on the transducer’s

specification and manufacturer’s recommendations for the transducer.

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12.5.1.17.1.10. Pressure gauges and transducers shall be calibrated before installation and periodically thereafter as

recommended by the manufacturer.

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12.5.1.17.1.11. Components may be initially hydrostatically proof tested after being assembled into a subsystem to 1.5 times

the system MOP. This approach requires prior approval from the PSWG and Range Safety.

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12.5.1.17.1.12. Pneumatic proof testing to a proof pressure of 1.25 times MAWP is permissible only if hydrostatic proof

testing is impractical, impossible, or jeopardizes the integrity of the system or system element. Prior approval for pneumatic

proof testing at the payload processing facility and/or launch site area shall be obtained from the local safety authority.

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12.5.1.17.2. Testing Flight Hardware Pneumatic and Hydraulic Systems After Assembly. All newly assembled pressure

systems shall be hydrostatically tested to 1.5 times MOP before use. MOP here refers to the maximum operating pressure that

personnel are exposed to. Where this is not possible, the PSWG and Range Safety shall determine the adequacy of component

testing and alternate means of testing the assembled system.

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12.5.1.17.3. Flight Hardware Pneumatic and Hydraulic System Leak Tests

12.5.1.17.3.1. All newly assembled pressure systems shall undergo a dedicated leak test at the system MOP before first use

at any payload processing facility and launch site area.

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12.5.1.17.3.2. This test shall be conducted at the payload processing facility and launch site area unless prior approval from

the PSWG and Range Safety has been obtained.

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12.5.1.17.3.3. Minimum test requirements are as follows:

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12.5.1.17.3.3.1 The gas used during the leak test shall be the same as the system fluid media except that for

hazardous gas systems, a system compatible, non-hazardous gas may be used that has a density as near as

possible to the system fluid; for example, helium should be used to leak test a gaseous hydrogen system.

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12.5.1.17.3.3.2. Mechanical connections, gasketed joints, seals, weld seams, and other items shall be visually bubble tight for

a minimum of 1 minute when an approved leak test solution is applied.

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12.5.1.17.3.3.3. Alternate methods of leak testing (such as the use of portable mass spectrometers) may be specified when

required on a case-by-case basis.

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12.5.1.17.4. Flight Hardware Pneumatic and Hydraulic System Validation and Functional Tests

12.5.1.17.4.1. All newly assembled pressure systems shall have a system validation test and a functional test of each

component at system MOP before first use at the payload processing facility and/or launch site area.

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12.5.1.17.4.2. These tests shall be conducted at the payload processing facility and launch site area unless prior approval from

the PSWG and Range Safety has been obtained.

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12.5.1.17.4.3. Minimum test requirements are as follows:

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12.5.1.17.4.3.1. These tests shall demonstrate the functional capability of all non-passive components such as valves,

regulators, and transducers.

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12.5.1.17.4.3.2. All prelaunch operational sequences for the system shall be executed.

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12.5.1.17.4.3.3. All parallel or series redundant components shall be individually tested to ensure all failure tolerant

capabilities are functional before launch.

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12.5.1.17.4.3.4. All shutoff and block valves shall be leak checked downstream to verify their shutoff capability in the

CLOSED position.

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12.5.1.17.5. Flight Hardware Pneumatic and Hydraulic System Bonding and Grounding Tests. All newly assembled

pressure systems containing flammable and combustible fluids or media shall be tested to verify that the requirements of

12.1.12 of this volume have been met.

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12.5.1.17.6. Test Requirements for Modified and Repaired Flight Hardware Pneumatic Systems

12.5.1.17.6.1. Any pressure system element, including fittings or welds, that has been repaired, modified, or possibly damaged

before having been proof tested, shall be retested at proof pressure before its normal use.

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12.5.1.17.6.2. A modified or repaired pressure system shall be leak tested at the system MOP before its normal use. This test

shall be conducted at the ranges unless prior approval from the PSWG and Range Safety has been obtained.

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12.5.1.17.6.3. A modified or repaired pressure system shall be revalidated and functionally tested at the system MOP before

its normal use.

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12.5.1.17.6.4. If any pressure system element such as a valve, regulator, gauges, or tubing has been disconnected or

reconnected for any reason, the affected system or subsystem shall be leak tested at MOP.

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12.5.2. Flight Hardware Hazardous Fluid System Components, Including Hypergolic, Cryogenic, and Hydraulic

Systems. Hypergolic and cryogenic components are required to meet the requirements in 12.6, 12.7, 12.8, and 12.9 in addition

to the following:

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12.5.2.1. Cycling capability for safety critical components shall be not less than 400 percent of the total number of expected

cycles, including system tests, but not less than 2,000 cycles.

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12.5.2.2. For service above a temperature of 160ºF an additional cycling capability equivalent to the above shall be required

as a maximum.

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The intent of this requirement is twofold: (1) to prevent viscosity breakdown from heat in hydraulic systems, and

(2) to consider the effects of elevated temperature in determining the safe cycle life of the components.

12.5.2.3. Safety critical actuators shall have positive mechanical stops at the extremes of safe motion.

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12.5.2.4. Hydraulic fluid reservoirs and supply tanks shall be equipped with remotely operated shutoff valves.

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12.5.2.5. Shuttle valves shall not be used in safety critical hydraulic systems where the event of a force balance on both inlet

ports may occur, causing the shuttle valve to restrict flow from the outlet port.

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12.5.2.6. Systems incorporating accumulators shall be interlocked to either vent or isolate accumulator fluid pressure when

power is shutoff.

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12.5.2.7. Adjustable orifice restrictor valves shall not be used in safety critical systems.

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12.5.2.8. When two or more actuators are mechanically tied together, only one lock valve shall be used to lock all the actuators.

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12.5.2.9. Lock valves shall not be used for safety critical lockup periods likely to involve extreme temperature changes unless

fluid expansion and contraction effects are safely accounted for.

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12.5.2.10. Flight Hardware Hazardous Fluid System Reservoirs:

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12.5.2.10.1. Whenever possible, the hydraulic reservoir should be located at the highest point in the system.

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12.5.2.10.2. If the requirement in 12.5.2.10.1 is not possible in safety critical systems, procedures shall be developed to detect

air in actuators or other safety critical components and to ensure that the system is properly bled before each use.

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12.5.2.11. Systems installations shall be limited to a maximum pressure of 15,000 psig.

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There is no intent to restrain development of systems capable of higher pressures; however, the use of such systems

shall be preceded by complete development and qualification that includes appropriate safety tests.

12.5.2.12. The inlet pressure of pumps in safety critical systems shall be specified to prevent cavitation effects in the pump

passages or outlets.

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12.5.2.13. Safety critical systems shall have positive protection against breaking the fluid column in the suction line during

standby.

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12.5.2.15. Systems that provide for manual takeover shall automatically disengage or allow by-pass of the act of manual

takeover.

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12.5.2.16. Safety critical systems or alternate bypass systems provided for safety shall not be rendered inoperative because of

back pressure under any set of conditions.

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12.5.2.17. The system shall be designed so that a lock resulting from an unplanned disconnection of a self-seating coupling

or other component shall not cause damage to the system or to adjacent property or injury to personnel.

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12.5.2.18. Systems using power-operated pumps shall include a pressure regulating device and an independent safety relief

valve.

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12.5.2.19. Flight Hardware Hazardous Fluid System Thermal Pressure Relief Valves:

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12.5.2.19.1. Thermal expansion relief valves shall be installed as necessary to prevent system damage from thermal expansion

of hydraulic fluid as in the event of gross overheating.

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12.5.2.19.2. Internal valve leakage shall not be considered an acceptable method of providing thermal relief.

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12.5.2.19.3. Thermal relief valve settings shall not exceed 150 psi above the value for system relief valve setting.

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12.5.2.19.4. Vents shall outlet only to areas of relative safety from a fire hazard.

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12.5.2.19.5. Hydraulic blow-out fuses (soft plugs) shall not be used in systems having temperatures above 160

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12.5.2.20. Pressure relief valves shall be located in the systems wherever necessary to ensure that the pressure in any part of

a power system shall not exceed the safe limit above the regulated pressure of the system.

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Flight Hardware Pneumatic System Design Requirements

Specific requirements for the design of flight hardware pneumatic systems and specific pneumatic system components are

described below:

12.6.1. Flight Hardware Pneumatic System Piping

12.6.1.1. NPT connectors shall not be used in hazardous pressure system piping.

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12.6.1.2. Socket-welded flanges shall not be used in hazardous pressure system piping.

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12.6.1.3. All piping and fitting welds shall be 100% radiographically inspected.

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12.6.2. Flight Hardware Pneumatic System Tubing. All tubing and fitting welds shall be 100% radiographically inspected

before and after the pressure test and inspected by surface NDE techniques before and after the pressure test.

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12.6.2.1. Welded connections shall meet the requirements of AWS D17.1, Specification for Fusion Welding for Aerospace

Applications, as prescribed by NASA-STD-5006, General Fusion Welding Requirements for Aerospace Materials Used in

Flight Hardware.

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12.6.2.2. Tube and fitting welded joints shall meet the inspection requirements of AIA/NAS 1514, Radiographic Standard for

Classification of Fusion Weld Discontinuities, and ASTM E1742, Standard Practice for Radiographic Examination.

Qualification of visual inspection personnel shall be a minimum of VT Level II as per SNT-TC-1A. Surface inspection, if

applicable, shall meet the requirements of ASTM E1417, Standard Practice for Liquid Penetrant Inspection.

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12.6.3. Flight Hardware Pneumatic System Regulators

12.6.3.1. Regulators shall be selected so that their working pressure falls within the center 50 percent of their total pressure

range if it is susceptible to inaccuracies or creep at either end of its pressure range.

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12.6.3.2. Pressure regulator actuators shall be capable of shutting off the fluid when the system is at the maximum possible

flow and pressure.

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12.6.3.3. Designs using uncontained seats are unacceptable.

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12.6.3.4. Systems that contain regulators that are remotely operated during prelaunch operations shall be designed to be fail-

safe if pneumatic or electric control power to the regulator is lost.

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12.6.4. Flight Hardware Pneumatic System Valves

12.6.4.1. Valve actuators shall be operable under maximum design flow and pressure.

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12.6.4.2. Manually operated valves shall be designed so that over torqueing the valve stem cannot damage soft seats to the

extent that seat failure occurs.

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12.6.4.3. Designs using uncontained seats are prohibited.

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12.6.4.4. Valves that are not intended to be reversible shall be designed or marked so that they shall not be connected in a

reverse mode.

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12.6.4.5. All electrical control circuits for remotely actuated valves shall be shielded or otherwise protected from hazardous

stray energy.

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12.6.4.6. Remotely controlled valves shall provide for remote monitoring of OPEN and CLOSED positions during prelaunch

operations.

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12.6.4.7. Systems that contain remotely operated valves shall be designed to be fail-safe if pneumatic or electric control power

to the valve is lost during prelaunch operations.

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12.6.4.8. Check valves shall be provided where back flow of fluids or media would create a hazard.

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12.6.4.9. Special care shall be taken in the design of oxygen systems to minimize the heating effect due to rapid increases in

pressure. Fast opening valves that can produce high velocity kinetic effects and rapid pressurization shall be avoided.

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12.6.4.10. Valve stem travel on manual valves shall be limited by a positive stop at each extreme position.

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12.6.4.11. The application or removal of force to the valve stem positioning device shall not cause disassembly of the pressure-

containing structure of the valve.

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12.6.5. Flight Hardware Pneumatic System Pressure Indicating Devices

12.6.5.1. A pressure indicating device shall be located on the downstream side of each pressure regulator and on any storage

system.

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12.6.5.2. These pressure indicating devices shall be designed to be remotely monitored during prelaunch operations.

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12.6.6. Flight Hardware Pneumatic System Flexible Hoses. Flexible hose requirements are specified in 12.1.10.4.

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12.6.7. Flight Hardware Pneumatic System Pressure Relief Devices

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12.6.7.1. Pressure relief devices shall be installed on all systems having an on-board pressure source that can exceed the

MAWP of any component downstream of that source unless the system is single failure tolerant against over pressurization

during prelaunch operations.

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12.6.7.2. Flight systems that require on-board pressure relief capability shall be designed to the following minimum

requirements:

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12.6.7.2.1. The pressure relief device shall be installed as close as practical downstream of the pressure reducing device or

source of pressure such as a compressor and gas generator.

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12.6.7.2.2. Pressure relief devices should be set to operate at a pressure not to exceed 110 percent of the system MOP/MEOP.

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12.6.7.2.3. The relieving capacity of the relief device and any vent outlet piping shall be equal to or greater than the maximum

flow capability of the upstream pressure reducing device or pressure source and should prevent the pressure from rising more

than 20 percent above the system MOP/MEOP.

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12.6.7.2.4. The relief device vent outlet piping shall be sized to prevent excessive back pressure from adversely affecting the

function of the relief device.

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12.6.7.2.5. All relief devices and associated piping shall be structurally restrained to minimize any thrust effects on the

pressure system vessels or piping.

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12.6.7.2.6. The effects of the discharge from relief devices shall be assessed and analyzed to ensure that operation of the

device shall not be hazardous to personnel or equipment. Items to be analyzed are thrust loads, noise, impingement of high

velocity gas or entrained particles, toxicity, oxygen enrichment, and flammability.

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12.6.7.2.7. All pressure relief devices shall be vented separately unless the following can be positively demonstrated:

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12.6.7.2.7.1. The creation of a hazardous mixture of gases in the vent system and the migration of hazardous substances into

an unplanned environment is impossible.

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12.6.7.2.7.2. The capacity of the vent system is adequate to prevent a pressure rise of more than 20 percent above MOP when

all attached pressure relief devices are wide open, and the system is at full pressure and volume generating capacity.

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12.6.7.2.8. No obstructions shall be placed downstream of the relief device.

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12.6.7.2.9. Relief devices shall be located so that other components cannot render them inoperative.

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12.6.8. Flight Hardware Pneumatic System Vents

12.6.8.1. Pressure systems shall be designed so that pressure cannot be trapped in any part of the system without vent

capability.

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12.6.8.2. Vent system outlets should be in a location normally inaccessible to personnel or shall be conspicuously identified.

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12.6.8.3. Vent outlets shall be protected against rain intrusion and entry of birds, insects, and animals.

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12.6.8.4. Oxidizer and fuel vent outlets to the atmosphere shall be separated sufficiently to prevent mixing of vented fluids.

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12.6.8.5. All vent outlets shall be designed to prevent accumulation of vented gases in dangerous concentrations (oxygen rich)

in areas frequented by unprotected personnel.

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12.6.8.6. Hydrogen vents shall discharge to atmosphere through an approved burner.

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12.6.8.7. Special attention shall be given to the design of vent line supports at vent outlets due to potential thrust loads.

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12.6.8.8. Each line venting into a multiple-use vent system shall be protected against back pressurization by means of a check

valve if the upstream system cannot withstand the back pressure or where contamination of the upstream system cannot be

tolerated.

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Flight Hardware Hydraulic System Design and Test Requirements

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In addition to the following requirements, flight hardware hydraulic systems shall meet the minimum design fabrication and

test requirements of 12.5.1 and 12.5.2.

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12.7.1. Flight Hardware Hydraulic System General Design Requirements

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12.7.1.1. Where necessary, hydraulic system low-points shall be provided a drain fitting (bleed ports) to allow draining of

condensates or residue for safety purposes.

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Entrapped air, moisture, and cleaning solvents are examples of foreign substances that may be hazardous to the

system, component, or control equipment.

12.7.1.2. Bleed ports shall be located so that they can be operated without removal of other components and shall permit the

attachment of a hose to direct the bleed off material into a container away from the positions of the operators.

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12.7.1.3. Test points shall be provided on hydraulic systems so that disassembly for test is not required.

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12.7.1.4. Test points shall be easily accessible for the attachment of ground test equipment.

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12.7.1.5. For all power-generating components, pump pulsations shall be controlled to a level that does not adversely affect

system tubing, components, and support installation.

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12.7.1.6. Where system leakage can expose hydraulic fluid to potential ignition sources, fire resistant, or flameproof hydraulic

fluid shall be used.

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12.7.2. Flight Hardware Hydraulic System Accumulators and Reservoirs. All accumulators and reservoirs that are

pressurized with gas to pressures greater than 100 psig shall be designed in accordance with 12.2.

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12.7.3. Flight Hardware Hydraulic System Pressure Indicating Devices

12.7.3.1. A pressure indicating device shall be located on any pressurized storage system with a pressure greater than 100

psig.

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12.7.3.2. These devices shall be designed to be remotely monitored during prelaunch operations.

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12.7.4. Flight Hardware Hydraulic System Pressure Relief Devices

12.7.4.1. Pressure relief devices shall be installed on all systems having an on-board pressure source that can exceed the

MAWP of any component downstream of that source unless the system is single failure tolerant against over pressurization

during prelaunch operations.

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12.7.4.2. Flight systems that require on-board pressure relief capability shall meet the following minimum requirements:

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12.7.4.2.1. The pressure relief device shall be installed as close as practical downstream of the pressure sources such as pumps,

turbines, or gas generators.

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12.7.4.2.2. Pressure relief devices shall be set to operate at a pressure not to exceed 110 percent of the system MOP.

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12.7.4.2.3. The relieving capacity of the relief device shall be equal to or greater than the maximum flow capability of the

upstream pressure source and should prevent the pressure from rising more than 20 percent above the system MOP.

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12.7.4.2.4. The effects of discharge from relief devices shall be assessed and analyzed to ensure that operation of the device

shall not be hazardous to personnel or equipment. Items to be analyzed include thrust loads, toxicity, combustibility,

flammability, and others as necessary.

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12.7.4.2.5. Relief devices shall be located so that other components cannot render them inoperative.

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12.7.4.2.6. No obstructions shall be placed downstream of the relief valve or burst disk outlet.

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12.7.5. Flight Hardware Hydraulic System Vent and Drain Systems. Hydraulic systems shall be designed so that pressure

and fluids cannot be trapped in any part of the system without vent and/or drain capability.

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12.7.6. Testing Flight Hardware Hydraulic System Components Before Assembly. All system elements pressurized with

gas to pressures greater than 100 psig shall be qualification tested in accordance with 12.2.4.1 and acceptance tested in

accordance with 12.2.4.2 and 12.5.1.17.1.

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12.7.7. Testing Flight Hardware Hydraulic Systems After Assembly

12.7.7.1. Tests shall meet the requirements of 12.5.1.17.2.

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12.7.7.2. Leak tests shall meet the requirements of 12.5.1.17.3.

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12.7.7.3. System validation and functional tests shall meet requirements of 12.5.1.17.4.

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12.7.7.4. Modified and repaired flight hardware shall meet the requirements of 12.5.1.17.6.

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Flight Hardware Hypergolic Propellant System Design and Test Requirements

12.8.1. Flight Hardware Hypergolic Propellant System General Design Requirements

12.8.1.1. Propellant systems shall have low point drain capability unless designed for positive pressure purging.

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12.8.1.2. Low point drains shall be accessible and located in the system to provide the capability of removing propellant from

the tanks, piping, lines, and components at all times after loading. Estimated residual and locations shall be identified.

Note: The design goal is the ability to depressurize and/or offload the entire quantity of propellant, if necessary, to safe the system

for transport to a payload processing facility. The maximum residual quantity of propellant remaining after contingency offloading

operations should be identified in contingency plans and procedures that reflect the required actions necessary for subsequent safing,

transportation, decontamination, and processing activities.

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12.8.1.3. Propellant systems shall be designed to be flushed with compatible fluids and purged with inert gas.

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12.8.1.4. For prelaunch failure modes that could result in a time-critical emergency, provision shall be made for automatic

switching to a safe mode of operation. Caution and warning signals shall be provided for these time-critical functions.

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12.8.1.5. Propellant systems shall also comply with the pneumatic system requirements of 12.6.

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12.8.1.6. Items used in any fuel or oxidizer system shall not be interchanged after exposure to the respective media.

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12.8.1.7. Bi-propellant systems shall have the capability of loading and/or unloading the fuel and oxidizer one at a time.

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12.8.1.8. Propellant (liquid or gas) migration into an associated pneumatic system shall be controlled.

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The pneumatic system should be compatible with all of the propellants served by the pneumatic supply.

12.8.2. Flight Hardware Hypergolic Propellant System Piping and Tubing

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12.8.2.1. All flight hardware hypergolic propellant system piping and tubing connectors and fittings shall be welded in

accordance with the design, performance and quality requirements prescribed in SAE Aerospace Recommended Practices

(ARP) 899, Tube Fittings, Fluid Systems, Permanent Type, General Requirements for.

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12.8.2.2. Fittings and connectors with NPT or socket weld flanges shall not be used in hypergolic propellant systems.

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Certain mechanically attached tube connections have been allowed in previous payload hypergolic propellant systems via the

NASA waiver process. Nonwelded fittings and connectors in hypergolic propellant systems may be considered on a case-by-case

basis but shall be used only in applications where additional hazard mitigations

are

included (i.e. upstream isolation valves, toxic

vapor detection, restrictions on personnel access during ground processing, etc.). The payload project must provide sufficient

details to allow for evaluation by the PSWG and Range Safety. All proposed applications of nonwelded fittings and connectors

in hypergolic propellant systems must be approved by the PSWG and Range Safety. The level of system details and the required

hazard mitigations will be determined by the PSWG and Range Safety based on fitting design, heritage, reliability, application,

quantity of propellant, response plans, etc

12.8.2.3. All pipe and tube welded joints shall be 100% radiographically inspected before and after the acceptance pressure

test and inspected by surface NDE techniques before and after the pressure test.

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12.8.3. Flight Hardware Hypergolic Propellant System Valves

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12.8.3.1. Valve actuators shall be operable under maximum design flow and pressure.

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12.8.3.2. A remotely operated flow control valve shall be installed as close as practical to tanks to allow for isolating the

tank(s) from the rest of the system when necessary. The valve shall be designed to be fail-safe if pneumatic or electric control

power is lost during prelaunch operations.

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12.8.3.3. Check valves shall be provided where back flow of fluids would create a hazard.

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12.8.3.4. Valve connectors and connections shall be designed, selected, or located, or, as a last resort, marked to prevent

connection to an incompatible system.

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12.8.3.5. Remotely controlled valves shall provide for remote monitoring of open and closed positions during prelaunch

operations. Monitoring of remotely controlled, pyrotechnically operated valve open and closed positions shall not be required

if the function power is deenergized (in other words, an additional fourth inhibit is in place between the power source and the

three required inhibits) and the control circuits for the three required inhibits are disabled (in other words, no single failure in

the control circuitry will result in the removal of an inhibit) until the hazard potential no longer exists.

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12.8.3.6. All electrical control circuits for remotely actuated valves shall be shielded or otherwise protected from hazardous

stray energy.

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12.8.3.7. Designs using uncontained seats are prohibited.

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12.8.3.8. Valves that are not intended to be reversible shall be designed or marked so that they cannot be connected in a

reverse mode.

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12.8.3.9. Manually operated valves shall be designed so that over torqueing the valve stem cannot damage soft seats to the

extent that seat failure occurs.

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12.8.3.10. Valve stem travel on manual valves shall be limited by a positive stop at each extreme position.

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12.8.3.11. The application or removal of force to the stem positioning device shall not cause disassembly of the pressure

containing structure of the valve.

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12.8.3.12. All electromechanical actuator electric wiring shall be sealed to prevent fluid ignition.

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12.8.4. Flight Hardware Hypergolic Propellant System Pressure Indicating Devices

12.8.4.1. A pressure indicating device shall be located on any storage vessel and on any section of the system where

pressurized fluid can be trapped.

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12.8.4.2. These pressure indicating devices shall be designed to be remotely monitored during prelaunch operations.

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12.8.5. Flight Hardware Hypergolic Propellant System Flexible Hoses. Flexible hose requirements are specified in

12.1.10.4 in addition to the following:

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12.8.5.1. Flexible hoses shall consist of a flexible inner pressure carrier tube (compatible with the service fluid). This tube

shall be constructed of plastic (typically polytetrafluoroethylene [PTFE]) or corrugated metal (typically 300 series stainless

steel) material reinforced by one or more layers of 300 series stainless steel wire and/or fabric braid.

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In applications where stringent permeability and leakage requirements apply, hoses with a metal inner pressure carrier tube

should be used. Where these hoses are used in a highly corrosive environment, consideration should be given to the use of

Hastalloy C-22 in accordance with ASTM B575 for the inner pressure carrier tube and C-276 material for the reinforcing braid.

12.8.5.2. Flexible hoses shall be dedicated to a service media. Interchanging of flexible hoses used in incompatible service

media, such as hypergolic propellants, is not permitted. Permeation is not totally negated by the cleaning process.

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12.8.6. Flight Hardware Hypergolic Propellant System Pressure Relief Devices

12.8.6.1. Pressure relief devices shall be installed on all systems having an on-board pressure source that can exceed the

MAWP or MOP of any component downstream of that source unless the system is single failure tolerant against over

pressurization during prelaunch operation.

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12.8.6.2. Flight systems that require on-board pressure relief capability shall be designed to the following minimum

requirements:

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12.8.6.2.1. The pressure relief device shall be installed as close as is practical downstream of the pressure reducing device or

source of pressure such as a compressor or gas generator.

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12.8.6.2.2. Pressure relief devices should be set to operate at a set pressure not to exceed 110% of the system MOP.

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12.8.6.2.3. The relieving capacity of the relief device shall be equal to or greater than the maximum flow capability of the

upstream pressure reducing device or pressure source and should prevent the pressure from rising more than 20% above the

system MOP.

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12.8.6.3. The relief device vent outlet piping shall be sized to prevent excessive back pressure from adversely affecting the

relief device function.

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12.8.6.4. All relief devices and associated piping shall be structurally restrained to minimize any thrust effects to the pressure

system vessels or piping.

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12.8.6.5. The effects of the discharge from relief devices shall be assessed and analyzed to ensure that operation of the device

shall not be hazardous to personnel or equipment. Items to be analyzed are thrust loads, toxicity, combustibility, flammability,

and others as deemed necessary by PSWG and Range Safety.

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12.8.6.6. All pressure relief devices shall be vented separately unless the following criteria can be positively demonstrated:

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12.8.6.6.1. The creation of a hazardous mixture of gases in the vent system and the migration of hazardous substances into an

unplanned environment is impossible.

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12.8.6.6.2. The capacity of the vent system is adequate to prevent a pressure rise more than 20% above MOP when all attached

pressure relief devices are fully opened, and the system is at full pressure and volume generating capacity.

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12.8.6.7. No obstructions shall be placed downstream of the relief device.

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12.8.6.8. Relief devices shall be located so that other components cannot render them inoperative.

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12.8.7. Flight Hardware Hypergolic Propellant Vent Systems.

12.8.7.1. All vent effluent resulting from routine operations shall be scrubbed and/or incinerated before venting to the

atmosphere through vent stacks.

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12.8.7.2. Hypergolic systems shall be designed so that vapors or liquids cannot be trapped in any part of the system without

vent and/or drain capability.

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12.8.7.3. Vent system outlets shall be in a location normally inaccessible to personnel and shall be conspicuously identified.

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12.8.7.4. Vent outlets shall be protected against rain intrusion and entry of birds, insects, and animals.

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12.8.7.5. Oxidizer and fuel vent outlets to the atmosphere shall be separated sufficiently to prevent mixing of vented fluids.

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12.8.7.6. Special attention shall be given to the design of vent line supports at vent outlets due to potential thrust loads.

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12.8.7.7. Each line venting into a multiple-use vent system shall be protected against back pressurization by means of a check

valve if the upstream system cannot withstand the back pressure or where contamination of the upstream system cannot be

tolerated.

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12.8.7.8. Pressure relief vents shall be designed and located so that vapors cannot enter any inhabited areas.

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12.8.7.9. Incompatible fluids shall not be discharged into the same vent or drain system.

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12.8.7.10. Fuel and oxidizer vent systems shall be equipped with a means of purging the system with an inert gas to prevent

explosive mixtures.

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12.8.8. Testing Flight Hardware Hypergolic Propellant System Components Before Assembly

12.8.8.1. All systems elements shall be qualification tested in accordance with 12.2.2.6 and acceptance tested in accordance

with 12.2.2.7 and 12.5.1.17.1.

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12.8.8.2. Pneumatic proof testing to a proof pressure of 1.25 times MOP/MEOP (not to exceed MAWP) is permissible only

if hydrostatic proof testing is impractical, impossible, or jeopardizes the integrity of the system or system element. Prior

approval for pneumatic proof testing at the payload processing facility and launch site area shall be obtained from PSWG and

Range Safety.

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12.8.8.3. All hypergolic propellant valves shall be tested for both internal and external leakage at their MAWP.

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12.8.8.3.1. No external leakage is allowed. Valves shall be visually bubble tight, using approved soap solution and techniques.

Internal leakage of valves shall not exceed limits specified in the valve performance specification.

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12.8.8.3.2. Certain critical system components may require helium leak checks using a mass spectrometer to verify leak rates

not to exceed 1 x 10

-6

cc/sec of helium gas at standard temperature and pressure (STP).

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12.8.9. Testing Flight Hardware Hypergolic Propellant Systems After Assembly. All newly assembled propellant

pressure systems shall meet the test requirements of 12.5.1.17.2 after assembly.

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12.8.9.1. Flight Hardware Hypergolic Propellant System Leak Tests

12.8.9.1.1. Pneumatic leak testing at system MOP/MEOP of all completely assembled and cleaned vessel pipe and tubing

sections, with components installed, shall be completed before introduction of propellant.

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12.8.9.1.2. Minimum test requirements are as follows:

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12.8.9.1.2.1. Test gas should use a minimum volume of 10 percent helium.

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12.8.9.1.2.2. All mechanical joints such as gasket joints, seals, and threaded joints and weld seams shall be visually bubble

tight, using approved soap solution and techniques.

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12.8.9.1.2.3. The functional validity of installed block valves should be checked by incrementally venting downstream

sections and pin hole leak checking. This test shall be conducted as a preparation to propellant loading operations at the

payload processing facility unless prior approval from PSWG and Range Safety has been obtained.

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12.8.9.1.3. When required, a more sensitive method of leak detection (e.g. mass spectrometers) may be specified on a case-

by-case basis.

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12.8.9.2. Flight Hardware Hypergolic Propellant System Validation and Functional Tests. All newly assembled

pressure systems shall meet the system validation and functional testing requirements of 12.5.1.17.4.

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12.8.9.3. Flight Hardware Hypergolic Propellant Systems Bonding and Grounding. All newly assembled pressure

systems shall meet the bonding and grounding requirements of section 12.1.12

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12.8.10. Testing Modified and Repaired Flight Hardware Hypergolic Propellant Systems. Modified and repaired flight

hardware propellant systems shall meet the test requirements of 12.5.1.17.6.

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Flight Hardware Cryogenic Systems Design and Test Requirements

12.9.1. Flight Hardware Cryogenic System General Design Requirements

12.9.1.1. Propellant systems shall have low point drain capability.

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12.9.1.1.1. Low point drains shall be accessible and located in the system to provide the capability of removing propellant

from the tanks, piping, lines, and components.

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12.9.1.1.2. In addition, the cryogenic fuel system shall be designed to be purged with inert fluids.

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12.9.1.2. Bi-propellant systems shall have the capability of loading the fuel and oxidizer one at the time.

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12.9.1.3. For prelaunch failure modes that could result in a time-critical emergency, provision shall be made for automatic

switching to a safe mode of operation. Caution and warning signals shall be provided for these time-critical functions.

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12.9.1.4. Pneumatic systems servicing cryogenic systems shall comply with the pneumatic pressure system requirements of

12.6.

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12.9.1.5. Cryogenic systems shall be designed to control liquefaction of air.

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12.9.1.6. For systems requiring insulation, nonflammable materials shall be used in compartments or spaces where fluids

and/or vapors could invade the area.

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12.9.1.7. Vacuum-jacketed systems shall be capable of having the vacuum verified.

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12.9.1.8. Purge gas for LH

and cold GH

lines should be gaseous helium (GH

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12.9.1.9. Precautions shall be taken to prevent cross-mixing of media through common purge lines by use of check valves to

prevent back flow from a system into a purge distribution manifold.

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12.9.1.10. Titanium and titanium alloys shall not be used where exposure to GOX (cryogenic) or LO

(LOX) is possible.

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12.9.2. Flight Hardware Cryogenic System Vessels and Tanks. Cryogenic vessels and tanks shall be designed in

accordance with the requirements in 12.2.

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12.9.3. Flight Hardware Cryogenic System Piping and Tubing

12.9.3.1. The amount and type of thermal insulation (insulation material or vacuum-jacketed) shall be determined from system

thermal requirements.

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12.9.3.2. The use of slip-on flanges shall be avoided.

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12.9.3.3. Flanged joints in LH

systems shall be seal welded.

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12.9.3.4. Flanged joint gaskets shall not be reused.

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12.9.3.5. Cryogenic systems shall provide for thermal expansion and contraction without imposing excessive loads on the

system.

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Bellows, reactive thrust bellows, or other suitable load relieving flexible joints may be used.

12.9.3.6. All pipe and tube welded joints shall be 100 percent radiographically inspected before and after the acceptance proof

test. The accept/reject criteria shall be submitted to PSWG and Range Safety for review and approval.

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12.9.3.6.1. Welded connections shall meet the requirements of AWS D17.1, Specification for Fusion Welding for Aerospace

Applications, as prescribed by NASA-STD-5006, General Fusion Welding Requirements for Aerospace Materials Used in

Flight Hardware.

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12.9.3.6.2. Tube and fitting welded joints shall meet the inspection requirements of AIAA/NAS 1514-72, Radiographic

Standard for Classification of Fusion Weld Discontinuities, and ASTM E 1742, Standard Practice for Radiographic

Examination, and be visually inspected using appropriate mechanical aids as needed to ensure compliance with weld

specifications and requirements in accordance with aerospace industry practices. Surface inspection, if applicable, shall meet

the requirements of ASTM E 1417, Standard Practice for Liquid Penetrant Inspection.

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12.9.4. Flight Hardware Cryogenic System Valves

12.9.4.1. Cryogenic systems shall be designed to ensure icing does not render the valve inoperable.

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12.9.4.2. Remotely controlled valves shall provide for remote monitoring of the open and closed positions.

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12.9.4.3. Remotely operated valves shall be designed to be fail-safe if pneumatic or electric control power is lost during

prelaunch operations.

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12.9.4.4. All electrical control circuits for remotely actuated valves shall be shielded or otherwise protected from hazardous

stray energy.

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12.9.4.5. Manually operated valves shall be designed so that over torqueing the valve stem cannot damage seats to the extent

that seat failure occurs.

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12.9.4.6. Valve stem travel on manual valves shall be limited by a positive stop at each extreme position.

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12.9.4.7. The application or removal of force to the stem positioning device shall not cause disassembly of the pressure

containing structure of the valve.

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12.9.4.8. Manual or remote valve actuators shall be operable under maximum design flow and pressure.

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12.9.4.9. Valves that are not intended to be reversible shall be designed or marked so that they cannot be connected in a

reverse mode.

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12.9.4.10. Stem position local or remote indicators shall sense the position of the stem directly, not the position of the actuating

device.

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12.9.4.11. All electromechanical actuator electrical wiring shall be sealed to prevent fluid ignition.

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12.9.5. Flight Hardware Cryogenic System Pressure Indicating Devices

12.9.5.1. A pressure indicating device shall be located on any cryogenic vessel and/or tank and on any section of the system

where cryogenic liquid can be trapped.

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12.9.5.2. These pressure indicating devices shall be designed to be remotely monitored during prelaunch operations.

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12.9.6. Flight Hardware Cryogenic System Flexible Hoses. Flexible hose requirements are specified in 12.1.10.4 in

addition to the following:

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12.9.6.1. Flexible hoses used in cryogenic system shall be of the single-wall, double-wall, or double-wall, vacuum-jacketed

type.

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12.9.6.2. All convoluted portions of flexible hoses shall be covered with stainless steel wire band.

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12.9.7. Flight Hardware Cryogenic System Pressure Relief Devices

12.9.7.1. All cryogenic vessels and tanks shall be protected against overpressure by means of at least one pressure relief valve.

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12.9.7.2. Minimum design requirements are as follows:

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12.9.7.2.1. The pressure relief device shall be installed as close as practical to the cryogenic vessel or tank.

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12.9.7.2.2. Pressure relief valves shall be set to operate at pressures determined on a case-by-case basis by the payload project.

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12.9.7.2.3. The relieving capacity of the relief valve shall be determined on a case-by-case basis by the payload project.

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12.9.7.3. All pressure relief devices shall be vented separately unless the following can be positively demonstrated:

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12.9.7.3.1. The creation of a hazardous mixture of gases in the vent system and the migration of hazardous substances into an

unplanned environment is impossible.

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12.9.7.3.2. The capacity of the vent system is adequate to prevent a pressure rise more than 20 percent above MOP when all

attached pressure relief devices are fully opened, and the system is at full pressure and volume generating capacity.

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12.9.7.4. All relief devices and associated piping shall be structurally restrained to eliminate any deleterious thrust effects on

cryogenic system vessels or piping.

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12.9.7.5. The effects of the discharge from relief devices shall be assessed and analyzed to ensure that operation of the device

shall not be hazardous to personnel or equipment.

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Items to be analyzed are thrust loads, impingement of high velocity gas or entrained particles, toxicity, oxygen

enrichment, and flammability.

12.9.7.6. No obstructions shall be placed downstream of the relief valves.

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12.9.7.7. Relief valves shall be located so that other components cannot render them inoperative.

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12.9.8. Flight Hardware Cryogenic System Vents

12.9.8.1. GH

shall be vented to atmosphere through a burner system.

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12.9.8.2. Cryogenic systems shall be designed so that fluids cannot be trapped in any part of the system without drain or vent

(relief valve or vent valve) capability.

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12.9.8.3. Each line venting into a multiple-use vent system shall be protected against back pressurization by a check valve if

the upstream system cannot withstand the back pressure or where contamination of the upstream system cannot be tolerated.

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12.9.8.4. Vents shall be placed in a location normally inaccessible to personnel and at a height or location where venting is

not normally deposited into habitable spaces.

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12.9.8.5. Each vent shall be conspicuously identified using appropriate warning signs, labels, and markings.

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12.9.8.6. Vent outlets shall be located far enough away from incompatible propellant systems and incompatible materials to

ensure no contact is made during vent operations.

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12.9.8.7. Incompatible fluids shall not be discharged into the same vent or drain system.

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12.9.8.8. Fuel vent systems shall be equipped with a means of purging the system with an inert gas to prevent explosive

mixtures.

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12.9.8.9. Vent outlets shall be protected against rain intrusion and entry of birds, insects, and animals.

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12.9.8.10. Special attention shall be given to the design of vent line supports at vent outlets due to potential thrust loads.

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12.9.9. Testing Flight Hardware Cryogenic System Components Before Assembly

12.9.9.1. All cryogenic vessels and tanks shall be qualification tested in accordance with 12.2.2.6 and acceptance tested in

accordance with 12.2.2.7.

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12.9.9.2. Flight hardware cryogenic system components shall meet the test requirements of 12.5.1.17.1 before assembly.

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12.9.10. Testing Flight Hardware Cryogenic Systems After Assembly

12.9.10.1. Flight hardware cryogenic systems shall meet the test requirements of 12.5.1.17.2 after assembly.

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12.9.10.2. All newly assembled cryogenic systems shall be leak tested.

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12.9.10.3. The system shall be pressurized to the system MOP using gaseous helium for LH

systems and GN

for LO

(LOX)

systems.

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12.9.10.4. Following the leak test, all newly assembled cryogenic systems shall have a system validation test performed at

system MOP before first operational use at the payload processing facility and launch site area.

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12.9.10.5. Minimum test requirements are as follows:

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12.9.10.5.1. The intended service fluid (LO

[LOX], LH

) shall be used as the validation test fluid.

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12.9.10.5.2. The functional capability of all components and subsystems shall be validated.

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12.9.10.5.3. All prelaunch operational sequences for the system shall be exercised, including emergency shutdown, safing,

and unloading procedures.

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12.9.10.5.4. Vacuum readings of all vacuum volumes shall be taken and recorded before, during, and after the test.

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12.9.10.5.5. No deformation, damage, or leakage is allowed.

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12.9.11. Testing Modified and Repaired Flight Hardware Cryogenic Systems

12.9.11.1. Any cryogenic system element, including fittings or welds, that have been repaired, modified, or possibly damaged

before the system leak test shall be retested.

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12.9.11.2. The component retest sequence shall be as follows:

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12.9.11.2.1. The component shall be hydrostatically proof tested at ambient temperature to 1.5 times the component

MOP/MEOP (not to exceed MAWP).

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12.9.11.2.2. The component shall be reinstalled into the cryogenic system and a leak check performed at system MOP/MEOP.

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12.9.11.2.3. The functional capability of the modified and/or repaired component shall be revalidated using the intended

service fluid at system MOP.

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12.9.11.3. If any cryogenic system elements such as valves, regulators, gauges, or pipes have been disconnected or

reconnected for any reason, the affected connection shall be leak checked at MOP/MEOP.

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Flight Hardware Pressure Systems Data Requirements

12.10.1. General. The minimum data required to certify compliance with the design, analysis, and test requirements of this

chapter are described below.

12.10.1.1. Data required by 12.10.2 through 12.10.5 shall be incorporated into the Missile System Prelaunch Safety Package

(MSPSP) or submitted as a separate package when appropriate.

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12.10.1.2. Data required by 12.10.2 through 12.10.6 shall be placed in a system certification file that shall be to be maintained

and updated by the hazardous pressure system operator.

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12.10.1.3. This data shall be reviewed and approved by the PSWG and Range Safety before the first operational use of

hazardous pressure systems at the payload processing facility and launch site area.

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12.10.2. Flight Hardware Pressure Systems General Data Requirements. The following general flight hardware pressure

systems data is required:

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12.10.2.1. Hazard analysis of hazardous pressure systems in accordance with a jointly tailored SSP. (See Volume 1,

Attachment 3.)

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12.10.2.2. A material compatibility analysis shall be performed in accordance with the requirements specified in 12.1.13 and

12.1.16 of this chapter.

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12.10.2.3. General flight hardware pressure systems data shall be submitted in accordance with Attachment 1, A1.2.4.7.1of

this volume.

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12.10.3. Flight Hardware Pressure System Design Data Requirements. Flight hardware pressure system design data shall

be provided in accordance with Attachment 1, A1.2.4.7.2 of this volume.

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12.10.4. Flight Hardware Pressure System Component Design Data

12.10.4.1. Identification of each component with a reference designation permitting cross-reference with the system

schematic.

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12.10.4.2. MAWP for all pressure system components and the MOP the component will see when installed in the system.

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12.10.4.3. Safety factors or design burst pressure for all pressure system components and identification of actual burst

pressures, if available.

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12.10.4.4. Proof pressure for each system component and identification of the proof pressure the component will see after

installation in the system, if applicable.

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12.10.4.5. Materials used in the fabrication of each element within the component including soft goods and other internal

elements.

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12.10.4.6. Cycle limits if fatigue is a factor of the component.

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12.10.4.7. Temperature limits of each system component.

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12.10.4.8. Component information shall be placed in tables.

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12.10.5. Flight Hardware Pressure System Test Procedures and Reports

12.10.5.1. All test plans, test procedures and test reports required by this chapter shall be submitted to the PSWG for PSWG

and Range Safety review and approval.

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12.10.5.2. A list and synopsis of all hazardous pressure system test procedures shall be submitted to the PSWG for PSWG

and Range Safety review and approval.

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12.10.6. Flight Hardware Pressure System Certification Files

12.10.6.1. Certification files shall be maintained and updated by the hazardous pressure system operator.

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12.10.6.2. These files shall be accessible for PSWG review and located at the ranges.

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12.10.6.3. The certification file for each hazardous pressure system shall contain the data required in 12.10.1 through 12.10.5

in addition to the following:

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12.10.6.3.1. As applicable, stress, safe-life, fatigue, and fracture mechanics analysis in accordance with 12.1.5.3, 12.1.5.4,

and 12.1.5.5.

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12.10.6.3.2. Specification drawings and documents for all components.

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12.10.6.3.3. If necessary, a cross-sectional assembly drawing of the component to assess the safety aspects of the internal

elements.

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12.10.6.3.4. Certification that welding and weld NDE meet applicable standards and have been performed by certified

personnel.

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12.10.6.3.5. Qualification and acceptance test plans and test reports.

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12.10.6.3.6. Certification documentation describing how pressure systems, vessels, and pressurized structures are designed,

fabricated, and tested in accordance with 12.1, 12.2, and 12.3, as applicable.

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12.10.6.3.7. Certification that all components, including pipe and tube fittings, have successfully passed a hydrostatic proof

test.

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ORDNANCE SYSTEMS

Ordnance Hazard Classification

Safety requirements for non-explosive actuators, ordnance devices, and circuits specific for NASA Payloads are

provided in this publication.

Note: For purposes of these requirements the term ordnance items is meant to include non-explosive actuators such as, paraffin

actuators, phase change devices, and others as determined by the PSWG and Range Safety.

13.1.1. Ordnance General Classification

13.1.1.1. Ordnance items shall be assigned the appropriate DoD and United Nations (UN) hazard classification and storage

compatibility group in accordance with DESR 6055.09_AFMAN 91-201, Explosive Safety Standard and NASA-STD-

8719.12, Safety Standard for Explosives, Propellants, and Pyrotechnics.

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13.1.1.2. Items that have not previously been classified and cannot be classified based on similarity with previously classified

items shall be tested in accordance with AFTO 11A-1-47/ (NAVSEAINST 8020.3/TB700-2/DLAR 8220.1), Explosive

Hazard Classification Procedures, and classified accordingly.

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13.1.1.3. Ordnance items shall also have a DOT classification. The payload project is responsible for obtaining DOT

classification.

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13.1.1.4. The payload project shall provide the UNO, DoD, and DOT documentation demonstrating proper classification for

review and approval by PSWG and Range Safety before delivering ordnance.

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Ordnance System General Requirements

All the remaining parts of this chapter establish the design requirements for hazardous ordnance and ordnance systems

during transportation, handling, storage, installation, testing, and connection on the ranges. Hazard division 1.4S ordnance

and ordnance systems, considered as articles that present no significant hazard, do not have to meet the design requirements

identified in this chapter; however, they shall meet the operational requirements identified in Volume 6 of this publication.

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13.2.1. Ordnance Subsystem Identification. Ordnance systems include the following subsystems. All of these subsystems

are subject to the design requirements described below.

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13.2.1.1. Power Source. The firing power source may be a battery, a dedicated power bus, or a capacitor.

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13.2.1.2. Firing Circuit (the path between the power source and the initiating device). The firing circuit includes the electrical

path and the optical path for laser initiated ordnance.

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13.2.1.3. Control Circuit. The control circuit activates and deactivates the safety devices in the firing circuit.

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13.2.1.4. Monitor Circuit. The monitor circuit monitors status of the firing circuits.

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13.2.1.5. Initiating Device. The initiating device converts electrical, mechanical, or optical energy into explosive energy.

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13.2.1.6. Receptor Ordnance. Receptor ordnance includes all ordnance items such as the explosive transfer system (ETS),

separation charge, explosive bolt installed downstream of the initiating devices.

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13.2.2. Preclusion of Inadvertent Firing. Ordnance devices and systems shall be designed to preclude inadvertent firing of

any explosive or pyrotechnic components when subjected to environments encountered during ground processing including

shock, vibration, and static electricity encountered during ground processing.

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13.2.3. Failure Mode Effects and Criticality Analysis. A comprehensive FMECA shall be performed on all ordnance systems

in accordance with MIL-STD-1629 Procedures for Performing a Failure Mode Effects and Criticality Analysis, or equivalent.

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Ordnance Electrical Circuits and Optical Circuits

13.3.1. Ordnance Electrical Circuit General Design Requirements

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13.3.1.1. Ordnance system circuitry shall be protected to preclude energy sources such as electromagnetic energy or stray

light from the ranges and/or launch vehicle from causing undesired output of the system.

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Solutions for protection of ordnance system circuitry include shielding, filtering, grounding, and other isolation techniques that

can preclude the energy sources such as electromagnetic energy or stray light from the ranges and/or launch vehicle from

causing undesired output of the system.

13.3.1.2. Hazardous ordnance systems shall be designed so that the initiating devices can be installed in the system just

before final electrical and/or optical hookup on the launch pad.

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It is understood that the requirement for designing ordnance so that the initiating devices can be installed in the system just

before final electrical hookup on the launch pad cannot always be met. Exceptions are handled on a case-by-case basis where

the payload processing facility and/or launch site user has demonstrated compliance with the intent.

13.3.1.2.1. Initiating device locations shall be accessible to facilitate installation and removal and electrical and/or optical

connections as late as possible in the launch countdown.

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13.3.1.2.2. Access required at the launch complexes shall be identified and demonstrated to accommodate this accessibility

requirement.

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13.3.1.3. Separate power sources and/or busses shall be required for ordnance initiating systems.

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13.3.1.4. RF energy shall not be used to ignite initiating devices.

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13.3.1.5. Electrical firing circuits shall be isolated from the initiating ordnance case, electronic case, and other conducting

parts of the flight hardware.

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13.3.1.5.1. If a circuit is grounded, there shall be only one interconnection (single ground point) with other circuits. Static

bleed resistors of 10 kilo-ohms to 100 kilo-ohms are not considered to violate the single point ground.

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13.3.1.5.2. This interconnection shall be at the power source only.

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13.3.1.5.3. Other ground connections with equivalent isolation shall be handled on a case-by-case basis.

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13.3.1.6. Ungrounded circuits capable of building up static charge shall be connected to the structure by static bleed resistors

of between 10 kilo-ohms and 100 kilo-ohms.

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13.3.1.7. Firing circuit design shall preclude sneak circuits and unintentional electrical paths due to such faults as ground

loops and failure of solid state switches.

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13.3.1.8. Redundant circuits shall be required if loss of power or signal may result in injury to personnel or be a detriment to

safety critical systems.

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13.3.1.9. The elements of a redundant circuit shall not be terminated in a single connector where the loss of such connector

will negate the redundant feature.

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Redundant circuits should be separated to the maximum extent possible.

13.3.2. Ordnance Electrical Circuit Shielding

13.3.2.1. Shields shall not be used as intentional current-carrying conductors.

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13.3.2.2. Electrical firing circuits shall be completely shielded or shielded from the initiating ordnance back to a point in the

firing circuit at which filters, or absorptive devices eliminate RF entry into the shielded portion of the system.

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13.3.2.3. RF shielding shall provide a minimum of 85 percent of optical coverage ratio.

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Optical coverage ratio is the percentage of the surface area of the cable core insulation covered by a shield. A solid shield rather

than a mesh shield would have 100 percent coverage.

13.3.2.4. There shall be no gaps or discontinuities in the termination at the back faces of the connectors or apertures in any

container that houses elements of the firing circuit.

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13.3.2.5. Electrical shields terminated at a connection shall be joined around the full 360 degree circumference of the shield.

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13.3.2.6. All metallic parts of the initiating ordnance subsystem that are physically connected shall be bonded with a DC

resistance of less than 2.5 milliohms.

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13.3.2.7. Firing, control, and monitor circuits shall all be shielded from each other.

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13.3.3. Ordnance Electrical Circuits Wiring

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13.3.3.1. Twisted shielded pairs shall be used unless other configurations such as coaxial leads can be shown to be more

effective.

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13.3.3.2. For low voltage circuits, insulation resistance between the shield and conductor at 500 volts DC minimum shall be

greater than 2 megaohms.

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13.3.3.3. For high voltage circuits, insulation resistance between the shield and conductor at 150 percent of rated output

voltage or 500 volts, whichever is greater, shall be greater than 50 mega-ohms.

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13.3.3.4. Wires shall be of sufficient size to adequately handle 150 percent of the design load for continuous duty signals (100

seconds or more) on the safety critical circuit.

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13.3.3.5. Splicing of firing circuit wires or overbraid shields is prohibited.

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13.3.3.6. The use of wire wrap to connect wire shields is prohibited.

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13.3.4. Ordnance Electrical Connectors

13.3.4.1. The outer shells of electrical connectors shall be made of metal.

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13.3.4.2. Electrical connectors shall be selected to eliminate the possibility of mis-mating. Mis-mating includes improper

installation as well as connecting wrong connectors.

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13.3.4.3. Electrical connectors shall be of the self-locking type or lock wiring shall be used to prevent accidental or inadvertent

demating.

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13.3.4.4. The design shall ensure that the shielding connection for an electrical connector is complete before the pin

connection.

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13.3.4.5. Shields need not be carried through a connector if the connector can provide RF attenuation and electrical

conductivity at least equal to that of the shield.

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13.3.4.6. Circuit assignments and the isolation of firing pins within an electrical connector shall be so that any single short

circuit occurring as a result of a bent pin shall not result in more than 10 percent of the no-fire current. A bent pin analysis

shall be performed on all electrical connectors.

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13.3.4.7. There shall be only one wire per pin and in no case shall an electrical connector pin be used as a terminal or tie-point

for multiple connections.

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13.3.4.8. Spare pins shall be allowed in electrical connectors except where a broken spare pin may have an adverse effect on

a firing or control circuit.

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13.3.4.9. Source circuits shall terminate in an electrical connector with female contacts.

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13.3.4.10. Electrical connectors shall not rely on spring force to mechanically lock mating halves together if they are to be

used on safety critical circuits.

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13.3.4.11. Electrical connectors shall be capable of adequately handling 150 percent of the designed electrical load continuous

duty signal (100 seconds or more) on safety critical circuits.

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13.3.4.13. Separate cables and connectors shall be used when redundant circuits are required.

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13.3.5. Ordnance Electrical Circuit Switches and Relays

13.3.5.1. Switches and relays shall be designed to function at expected operating voltage and current ranges under worst case

ground environmental conditions, including maximum expected cycle life.

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13.3.5.2. Switches and relays used for inhibits shall not be considered adequate for RF isolation and absorption unless

demonstrated by analysis and test for the specific environment of use.

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13.3.6. Ordnance Electrical Monitoring, Checkout, and Control Circuits

13.3.6.1. All circuits used to arm or disarm the firing circuit shall contain means to provide remote electrical indication of

their armed or safe status.

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13.3.6.1.1. These inhibits shall be directly monitored.

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13.3.6.1.2. GSE shall be provided to electrically monitor arm and safe status of the firing circuit at all processing facilities

including launch complexes up to launch.

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13.3.6.2. Monitoring, control, and checkout circuits shall be completely independent of the firing circuits and shall use a

separate and non-interchangeable electrical connector.

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13.3.6.3. Monitoring, control, and checkout circuits shall not be routed through arm or safe plugs.

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13.3.6.4. The electrical continuity of one status circuit (safe or arm) shall completely break before the time that electrical

continuity is established for the other status circuit (arm or safe).

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13.3.6.5. The safety of the ordnance system shall not be affected by the external shorting of a monitor circuit or by the

application of any positive or negative voltage between 0 and 35 volts DC to a monitor circuit.

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13.3.6.6. Monitoring and checkout of current in a low voltage electro-explosive system firing line shall not exceed 1/10 the

no-fire current of the EED or 50 milliamperes, whichever is less.

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13.3.6.7. Monitor circuits shall be designed so that the application of the operational voltage will not compromise the safety

of the firing circuit nor cause the ordnance system to be armed.

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13.3.6.8. Tolerances for monitor circuit outputs shall be compatible with the tolerances specified for the PSWG and Range

Safety required parameter to be verified. Tolerances for monitor circuit outputs shall be specified for both RF and hardline.

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13.3.6.9. Maximums and minimums for monitor circuit outputs shall be specified.

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13.3.6.10. No single point failure in monitoring, checkout, or control circuitry and equipment shall compromise the safety

of the firing circuit.

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13.3.6.11. Firing circuits that do not share a common fire command shall be electrically isolated from one another so that

current in one firing circuit does not induce a current greater than 20 dB below the no-fire current in any firing output circuit.

Control circuits shall be electrically isolated so that a stimulus in one circuit does not induce a stimulus greater than 20 dB

below the activation level in any firing circuit.

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13.3.6.12. The monitor circuit that applies current to the EED shall be defined to limit the open circuit output voltage to 1

volt.

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Initiator Electrical Circuits

13.4.1. Electrical Low Voltage Electromechanical Circuits Design Requirements

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13.4.1.1. All solid rocket motor ignition circuits and other high hazard ordnance systems (as determined by the PSWG and

Range Safety) using low voltage initiators shall provide a minimum of three independent inhibits.

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The term high hazard refers to specific catastrophic events such as the inadvertent firing of a solid rocket motor or actuation of

a destruct system that could result in multiple fatalities, typically threatening more than just the ordnance technicians handling

the hazardous item, and/or "total" destruction of high value hardware such as the payload, launch vehicle, or facility.

13.4.1.2. EED ordnance systems other than solid rocket motor ignition circuits and other high hazard ordnance systems shall

provide two independent inhibits. At least one inhibit shall be a mechanical device like a safing plug. Any alternative not

including such a mechanical device requires PSWG and Range Safety approval.

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Table 13.1. Clarification on Valid and Independent Inhibits.

A key consideration in providing inhibits in an ordnance circuit is that they be both valid and independent. Valid means

that the inhibits reside in the direct current path for firing the EED, not in the control circuit used to change the status of an

inhibit. For example, if a two-inhibit compliance approach is to close two control circuit relays to close a single firing line

relay, it is not compliant because there are not two valid inhibits. In other words, the single firing line relay is the only

inhibit. Independent means a singular action to remove a singular inhibit. Two inhibits is possible; for example, two open

relays in a firing line. However, if a single command removes both inhibits, (for example, closes both relays), then the inhibits

are not independent. In other words, there are not two independent inhibits. A concept that is often overlooked is that

inhibits are not independent if a single failure can negate both inhibits.

13.4.1.3. The safe plug shall provide interruption of the circuit after the “enable” and “fire” switches and as close to the end

item ordnance as possible.

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13.4.1.4. The final electrical connection of an EED to the firing circuit shall be as close to the EED as possible.

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13.4.1.5. EEDs shall be protected from electrostatic hazards by the placement of resistors from line-to-line and line-to-ground

(structure). The placement of line-to-structure static bleed resistances is not considered to violate the single point ground

requirement as long as the parallel combination of these resistors is 10 kilo-ohms or more.

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13.4.1.6. The system circuitry shall be designed and/or located to limit RF power at each EED (produced by range and/or

vehicle transmitter) to a level at least 20 dB below the pin-to-pin DC no-fire power of the EED.

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Electromagnetic environment evaluation should either be by analysis or electromagnetic compatibility (EMC)

testing. RF power density levels for facilities are available from the SLD 30 and SLD 45 for VSFB and CCSFS,

respectively, and the KSC Electromagnetics Lab.

13.4.2. High Voltage Exploding Bridgewire Circuits

13.4.2.1. Launch vehicles and payloads using exploding bridgewire (EBW) systems shall include an EBW-firing unit (EBW-

FU) or an electronic safe-and-arm-device firing unit (ESAD-FU).

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13.4.2.2. An EBW-FU shall be required on all other EBW systems. A manual arming and safing plug may also be required

depending on the degree of hazard and confidence in inhibits as determined by the PSWG and Range Safety.

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Ordnance Safety Devices

13.5.1. Ordnance Safety Device General Design Requirements. Ordnance safety devices are electrical, electromechanical,

or mechanical devices used in all ordnance subsystems to provide isolation between the power source to firing circuits and

firing circuits to initiating devices or receptor ordnance.

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Examples of ordnance safety devices include S&A devices, arm/disarm devices, relays, switches, EBW-FUs, and manual

arming/safing plugs.

13.5.1.1. Electrical and electronic safety devices shall remain or transfer back to their safe state in the event of input power

loss.

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13.5.1.2. All safety devices shall be capable of being functionally tested by ground test equipment.

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13.5.1.3. Manual safety devices on the payload that are required to be in place in order for the launch pad to be open for

normal work shall be accessible up to launch, requiring only a minimal crew to access the device and safe it.

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Maintaining accessibility to manual safety devices up to launch and maintaining accessibility to remotely

activated devices up to launch and after launch abort cannot always be met. Exceptions are handled on a case-

by-case basis and supported with the detailed system design and hazard assessment.

13.5.1.4. The arrangement of safety devices shall maximize safety by placing the most positive and reliable form of interruption closest to

the initiating device.

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For example, a safe plug would be located downstream of a solid state switch.

13.5.1.5. Ordnance mechanical barriers used for safety devices shall demonstrate a reliability of 0.999 at the 95 percent

confidence level to prevent initiation of the receptor ordnance. The test method shall be a Bruceton procedure or other

statistical testing method acceptable to the PSWG and Range Safety.

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13.5.1.6. Safety devices shall not require adjustment throughout their service life.

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13.5.1.7. Each safety device shall be designed for a service life of at least 10 years after passing the acceptance test.

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13.5.2. Ordnance Arming and Safing Plugs

13.5.2.1. Safing plugs shall be designed to be manually installed to provide electrical isolation of the input power from the

electrical and optical ordnance firing circuits.

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13.5.2.2. Arming plugs shall be designed to be manually installed to provide electrical continuity from the input power to the

electrical and optical ordnance firing circuits.

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13.5.2.3. Safe and arm plugs on the payload that are required to be in place in order for the launch pad or processing facility

to be open for normal work shall be accessible at all times, requiring only a minimal crew to access the plug and remove/install

it.

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Maintaining accessibility to arming and safing plugs up to just before final launch complex clear cannot always be

met. Exceptions are handled on a case-by-case basis and supported with detailed system design and hazard

assessments.

13.5.2.4. Arming and safing plugs shall be designed to be positively identifiable by color, shape, and name.

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13.5.2.5. For low voltage systems (EEDs) that use a safing plug instead of an electromechanical S&A, the safing plug shall

be designed to electrically isolate and short the initiator side of the firing circuit. Isolation shall be a minimum of 10 kilo-

ohms.

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13.5.3. Low Voltage EED Electromechanical S&As

13.5.3.1. Electromechanical S&As shall provide mechanical isolation of the EED from the explosive train and electrical

isolation of the firing circuit from the EEDs.

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13.5.3.2. When the S&A is in the safe position, the power and return lines of the firing circuit shall be disconnected. The

bridgewire shall be shorted and grounded through a 10 kilo-ohm to 100 kilo-ohm resistor and the explosive train shall be

interrupted by a mechanical barrier capable of containing the EED output energy without initiating the explosive.

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13.5.3.3. Transition from the safe to arm position shall require 90 degrees of rotation of the mechanical barrier for rotating

S&As containing ordnance in the barrier. Safe to arm transition tolerances for other electromechanical S&A devices require

PSWG and Range Safety approval.

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13.5.3.4. The S&A device shall not be capable of propagating the detonation with the barrier rotated at least 50 degrees from

safe for a 90-degree rotational barrier. This position shall be 50 percent of the travel distance between arm and safe for sliding

barriers.

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13.5.3.5. The mechanical lock in the S&A shall prevent inadvertent transfer from the arm to safe position (or vice versa)

under all ground operational environments without the application of any electrical signal.

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13.5.3.6. S&A design shall incorporate provisions to safe the ordnance train from any rotor and/or barrier position.

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13.5.3.7. S&As shall be capable of being remotely safed and armed. They shall not be capable of being manually armed but

shall be capable of being manually safed.

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13.5.3.8. Remote and manual safing shall be accomplished without passing through the arm position.

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13.5.3.9. The S&A safe signal shall not be indicated visually or remotely unless the device is less than 10 degrees from the

safe position for rotating systems or 10 percent from the safe position for sliding barriers.

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13.5.3.10. No visual indication of safe or arm shall appear if the device is in between the safe and arm positions. The S&A

will be considered “not safe” or armed if the indicator does not show “safe.”

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13.5.3.11. The electrical continuity of one status circuit of the S&A device (safe or arm) shall completely break before the

time that the electrical continuity is established for the other status circuit (arm or safe).

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13.5.3.12. A remote status indicator shall be provided to show the armed or safed condition.

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13.5.3.12.1. The device shall also indicate its arm or safe status by visual inspection.

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13.5.3.12.2. There shall be easy access to this visual indication throughout ground processing.

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13.5.3.13. S&A device locations on the vehicle shall be accessible to facilitate installation and removal and electrical and

ordnance connections during final vehicle closeout.

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13.5.3.14. A safing pin shall be used in the S&A to prevent movement from the safe to the arm position when the arming

signal is applied.

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13.5.3.14.1. Rotation and/or transition of the mechanical barrier to align the explosive train and electrical continuity of the

firing circuit to the EEDs shall not be possible with the safing pin installed.

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13.5.3.14.2. When inserted and rotated, the pin shall manually safe the device.

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13.5.3.14.3. Safing pins on the launch vehicle and the payload that are required to be in place in order for the launch pad to

be open for normal work shall be accessible up to launch, requiring only a minimal crew to access the device and safe it.

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13.5.3.14.4. Safing pin insertion shall require a reasonable force of resistance.

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The force required for safing pin insertion should be between 20 and 40 pounds and/or 20 to 40 inch-pounds of torque.

13.5.3.14.5. The safing pin shall provide a means of attaching warning streamers.

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13.5.3.14.6. When installed, each safing pin shall be marked by a red streamer.

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13.5.3.14.7. The following requirements apply whenever the arm command has been energized:

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13.5.3.14.7.1. Removal of the safing pin shall not be possible if the arming circuit is energized.

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13.5.3.14.7.2. The safing pin retention mechanism shall be capable of withstanding applied forces of tension or torque without

failure.

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Typical values for previously approved designs had the S&A safing pin retention mechanism capable of withstanding an applied

force of at least 100 pounds tension or a torque of at least 100 inch-pounds without failure.

13.5.3.14.8. The following requirements apply whenever the arm command is not energized:

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13.5.3.14.8.1. Removal of the safing pin shall not cause the S&A to automatically arm.

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13.5.3.14.8.2. Removal of the safing pin shall be inhibited by a locking mechanism requiring 90 degrees rotation of the pin.

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The removal force should be 3 to 10 inch-pounds of torque.

13.5.3.15. All S&A devices shall be designed to withstand repeated cycling from arm to safe for at least 1,000 cycles, or at

least 5 times the expected number of cycles, whichever is greater, without any malfunction, failure, or deterioration in

performance.

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13.5.3.16. A constant 1-hour application of S&A arming voltage with the safing pin installed shall not cause the explosive in

the unit to function or degrade to a point that it will no longer function if such a failure could create a hazard.

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13.5.3.17. The time required to arm or safe an S&A device shall not exceed 1 second after application of the actuation signal.

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13.5.3.18. The S&A shall not initiate and shall be safe to handle for subsequent disposal after being subjected to a 20-foot

drop on to a steel plate.

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13.5.3.19. The S&A shall have shielding caps attached on the firing connectors during storage, handling, transportation, and

installation up to firing line connection.

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13.5.3.20. The shielding cap shall have a solid metal outer shell that makes electrical contact with the firing circuit case in the

same manner as the mating connector.

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13.5.4. Mechanical S&As

13.5.4.1. Electrically actuated S&As shall be used unless justification for mechanical S&As is provided to and approved by

PSWG and Range Safety.

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13.5.4.2. Mechanical S&As shall incorporate the same features as electrically actuated devices except that arming and safing

is performed mechanically.

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Normally, these devices are armed by a liftoff lanyard or by stage separation.

13.5.4.3. These S&As shall be designed to withstand repeated cycling from the arm to the safe position for at least 300 cycles

without malfunction, failure, or deterioration in performance.

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13.5.5. EBW-Firing Units (FUs)

13.5.5.1. The EBW-FU shall provide circuits for capacitor charging, bleeding, charge interruption, and triggering.

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13.5.5.2. The charged capacitor circuit shall have a dual bleed system with either system capable of independently bleeding

off the stored capacitor charge.

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The time interval for bleeding of stored capacitor charge should be based on the level of associated hazard and concept of

operations, but not to exceed 5 minutes after power removal.

13.5.5.3. Two separate and independent ground command actions shall be required for removing capacitor charging inhibits

and shall be positively locked out and limited to only authorized personnel.

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13.5.5.4. EBW-FU design shall provide a positive remotely controlled means of interrupting the capacitor charging circuit.

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13.5.5.5. A gap tube shall be provided that interrupts the EBW trigger circuit.

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13.5.5.6. EBW-FUs shall be designed to be discriminatory to spurious signals in accordance with MIL-STD-461 G,

Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment.

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13.5.5.7. At a minimum, EBW-FU monitor circuits shall provide the status of the trigger capacitor, high voltage capacitor,

arm input, inhibit input (if used), and power.

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13.5.5.8. The insulation resistance between each EBW-FU high voltage output circuit and the case shall be designed to not

be less than 50 mega-ohms at 500 VDC.

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13.5.5.9. The isolation resistance between EBW-FU output circuits and any other circuits shall not be less than 50 mega-

ohms at 500 VDC.

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13.5.5.10. Remote discharged indicators for EBW-FUs shall not appear unless the capacitor bank voltage is one-tenth or less

of the no-fire voltage of the EBW. The EBW-FU shall be considered “not safe” if the indicator does not show “discharged.”

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13.5.5.11. The EBW-FU shall be capable of being remotely safed and armed.

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13.5.6. Laser Firing Units, Optical Barriers, Optical S&As, and Ordnance S&As

Note: Laser Firing Units, Optical Barriers, Optical S&As are not anticipated to be used. If they are used, they must comply with

AFSPCMAN 91-710, Volume 3, section 13.5.6.

13.5.6.6. Ordnance S&As

13.5.6.6.1. Ordnance S&A General Design Requirements

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13.5.6.6.1.1. Ordnance S&As shall provide mechanical isolation of the explosive train.

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13.5.6.6.1.2. When the device is in the safe position, the explosive train shall be interrupted by a mechanical barrier capable

of containing the explosive.

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13.5.6.6.1.3. Safe to Arm Transition

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13.5.6.6.1.3.1. Transition from the safe to arm position shall require 90 degrees of rotation of the mechanical barrier for

rotating S&As containing ordnance in the barrier.

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13.5.6.6.1.3.2. Safe to arm transition tolerances for other electromechanical S&A devices shall be approved by PSWG and

Range Safety.

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13.5.6.6.1.4. Detonation Propagation

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13.5.6.6.1.4.1. The device shall not be capable of propagating the detonation with the barrier rotated less than 50 degrees from

safe for a 90-degree rotational barrier.

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13.5.6.6.1.4.2. The device shall not be capable of propagating the detonation with the barrier at 50 percent of the travel

distance between arm and safe for sliding barriers.

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13.5.6.6.1.5. Ordnance S&A device locations shall be accessible to facilitate installation and/or removal of ordnance

connections, including accessibility on the launch pad.

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13.5.6.6.1.6. The S&A shall not initiate and shall be safe to handle for subsequent disposal after being subjected to a 20-foot

drop on to a steel plate.

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13.5.6.6.2. Ordnance S&A Arm and Safe Mechanisms

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13.5.6.6.2.1. The S&A device shall be designed to incorporate provisions to safe the ordnance train from any rotor or barrier

position.

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13.5.6.6.2.2. The time required to arm or safe an S&A device shall not exceed one second after application of the actuation

signal.

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13.5.6.6.2.3. All S&A devices shall be designed to withstand repeated cycling from arm to safe for at least 1,000 cycles or at

least 5 times the expected number of cycles, whichever is greater, without any malfunction, failure, or deterioration in

performance.

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13.5.6.6.2.4. A mechanical lock in the S&A shall prevent inadvertent transfer from the arm to safe position or the safe to arm

position under all operating environments without the application of any electrical signal.

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13.5.6.6.2.5. S&As shall be capable of being remotely safed and armed.

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13.5.6.6.2.6. Ordnance S&As shall not be capable of being manually armed but they shall be capable of being manually safed.

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13.5.6.6.2.7. Remote and manual safing shall be accomplished without passing through the armed position.

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13.5.6.6.3. Ordnance S&A Status Indicators

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13.5.6.6.3.1. The electrical continuity of one status circuit of the S&A device (safe or arm) shall completely break before the

time that the electrical continuity is established for the other status circuit (arm or safe).

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13.5.6.6.3.2. Ordnance S&A Remote and Visual Status Indicators

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13.5.6.6.3.2.1. A remote status indicator shall be provided to show the armed or safed condition.

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13.5.6.6.3.2.2. A visual status indicator shall be provided to show the armed or safed condition by simple visual inspection.

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13.5.6.6.3.2.3. Easy access to the visual status indicator shall be provided throughout ground processing.

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13.5.6.6.3.3. The S&A safe signal shall not be indicated visually or remotely unless the device is less than 10 degrees from

the safe position for rotating systems or 10 percent from the safe position for sliding barriers.

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13.5.6.6.3.4. No visual indication of safe or arm shall appear if the device is in between safe and arm positions. The S&A

will be considered “not safe” or armed if the indicator does not show “safe.”

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13.5.6.6.4. Ordnance S&A Safing Pins

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13.5.6.6.4.1. A safing pin shall be used in the S&A device to prevent movement from the safe to the arm position when an

arming signal is applied.

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13.5.6.6.4.2. Rotation and/or transition of the mechanical barrier to align the explosive train shall not be possible with the

safing pin installed.

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13.5.6.6.4.3. When inserted and rotated, the pin shall manually safe the device.

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13.5.6.6.4.4. Safing pins on the payload that are required to be in place in order for the launch pad to be open for normal work

shall be accessible up to launch, requiring only a minimal crew to access the device and safe it.

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13.5.6.6.4.5. Safing pin insertion shall require a reasonable force of resistance.

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The force required for safing pin insertion should be between 20 and 40 pounds and/or 20 to 40 inch-pounds of torque.

13.5.6.6.4.6. The safing pin shall provide a means of attaching warning streamers.

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13.5.6.6.4.7. When installed, each safing pin shall be marked by a red streamer.

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13.5.6.6.4.8. A constant one-hour application of S&A arming voltage, with the safing pin installed, shall not cause the

explosive in the unit to function.

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13.5.6.6.4.9. The following requirements apply whenever the arm command has been energized:

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13.5.6.6.4.9.1. Removal of the safing pin shall not be possible if the arming circuit is energized.

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13.5.6.6.4.9.2. The safing pin retention mechanism shall be capable of withstanding applied forces of tension or torque without

failure.

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Typical values for previously approved designs had the S&A safing pin retention mechanism capable of withstanding an applied

force of at least 100 pounds tension or a torque of at least 100 inch pounds without failure.

13.5.6.6.4.10. The following requirements apply whenever the arm command is not energized:

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13.5.6.6.4.10.1. Removal of the safing pin shall not cause the S&A to automatically arm.

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13.5.6.6.4.10.2. Removal of the safing pin shall be inhibited by a locking mechanism requiring 90 degrees rotation of the pin.

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The removal force should be 3 to 10 inch-pounds of torque.

Ordnance Initiating Devices

13.6.1. Ordnance Initiating Device General Design Requirements

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13.6.1.1. The explosive or pyrotechnic mix shall not degrade, decompose, or change chemically over its service life,

causing a more sensitive device.

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13.6.1.2. Periodic testing of ordnance to verify that no sensitivity changes have occurred shall be in accordance with AIAA

S-113A-2016, Criteria for Explosive Systems and Devices on Space and Launch Vehicles , unless it can be shown that

sensitivity with aging is not a credible concern with the specific explosive composition.

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13.6.1.3. Ordnance should be designed for a service life of at least 10 years with a design goal of 15 years.

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13.6.1.4. The decomposition, cook-off, and melting temperatures of all explosives shall be at least 30

C higher than the

maximum predicted environmental temperature to which the material will be exposed during storage, handling, transportation,

and launch.

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13.6.2. Low Voltage EEDs

13.6.2.1. One amp/one watt no-fire survivability of low voltage EEDs is required, as determined from the 0.1 percent firing

level of the EED with 95 percent confidence using the Bruceton test or other statistical testing methods acceptable to the

PSWG and Range Safety.

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13.6.2.2. EEDs shall be designed to withstand a constant DC firing pulse of one ampere and one watt power for a period of

five minutes without initiation or deterioration of performance.

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13.6.2.3. The EED main body shall not rupture or fragment when the device is fired. Displacement or deformation of the

connector and main housing is permissible; rupture or deformation of the outer end is permissible.

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13.6.2.4. The auto-ignition temperature shall not be less than 150

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13.6.2.5. Carbon bridgewires and conductive mixes without bridgewires are prohibited.

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13.6.2.6. EEDs shall not fire or deteriorate in performance (if failure can create a hazard) as a result of being subjected to an

electrostatic discharge of 25 kV from a 500 picofarad capacitor applied in the pin-to-case mode without a series resistor, and

in the pin-to-pin mode with a 5 kilo-ohms resistor in series.

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13.6.2.7. The EED shall not initiate and will perform to specification (if failure can create a hazard) after being subjected to

a 6-foot drop on to a steel plate.

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13.6.2.8. The EED shall not initiate or be damaged to the extent it is unsafe to handle after being subjected to a 40-foot drop

on to a steel plate.

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13.6.2.9. Insulation resistance between pin-to-case shall not be less than 2 mega-ohms at 500 VDC.

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13.6.2.10. The outer case of the EED main body shall be made of conductive material, preferably metal.

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13.6.2.11. RF survivability shall meet the testing criteria described in AIAA S-113A-2016, Criteria for Explosive Systems

and Devices on Space and Launch Vehicles.

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13.6.2.12. Shielding caps shall be provided and placed on the EED during shipment, storage, handling, and installation up to

the point of electrical connection.

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13.6.2.12.1. The shielding cap shall have an outer shell made of conductive material that provides an RF shield and makes

electrical contact with the EED case.

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13.6.2.12.2. There shall be no RF gaps around the full 360-degree mating surface between the shielding cap and EED case.

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13.6.2.12.3. The shielding cap shall be designed to accommodate the torque tool during installation.

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13.6.2.12.4. Shorting plugs (caps) shall not be used as a substitute for shielding caps.

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13.6.3. High Voltage Exploding Bridgewires

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13.6.3.1. Explosive materials shall be secondary explosives.

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Examples of secondary explosives include pentaerythritoltetranitrate (PETN) or cyclotrimethylenetrinitramine (RDX).

13.6.3.2. Insulation resistance pin-to-case shall be designed to not be less than 50 mega-ohms at 500 VDC.

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13.6.3.3. A voltage blocking gap shall be provided.

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13.6.3.3.1. The gap breakdown voltage shall not be less than 650 VDC when discharged from a 0.025 +10 percent microfarad

capacitor.

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13.6.3.3.2. The nominal gap breakdown voltage tolerance shall be specified and approved by the PSWG and Range Safety.

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13.6.3.4. The EBW shall not fire or deteriorate in performance (if failure can create a hazard) upon being subjected to a

voltage of 125 to 130 volts root mean square (Vrms) at 60 Hz applied across the terminals or between the terminals and the

EBW body for 5 minutes +10 sec.

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13.6.3.5. The EBW shall not fire or degrade to the extent that it is unsafe to handle when 230 +10 Vrms at 60 Hz is applied

across the terminals or between the terminals and EBW body for 5 minutes +10 sec.

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13.6.3.6. The EBW shall not fire or deteriorate in performance (if failure can create a hazard) upon being subjected to a source

of 500 +25 VDC having an output capacitance of 1.0 +10 percent microfarads applied across the terminals or between the

terminals and the EBW body for 60 to 90 seconds.

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13.6.3.7. The EBW shall not fire or deteriorate in performance (if failure can create a hazard) after exposure to that level of

power equivalent to absorption by the test item of 1.0 watt average power at any frequency within each RF energy range, as

specified in Table 13.3. The frequency shall be applied across the input terminals of the EBW detonator for 5.0 to 6.0 seconds.

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13.6.3.8. The EBW shall not fire or deteriorate in performance (if failure can create a hazard) as a result of being subjected to

an electrostatic discharge of 25 kV from a 500 picofarad capacitor applied in the pin-to-case mode without a series resistor

and in the pin-to-pin mode with a 5 kilo-ohm resistor in series.

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13.6.3.9. The autoignition temperature of the EBW shall not be less than 150

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13.6.3.10. The EBW shall not initiate and shall perform to specification (if failure can create a hazard) after being subjected

to a 6-foot drop on to a steel plate.

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13.6.3.11. The EBW shall not initiate or be damaged to the extent it is unsafe to handle after being subjected to a 40-foot drop

on to a steel plate.

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13.6.4. Laser Initiated Devices

Note: Laser initiated devices are not anticipated to be used. If they are used, they must comply with AFSPCMAN 91-710, Volume 3

section 13.6.4.

13.6.5. Percussion Activated Devices

13.6.5.1. Stab initiation of percussion activated devices (PADs) is prohibited.

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Frequency (in MHz.)

Type

5 – 100

Continuous Wave

250 – 300

Continuous Wave

400 – 500

Continuous Wave

800 – 1,000

Continuous Wave

2,000 – 2,400

Continuous Wave

2,900 – 3,100

Continuous Wave

5,000 – 6,000

Continuous Wave

9,800 – 10,000

Continuous Wave

16,000 – 23,000

Pulse Wave *

32,000 – 40,000

Pulse Wave *

* Pulsed repetition frequency shall not be less than 100 Hz and

the pulse width shall be a minimum of 1.0 microseconds.

Table 13.3. RF Sensitivity

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13.6.5.2. Each initiator shall have a positive safety interrupter feature that can be mechanically locked in place.

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13.6.5.3. The initiator and its interrupter shall be designed to withstand all transportation, handling, and installation

environments.

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13.6.5.4. The interrupter safety lock shall be designed to remain in place during and after installation.

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13.6.5.5. The interrupter safety lock shall be designed to be removed after installation.

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13.6.5.6. The design shall ensure the PAD cannot be assembled without the interrupter.

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13.6.5.7. Percussion initiators shall be designed so that the operating energy is at least twice the all-fire energy.

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13.6.5.8. Percussion initiator no-fire energy shall be such that the percussion initiator shall not fire when subjected to an

energy of 50 percent of the all-fire energy.

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13.6.6. Non-Explosive Initiators. Non-explosive initiators (NEI s) shall be handled on a case-by-case basis to ensure safety

of the system design.

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Explosive Transfer Systems and Receptor Ordnance

Explosive Transfer Systems and Receptor Ordnance. Explosive transfer systems (ETS) are used to transmit the initiation

reaction from the initiator to the receptor ordnance. ETSs shall be designed to meet the applicable safety sections of AIAA

S-113A-2016, Criteria for Explosive Systems and Devices on Space and Launch Vehicles and the requirements below.

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Most ETS harnesses contain flexible confined detonation cord, mild detonating cord, or mild detonating fuse terminated by end

booster caps or manifolds.

13.7.1. The explosive or pyrotechnic mix shall not degrade, decompose, or change chemically over its life causing a more

sensitive device.

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13.7.2. Periodic testing of ordnance to verify no sensitivity changes shall be in accordance with AIAA S-113A-2016, Criteria

for Explosive Systems and Devices on Space and Launch Vehicles, unless it can be shown that the sensitivity with aging is

not a credible concern with the specific explosive composition.

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13.7.3. Explosives used in ETS lines shall be secondary explosives.

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13.7.4. Flexible confined detonation cord (FCDC) shall not fragment or separate from end fittings upon initiation. Gaseous

emission is permissible.

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13.7.5. The ETS shall not detonate and shall be capable of performing its function (if failure can create a hazard) after being

subjected to a 6-foot drop on to a steel plate.

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13.7.6. The ETS shall not initiate or be damaged to the extent it is unsafe to handle after being subjected to a 40-foot drop

on to a steel plate.

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13.7.7. All ETS interconnections shall provide for safety (lock) wiring or a PSWG and Range Safety approved equivalent.

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13.7.8. An electrically conductive path shall exist between ETS components and their attachment fittings. The bonding

resistance should be designed to be 2.5 milliohms but in no case shall the resistance exceed 5 ohms.

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13.7.9. ETS fittings shall be designed and located to facilitate installation of the end receptor ordnance components in the

launch vehicle as late as practical.

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13.7.10. Fittings that should not be reversed or interchanged (because they may cause a hazard) shall be designed so that

reverse installation or interchange is not possible.

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13.7.11. Exposed end fittings shall be equipped with protective caps.

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13.7.12. Receptor ordnance shall be designed to meet the applicable safety sections of AIAA S-113A-2016 and this part and

shall use secondary high explosives.

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Examples of secondary high explosives used for receptor ordnance include such items as PETN, RDX,

cyclotetramethylenetetranitramine (HMX), or 2,2,4,4,6,6 hexanitrostilbene (HNS).

13.7.12.1. Explosives shall be non-hygroscopic.

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13.7.12.2. Specific approval from the PSWG and Range Safety is required for all explosive compositions.

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13.7.13. The receptor ordnance shall not detonate after being subjected to a 6-foot drop test on to a steel plate.

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13.7.14. The receptor ordnance shall not initiate or be damaged to the extent it is unsafe to handle after being subjected to a

40-foot drop onto a steel plate.

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Ordnance Test Equipment

13.8.1. Ordnance Test Equipment General Design Requirements

13.8.1.1. All ordnance test equipment, such as continuity and bridgewire resistance measurement devices, shall be inspected

and tested for voltage and optical isolation and limitation.

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13.8.1.1.1. These devices shall be designed so that they will not pass greater than 1/10 of the no-fire energy across an EED

bridgewire, or 50 mA, whichever is less.

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13.8.1.1.2. These devices shall be analyzed to verify that rough handling, dropping, or single component failure will not result

in negating the current-limiting feature.

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13.8.1.1.3. Clear cases of unacceptable energy or current for a particular resistance range or ranges shall be excluded from

use by disablement by the manufacturer or local authority before certification.

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13.8.1.1.4. Certification of each device shall include a tabular listing (to be kept with or marked on each meter) of the energy

level and current levels available at each of the selectable ranges for the meter.

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13.8.1.1.5. All test equipment shall be designed to meet standard industry safety requirements such as those established by

ANSI, IEEE, and NFPA, as well as applicable Volume 3, Chapter 14 requirements.

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13.8.1.2. The test results shall be submitted to the PSWG for PSWG and Range Safety approval before equipment use at the

payload processing facility and launch site area.

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13.8.2. Stray Current Monitors

13.8.2.1. A stray current monitor shall be provided for all low voltage (EED) solid rocket motor ignition circuits and other

high hazard ordnance systems as determined by the PSWG and Range Safety.

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The term high hazard refers to specific catastrophic events such as the inadvertent firing of a solid rocket motor or actuation of

a destruct system that could result in multiple fatalities, typically threatening more than just the ordnance technicians handling

the hazardous item, and/or "total" destruction of high value hardware such as the payload, launch vehicle, or facility.

13.8.2.2. The stray current monitor shall be installed and remain connected until the electrical connection of the actual

initiators is accomplished. The monitor shall be installed at a time determined by the PSWG, Range Safety and the payload

project.

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13.8.2.3. The stray current monitor shall provide a stray current device capable of detecting 1/10 of the maximum safe no-

fire current.

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Fuses or automatic recording systems capable of detecting 1/10 of the maximum safe no-fire current are acceptable stray current

devices for the stray current monitor.

13.8.2.4. The monitoring device shall be installed in the firing line.

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13.8.3. Ground Support Test Equipment. The design of test equipment used to test ground support equipment shall be

reviewed and approved by the PSWG and Range Safety.

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13.8.4. Laser Test Equipment

Note: Laser test equipment are not anticipated to be used. If they are used, they must comply with AFSPCMAN 91-710,

Volume 3, section 13.8.4.

Ordnance and Non-Explosive Initiator Data Requirements

Ordnance data items shall be submitted in accordance with the requirements of Attachment 1, A1.2.4.9 and A1.2.5.11. of this

volume.

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13.9.1. Data to verify compliance with the design and test requirements of this volume shall be submitted to the PSWG for

PSWG and Range Safety review and approval before the arrival of ordnance at the payload processing facility and launch site

area.

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13.9.2. All schematics and functional diagrams shall have well defined, standard Institute of Electrical and Electronics

Engineers (IEEE) Std 315-1975 (ANSI Y32.2-1975) terminology and symbols.

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ELECTRICAL AND ELECTRONIC EQUIPMENT

Electrical and Electronic Ground Support Equipment and Flight Hardware General Design

Requirements and Standards

14.1.1. Electrical equipment shall be designed, fabricated, inspected, and tested in accordance with NFPA 70.

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MIL-HDBK-454, General Guidelines for Electronic Equipment, should be used as guidance in the design, fabrication,

inspection, and Mismating testing of electrical equipment.

14.1.2. All wiring shall be copper and contact with dissimilar metals shall be avoided. Aluminum wire shall not be used.

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14.1.3. At a minimum, Electrical and Electronic Ground Support Equipment (EGSE) shall be designed to operate within the

voltage ratings of ANSI C84.1, Electric Power Systems and Equipment - Voltage Ratings (60 Hz).

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14.1.4. Electrical and Electronic Ground Support Equipment and Flight Hardware Power Cutoff. All EGSE and flight

hardware shall have a means to cut off power before installing, replacing, or interchanging units, assemblies, or portions

thereof.

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14.1.5. EGSE and Flight Hardware Power Transient. Safety critical systems shall be protected against power transients and

power outages.

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14.1.6. EGSE and Flight Hardware Connectors. Connector design shall avoid the generation of a hazardous condition that

could lead to a hazardous event.

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A hazardous condition is where there is a possibility for the inadvertent connection of an electrical circuit to cause

unintentional current to flow where it would cause a short, spark, energize equipment, or initiate ordnance that

would create a hazardous event.

14.1.6.1. If a hazardous condition can be created by mismating or reverse polarity, a positive means of preventing connector

mismating shall be provided.

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Mismating includes improper installation as well as connecting wrong connectors. Prevention of connector mis-

mating includes alignment pins and key-way arrangements or other possible means to make it impossible to

mismate. Color coding may be used in addition to, but not in lieu of, the more positive means of connector mis-

mate prevention.

14.1.6.2. If a hazardous event can occur, the following precautions shall be taken:

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14.1.6.2.1. Power and signal leads shall not be terminated on adjacent pins of a connector.

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14.1.6.2.2. Wiring shall be isolated so that a single short circuit occurring in a connector cannot affect other components.

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14.1.6.2.3. Pin locations shall be assigned to prevent inadvertent pin-to-pin and pin-to-case shorts.

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14.1.6.2.4. Spare pins shall not be used in connectors controlling hazardous operations or safety critical functions.

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14.1.6.2.5. The payload project shall provide a bent pin analysis to the PSWG for PSWG and Range Safety review on all

safety critical and/or hazardous system connectors.

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14.1.6.3. Connectors used in safety critical or hazardous systems shall be of the locking type.

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14.1.6.4. Connectors relying solely on springs to maintain an electrical contact shall not be used in safety critical or hazardous

systems. Connectors for safety critical or hazardous systems shall have a positive locking mechanism to prevent inadvertent,

momentary electrical disruption or disconnection of the circuit

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14.1.6.5. Plug and socket type connectors shall be used in safety critical or hazardous systems.

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14.1.6.6. Connectors shall be of a “scoop-proof design” that will prevent a partial inadvertent mismate from providing

incorrect pin to pin contact or shell-to-pin contact.

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14.1.7. EGSE and Flight Hardware Grounding, Bonding, and Shielding

14.1.7.1. Equipment shall be designed and constructed to ensure that all external parts, shields and surfaces, exclusive of

radiating antennas and transmission line terminals, are at ground potential.

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14.1.7.2. Shields shall not be used as current carrying ground connections, except for coaxial cables.

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14.1.7.3. Circuits that operate safety critical or hazardous functions shall be protected from the electromagnetic environment

to preclude inadvertent operation.

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14.1.8. EGSE and Flight Hardware Cables

14.1.8.1. Cables shall be supported and protected against abrasion or crimping.

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14.1.8.2. Cables shall be located or protected so as not to present a tripping hazard.

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14.1.8.3. Cables in hazardous areas shall be designed so that they do not, in and of themselves, create a hazard.

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14.1.8.4. Cables shall be selected to include factors such as toxicity, combustibility and smoke production, off-gassing, and

compatibility with liquids in the area and environmental exposure.

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14.1.9. EGSE and Flight Hardware Batteries

14.1.9.1. EGSE and Fight Hardware Battery General Design Requirements

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14.1.9.1.1. All batteries shall be capable of being readily accessible for electrical disconnection and/or removal.

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14.1.9.1.2. Battery connectors shall be designed to prevent reverse polarity.

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14.1.9.1.3. The capability for reverse current to cause a hazardous condition shall be prevented.

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Diodes may be used to prevent reverse current. Diodes may be placed in the battery or in external circuitry.

14.1.9.1.4. If a battery is not connected to the system, the battery terminals or connector plug shall be given positive protection

against shorting.

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Protection against shorting of connector terminals may be accomplished by taping or guarding with a suitable

temporary connector.

14.1.9.1.5. Polarity of battery terminals shall be marked

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14.1.9.1.6. Identification. Each battery shall be permanently identified with the following appropriate information:

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14.1.9.1.6.1. Component name.

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14.1.9.1.6.2. Type of construction; for example, lead-acid or nickel-cadmium, lithium, lithium-Ion, etc, etc.

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14.1.9.1.6.3. Manufacturer identification.

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14.1.9.1.6.4. Part number.

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14.1.9.1.6.5. Lot and serial number.

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14.1.9.1.6.6. Date of manufacture.

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14.1.9.2. EGSE and Flight Hardware Lithium Batteries. The following additional requirements are applicable to lithium

batteries used in flight hardware and EGSE.

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Note: Batteries that have a UL listing and are intended for public use and used in a manner consistent with the UL

certification are exempt from these requirements.

14.1.9.2.1. All lithium battery designs shall be reviewed and approved by the PSWG and Range Safety before arrival, usage,

packing, storage, transportation, or disposal at the payload processing facility and launch site area.

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14.1.9.2.2. Safety devices shall be incorporated into the lithium battery design.

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Table 14.1. Safety Devices for Lithium Battery Design.

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Safety devices include fuses, overpressure relief devices, over temperature cutoff, reverse current blocking diode, current limiting

resistor, or other device determined to be acceptable by the PSWG and Range Safety. The following are examples of safety

devices that should be incorporated into the lithium battery design:

(1) The use of thermistors or fuses for each battery output.

(2) Placement of internal diodes between each cell, unless proven by test that any single cell cannot be driven into reversal by

the remaining cells.

(3) The use of shunt diode protection for cells in series.

(4) The use of blocking diodes for parallel rows of cells.

14.1.9.2.3. Each electrical safety device shall have a specific quality control program approved by the PSWG and Range

Safety.

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14.1.9.2.4. Safety critical steps and processes shall be identified during development for the manufacturing process. These

points in manufacturing shall be reviewed by the appropriate local safety authorities identified by the PSWG and Range Safety

and a determination made of what points require approval before change and what points the payload project can approve with

just notification after the fact.

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14.1.9.2.5. Batteries shall be designed not to create a catastrophic hazard even when the safety tests described

in 14.4 are performed.

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14.1.9.3. EGSE and Flight Hardware Lithium-ion Batteries. In addition to the other design and operational requirements

of this publication, the following requirements are applicable to lithium-ion batteries used in flight hardware and EGSE.

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The following Li-Ion system safety requirements are applicable to any flight hardware or aerospace ground support equipment

(GSE) without UL or Mine Safety Appliances (MSA) approval for the cells, batteries, and battery chargers approved specifically

for the cell pack used.

The following Lithium-ion (Li-Ion) battery system safety requirements are not applicable to Li-Ion batteries used in UL or MSA-

approved appliances that have Li Ion batteries as part of the certification. Examples include batteries that are in cell phones and

computers.

Lithium-ion battery designs should address requirements contained in RTCA DO-311, Minimum Operational Performance

Standards for Rechargeable Lithium Battery Systems.

14.1.9.3.1. Charging and Discharging

14.1.9.3.1.1. GSE used for charging and discharging shall prevent each cell from exceeding 4.4 volts or driving cells to less

than 0 volts.

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14.1.9.3.1.2. The GSE used for charging and discharging shall be dual failure tolerant.

Note: The requirements for charging and discharging are also applicable to any charging, power, or battery management

activities such as current compensation, topping charge, constant current, constant voltage (CCCV) charging, etc. where a

battery is in the same circuit as the external voltage and/or current source.

Note: Individual cells that have an internal design which provides high rate discharge protection, (e.g., Positive Temperature

Coefficient Devices and Internal Fuses) may be considered to already have one inhibit.

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14.1.9.3.1.3. Battery/cell monitoring and recording is required during charging and discharging.

(1) Cell voltages shall be recorded at least every minute. For charge rates that exceed the battery capacity (i.e., if capacity is

1 Amp-Hour and charger is supplying greater than 1 Amp of current), record voltages every 10 seconds for charge rates

between 1 and 2 times battery capacity and every second for charge rates that exceed 2 times battery capacity.

(2) Data shall be reviewed for anomalies and verification of voltage limits real-time throughout charging or discharging

activities.

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14.1.9.3.1.4. Charging, monitoring, and recording EGSE shall be intrinsically safe if used within the Class I Division 1 or

Division 2 areas and shall prevent high heat, sparking, and high charge/ discharge current rates.

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14.1.9.3.1.5. Discharge shall not take place below -20C or above 60C.

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14.1.9.3.2. Battery and Cell Case Design

14.1.9.3.2.1. High pressure protection for cells is required.

Note: Examples include burst disks and heat-sealed pouches.

(1) Battery and cell case design shall have a minimum 3:1 burst pressure based on operating pressure. Note: The cell

case operating pressures shall be defined based on normal use from beginning of cell life to design end of life.

(2) Cell pressure relief devices shall be demonstrated by test to show that the vent operates as intended and that the

vent is adequate to prevent cell fragmentation.

(3) Battery case design/cell/cell pack integration shall not impede cell safe functional operation. Battery design shall

accommodate the worst-case condition of cells within the battery experiencing internal pressure relief. The worst-

case venting condition shall be demonstrated by test or analysis.

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14.1.9.3.2.2. Batteries/cells shall be evaluated for toxic, reactive, flammable, and combustion materials. This evaluation

shall include the products if the cell case vents. Fratricide of all cells in a pack will be assumed in this evaluation unless the

design incorporates mechanical and thermal barriers between cells that are proven by test to prevent fratricide.

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14.1.9.3.3. Design Requirements for Li-Ion Batteries/Cells

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Table 14.2. Li-Ion Battery Maximum Operating Pressure (MOP) Clarification. In the case of small cell formats (e.g., 18650, 26650,

21700 cells), purchased in large cell lots and manufactured under specifically applicable consensus industry standards, MOP will be

characterized as a quality within the context of that lot buy. If MOP is demonstrated to be a De Minimis quality for nominal cell

operation, pressure specific items do not need to be addressed.

14.1.9.3.3.1. Cell design shall have a minimum 1.5:1 burst pressure based on maximum venting pressure. The cell case shall

demonstrate leak before burst characteristics. Cell burst pressure to vent pressure ratio may be tailored based on test

qualification data showing consistent margin of system vent before reaching burst pressure.

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14.1.9.3.3.2. Each cell and battery shall incorporate a safety-venting device or be designed and manufactured in such a manner

that will preclude a violent rupture as a result of the cell venting. The design and construction of the integrated battery will not

degrade or obstruct the vent.

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14.1.9.3.4. Test Requirements for Li Ion Batteries/Cells.

14.1.9.3.4.1. Battery/Cell Case LBB Failure Mode Qualification Testing.

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14.1.9.3.4.1.1. Safety-venting shall be demonstrated by test to show that the venting operates as intended and that the vent is

adequate to prevent cell/battery fragmentation.

Recommended test is NAVSEA 9310 High Temperature Test.

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14.1.9.3.4.1.2. Qualification tests shall be conducted on flight quality batteries to demonstrate structural adequacy of the

design.

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14.1.9.3.4.1.3. Nondestructive inspection (NDI) techniques and methodologies shall be identified in the acceptance test

plan.

Microfocus X-ray technology may be an acceptable NDI technique to verify the integrity of the pressure relief

mechanism.

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14.1.9.3.4.1.4. Qualification tests shall be conducted on flight quality batteries to ensure the battery can withstand grounds

environments during transportation, storage and processing.

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14.1.9.3.4.1.5. The Safety Data Package shall state lot testing specifications for safety venting device to be reviewed and

approved by the PSWG and Range Safety.

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14.1.9.3.4.1.6. Pressure testing. A pressure cycle test shall be conducted on battery cells. The peak pressure minimum shall

be equal to the ground MOP of the battery cells during each cycle, and the number of cycles shall be a minimum of 4 times

the predicted number of ground cycles or 50 cycles, whichever is greater. After the completion of the pressure cycle test, the

pressure shall be increased to actual burst of the battery cell. This pressure test may be satisfied by life cycle testing.

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14.1.9.3.4.1.7. Cell Short Circuit Test.

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14.1.9.3.4.1.7.1. Simulating a battery short circuit failure mode, or if a pressure relief mechanism is not provided, case integrity

shall be determined under conditions simulating a battery short circuit failure mode.

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14.1.9.3.4.1.7.2. After all internal electrical safety devices have been bypassed, the battery shall be shorted, through a load of

0.1 ohms or less, leaving the load attached for not less than 24 hours or the cell case temperature has returned to ambient +/-

10° C.

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14.1.9.3.4.1.7.3. Voltage, current, pressure, and temperature shall be continuously monitored and recorded.

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14.1.9.3.5. Operational Requirements for Li Ion Batteries/Cells.

14.1.9.3.5.1. Storage of the batteries (when not installed in GSE or Airborne hardware) shall be in approved battery storage

locations.

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14.1.9.3.5.2. Battery and cells shall be treated as always having a voltage potential; therefore, connection or disconnection

of battery shall be considered an electrical personnel hazard and a ”spark” potential.

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14.1.9.3.5.3. Range users shall have an operational plan for battery/cell handling that includes emergency contingency

operations for physical abuse incident and battery installation/removal.

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14.1.9.3.5.4. Support equipment (ground or airborne) shall be verified to operate correctly prior to first operational use,

including all failure tolerant devices or subsystems, prior to connecting battery. Verification shall include inducing

overvoltage/under-voltage/temperature extremes to the monitoring devices as intended when in use prior to connecting of

the battery.

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14.1.9.3.5.5. Transportation to the launch site shall meet DOT requirements. When batteries are not incorporated into

flight hardware, they shall meet the following:

(1) Transported on publicly-accessed roadways, they shall not exceed 50 percent of rated charge.

(2) When lithium content exceeds 8.0 grams per battery, transportation packaging of individual batteries shall have caution

labels in accordance with 49 CFR 173.185.

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14.1.9.3.5.6. Batteries that are transported incorporated into flight hardware shall be approved on a case-by-case basis.

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14.1.9.3.5.7. External heating sources for battery/cell maintenance shall be dual fault tolerant and provide feedback

monitoring capability or be analyzed for failure modes on cell/battery heating.

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EGSE Design Requirements

14.2.1. EGSE Design Standards. The following requirements supplement the requirements specified in the 14.1, NFPA 70,

and the guidance provided in MIL-HDBK-454, Requirement 1.

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14.2.2. EGSE Switches and Controls

14.2.2.1. A main power switch shall be provided to cut off power to all circuits in the equipment. A power indicator light

shall be provided. If fault isolation switches are incorporated, they shall not operate independently of the main power switch.

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14.2.2.2. Power switches shall be located so that accidental contact by personnel cannot place equipment in operation.

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14.2.2.3. All switches and controls shall be clearly marked.

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14.2.2.4. Switches and controls shall be sufficiently separated and protected if they could be inadvertently actuated, creating

a hazardous condition.

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14.2.2.5. Critical switches that can produce or induce hazardous conditions if inadvertently activated shall have a protective

cover over them.

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14.2.3. EGSE Circuit Protection

14.2.3.1. Protective devices shall be provided for EGSE primary circuits.

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Protective devices include fuses and circuit breakers that are suitable to provide overload/short circuit protection.

14.2.3.2. Protective devices shall be connected to the load side of the main power switch unless neutral power sensing is

essential for proper protection of the equipment.

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14.2.3.3. Protection shall be provided in each of the three ungrounded conductors of all three-phase EGSE motors so that

failure of one conductor shall result in de-energizing all three conductors.

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14.2.3.4. All safety devices shall be located for easy access.

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Safety devices include fuses, circuit breakers, resets, and others.

14.2.3.5. Circuit breaker trips shall be detectable by visual inspection.

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14.2.3.6. Replaceable components and test points shall be readily accessible.

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14.2.3.7. Electrical fuse and switch boxes shall be properly marked to show the voltage present, rated fuse capacity, and

EGSE that the circuit controls.

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Outside marking should be made on enclosures to identify the existence of a safety protective device within the enclosure. The

safety device rating should be marked on the outside or inside of the enclosure/switchbox.

14.2.3.8. Each redundant EGSE circuit shall have its own circuit breaker or fuse.

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14.2.3.9. Each circuit shall not have the capability to inhibit, by loss of control, more than one safety critical control device.

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14.2.3.10. Megohm meters (Megger high voltage resistance meters) shall be current limited depending on application.

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Fuses or equivalent devices may be used as current limiting devices, as applicable.

14.2.4. EGSE Cables. EGSE cables shall not share the same trench as propellant lines.

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14.2.5. EGSE Batteries

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14.2.5.1. Sufficient ventilation shall be provided for EGSE batteries that produce flammable gasses to ensure concentrations

of vapor do not reach 25 percent of the Lower Explosive Limit (LEL).

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14.2.5.2. Polarity of EGSE battery terminals shall be marked.

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14.2.6. EGSE Battery Charging Equipment

14.2.6.1. Battery charging EGSE shall be current limited by design and shall provide protection and monitoring to prevent

battery damage or failure.

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For protection of the battery, the EGSE battery charging equipment charging rate should not be able to initiate or sustain a

run-away failure of the battery. A temperature monitoring system should also be used in addition to other methods of charge

control to protect the battery.

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14.2.6.2. Analysis or testing shall be conducted to demonstrate compliance with the requirements of paragraph 14.2.6.1

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14.2.7. Fixed and Portable EGSE in Hazardous Locations

14.2.7.1. General. At a minimum, electrical equipment and its installation shall comply with the requirements of the most

recent edition of the NFPA 70 (NEC). The PSWG and Range Safety shall approve exceptions.

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14.2.7.2. Definition of Hazardous (Classified) Locations. Hazardous (Classified) locations are defined in NEC Article 500,

Hazardous (Classified) Locations. Definition of Hazardous (Classified) Locations. Hazardous (Classified) locations are

defined in NFPA 70 (NEC) Article 500, Hazardous (Classified) Locations.

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14.2.7.3. Explosives and Propellants Not Covered in NEC Article 500. The following paragraphs define the minimum

requirements to be applied in the definitions of locations in which explosives, pyrotechnics, or propellants are present or are

expected to be present. These requirements shall be followed unless less stringent classifications are justified and approved

as part of the design data submittal process. PSWG, Range Safety and local Fire Marshal shall approve all potential critical

facility hazardous location designations.

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14.2.7.3.1. Class I, Division 1. Complete definitions of classified locations are found in NFPA 70. These include the

following locations:

14.2.7.3.1.1. Within 25 feet of any vent opening unless the discharge is normally incinerated or scrubbed to nonflammable

conditions [less than 25 percent of Lower Explosive Limit (LEL)]. This distance may be increased if the vent flow rate creates

a flammability concern at a distance greater than 25 feet.

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14.2.7.3.1.2. Below grade locations in a Class I, Division 2 area.

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14.2.7.3.1.3. Locations in which flammable liquids, vapors, or gases may be present in the air during normal operations.

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14.2.7.3.1.4. Locations in which there is a credible risk that ignitable concentration of vapors or gases may be present in the

air during abnormal operations due to a failure, leakage, or maintenance/repair.

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14.2.7.3.2. Class I, Division 2. Complete definitions of classified locations are found in NFPA 70. These include the

following locations:

Class I, Division 2 usually includes locations where volatile flammable liquids or flammable gases or vapors are used but, in the judgment

of the appropriate local safety authorities as identified by the PSWG and Range Safety and the local Fire Marshal, would become

hazardous only in case of an accident or of some unusual operating condition. The quantity of flammable material that might escape in

case of an accident, the adequacy of ventilating equipment, and the total area involved are all factors that merit consideration in

determining the classification and extent of each location.

14.2.7.3.2.1. Piping without valves, check valves, meters, and similar devices would not ordinarily introduce a hazardous

condition even though used for flammable liquids or gases. Locations used for the storage of flammable liquids or of liquefied

or compressed gases in sealed containers would not normally be considered hazardous unless also subject to other hazardous

conditions.

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14.2.7.3.2.2. As determined by the PSWG and Range Safety and the local Fire Marshal, locations may actively change

classification depending on the flammable fluid system activity and configuration. For these types of locations, fixed or

permanently installed electrical equipment shall be designed for the worst case hazardous environment.

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14.2.7.3.2.3. Portable electrical equipment shall be designed for the worst case hazardous environment in which it will be

used. Portable equipment that is not designated for use in a particular hazardous environment is not allowed in that

environment.

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14.2.7.3.2.4. Class I, Division 2 locations include the following equipment or areas:

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14.2.7.3.2.4.1. Storage vessels (including carts and drums): 25 feet horizontally and below to grade and 4 feet vertically

above the vessel (25 feet in any direction for hydrogen).

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14.2.7.3.2.4.2. Transfer lines: 25 feet horizontally and below to grade and 4 feet above the line (25 feet in any direction for

hydrogen).

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14.2.7.3.2.4.3. Liquid fueled vehicle, stage, or payload: 100 foot radius horizontally from and 25 feet vertically above (100

feet for hydrogen) the highest leak or vent source and below the vehicle to grade.

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14.2.7.3.2.4.4. Enclosed locations such as rooms, work bays, and launch complex clean rooms that are used to store and

handle flammable and combustible propellants when the concentration of vapors inside the room resulting from a release of

all fluids stored and handled equals or exceeds the LEL. The quantity of fluids used in the analysis to determine vapor

concentration shall be the maximum amount allowed in the explosives site plan.

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14.2.7.3.2.4.5. Locations adjacent to a Class I, Division 1 location into which ignitable concentrations of gases or vapors

might occasionally be communicated, unless communication is prevented by adequate positive pressure ventilation from a

source of clean air and effective safeguards against ventilation failure are provided.

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14.2.7.3.3. Hazardous Commodity Groups. Hazardous commodities are grouped by similar characteristics.

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14.2.7.3.3.1. These fuels shall be considered ignitable regardless of the ambient temperature.

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14.2.7.3.3.2. The following fuels shall be categorized as follows:

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14.2.7.3.3.2.1. Group B: Liquid or gaseous hydrogen.

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14.2.7.3.3.2.2. Group C: Hypergolic propellant fuels such as N

, MMH, UDMH, A50.

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14.2.7.3.3.2.3. Group D: Hydrocarbon fuels (RP and JP).

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14.2.7.3.3.2.4. Group D: Oxidizers. Oxidizers shall be considered Group D hazardous substances in addition to the fluids

listed in NFPA 497, Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and Hazardous

(Classified) Locations for Electrical Installations in Chemical Process Areas.

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14.2.7.3.3.2.5. Exposed Solid Propellants. The atmosphere within 10 feet horizontally and directly overhead of exposed solid

propellant shall be classified as a Class I, Division 2, Group D location. Solid rocket motors are considered exposed in the

following situations:

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14.2.7.3.3.2.5.1. The motor nozzle is not attached, and the aft end of the motor does not have a cover.

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14.2.7.3.3.2.5.2. The motor nozzle is attached but does not have a nozzle plug.

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14.2.7.3.3.2.5.3. The unassembled motor segments do not have front and rear covers.

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14.2.7.3.3.2.5.4. The igniter is removed from the motor and cover is not provided.

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14.2.7.4. Electrical Systems and Equipment Hazard Proofing. Electrical systems and equipment used in hazardous

locations shall be designed and listed for the locations in accordance with the following requirements:

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14.2.7.4.1. Explosion proof apparatus shall meet the requirements of NFPA 70, Article 501 for Class I, Division 1 or Division

2, and shall be listed and labeled by a nationally recognized testing laboratory per 29 CFR 1910.7, Definition and Requirements

for a Nationally Recognized Testing Laboratory.

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14.2.7.4.2. Non-incendive apparatus shall meet the requirements of NFPA 70, Article 501 and are restricted to installations

in Class I, Division 2 locations only. They shall be listed and labeled by a nationally recognized testing laboratory such as

UL, FM, or those accredited by OSHA under the Nationally Recognized Testing Laboratory (NRTL) accreditation program,

29 CFR 1910.7, Definition and Requirements for a Nationally Recognized Testing Laboratory.

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14.2.7.4.3. Intrinsically safe equipment and systems intended for Class I, Division 1 or Division 2 locations shall meet the

requirements of the NEC Article 504, Intrinsically Safe Systems, and UL 913, Standard for Safety, Intrinsically Safe Apparatus

and Associated Apparatus for Use in Class I, II, and III, Division 1 Hazardous Areas, and be listed and labeled by a nationally

recognized laboratory such as UL, FM, or those accredited by 29 CFR 1910.7.

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14.2.7.4.4. The use of purged and pressurized electrical enclosures, designed in accordance with NFPA 496, Purges and

Pressurized Enclosures for Electrical Equipment, for the purpose of eliminating or reducing the hazardous location

classification as defined in NFPA, Article 500 is acceptable with the following additional requirements:

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For example, a fueled payload flight hardware liquid propulsion system would normally result in the classification of a

location as Class I, Division 2, Zone 2. Type Z Pressurizing of the protected enclosure of the EGSE is normally adequate to

reduce the area to an unclassified location as specified in NFPA 496.

14.2.7.4.4.1. The purged and pressurized enclosure shall be maintained at a nominal 1/2 inch of water. In no case shall the

pressure in the enclosures be less than 1/10 inch of water.

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14.2.7.4.4.2. Rooms into which unprotected personnel may enter shall be purged with air only.

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14.2.7.4.4.3. Purged rooms and enclosures shall be provided with an audible alarm set to trigger when the pressure drops

below 1/4 inch water. The alarm shall be at a constantly attended location. The alarm trigger shall monitor the purged

enclosure and not the purge gas supply.

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Instrument quality air is preferred over other protective non-flammable gases such as nitrogen. Purged systems that use other

media may require compliance to confined space or potentially oxygen deficient atmosphere requirements due to asphyxiation

hazards.

14.2.7.4.4.4. Protective gas supplies shall be free of flammable vapor or gas and designed to prevent contaminants from

entering system.

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14.2.7.4.4.5. Purge supply lines shall be constructed of noncombustible material, designed to prevent migration of flammable

gas, dust or vapor into the protective gas.

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14.2.7.4.5. Equipment inspected and tested to other government standards such as MIL-STD-810, Environmental Engineering

Considerations and Laboratory Testing, may be used if approved by the PSWG and Range Safety.

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Electrical and Electronic Flight Hardware

14.3.1. Electrical and Electronic Flight Hardware Design Standards. To prevent payloads from igniting a flammable

atmosphere that may result from a fuel leak during dynamic operations (e.g., fueling, spin tests, lifts, transport, other payload

movements), airborne electrical and electronic equipment shall be designed to meet the intent of NFPA 70, Article 501, Class

I Locations, to the maximum extent possible.

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The preferred method for providing payload electrical safety during fueling and other dynamic operations is to power down the

payload in a manner that restricts current from flowing to payload electrical systems.

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14.3.2. Flight Hardware Electromechanical Initiating Devices and Systems

14.3.2.1. Electromechanical initiating devices and systems shall be evaluated to determine associated ordnance hazard

classification.

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Electromechanical initiating devices and systems, including nonexplosive initiators (NEIs), are used for such purposes as

structure deployment or actuation release mechanisms.

14.3.2.2. Design, test, and data requirements shall be determined by the PSWG and Range Safety on a case-by-case basis.

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14.3.2.3. At a minimum, the system safety failure tolerances described in Chapter 3 of this volume and the initiating ordnance

design requirements shall be addressed.

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14.3.3. Flight Hardware Batteries

14.3.3.1. Flight battery cases shall be designed to an ultimate safety factor of 3 to l with respect to worst case pressure buildup

for normal operations. For flight hardware batteries with LBB failure modes, 12.4.1.1 (factor of safety of 1.5) applies.

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14.3.3.1.1. This pressure buildup shall consider hydraulic and temperature extremes.

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14.3.3.1.2. Batteries that have chemically limited pressure increases and whose battery/cell case can be designed to withstand

worst case pressure buildup in abnormal conditions can reduce the safety factor to 2:1 (ultimate) and 1.5:1 (yield). Lower

factors of safety determined by PSWG and Range Safety approved analysis can be used on a case-by-case basis.

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Batteries that have nickel hydrogen chemistries are examples of batteries that have chemically limited pressure increases.

Examples of abnormal conditions are direct short and extreme temperatures. PSWG and Range Safety approved analyses

include fracture mechanics that can be used on a case-by-case basis.

14.3.3.2. Sealed batteries shall have pressure relief capability unless the battery case is designed to a safety factor of at least

3 to 1 based on worst case internal pressure.

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14.3.3.2.1. Pressure relief devices shall be set to operate at a maximum of 1.5 times the operating pressure and sized so that

the resulting maximum stress of the case does not exceed the yield strength of the case material.

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14.3.3.2.2. Nickel-hydrogen batteries and/or cells that are proven by test to withstand worst case pressure buildup in abnormal

conditions (such as direct short and thermal extremes that can be experienced when installed with no reliance on external

controls such as heaters and air conditioning) are not required to have pressure relief capability.

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14.3.3. Flight Hardware Batteries with LBB (Leak Before Burst) Failure Mode. The battery cells shall be demonstrated to

have a LBB failure mode per 12.2.2; and when sealed battery cases are used, they shall also be demonstrated to have a LBB

failure mode. If a cell case design incorporates no pressure relief devices and cell leakage is determined to be a catastrophic

hazard, the cell case shall be demonstrated to comply with the Hazardous LBB requirements per 12.2.3 of this volume.

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14.3.3.3.1. Flight Hardware Batteries with LBB Failure Mode Factor of Safety. Unless otherwise specified, and approved by

the PSWG and Range Safety, flight battery cells and cases shall be designed to an ultimate safety factor of 3:1 with respect to

the worst case pressure buildup for normal operations.

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14.3.3.3.2. Flight Hardware Batteries with LBB Failure Mode Fatigue-Life Demonstration. In addition to the stress analysis

conducted in accordance with the requirements of 12.1.5.3, a conventional fatigue-life analysis shall be performed, as

appropriate, on the unflawed structure to ascertain that the pressure vessel, acted upon by the spectra of operating loads,

pressures and environments, meets the life requirements.

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14.3.3.3.2.1. A life factor of 5 shall be used in the analysis.

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14.3.3.3.2.2. Testing of unflawed specimens to demonstrate fatigue-life of a specific pressure vessel together with stress

analysis is an acceptable alternative to fatigue test of the vessel.

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14.3.3.3.2.3. Fatigue-life requirements are considered demonstrated when the unflawed specimens that represent critical areas

such as membrane section, weld joints, heat-affected zone, and boss transition section successfully sustain the limit loads and

MOP in the expected operating environments for the specified test duration without rupture.

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14.3.3.3.2.4. The required test duration is 4 times the specified service life.

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14.3.3.3.3. Flight Hardware Batteries with LBB Failure Mode Qualification Testing

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14.3.3.3.3.1. Qualification tests shall be conducted on flight quality batteries to demonstrate structural adequacy of the design.

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14.3.3.3.3.2. The following tests are required.

14.3.3.3.3.2.1. Random Vibration Testing. Random vibration testing shall be performed on batteries per the requirements of

SMC-S-016 as tailored.

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14.3.3.3.3.2.2. Thermal Vacuum Testing. Thermal vacuum test shall be performed on batteries per requirements of SMC-S-

016 as tailored.

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14.3.3.3.3.2.3. Pressure Testing. A pressure cycle test shall be conducted on battery cells. The peak pressure shall be equal

to the MOP of the battery cells during each cycle, and the number of cycles shall be 4 times the predicted number of operating

cycles or 50 cycles, whichever is greater. After the completion of the pressure cycle test, the pressure shall be increased to

actual burst of the battery cell. The actual burst pressure shall be greater than or equal to 1.5 times MOP of the battery cell.

For batteries having sealed cases, similar tests shall be conducted on the sealed cases, if applicable.

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14.3.3.3.4. Flight Hardware Batteries with LBB Failure Mode Acceptance Test Requirements

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14.3.3.3.4.1. Acceptance tests shall be conducted on batteries before being committed to flight.

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14.3.3.3.4.2. The following tests are required:

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14.3.3.3.4.2.1. Proof Pressure Test. Whenever feasible, battery cells shall be proof pressure tested to 1.25 times the MOP of

the cells. For sealed battery cases, pressure tests shall be performed at a level of 1.25 times the MOP of the cases.

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14.3.3.3.4.2.2. Nondestructive Inspection. Surface and volumetric NDE techniques shall be performed after the proof pressure

test.

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14.3.3.3.5. Flight Hardware Batteries with LBB Failure Mode Recertification Test Requirements

14.3.3.3.5.1. All refurbished pressure vessels shall be recertified after each refurbishment by the acceptance test requirements

for new hardware to verify their structural integrity and to establish their suitability for continued service before commitment

to flight.

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14.3.3.3.5.2. Pressure vessels that have exceeded the approved storage environment (temperature, humidity, time, and others)

shall also be recertified by the acceptance test requirements for new hardware.

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14.3.3.3.6. Flight Hardware Batteries with LBB Failure Mode Special Requirements. Batteries shall be designed such that

battery cells are within containment devices (or cases). These containment devices (or cases) shall be demonstrated to be able

to prevent the escape of any hazardous contents over an insignificant quantity deemed acceptable by the procuring and safety

agencies.

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14.3.3.4. Flight Hardware Batteries with Brittle Fracture Failure Mode

14.3.3.4.1. Batteries with battery cells exhibiting brittle fracture failure mode shall meet the requirements defined in 12.2.3.

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14.3.3.4.2. In addition, a thermal vacuum test shall be conducted as part of the qualification testing.

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14.4. Test Requirements for Lithium Batteries.

Li-Ion battery safety see section 14.1.9.3

Detailed design, analysis, and test requirements for batteries, which are classified as special pressurized equipment, are described

below, and shall meet the requirements of ANSI/AIAA S-080.

Table 14.5. Lithium Batteries.

Lithium batteries are thermal batteries, also called molten salt batteries. Lithium batteries are different from Li-ion batteries,

even though they both contain the element Lithium. Lithium batteries are primary cell batteries, that is, batteries where the

electrochemical reaction is not reversible. Lithium batteries are non-rechargeable.

14.4.1. Unless otherwise agreed to by PSWG and Range Safety, the following tests shall be performed before the use or

storage of lithium batteries at a NASA facility or the payload processing facility and launch site area. These tests are likely to

cause violent reactions, so all possible safety precautions shall be observed.

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Batteries that have a UL listing and are intended for public use are exempt from these requirements.

14.4.2. Lithium Battery Constant Current Discharge and Reversal Test

14.4.2.1. The constant current discharge and reversal test shall determine if the pressure relief mechanism functions properly

or case integrity is sustained under circumstances simulating a high rate of discharge.

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14.4.2.2. The test shall be performed according to the following criteria:

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14.4.2.2.1. The test shall consist of a constant current discharge using a DC power supply.

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14.4.2.2.2. The fusing of the battery shall be bypassed (shorted).

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14.4.2.2.3. The discharge shall be performed at a level equal to the battery fuse current rating and the voltage of the battery.

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14.4.2.2.4. After the battery voltage reaches 0 volts, the discharge shall be continued into voltage reversal at the same current

for a time equivalent to l.5 times the stated ampere-hour capacity of the battery pack.

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14.4.2.2.5. Voltage, pressure, and temperature shall be continuously monitored and recorded.

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14.4.3. Lithium Battery Short Circuit Test

14.4.3.1. The short circuit test shall determine if the pressure relief mechanism functions properly under conditions simulating

a battery short circuit failure mode; or if a pressure relief mechanism is not provided, case integrity shall be determined under

conditions simulating a battery short circuit failure mode.

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14.4.3.2. The test shall be performed according to the following criteria:

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14.4.3.2.1. After all internal electrical safety devices have been bypassed, the battery shall be shorted, through a load of 0.0l

ohms or less, leaving the load attached for not less than 24 hours.

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14.4.3.2.2. Voltage, current, pressure, and temperature shall be continuously monitored and recorded.

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14.4.4. Lithium Battery Drop Test. A drop test shall be performed according to the following criteria:

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Other tests may be required by the PSWG and Range Safety depending upon design, storage, operating environments, and

other criteria. If required, additional tests shall be identified by the PSWG and Range Safety. Manufacturing lot acceptance

tests may be required of safety devices in the battery design to ensure safety critical functions have not been altered.

14.4.4.1. The battery in the activated state shall be dropped from a 3-foot height to a concrete pad on the edge of the battery,

on the corner of the battery, and on the terminals of the battery.

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14.4.4.2. The battery shall not vent or start a hazardous event when dropped.

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14.4.4.3. A physical analysis shall be performed after the drop test to determine what handling procedures are required to

safely dispose of the batteries if dropped at the payload processing facility and launch site area.

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14.5. Electrical and Electronic Equipment Data Requirements. EGSE data shall be submitted in accordance with the

requirements of Attachment 1, A1.2.5.10 of this volume.

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MOTOR VEHICLES

General

15.1.1. This chapter applies to payload project provided motor vehicle under their responsibility (e.g., leased, rented, etc.).

For purposes of this chapter, the term motor vehicles encompass conventional trucks, truck-tractors, trailers, tankers, and lift

trucks and special-purpose trailers intended for exclusive use on the payload processing facility and launch site area and/or

the range.

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15.1.2. These design, test, and documentation requirements apply to motor vehicles used for general purposes and to transport

critical hardware or bulk hazardous materials such as toxics, flammables, combustibles and explosives, and hazardous

commodities at payload processing facility and launch site area, on range roads and tracks.

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15.1.3. Hazardous commodities not listed in NFPA 497 shall be evaluated by the PSWG and Range Safety for appropriate

hazard classification on a case-by-case basis.

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Motor Vehicles Other Than Lift Trucks

15.2.1. General Design Standards

15.2.1.1. Motor vehicles that do not meet DOT public transportation requirements shall not be permitted to transport

hazardous materials at the payload processing facility and launch site area unless the vehicle is covered by a formal DOT

exemption and is approved by the PSWG and Range Safety. Motor vehicles shall also comply with state and municipal

regulations.

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15.2.1.2. Motor vehicles for the transport of explosives shall conform to DESR 6055.09_AFMAN 91-201, Explosive Safety

Standards when on Air Force property, and NASA-STD-8719.12 when on NASA property.

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15.2.1.3. Special-purpose trailers for range use only shall conform to DESR 6055.09_AFMAN 91-201, Explosive Safety

Standards.

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15.2.1.4. If the motor vehicle does not meet DOT and DoD requirements, the following data shall be submitted by the payload

project before using the vehicles at the payload processing facility and launch site area:

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15.2.1.4.1. Design, test, and NDE inspection requirements for vehicles.

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15.2.1.4.2. FMECA in accordance with MIL-STD-882 or equivalent on selected applications.

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15.2.1.4.3. Engineering documentation such as analyses (performance, stress, SFPs), tests, and inspections that justifies

acceptance of DOT noncompliances based on “equivalent safety” or “meets DOT intent” criteria.

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15.2.2. Special-Purpose Trailers Used to Transport Critical or Hazardous Loads Design Requirements:

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15.2.2.1. Trailers and their ancillary support equipment such as outriggers and support stands shall be designed with a yield

factor of safety of at least 2 based on limits loads and material minimum yield strength and 1.5 against overturning at worst

case conditions expected over the transit route.

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15.2.2.2. Load test tags shall be attached to the trailer and marked with the following minimum information:

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15.2.2.2.1. Part number.

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15.2.2.2.2. Date and weight of most recent load test (or date of next load test).

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15.2.2.2.3. Rated load.

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15.2.2.2.4. Date of most recent NDE (or date of next NDE).

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15.2.3. Special-Purpose Trailers Used to Transport Critical or Hazardous Loads Tests:

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15.2.3.1. Initial Tests. At a minimum, the following tests shall be performed before first operational use at the payload

processing facility and launch site area:

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15.2.3.1.1. Road/load test at 125 percent rated load at typical terrain and design speeds for selected applications.

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15.2.3.1.2. Volumetric and surface NDE shall be performed on all SFP components and SFP welds and 10 percent of non-

SFP welds located in the load path before and after the road/load test.

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15.2.3.2. Periodic Tests. A periodic road/load test at 100 percent rated load shall be performed on trailers used to transport

flight hardware (hazardous or non-hazardous) on the ranges every 4 years, with SFP weld inspection limited to surface NDE.

Unless otherwise agreed to by the PSWG and Range Safety, the initial road/load test shall also be performed after a trailer has

experienced structural modification or repair.

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15.2.4. Motor Vehicles Used to Transport Critical or Hazardous Loads Data Requirements. Initial and recurring data

requirements shall be submitted in accordance with the requirements of Attachment 1, A1.2.5.17 of this volume.

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Lift Trucks

15.3.1. Lift Truck Standards

15.3.1.1. Lift trucks shall be in accordance with NFPA 505, Fire Safety Standard for Powered Industrial Trucks Including

Type Designations, Areas of Use, Conversions, Maintenance, and Operation and UL 583, UL Standard for Safety Electric-

Battery-Powered Industrial Trucks.

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15.3.1.2. Lift trucks to be used in locations classified as hazardous by the NEC Article 500 shall meet the requirements of

NFPA 505, Fire Safety Standard for Powered Industrial Trucks Including Type Designations, Areas of Use, Conversions,

Maintenance, and Operation. Replacement tires and other components shall be those approved for the specific application

and/or environment.

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Battery powered equipment and its use shall comply with OSHA and NFPA standards. Type EX rated battery powered equipment

is the only equipment approved for use in specifically named Class I, Group D or Class II, Group G hazardous locations.

15.3.1.3. Lift trucks used to transport explosives and propellants or operate in explosive and propellant locations shall also

meet the requirements of NASA-STD-8719.12, and DESR 6055.09_AFMAN 91-201, Explosive Safety Standards.

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15.3.2. Lift Truck General Design Requirements

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15.3.2.1. Lift trucks shall be equipped with shoulder-high Range Safety seats with seatbelts.

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15.3.2.2. Personnel platforms attached to lift trucks shall be designed and tested in accordance with 6.4 of this volume.

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15.3.2.3. Critical loads shall not exceed 75 percent of the lift truck rated capacity.

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15.3.3. Lift Truck Tests. Lift trucks shall be tested in accordance with ASME B56 Series Safety Standards, NFPA 505 and

UL 583.

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15.3.4. Lift Truck Data Requirements. Initial and recurring data requirements shall be submitted in accordance with the

requirements of Attachment 1, A1.2.5.17 of this volume.

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COMPUTER SYSTEMS AND SOFTWARE

General

16.1.1. NPR 7150.2, NASA Software Engineering Requirements, provides requirements for project computer systems and

software. The payload project shall follow the requirements of NASA-STD-7150.2, NASA-STD-8739.8, Software

Assurance and Safety Standard for project computer systems and software. The requirements for computer systems and

software that are used to control and/or monitor operations identified as safety critical are described in NASA-STD-8739.8

and below. The term software, as used in this publication, includes firmware and software that is executed on processors in

operations within complex electronics. Software requirements do not apply to the design or hardware description language

for complex electronic devices. Firmware is software stored in nonvolatile memory and it does not represent complex

electronic devices.

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Complex electronics encompasses programmable and designable complex integrated circuits. “Programmable” logic devices

can be programmed by the user and range from simple chips to complex devices capable of being programmed on-the-fly.

“Designable” logic devices are integrated circuits that can be designed but not programmed by the user.

These requirements are not intended to be used as a checklist; instead, they are to be used in conjunction with safety analyses

performed in accordance with applicable standards and directives.

16.1.2. The requirements shall be tailored to the system or system type under development. Unless specifically excluded by

the PSWG and Range Safety, these requirements shall apply to all computer systems and subsystems that perform safety

critical functions during the assembly, handling, checkout, test, and launch of payloads.

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These systems and subsystems include ground support equipment (such as test equipment, battery charging/monitoring

equipment), and spaceflight hardware systems supplied by the payload project. The payload project should assess all such

equipment for possible safety critical computer system functions in software and firmware use.

16.1.3. In addition to contractor-developed computer systems and software, these requirements shall apply to programmable

logic controllers (PLCs), firmware such as erasable programmable read only memory (EPROM), commercial off-the-shelf

(COTS) and government off-the-shelf (GOTS) products, and reused code. These requirements shall apply to software that is

executed on processors (where applicable) on Complex Programmable Logic Devices (CPLDs), Field Programmable Gate

Arrays (FPGAs), Application Specific Integrated Circuits (ASICs), and System on a Chip (SOC) applications, but not to the

devices themselves or the hardware description language logic or text.

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Table 16.1. Firmware, COTS, GOTS and Reused Software.

Chapter 16, in its entirety, applies to all forms of software and firmware; however, special attention should be paid to the

following:

(1) EPROMs or EEPROMs should contain unique version identifiers and be validated via checksum or some other method

before installation and use.

(2) COTS, GOTS, and re-use software should be examined and evaluated as to their appropriateness for the intended new use.

Unused portions of re-use software should be removed.

16.1.4. Software shall be classified, designed, developed, tested, and assessed for risk in accordance with MIL-STD-882,

which in turn references the Joint Software Systems Safety Engineering Handbook (JSSSEH) for further details. Joint Services

– Software Safety Authorities Software System Safety – Implementation Process and Tasks Supporting MIL-STD-882 (JS-

SSA-IG), provides implementation details and options for how developers can take the requirements of MIL-STD-882 and

the guidance of the JSSEH to define processes and tasks required for a compliant software safety program. Software design,

development and testing shall be conducted according to a software safety plan which is integrated into the overall system

safety plan.

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Determination of Safety Critical Computer System Functions

The payload project shall perform reliability and hazard analysis to identify all safety critical software and Safety Critical

Computer Systems Functions (SCCSFs) in accordance with NASA-STD-8739.8, Software Assurance and Software Safety

Standard, and the provisions of this document.

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It is recommended that SCCSFs be identified and agreed to by the PSWG and Range Safety very early in the program along with

detailed documentation for each.

16.2.1. The payload project shall identify all of the following:

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16.2.1.1. All software contributions to system hazards. Safety-significant functions shall be positively identified in

hardware, software, and firmware domains.

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Table 16.2. Safety Significant Software Functions.

Safety-significant is a term applied to a condition, event, operation, process, or item that is identified as either safety-

critical or safety-related. Safety-critical applies when the mishap severity consequence is either catastrophic or

critical, and safety-related applies when the mishap severity consequence is either marginal or negligible. It is

recommended that safety critical functions (SCF) be identified and agreed to by PSWG and Range Safety very early

in the program along with detailed documentation. SCFs are defined as any computer system function that,

(1) if not performed, (2) if performed out of sequence, or (3) if performed incorrectly, may directly or indirectly

cause a safety hazard to exist.

16.2.1.2. The safety requirements associated with safety-significant software components and safety-related items.

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16.2.1.3. All safety-critical functions, which include, but are not necessarily limited to:

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16.2.1.3.1. Software used to control and/or monitor safety critical systems.

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16.2.1.3.2. Software used for fault detection in safety critical computer hardware or software.

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16.2.1.3.3. Software used to transmit safety critical data, including time-critical data and data about hazardous conditions.

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16.2.1.3.4. Software that responds to the detection of a safety critical fault.

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16.2.1.3.5. FTS Software.

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16.2.1.3.6. Software that computes safety critical data.

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16.2.1.3.7. Software used to access safety critical data.

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16.2.1.3.8. Processor interrupt software associated with previously designated safety critical computer system functions.

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16.2.1.4. The mapping to the architecture, interfaces, and designs of safety-significant functions.

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16.2.1.5. The identification of the software assurance process as it relates to developing safe software using a software control

category (SCC), software safety criticality level, and level of rigor (LOR) approach to software development and testing.

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16.2.1.6. The identification of how defined safety-significant functions possess the appropriate integrity within the design (as

defined by the level of rigor tasks) for fault detection, isolation, annunciation, tolerance, and recovery.

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16.2.2. Safety-significant software functions (SSSF) shall be assigned a software criticality index (SwCI) based on severity

and SCC, as outlined in MIL-STD-882, Table V – Software Safety Criticality Matrix. Derivation of criticality shall be based

on both requirements and concept of operations.

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It is recommended that SwCI 1 software functions be avoided and that additional levels of protection be implemented as a

preferred means of hazard mitigation strategy. At SwCI 3 or above, configuration control must apply to the smallest compiled

module or unit.

16.2.3. Application of LOR shall be based on SwCI in accordance with Appendix A of the JS-SSA-IG, as tailored by the

program. Appendix A LOR requirements specify minimum design, analysis, development, test, inspection, and data

requirements for safety software. Single-point failure analysis shall account for potential system failures due to software and

its interaction with other software components, hardware components, and human components of the system.

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Table 16.3. Level of Rigor (LOR)Lessons Learned.

Failure to achieve all LOR requirements will result in safety program requirements to re-assess risk with missing or deficient

artifacts or processes. Failure to achieve all LOR requirements does not mean increased risk but unknown uncharacterized

software behavior that may increase safety risk.

If the safety system is susceptible to security vulnerabilities, then consultation with security personnel may be warranted to discuss

the security concerns during the planning phase and tailoring. If security implementations would adversely affect personnel or

public safety, preference must be given to the safety software.

Hardware and Software Safety Design Requirements

16.3.1. Computer Systems. The following subparagraphs identify general hardware that shall be met for all safety critical

computer system functions.

16.3.1.1. Computer systems shall be validated for operation in the intended environment.

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Validation of central processing unit (CPU) functionality should be based on testing.

16.3.1.2. Under maximum system loads, CPU throughput shall not exceed 80 percent of its design value.

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Although CPU throughput of 80 percent is acceptable, experience has shown that a value of 70 percent is desirable.

16.3.1.3. Computer system architecture shall be single fault tolerant.

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16.3.1.3.1. No single software failure/output shall initiate a hazardous operation.

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Safety will also be enhanced if the system is designed so that memory locations not intended to be used during a particular

operation will tend to bring the system to a safe or stable state if inadvertently executed.

16.3.1.3.2. No single software failure/output shall cause a critical accident.

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16.3.1.3.3. No single or double software failure/output shall cause a catastrophic accident.

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16.3.1.3.4. Fulfilling the following requirements in addition to the other requirements in Chapter 16 shall constitute meeting

the computer system requirements in 16.3.1.3.1 through 16.3.1.3.3 above. The payload project shall identify and provide the

following items to the PSWG and Range Safety:

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16.3.1.3.4.1. All hazardous operations that can be triggered by software, either intentionally or unintentionally.

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16.3.1.3.4.2. All critical accidents that can be triggered by software.

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16.3.1.3.4.3. Catastrophic accidents that can be triggered by software.

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16.3.1.3.4.4. Scenarios where a single software failure/output can create a condition that can trigger a hazardous operation or

critical accident. Consideration shall be given to data integrity, memory use, timeliness and correct sequencing of data, and

situations where the interaction of modules, hardware, software, and/or users may be problematic.

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16.3.1.3.4.5. Scenarios where a single or double software failure/output can produce a condition that can trigger a catastrophic

accident.

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16.3.1.3.4.6. Analyses and test reports that verify the capability to monitor the system during runtime to ensure the faulty

conditions are corrected.

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16.3.1.4. Safety critical computer system function flight architecture that will be exposed to cosmic radiation shall protect

against CPU single event upset (SEU) and other single event effects (SEE). An SEU occurs when an energetic particle travels

through a transistor substrate and causes electrical signals within the transistor.

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SEUs can be protected against through redundancy, error correcting memory, voting between parallel CPUs, or other approved

approaches.

16.3.1.5. Sensitive components of computer systems shall be protected against the harmful effects of electromagnetic radiation

and/or electrostatic discharge.

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16.3.1.6. The computer system shall periodically verify that safety critical hardware and SCCSF, including safety data

transmission, are operating correctly, as agreed to by the PSWG and Range Safety.

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16.3.2. Computer System Power

16.3.2.1. Computer systems shall be powered up and/or restarted in a safe state.

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16.3.2.2. A computer system shall not enter a hazardous state as a result of an intermittent power transient or fluctuation.

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16.3.2.3. In the event of the single failure of primary power to a computer system or computer system component, that system

or some cooperating system shall take action automatically to transition to a stable state.

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In the context of response to failure or retreat from some unsafe state, a stable state is the safest possible state that can be

achieved without causing a more hazardous state to occur during that transition.

16.3.2.4. Software used to power up safety critical systems shall power up the required systems in a safe state.

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16.3.3. Computer System Anomaly and Failure Detection

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Table 16.4. Anomaly and Failure Detection Alerts.

In addition to those anomalies listed, software should be designed to alert appropriate operators to such things as:

(1) CPU running at greater than 80 percent of specified load.

(2) Pending memory overflow.

(3) Pending buffer overflows.

16.3.3.1. Before initiating hazardous operations, computer systems shall perform checks to ensure that they are in a safe state

and functioning properly. These checks include checking safety critical circuits, components, inhibits, interlocks, exception

limits, safing logic, memory integrity, and program loads.

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16.3.3.2. The following hazardous conditions and failures, including those from multiple sources, shall be detected:

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16.3.3.2.1. Invalid input - data or sequences of data passed to software modules, either by human input, other software

modules, or environmental sensors, that are outside a specified range for safe operation.

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16.3.3.2.2. Invalid output - data output from software modules that are outside a specified range for safe operation.

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16.3.3.2.3. Timing errors - the state when software-timed events do not happen according to specification.

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16.3.3.2.4. Data transmission errors.

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16.3.3.2.5. Loss of memory integrity.

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16.3.3.2.6. Greater than allowed safe input data rates.

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16.3.3.2.7. The existence of an invalid pattern regardless of its storage location.

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16.3.3.2.8. Software exceptions, such as “divide by zero” or “file not found.”

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16.3.3.2.9. Data transfer messages corrupted or not in the proper format.

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16.3.4. Computer System Anomaly and Failure Response

16.3.4.1. All events mentioned in 16.3.3 shall be reported to the appropriate system operator consoles in real time, prioritized

as to severity, and logged to an audit file.

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Table 16.5. Safety Critical Function (SCF) Display Alerts.

Displays that support SCCSFs can vary widely but every attempt should be made to ensure that the operators are alerted to the

most important anomalies. A method of prioritization is necessary. For example, anomalies of the same priority should be

grouped together; all warnings displayed first, cautions next, and advisories last. The most recent anomaly should be displayed

at the top of the priority subgroup. Details of each anomaly should be accessible with a single operator action.

16.3.4.1.1. The display shall distinguish between read and unread anomaly alerts.

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16.3.4.1.2. The display shall support reporting multiple anomalies.

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16.3.4.1.3. The display shall distinguish between anomaly alerts for which corrective action has been taken and those that are

still pending.

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16.3.4.2. Upon detecting an event described in 16.3.3, the software shall remain in or revert to a stable state.

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16.3.4.3. For payloads with a FTS, upon detecting a failure during processing, the software shall maintain the FTS in its

current state in addition to meeting the requirements in 16.3.4.1 and 16.3.4.2 above.

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16.3.4.3.1. The software shall maintain the FTS in the safe state before arming.

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16.3.4.3.2. After the FTS is armed, the software shall retain the FTS in the armed state.

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16.3.4.3.3. When the FTS receiver is on internal power, the software shall maintain the FTS receiver on internal power.

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16.3.4.3.4. During flight, all detected FTS-related system errors shall be transmitted to the range.

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16.3.5. Computer System Testing and Maintenance

16.3.5.1. Non-operational hardware and software required for testing or maintenance shall be clearly identified.

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16.3.5.2. Systems shall include interlocks, as necessary, to mitigate hazards when performing maintenance or testing.

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16.3.5.3. Interlocks shall be designed to prevent an inadvertent override.

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16.3.5.4. Interlocks that are required to be overridden shall not be autonomously controlled by a computer system, unless

dictated by a timing requirement.

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16.3.5.5. Interlocks that are required to be overridden and are autonomously controlled by a computer system shall be designed

to prevent an inadvertent override.

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16.3.5.6. The status of overridden interlocks shall be displayed on the appropriate operator console(s).

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16.3.5.7. A positive indication of interlock(s) restoration shall be provided and verified on the appropriate operator console(s)

before restoring a system to its operational state.

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16.3.5.8. Compilers

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16.3.5.8.1. Existing code compiled with a new compiler or new release of a compiler shall be regression tested.

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16.3.5.8.2. Beta test versions of language compilers shall not be used for safety critical functions.

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Software Requirements

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16.4.1. Software Design, Development, and Test Requirements. NPR 7150.2 NASA Software Engineering Requirements

provides requirements for software design, development, and testing. Additionally, software shall be designed, developed,

and tested in accordance with NASA-STD-8739.8, Software Assurance and Software Safety Standard, and commercial

software development standard IEEE/EIA 12207, Standard for Information Technology.

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NASA-GB-8719.13, NASA Software Safety Guidebook, is recommended for guidance in ensuring software safety.

16.4.1.1. SCF software test documentation shall be coordinated with SLD 30/SE and SLD 45/SE. SCF software testing shall

be conducted IAW the approved test plan and include the following:

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16.4.1.1.1. Reaction of software to system (hardware, software, or combination of hardware and software) errors or failures.

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16.4.1.1.2. Boundary conditions (in, out, crossing).

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16.4.1.1.3. Critical values (e.g., singularities and behavior around singularities such as crossing over a singularity or

approaching a singularity from either direction).

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For example, zero is a special case of a more general issue in that certain numeric representations may cause a fault (e.g.,

floating point exception).

16.4.1.1.4. Minimum and maximum input data rates in worse case configurations.

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16.4.1.1.5. Regression testing for changes to SCF software code.

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16.4.1.1.6. Operator interface/human errors during SCF operations.

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16.4.1.1.7. Error handling.

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16.4.1.1.8. Special features such as partitioning upon which the protection of SCF features is based.

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16.4.1.1.9. Formal testing for software to include analysis and documentation (software analysis, test plan, and test report).

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16.4.1.1.10. Test coverage for all execution paths; with all statements executed at least once and every branch tested at least

once.

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16.4.1.1.11. A revised inventory, relative to software CDR, of safety critical data (local and configuration) and non-safety

critical data along with justification for the partitioning. Justification should be based on safety analysis performed and defined

system engineering processes.

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16.4.1.1.12. Revised analysis results, relative to software CDR, for safety critical data analysis performed, including

verification of data items between and within software modules, reaction of the software system to faults and transformation

of fault types between system elements, and the progression of data through the system. Software analysis tools should be

used to the greatest extent practical.

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16.4.2. Software Coding Practices. The payload project’s software developers should develop or adopt software coding

practices applicable to the programming languages used.

Some examples include Appendixes D and E of the Joint Software Safety Committee, Software System Safety Handbook; Code

Conventions for the Java Programming Language by Sun Microsystems; and C++ Coding Standards by Herb Sutter and Andrei

Alexandrescu.

Experience has indicated that computer systems architectures that contain separate instruction and data memory and buses, or

separate program memory and data memory through memory protection hardware, segment protection, or page protection prove

useful for risk mitigation.

16.4.3. Human-Computer Interface

16.4.3.1. General human-computer interface requirements are found in the Global Information Grid (GIG) Technical

Guidance Federation.

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MIL-STD-1472, Human Engineering, provides requirements for displays and controls designated specifically for government

operator use.

16.4.3.2. The system shall be designed such that the operator may exit current processing to a known stable state with a single

action.

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Care should be taken to prevent the operator from inadvertently initiating a hazardous operation; therefore, the "single action"

should be designed to minimize that possibility. That action may include pressing two keys at the same time.

16.4.3.3. Computer systems shall minimize the potential for inadvertent actuation of hazardous operations.

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16.4.3.4. Only one operator at a time shall control safety critical computer system functions.

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16.4.3.5. Operator-initiated hazardous functions shall require two or more independent operator actions.

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Table 16.6. Examples of acceptable actions to initiate a hazardous operation are:

(1) Pressing a key which produces an alert to notify the operator of the impending hazardous operation, followed by a second

keystroke to invoke the operation.

(2) Removal of a physical block such as a switch cover followed by flipping the switch.

(3) Moving a cursor on a display monitor to a desired position to highlight a selection, followed by clicking to confirm and accept

the highlighted selection.

16.4.3.6. Software shall provide confirmation of valid command and/or data entry to the operator.

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16.4.3.7. Software shall provide two different sensory feedback methods to the operator that indicates command receipt and

status of the operation commanded.

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The system should provide both visual and aural feedback to ensure the operator knows that the system has accepted the action

and is processing it.

16.4.3.8. Software shall provide the operator with real-time status reports of operations.

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16.4.3.9. Error messages that distinguish safety critical states/errors from non-safety critical states/errors shall be provided.

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16.4.3.10. The system shall ensure that a single failure or error cannot prevent the operator from taking safing actions.

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16.4.4. Software Data Standards

16.4.4.1. Software shall not use a bit pattern of all 1s or all 0s to denote the safe and arm (potentially hazardous) states.

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16.4.4.2. The arm and safe states shall be represented by unique bit patterns of length at least 4 bits in such a way that the safe

state pattern cannot represent the arm pattern as a result of a 1 or 2-bit error.

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16.4.5. Configuration Control

16.4.5.1. The payload project shall provide a software configuration management (SCM) plan in accordance with NPR

7150.2, Software Engineering Requirements, to the PSWG for PSWG and Range Safety review.

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The system should be designed to prevent or minimize the chance for inadvertent or unauthorized access to and modification of

system software by system operators.

16.4.5.2. Software and firmware shall be put under formal configuration control as soon as a software baseline is established.

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16.4.5.3. A Software Configuration Control Board (SCCB) shall be established to approve changes to configuration-

controlled software before implementation.

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16.4.5.4. A member from the system safety engineering team shall be a member of the SCCB and tasked with the

responsibility of evaluating all software changes for their potential safety impact.

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16.4.5.5. A member of the hardware Configuration Control Board (CCB) shall be a member of the SCCB and vice versa to

keep members apprised of hardware/software changes and to ensure that hardware/software changes do not conflict with or

introduce potential safety hazards due to hardware/software incompatibilities.

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16.4.5.6. Object code patches shall not be performed unless the SCCB and the PSWG and Range Safety give specific approval.

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Computer System and Software Data Requirements

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16.5.1 Computer system and software data shall be provided in accordance with Attachment 1, A1.2.4.14 and A1.2.5.18 of

this volume.

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Independent Verification and Validation (IV&V) Analysis Support

Table 16.7. Independent Verification and Validation (IV&V) Analysis Support.

IV&V analysis support should be considered for SCFs with a serious SwCI or high risk SwCI. This determination

should be based on the tailored application of the software safety standards as contained in the Range User’s program

specific SSP and further defined in the software safety plan.

16.6.1. IV&V Support.

16.6.1.1. The payload project shall ensure appropriate V&V requirements are established at the beginning of the program to

ensure proper implementation of software safety requirements. This includes an assessment of the scope and level of IV&V

to be planned and implemented based on the level of criticality and risk of the software application.

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16.6.1.2. IV&V shall be performed by an independent third (3rd) party. The assessor shall not be part of the developer’s

company or its subsidiaries unless specifically approved by SLD 30/SE and SLD 45/SE , given sufficient separation exists

and can be demonstrated.

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16.6.1.3. The IV&V process shall begin during the definition phase and encompass the requirements, design, development,

operational evaluation and test, and life cycle program phases.

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16.6.1.4. Efforts of V&V used to identify where IV&V is required shall encompass:

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16.6.1.4.1. Validation that software-to-software interfaces and software-to-hardware interfaces have been correctly

implemented.

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16.6.1.4.2. Independent analysis program to evaluate selected hardware, software, firmware and interfaces to demonstrate the

algorithms and logic are correctly implemented.

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16.6.1.4.3. Model and simulation of selected hardware, software, firmware and interfaces to demonstrate compliance to system

and operational requirements.

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16.6.1.5. IV&V shall report and track through closure all anomalies throughout the development and operational

implementation process.

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16.6.1.6. All serious and high risk SwCI anomalies shall be closed with PSWG and Range Safety approval prior to use of

SwCI at the range. Unverifiable failures that cannot be tracked to a specific piece of hardware or software shall be documented

as such. Unverifiable failures shall be documented with any analysis done, special testing performed, configuration of the

system at the time of the failure, and any other applicable information for the future.

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WESTERN RANGE SEISMIC DESIGN

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The probability of the WR being exposed to a severe earthquake is great enough to require taking specific mitigating measures

in design. This chapter identifies equipment seismic design requirements. Equipment includes aerospace ground equipment

(AGE), ground support equipment (GSE), flight hardware integrated with GSE, and ground support systems (GSS). For

simplification, the terms equipment and/or GSE are used in this chapter to include AGE, GSE, and GSS. Seismic requirements

do not apply to the spacecraft itself but do apply to spacecraft integrated with GSE. For example, a spacecraft mounted on a

support stand would be analyzed as a unit and protected accordingly.

Applicability of Design and/or Anchorage or Restraint Requirements

17.1.1. Equipment needed/required for post-earthquake recovery, essential equipment (per code definition), or safety critical

equipment, shall be designed to remain operational or revert to a “safe mode” during a seismic event, and to be operational

immediately following a seismic event. This equipment shall be designed with an importance factor of 1.5 (I = 1.5). If the

payload project, PSWG and Range Safety determine that the equipment is not essential to life safety, an importance factor of

1 may be used.

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17.1.2. Equipment whose failure or excessive deflections during a seismic event could propagate to a catastrophic event or

endanger personnel, high-pressure systems, or systems used to store hazardous or toxic materials shall be designed and

anchored to withstand a seismic event. The equipment need not remain operational after the seismic event as long as personnel

and environmental safety are preserved; however, equipment whose failure could result in a catastrophic event or endanger

personnel shall be designed to revert to an established “safe mode” in the event of a seismic event.

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17.1.3. Equipment whose movement could propagate to a catastrophic event, block personnel egress avenues, or injure

personnel shall be secured to prevent movement.

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17.1.4. Transportation equipment shall be stored with the casters or wheels locked or blocked. Transportation equipment

shall be stored in open areas so that if movement occurs during an earthquake, the equipment shall not impact adjoining

structures (for example, building columns) and propagate into a facility failure.

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17.1.5. Gravity friction shall not be used as the only means to anchor or restrain equipment.

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Basis for Design

17.2.1. Seismic design of equipment, supports and/or anchorages shall be in accordance with the International Building Code

(IBC), American Society of Civil Engineers Minimum Design Loads for Buildings and Other Structures (ASCE/SEI 7-10),

and the additional requirements specified in this publication.

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17.2.2. Local Geotechnical shall be used to determine site soil classification. Data may be available within 300 ft of the

equipment or facility and can be used to determine the site soil classification. If a geotechnical report is too costly and not

available, a site soil classification D shall be used if deemed appropriate by the payload project, PSWG and Range Safety.

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17.2.3. Appropriate seismic hazard mitigation shall be implemented for high cost computer or electronic equipment.

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Where it is cost-effective, high-cost computer or electronic equipment should be mounted on seismic isolation bearings to mitigate

damage during an earthquake. FEMA 74, Reducing the Risks of Non-Structural Earthquake Damage, A Practical Guide,

should be used as a guide to reduce the risk of earthquake non-structural damage.

17.2.4. Seismic Loading and Loads Combinations

17.2.4.1. Seismic loads for AGE/GSE shall be calculated in accordance with the IBC and ASCE/SEI 7-10.

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17.2.4.2. Seismic loading shall include vertical component in addition to the horizontal component to evaluate the total

earthquake load. This is accomplished per ASCE/SEI 7-10 by multiplying 0.2 by the spectral response and the dead load

(0.2*S

*D).

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17.2.4.3. Calculation of the seismic loads shall consider dynamic amplification and the dynamic characteristics of the GSE

and their supports and anchorage to ensure the proper seismic response factor is selected.

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17.2.4.5. Loads combinations shall be in accordance with IBC and ASCE/SEI 7-10, American Society of Civil Engineers

Minimum Design Loads for Buildings and Other Structures.

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17.2.5. Exemptions. GSE that meets any of the following criteria shall be exempt from seismic design and/or restraint

requirements:

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17.2.5.1. Internal operational elements of GSE that are confined within the GSE structure.

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17.2.5.2. Man-handled GSE physically attached to flight hardware or GSE.

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17.2.5.3. GSE categorized as hand tools.

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17.2.5.4. GSE temporarily positioned in support of operations, on a case-by-case basis, those items may be ruled exempt by

the PSWG, and Range Safety based on the results of a risk analysis. The analysis shall address risk for catastrophic failure of

the equipment, or any potential catastrophic event the equipment may precipitate. These include but are not limited to:

excessive movement that may impact another hazardous system, movement that may block and egress routes, release of stored

energy or hazardous commodity, whether the identified equipment may be needed for post-earthquake recovery, or a tipping

hazard which may present a crushing or pinching hazard.

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17.2.6. Existing Equipment. For programs and/or projects planning to reuse existing GSE that does not meet the requirements

in this publication, payload project safety and engineering shall assess that equipment for potential risk. The payload project

shall coordinate the risk assessment with the PSWG and Range Safety and formulate risk mitigation plans for the GSE in

question.

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WR Seismic Data Requirements

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The GSE data package shall be submitted in accordance with the requirements in Attachment 1, A1.2.5.19 of this volume

and shall identify the equipment and potential for seismic hazard and risk.

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Earthquake Emergency Planning and Post Recovery Response

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The payload project shall develop emergency and recovery procedures for a seismic event. These procedures shall detail

emergency shutdown and inspections of critical systems to ensure operation of safety controls were not compromised during

the seismic event. An assessment of the facility and its components shall be completed before resuming normal operations.

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SOLID ROCKET MOTORS, ROCKET MOTOR SEGMENTS, AND ROCKET

MOTOR COMPONENTS

General

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In addition to the requirements in Chapter 6 and Chapter 13 of this volume, the following data and analysis shall be provided

for solid rocket motors and rocket motor segments:

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18.1.1. Structural analyses for all aerospace ground equipment used to handle rocket motors and segments. This includes

items such as handling rings, special breakover fixtures, air pallets, segment and motor stands, special lifting fixtures, and

critical motor component installation fixtures.

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18.1.2. Initial and periodic NDE plans for the aerospace ground equipment, as required in 6.1.1.3.2.1. Single failure items

and SFP welds shall be clearly identified.

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Failure Modes, Effects, and Criticality Analysis (FMECA) and Operating & Support Hazards

Analysis (O&SHA)

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FMECA and operational hazard analysis (OHA) for all aspects of solid rocket segment and/or motor handling and buildup.

This analysis shall include the following:

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18.2.1. An assessment of the probability of the motor, segment, or component igniting and possibly becoming propulsive

upon mechanical, electrical, or thermal shock.

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18.2.2. An assessment of the requirements for onsite NDE testing of rocket motor segment, motors, and/or components. X-

ray or ultrasonic testing equipment failure modes, and their effect on the rocket motor/segment shall be analyzed. This analysis

is particularly important for equipment used to inspect rocket motor bore.

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Lightning Effects Hazard Analysis

18.3.1. A lightning effects hazard analysis shall be performed on each facility used to store and process solid rocket

segments/motors.

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18.3.2 An induced effects lightning hazard analysis shall be performed to determine the effects on each solid rocket

motor/segment undergoing storage and/or processing operations in a facility should the facility experience a direct lightning

strike.

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18.3.3 These analyses shall specify any operational restrictions needed to ensure lightning safety during

storage and processing.

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Solid Rocket Motor and Motor Segment Data Requirements

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The data requirements found in Attachment 1, A1.2.4.9.6 of this volume shall be submitted for solid rocket motors, motor

segments, and components.

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ATTACHMENT 1 SAFETY DATA PACKAGE

INTRODUCTION

A1.1.1. Purpose. The Safety Data Package (SDP) or equivalent of the Missile System Prelaunch Safety Package (MSPSP)

is a documentation data submittal that provides a detailed description of hazardous and safety critical ground support and flight

hardware equipment, systems, and materials and their interfaces used in the launch of launch vehicles and payloads. It is one

of the media through which missile system prelaunch safety approval is obtained. NPR 8715.7 provides the payload safety

review and approval process including required safety documentation and SDP submittal time line for the Payload Safety

Introduction Briefing, Safety Review I (project’s mission PDR time frame), Safety Review II (project’s mission CDR time

frame) and Safety Review III (prior to payload shipping reviews).

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A1.1.2. Content. This attachment contains the content preparation instructions for the data generated by the requirements

specified in Volume 3.

A1.1.3. Applicability. The requirements in this attachment are applicable to all NASA Payloads, and related ground support

systems, including AGE, GSE, and facilities.

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A1.1.4. Submittal Process. A Safety Data Package (SDP) (MSPSP) shall be submitted to the PSWG in conjunction with

Range Safety by the payload project with overall responsibility for the payload systems for review and approval by the PSWG

and Range Safety.

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A1.1.5. Final Approval. A final SDP (MSPSP) that satisfies all PSWG and Range Safety concerns addressed at the project’s

mission CDR shall be submitted to the PSWG for review and approval by the PSWG and Range Safety at least 45 calendar

days prior to payload (spacecraft) shipment or as determined by the PSWG.

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PREPARATION INSTRUCTIONS

A1.2.1. Content

A1.2.1.1. The SDP (MSPSP) contains technical information concerning hazardous and safety critical equipment, systems,

and materials and their interfaces used in the pre-launch processing and launch of payloads.

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A1.2.1.2. The SDP (MSPSP) is a detailed description of the design, test, and inspection requirements for all ground support

systems and flight hardware and materials and their interfaces used in the pre-launch and launch of payloads. Hazard Analyses

and Hazard Reports shall be contained in the SDP or provided separately and submitted with the SDPs (see A1.2.4.1.9 and

A3.2.4.4). All schematics, functional diagrams, and operational manuals shall have well defined, standard IEEE or Mil-Spec

terminology and symbols.

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A1.2.1.3. The payload project shall develop the SDP and submit it in three phases (SDP I, II, and III) unless agreed to

otherwise by the PSWG and Range Safety.

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A1.2.1.3.1. SDP I is due no later than 30 days prior to the project’s mission PDR (see NPR 8715.7). SDP I shall contain

technical information, hazard analysis and hazard reports commensurate with PDR-level design and operations. For a project

utilizing a previously launched payload bus SDP I shall include identification and description of any payload safety-related

problems, mishaps, or failures that occurred during fabrication, testing, processing, or integration that could affect the safety

of the flight hardware or software, ground support equipment, personnel, or other NASA concerns.

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A1.2.1.3.2. SDP II is due no later than 30 days prior to the project’s mission CDR (see NPR 8715.7). SDP II shall contain

updated technical information from SDP I commensurate with CDR-level design and operations. A cross-reference shall be

provided identifying the disposition of review comments of SDP I indicating where changes were made.

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A1.2.1.3.3. SDP III is the Final SDP and is due no later than 90 days prior to the payload shipment to the processing site (see

NPR 8715.7). SDP III shall address all comments and incorporate all changes reflecting the as-built configuration and planned

processing activities. A cross-reference shall be provided identifying the disposition of review comments since the last SDP

submittal to indicate where incorporated changes to the SDP were made. SDP III shall contain final hazard reports, the Final

GOP (in SDP III or as a stand-alone document), and a signed copy of any approved safety waivers (with attachments provided

upon request). SDP III shall also contain a record of test failures, anomalies and mishaps involving qualification hardware,

flight hardware, ground support equipment, and software (if used for hazard control), and an assessment of the resolution and

safety implications of these events.

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A1.2.2. Format. The payload project format is acceptable provided the information described below is provided. Suggested

formats are shown as applicable. The format presented in this attachment provides two distinct sections: Flight Hardware

Systems and Ground Support Systems.

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A1.2.2.1. Table of Contents and Glossary. The SDP (MSPSP) shall contain a table of contents and a glossary.

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A1.2.2.2. Introduction. The “introduction” section shall address the scope and purpose of the SDP (MSPSP).

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A1.2.3. General Description. The “general description” section provides an overview of the payload or ground support

system as a prologue to the subsystem descriptions. The following information is included in this section:

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A1.2.3.1. Physical dimensions and weight.

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A1.2.3.2. Nomenclature and description of major subsystems.

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A1.2.3.3. Types of motors and propellants to be used.

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A1.2.3.4. Sketches and/or photographs of the launch vehicle, payload, or ground support system.

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A1.2.3.5. Synopsis of each hazardous and safety critical subsystem.

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A1.2.3.6. A list of hazardous subsystems addressed in Volume 3 of this publication that are not present in the launch vehicle

or payload system.

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A1.2.4. Flight Hardware Subsystems

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A1.2.4.1. At a minimum, the “flight hardware subsystems” section shall include the following information and the specific

data requirements listed in A1.2.4.6 through A1.2.4.14 below:

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A1.2.4.1.1. Subsystem overview.

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A1.2.4.1.2. Nomenclature of major subsystems.

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A1.2.4.1.3. Function of the subsystem.

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A1.2.4.1.4. Location of the subsystem.

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A1.2.4.1.5. Operation of the subsystem.

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A1.2.4.1.6. Subsystem design parameters.

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A1.2.4.1.7. Subsystem test requirements.

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A1.2.4.1.8. Subsystem operating parameters.

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A1.2.4.1.9. Summaries of any PSWG and Range Safety required hazard analyses conducted.

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A1.2.4.2. Supporting data shall be included or summarized and referenced as appropriate with availability to the PSWG and

Range Safety upon request.

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A1.2.4.3. Tables, matrixes, and sketches are required for systems and component data. (See A1.2.4.7.2 and A1.2.4.7.3 below

for suggestions.)

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A1.2.4.4. Required analyses, test plans, and test results may be included in the SDP as appendixes or submitted separately.

At a minimum, analyses, test plans, and test reports shall be listed, referenced, and summarized in the SDP.

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A1.2.4.5. A list of all the PSWG and Range Safety approved noncompliances.

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A1.2.4.6. Flight Hardware Structures and Mechanisms

A1.2.4.6.1. Flight Hardware Structures and Mechanisms General Requirements. In addition to the information required in

A3.2.4.1, the material properties of the main structures, mechanisms, and deployable’ s used on launch vehicles and payloads

shall be included in the SDP .

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A1.2.4.6.2. Flight Hardware Used in Lifting Critical Loads. At a minimum, the following documentation is required:

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A1.2.4.6.2.1. SFP analysis.

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A1.2.4.6.2.2. NDE plan and test results for SFP components and SFP welds.

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A1.2.4.6.2.3. Initial proof load test plan and test results.

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A1.2.4.6.2.4. Stress analysis.

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A1.2.4.7. Flight Hardware Pressure, Propellant, and Propulsion Systems

A1.2.4.7.1. General Data. A detailed description of the pressure, propellant, and propulsion systems of the payload shall be

provided. The description shall include the information identified in A1.2.4.1 plus the following:

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A1.2.4.7.1.1. Material compatibility analysis.

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A1.2.4.7.1.2. Physical and chemical properties and general characteristics of the propellant, test fluid, and gases.

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A1.2.4.7.1.3. For hazardous propellants, fluids, and gases, the following shall be submitted:

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A1.2.4.7.1.3.1. Specific health hazards such as toxicity and physiological effects.

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A1.2.4.7.1.3.2. Threshold limit value (TLV) and maximum allowable concentration (MAC) for eight-hour day, five-day week

of continuous exposure.

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A1.2.4.7.1.3.3. Emergency tolerance limits including length of time of exposure and authority for limits (for example, Surgeon

General, National Institute for Occupational Safety and Health [NIOSH], independent study).

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A1.2.4.7.1.3.4. Maximum credible spill size including volume and surface area and supporting analyses.

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A1.2.4.7.1.3.5. Description of hazards other than toxicity such as flammability and reactivity.

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A1.2.4.7.1.3.6. Personal protective equipment to be used in handling and using the propellants when this equipment will be

used during an operation, and the manufacturer, model number, and other identifying data.

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A1.2.4.7.1.3.7. Manufacturer, model number, specifications, operating limits, type of certification, and general description of

vapor detecting equipment.

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A1.2.4.7.1.3.8. Identification of material incompatibility problems in the event of a spill.

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A1.2.4.7.1.3.9. Recommended methods and techniques for decontamination of areas affected by spills or vapor clouds and

hazardous waste disposal procedures.

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A1.2.4.7.2. Flight Hardware Pressure, Propellant, and Propulsion System Data. A schematic diagram shall be submitted

for all systems: The schematic shall present the system in a clear and easily readable form with complete subsystems grouped

and labeled accordingly. The schematic or a corresponding data sheet shall provide the following information:

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Nomenclature of each element should be made adjacent to or in the vicinity of each element.

A1.2.4.7.2.1. Identification of all pressure system components such as valves, regulator, tubes, hoses, vessels, and gauges

using standard symbols.

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A legend is recommended. The original mechanical drawings should be referenced.

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A1.2.4.7.2.2. MOP of all systems and subsystems at expected operating temperatures.

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A1.2.4.7.2.3. Identification of expected source pressures and expected delivery pressures.

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A1.2.4.7.2.4. All relief valve pressure settings and flow rates.

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A1.2.4.7.2.5. System fluid and maximum expected temperature.

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A1.2.4.7.2.6. Pressure ranges of all pressure transducers.

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A1.2.4.7.2.7. Pressure settings of pressure regulators.

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A1.2.4.7.2.8. Charging pressure of reservoirs and vessels, their nominal capacities, and wall thickness.

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A1.2.4.7.2.9. Pressure setting of all pressure switches.

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A1.2.4.7.2.10. The nominal outside diameter and wall thickness of all tubing and piping.

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A1.2.4.7.2.11. Flow path through all components.

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When the system is to be used in several operating modes, it is easier to provide a separate schematic that depicts flow paths for

each operating mode.

A1.2.4.7.2.12. Reference designations for each component so that a cross-reference between schematics and drawings and a

pressure system component list or other documentation is possible.

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A1.2.4.7.2.13. End-to-end electrical schematics of electrical and electronic components giving full functional data and current

loads.

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A1.2.4.7.2.14. Connections for testing or servicing.

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A1.2.4.7.2.15. A narrative description of the system or subsystem and its operating modes, including a discussion of

operational hazards and accessibility of components.

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A1.2.4.7.2.16. A sketch or drawing of the system that shows physical layout and dimensions.

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A1.2.4.7.2.17. System information shall be placed in tabular form; suggested format is shown below.

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Table A3.1. Example Systems Data Format

System ID Number

System Title

Location

MOP

Commodity

Responsible Organization

Number of Vessels

Recertification Date (GSE only)

Recertification Period (GSE only)

Material(s)

Inspection Results

ISI Requirements (GSE only)

A1.2.4.7.3. Flight Hardware Pressure, Propellant, and Propulsion Component Design Data. The following information shall

be submitted for each component:

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A1.2.4.7.3.1. Identification of each component by a reference designation permitting cross reference with the system

schematic.

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A1.2.4.7.3.2. The MAWP for all pressure system components.

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A1.2.4.7.3.3. The MOP at which the component shall operate when installed in the system.

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A1.2.4.7.3.4. Safety factors or design burst pressure for all pressure system components.

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A1.2.4.7.3.5. Actual burst pressures, if available.

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A1.2.4.7.3.6. Pre-assembly hydrostatic test proof pressure for each system component.

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A1.2.4.7.3.7. If applicable, the proof pressure the component will be tested to after installation in the system.

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A1.2.4.7.3.8. Materials used in the fabrication of each element in the component, including soft goods and other internal

elements.

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A1.2.4.7.3.9. Cycle limits if fatigue is a factor of the component.

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A1.2.4.7.3.10. Temperature limits of each system component.

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Table A1.2. Example Vessels Data Format:

Vessel ID Number

System ID Number

Manufacturer Name

Manufacturer Serial No.

Manufacturer Drawing No.

Commodity

Original MAWP

Burst Pressure

Volume

Location

DOT Specification (GSE only)

Year of Manufacture

National Board No. (GSE only)

Code Stamps (GSE only)

Recertification MAWP (GSE only)

Recertification Date (GSE only)

Recertification Period (GSE only)

Cyclic Limit

Test Pressure

Vessel Design

Material

Temperature Limits

Maximum Stress

Inside Radius

Thickness

Dimensions

ISI Information and ISI Results (GSE only)

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Table A1.3. Example Relief Devices Data Format:

ID Number

System Number

Type

Manufacturer

Manufacturer Part No.

Code Stamps (GSE only)

Manufacturer Date

Inlet Size

Outlet Size

Set or Burst Pressure

System MOP

System Commodity

Flow Capacity

Material

Temperature Limits

Test Pressure

ISI Requirements and ISI Results (GSE only)

Table A1.4. Example Pressure Gauges and Sensors Data Format:

ID Number

System Number

Manufacturer

Manufacturer Date

Manufacturer Part No.

Pressure Range

Material

System Commodity

MAWP

Burst Pressure

System MOP

Inlet Size

ISI Requirements and ISI Results (GSE only)

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Table A1.5. Example Flexible Hoses Data Format:

ID Number

System Number

Manufacturer

Manufacturer Part No.

Manufacturer Date

Materials

Temperature Limits

MAWP/Manufacturer Rated Working Pressure

Size (diameter, length)

Burst Pressure

Cyclic Limit

Test Pressure

Shelf Life

ISI Requirements and ISI Results (GSE only)

A1.2.4.7.4. Flight Hardware Pressure, Propellant, and Propulsion Initial Test Plans and Procedures. A list and

summary of all initial test plans, test procedures, and test results for all flight hardware pneumatic, hydraulic, hypergolic, and

cryogenic fluid and propellant systems, as applicable in accordance with Chapter 12.

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A1.2.4.8. Flight Hardware Electrical and Electronic Subsystems

A1.2.4.8.1. General Data. A detailed description of the electrical and electronic subsystems of the launch vehicle or payload

shall be provided. The description shall include the information identified in A3.2.4.1.

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A1.2.4.8.2. Flight Hardware Battery Design Data. The following information shall be submitted for flight hardware

batteries:

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A1.2.4.8.2.1. Design versus actual operating parameters of cells and battery.

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A1.2.4.8.2.2. Cell chemistry and physical construction.

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A1.2.4.8.2.3. Cell vent parameters.

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A1.2.4.8.2.4. Toxic chemical emission of cells and evaluation of hazards.

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A1.2.4.8.2.5. EPA classification of the battery.

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A1.2.4.8.2.6. DOT classification of the battery.

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A1.2.4.8.2.7. Physical and electrical integration of cells to form the battery.

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A1.2.4.8.2.8. Description of safety devices.

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A1.2.4.8.2.9. Case design including vent operation and cell and battery case housing yield point.

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A1.2.4.8.2.10. A description of all operations to include packing, transportation, and storage configuration; activation;

installation; checkout; charging; usage; removal; and disposal.

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A1.2.4.8.2.11. Identification of the hazards associated with each activity in A3.2.4.8.2.10 above and the safety controls that

shall be in effect.

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A1.2.4.8.2.12. Manufacturing qualification and acceptance testing results that are considered safety critical.

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A1.2.4.8.2.13. Battery size and weight.

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A1.2.4.8.2.14. Specification of the system that uses the battery.

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A1.2.4.8.2.15. A description of the EGSE used for packing, transportation, and storage; activation; installation; checkout;

analysis; charging; usage; removal; and disposal of the battery.

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A1.2.4.8.2.16. A list and summary of test plans, test procedures, and test results in accordance with 14.4.

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A1.2.4.8.3. Flight Hardware Electrical and Electronic Subsystem Data. The following information shall be submitted

for electrical and electronic subsystems operating in hazardous atmospheres:

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A1.2.4.8.3.1. A brief description of power sources and the power distribution network, including schematics and line drawings

of the distribution network.

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A1.2.4.8.3.2. A description of how faults in electrical circuitry are prevented from propagating into hazardous subsystems,

including such information as dedicated power sources and buses, use of fuses, and wiring sizing.

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A1.2.4.8.3.3. A description of how inadvertent commands that can cause a hazardous condition are prevented.

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A1.2.4.8.3.4. Identification of potential shock hazards.

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A1.2.4.8.3.5. A description of how the intent of hazard proofing is met for electrical and electronic systems.

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A1.2.4.8.3.6. Complete grounding and bonding methodology.

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A1.2.4.8.3.7. A bent pin analysis for all connectors for safety critical or hazardous systems that have spare pins.

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A1.2.4.9. Flight Hardware Ordnance Subsystems

A1.2.4.9.1. General Data. A detailed description of the ordnance subsystems of the launch vehicle or space craft shall be

provided. The description shall include the information identified in A1.2.4.1.

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A1.2.4.9.2. Flight Hardware Ordnance Hazard Classifications and Categories. The following ordnance hazard classification

data shall be submitted:

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A1.2.4.9.2.1. UNO classifications and DOD hazard classifications, including class, division, and compatibility group, in

accordance with DESR 6055.09_AFMAN 91-201, Explosive Safety Standards, and NASA-STD-8719.12 respectively.

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A1.2.4.9.2.2. DOT classification.

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A1.2.4.9.2.3. The ordnance device and system hazard classification for each ordnance item and system; test results and/or

analysis used to classify the ordnance devices and systems.

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A1.2.4.9.3. Flight Hardware Ordnance System Data. The following ordnance system data shall be submitted:

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A1.2.4.9.3.1. A block diagram of the entire ordnance system.

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A1.2.4.9.3.2. A complete line schematic of the entire ordnance system from the power source to the receptor ordnance,

including telemetry pick-off points and ground (umbilical) interfaces.

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A1.2.4.9.3.3. Diagrams showing the location of all ordnance components on the vehicle.

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A1.2.4.9.3.4. A description of wiring, ETS, and FOC routing.

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A1.2.4.9.3.5. A description of electrical, ETS, and optical connections and connectors.

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A1.2.4.9.3.6. Detailed, complete schematics of the entire ordnance system showing component values such as resistance and

capacitance, tolerances, shields, grounds, connectors, and pin outs.

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A1.2.4.9.3.6.1. The schematics shall include all other vehicle components and elements that interface or share common usage

with the ordnance system.

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A1.2.4.9.3.6.2. All pin assignments shall be accounted for.

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A1.2.4.9.3.7. Detailed narrative description and functional schematic of the operation of the ordnance system. The narrative

description and functional schematic shall be capable of being used to determine the configuration and resulting failure

tolerance of the vehicle and ground ordnance systems at any time during prelaunch processing, launch countdown, or launch,

including all credible failure scenarios.

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A1.2.4.9.3.8. The FMECA for each ordnance system.

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A1.2.4.9.3.9. An operational flow of the ordnance system processing and checkout, including timelines and summaries of

each procedure to be used.

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A1.2.4.9.3.10. A sketch showing the accessibility of manual arming and safing devices.

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A1.2.4.9.3.11. Specification drawings and documents for all airborne and ground ordnance systems.

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A1.2.4.9.4. Flight Hardware Ordnance Component Design Data. The following ordnance component design data shall

be submitted:

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A1.2.4.9.4.1. A complete and detailed description of each ordnance system component and how it functions.

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A1.2.4.9.4.2. Specification drawings and documents for all airborne and ground ordnance components.

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A1.2.4.9.4.3. Illustrated breakdown of all mechanically operated ordnance components.

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A1.2.4.9.4.4. Part number, manufacturer, and net explosive weight for each ordnance item.

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A1.2.4.9.4.5. Temperature and humidity requirements for each ordnance item.

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A1.2.4.9.4.6. Bridgewire resistance, maximum safe no-fire current, and minimum all-fire current for each low voltage EED.

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A1.2.4.9.4.7. Maximum no-fire voltage and minimum all-fire voltage for each EBW.

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A1.2.4.9.4.8. Maximum no-fire energy and minimum all-fire energy for each LID and PAD.

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A1.2.4.9.4.9. A list and summary of test plans procedures, and results, as required.

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A1.2.4.9.4.10. 8 x 10 inch color photographs or electronic copies of all ordnance items.

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The photographs or electronic copies should be of sufficient detail to identify individual ordnance items as well as to show the

ordnance item(s) in installed configuration on the payload. These photographs are intended to ensure the safety of Explosive

Ordnance Disposal personnel who may be directed to render the ordnance safe.

A1.2.4.9.5. Flight Hardware Ordnance Component Handling and Storage Data. Specific requirements for handling and

storing the flight ordnance shall be submitted.

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A1.2.4.9.6. Solid Rocket Motors, Rocket Motor Segments, and Associated Components. In addition to the requirements

listed for ordnance, the following data shall be provided for solid rocket motors, rocket motor segments, and associated

components:

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A1.2.4.9.6.1. Propellant Properties.

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A1.2.4.9.6.1.1. Propellant explosive hazard classification (DoD, UNO, DOT, including test results), if not previously

addressed by A3.2.4.9.2.1.

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A1.2.4.9.6.1.2. Propellant formulation (composition).

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A1.2.4.9.6.1.3. Propellant auto-ignition température.

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A1.2.4.9.6.1.4. Propellant static sensitivity (energy in Joules required to ignite the propellant).

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A1.2.4.9.6.1.5. Propellant conductivity.

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A1.2.4.9.6.2. Propellant Reactions to Impact on Hard Surface.

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A1.2.4.9.6.2.1. Ignition threshold drop height.

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A1.2.4.9.6.2.2. Low order detonation threshold drop height.

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A1.2.4.9.6.2.3. Critical impact velocity (threshold velocity required to break up propellant sufficiently so that it will transit

from deflagration to detonation in a 1 inch diameter schedule 40 steel pipe).

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A1.2.4.9.6.3. Igniter data

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A1.2.4.9.6.3.1. Type of propellant and propellant properties data as specified in A3.2.4.9.6.1 and A3.2.4.9.6.2 above.

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A1.2.4.9.6.3.2. Data on each igniter initiator, such as a through bulkhead initiator (TBI).

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A1.2.4.9.6.3.3. Igniter weight.

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A1.2.4.9.6.3.4. Igniter grounding provisions.

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A1.2.4.9.6.3.5. Igniter storage requirements.

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A1.2.4.9.6.3.6. Igniter handling requirements.

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A1.2.4.9.6.3.7. Igniter testing and inspection requirements.

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A1.2.4.9.6.3.8. Igniter packaging requirements (if shipped separately).

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A1.2.4.9.6.3.9. Igniter case description, including design safety factors.

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A1.2.4.9.6.4. Rocket Motor/Segment Data.

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A1.2.4.9.6.4.1. Motor/segment case description, including design safety factors.

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A1.2.4.9.6.4.2. Method of proof testing the rocket motor/segment case before propellant loading.

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A1.2.4.9.6.4.3. Weight of propellant.

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A1.2.4.9.6.4.4. Cross-section drawings showing propellant grain design details, case insulation, including physical

dimensions, and joint details for segmented rocket motors.

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A1.2.4.9.6.4.5. Motor/segment nondestructive testing requirements.

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A1.2.4.9.6.4.6. Motor/segment storage requirements.

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A1.2.4.9.6.4.7. Motor/segment handling requirements.

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A1.2.4.9.6.4.8. Motor/segment grounding requirements.

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A1.2.4.9.6.4.9. Description of structural, mechanical, and electrical subsystems.

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A1.2.4.9.6.4.10. Description of materials and properties of seals and O-rings.

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A1.2.4.9.6.5. Data submission and analysis, as described in Chapter 18. If these data and analysis are submitted as part of

another section of the SDP (MSPSP), shall cross-reference that analysis here.

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A1.2.4.10. Flight Hardware Non-Ionizing Radiation Sources

A1.2.4.10.1. General Data. A detailed description of the non-ionizing radiation sources shall be provided. The description

shall include the information identified in A3.2.4.1.

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A1.2.4.10.2. Flight Hardware RF Emitter Data. The following information shall be submitted for RF emitters:

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A1.2.4.10.2.1. Site Plans. Site plans shall be submitted to Range Safety and the RPO/RSO for all RF generating equipment.

The site plan shall include the following information:

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A1.2.4.10.2.1.1. Location of generating equipment.

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A1.2.4.10.2.1.2. RF hazard areas.

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A1.2.4.10.2.1.3. Description and use of nearby facilities and operating areas.

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A1.2.4.10.2.2. Design and Test Data. At a minimum, the following RF emitter design and test data shall be submitted:

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A1.2.4.10.2.2.1. Emitter peak and average power.

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A1.2.4.10.2.2.2. Pulse widths.

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A1.2.4.10.2.2.3. Pulse repetition frequencies.

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A1.2.4.10.2.2.4. Pulse codes.

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A1.2.4.10.2.2.5. Maximum rated duty cycle.

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A1.2.4.10.2.2.6. Type and size of antenna.

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A1.2.4.10.2.2.7. Antenna gain and illumination.

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A1.2.4.10.2.2.8. Beam width and beam skew.

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A1.2.4.10.2.2.9. Operating frequency in MHz.

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A1.2.4.10.2.2.10. Insertion loss between transmitter and antenna.

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A1.2.4.10.2.2.11. Polarization of transmitted wave hardware.

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A1.2.4.10.2.2.12. An analysis of the RF hazard area with and without antenna hats/dummy load, and results of any testing.

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A1.2.4.10.2.2.13. A table that lists all of the RF emitters aboard a launch vehicle, payload, and ground support systems and

their hazard areas (distances).

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A1.2.4.10.2.2.14. A description of interlocks, inhibits, and other safety features that prevent inadvertent exposures.

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A1.2.4.10.2.2.15. A copy of the RPO/RSO approved Radiation Protection Program RF Use Request Authorization.

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A1.2.4.10.2.2.16. A copy of the PSWG and Range Safety and RPO/RSO (appropriate local safety authority) approved site

plan.

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A1.2.4.10.2.2.17. A list and summary of test plans, test procedures, and test results in accordance with 8.1.3.

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A1.2.4.10.3. Flight Hardware Laser System (Class 1M, 2M, 3B, and 4) Data. At a minimum, the following laser system

data shall be submitted:

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A1.2.4.10.3.1. A general description of the system and its operation including how, where, why, and by whom the laser will

be used; the laser system also includes calibration equipment.

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A1.2.4.10.3.2. Drawings of the system that identify and show the location and operation of all components, interfaces, safety

interlocks, and stops.

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A1.2.4.10.3.3. For lasers that generate or use hazardous or corrosive materials, the data required for hazardous materials as

described in A1.2.4.13.2 of this attachment.

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A1.2.4.10.3.4. For lasers that use cryogenic fluids for cooling or operational enhancement, the data required for cryogenic

systems and hazardous materials as described in A1.2.4.13.2 of this attachment.

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A1.2.4.10.3.5. For laser systems using high voltages and/or high capacitance, the data required for electrical ground support

equipment as described in A1.2.5.10 of this attachment.

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A1.2.4.10.3.6. Laser System Performance Data.

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A1.2.4.10.3.6.1. Type, class, nomenclature, manufacturer model number, general identification, and other pertinent

information.

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A1.2.4.10.3.6.2. General description of the test, pertinent drawing of the operation site, and associated equipment.

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A1.2.4.10.3.6.3. Lasing material.

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A1.2.4.10.3.6.4. Continuous wave (CW) or pulse identification.

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A1.2.4.10.3.6.5. Wavelength.

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A1.2.4.10.3.6.6. Bandwidth.

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A1.2.4.10.3.6.7. Average power and/or energy per pulse and/or maximum output energy.

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A1.2.4.10.3.6.8. Pulse duration and pulse rate.

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A1.2.4.10.3.6.9. Beam width at 1/e point for both axes.

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A1.2.4.10.3.6.10. A sketch of the beam pattern and location and energy density of hot spots and effects of weather and

reflectivity.

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A1.2.4.10.3.6.11. Beam divergence at 1/e point for both axes.

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A1.2.4.10.3.6.12. Emergent beam diameter.

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A1.2.4.10.3.6.13. Coolant.

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A1.2.4.10.3.6.14. Amount of energy reflected back through the eyepiece or pointing device.

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A1.2.4.10.3.6.15. Electrical voltage applied to the system.

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A1.2.4.10.3.6.16. Any other pertinent laser parameter such as distribution of energy on-beam and scan rate as determined by

the payload project or the PSWG and Range Safety.

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A1.2.4.10.3.6.17. Composition, color, and specularly or diffusely reflected surface characteristics of intended targets.

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A1.2.4.10.3.6.18. Maximum incident energy on targets.

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A1.2.4.10.3.6.19. Target characteristics including secondary hazards that may be affected by the laser, including fuels and

other flammables, sensitive electronic components, FTSs (as applicable), and others.

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A1.2.4.10.3.6.20. Intended method (such as binoculars or spotter scope) of viewing the beam and/or its reflections.

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A1.2.4.10.3.6.21. Safety devices such as interlocks, filters, shutters, and aiming devices.

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A1.2.4.10.3.6.22. Azimuth and elevation and/or electrical and mechanical elevation stops.

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A1.2.4.10.3.7. Hazard Evaluation Data. Analysis and supporting data outlining possible laser system failures for all phases

of laser system uses shall be submitted. Such data includes the following:

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A1.2.4.10.3.7.1. All critical failure modes, failure mode effects, and failure probabilities including possible effects on

secondary hazards and the subsequent results.

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A1.2.4.10.3.7.2. Routine occupational hazard exposure that has been experienced in the past with the system or similar

systems along with recommended methods for reducing or eliminating the hazards.

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A1.2.4.10.3.8. Biophysiological Data

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A1.2.4.10.3.8.1. Safe eye and skin distances based on occupational exposure limits.

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A1.2.4.10.3.8.2. Safety clearance and hazard zones.

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A1.2.4.10.3.8.3. Personal protective equipment required for personnel remaining inside clearance zones.

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A1.2.4.10.3.9. A copy of the RPO/RSO approved Radiation Protection Plan Laser Use Request Authorization.

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A1.2.4.10.3.10. A list and summary of test plans, test procedures, and test results in accordance with 8.2.3.

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A1.2.4.11. Flight Hardware Ionizing Radiation Sources

A1.2.4.11.1. General Data. A detailed description of the ionizing radiation sources shall be provided. The description shall

include the information identified in A1.2.4.1.

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A1.2.4.11.2. Flight Hardware Ionizing Radiation Subsystem Data. The following data shall be submitted:

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A1.2.4.11.2.1. The final SAS (Safety Analysis Summary) as required by NPR 8715.26, Nuclear Flight Safety, and AFMAN

91-110, Nuclear Safety Review and Launch Approval for Space or Missile Use of Radioactive Material and Nuclear Systems,

Attachment 3, Launch Forecast Report. The SAS shall be referenced in the SDP (MSPSP) and submitted as an accompanying

document.

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A1.2.4.11.2.1.1. Status reports on the SAS approval.

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A1.2.4.11.2.1.2 Verification of approval for launch by separate correspondence in accordance with the requirements of NPR

8715.3, Chapter 6, AFMAN 91-110 Nuclear Safety Review and Launch Approval for Space or Missile Use of Radioactive

Material and Nuclear Systems, or the equivalent.

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A1.2.4.11.2.2. Manufacturer of the source.

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A1.2.4.11.2.3. Date of source preparation.

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A1.2.4.11.2.4. Source identification number.

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A1.2.4.11.2.5. Cross-sectional sketch showing dimensions of the source.

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A1.2.4.11.2.6. Source container or holder construction material.

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A1.2.4.11.2.7. Physical source form such as powder or plate.

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A1.2.4.11.2.8. Chemical source form such as metal or oxide.

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A1.2.4.11.2.9. Strength in curies.

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A1.2.4.11.2.10. Type of protective cover material over the source.

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A1.2.4.11.2.11. Date and result of last wipe test.

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A1.2.4.11.2.12. Method of sealing against leakage.

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A1.2.4.11.2.13. Radionuclide solubility in sea water.

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A1.2.4.11.2.14. Description, including diagrams, showing exact placement of the source in the vehicle or payload.

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A1.2.4.11.2.15. A brief description of intended use.

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A1.2.4.11.2.16. Radiation levels in millirem per hour for all modes of operation and all radiation container surfaces accessible

to personnel.

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A1.2.4.11.2.17. Description of potential accidents that would cause release of radioactive material including potential

personnel exposure and ground contamination.

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A1.2.4.11.2.18. A summary of the possible consequences of a release of radioactive material at the payload processing facility

and launch site area including the maximum credible release and recommendations for methods to reduce or eliminate the

resulting hazards.

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A1.2.4.11.2.19. Description of recovery plans for land and sea launch abort scenarios.

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A1.2.4.11.2.20. Location and name of responsible organization and licensed individual assigned to supervise handling of this

material.

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A1.2.4.11.2.21. Detailed nuclear system design.

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A1.2.4.11.2.22. Normal and potentially abnormal environments and failure modes that can affect the processing, launch, and

flight of a nuclear system.

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A1.2.4.11.2.23. The predicted responses of the nuclear system to processing, launch, and flight environments and failures.

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A1.2.4.11.2.24. The predicted resulting nuclear risk.

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A1.2.4.11.2.25. Ground support systems design data as required by the appropriate sections of this publication.

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A1.2.4.11.2.26. Detailed ground processing flow.

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A1.2.4.11.2.27. A copy of the RPO/RSO approved Use Authorization or Radiation Protection Plan, as required by local

Radiation Protection Program [i.e., KNPR 1860.1, KSC Ionizing Radiation Protection Program; AFI 40-201, 45TH Space

Wing Supplement Radioactive Material (RAM) Management (ER only)].

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A1.2.4.11.2.28. A copy of the Radiation Protection Plan as required by the (SLD30)30

SW RADSAFCOM (WR only).

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A1.2.4.11.2.29. A list and summary of test plans, test procedures, and test results in accordance with 9.2.2.

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A1.2.4.11.3. Flight Hardware Ionizing Radiation Producing Equipment and Devices. The following data shall be submitted:

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A1.2.4.11.3.1. Manufacturer and model number.

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A1.2.4.11.3.2. A description of the system and its operation.

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A1.2.4.11.3.3. A description of the interlocks, inhibits, and other safety features.

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A1.2.4.11.3.4. If installed on a flight system, a diagram showing the location of the equipment or devices.

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A1.2.4.11.3.5. A description of the radiation levels, in millirems per hour, accessible to personnel for all modes of operation

and all surfaces accessible to personnel; levels with doors and access panels removed shall be included.

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A1.2.4.11.3.6. A copy of the RPO/RSO approved Use Authorization or Radiation Protection Plan, as directed by the PSWG

and required by local Radiation Protection Programs [i.e., KNPR 1860.1, KSC Ionizing Radiation Protection Program; AFI

40-201, 45TH Space Wing Supplement Radioactive Material (RAM) Management , (ER only), etc.], allowing the use of these

radiation sources during ground processing activities.

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A1.2.4.11.3.7. A copy of the Radiation Protection Plan as required by the (SLD30) 30

SW RADSAFCOM (WR only).

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A1.2.4.12. Flight Hardware Acoustical Subsystems

A1.2.4.12.1. General Data. A detailed description of acoustical hazard sources shall be provided. The description shall

include the information identified in A1.2.4.1.

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A1.2.4.12.2. Flight Hardware Acoustics Hazards Data. The following data requirements shall be submitted for acoustic

hazards:

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A1.2.4.12.2.1. The location of all sources generating noise levels that may result in hazardous noise exposure for personnel

and the sound level in decibels on the A scale (dBA) for that noise.

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A1.2.4.12.2.2. The anticipated operating schedules of these noise sources.

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A1.2.4.12.2.3. Methods of protection for personnel who may be exposed to sound pressure levels above 85 dBA (8-hour time

weighted average).

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A1.2.4.12.2.4. A copy of the Bioenvironmental Engineering approval, as applicable, stating the equipment and controls used

are satisfactory.

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A1.2.4.13. Flight Hardware Hazardous Materials Subsystems

A1.2.4.13.1. General Data. A detailed description of the hazardous materials shall be provided. The description shall include

the information identified in A1.2.4.1.

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A1.2.4.13.2. Flight Hardware Hazardous Materials Data. At a minimum, the following hazardous materials data shall be

submitted:

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A1.2.4.13.2.1. A list of all hazardous materials on the flight system and used in ground processing.

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A1.2.4.13.2.2. A description of how each of these materials and liquids is used and in what quantity.

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A1.2.4.13.2.3. A description of flammability and, if applicable, explosive characteristics.

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A1.2.4.13.2.4. A description of toxicity including TLV and other exposure limits, if available.

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A1.2.4.13.2.5. A description of compatibility including a list of all materials that may come in contact with a hazardous liquid

or vapor with test results provided or referenced.

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A1.2.4.13.2.6. A description of electrostatic characteristics with test results provided or referenced, including bleed-off

capability of the as used configuration.

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A1.2.4.13.2.7. A description of personal protective equipment to be used with the hazardous material and liquid.

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A1.2.4.13.2.8. A summary of decontamination, neutralization, and disposal procedures.

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A1.2.4.13.2.9. A Safety Data Sheet (SDS) for each hazardous material and liquid on flight hardware or used in ground

processing; the SDS shall be available for review at each location in which the material is stored or used.

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A1.2.4.13.2.10. Description of any detection equipment, location, and proposed use.

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A1.2.4.13.2.11. Additional Data for Plastic Materials

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A1.2.4.13.2.11.1. Identification of the cleaning methods to be used to maintain surface cleanliness and conductivity, if

applicable.

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A1.2.4.13.2.11.2. Identification of the minimum acceptable voltage accumulation levels for the plastic materials or operations.

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A1.2.4.13.2.11.3. Identification of the method for ensuring conductivity between adjoining pieces of the plastic materials.

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A1.2.4.13.2.11.4. Assessment of the environmental effects on plastic materials such as humidity, ultraviolet light, and

temperature that could cause degradation of conductivity flammability or electrostatic properties.

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A1.2.4.13.2.12. A list and summary of test plans, test procedures, and test results in accordance with Volume 3 section 10.2.

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A1.2.4.14. Computing Systems Data. The payload project shall provide the following information to the PSWG and Range

Safety in the SDP (MSPSP):

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A1.2.4.14.1. System description including hardware, software, and layout of operator console and displays.

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A1.2.4.14.2. Flow charts or diagrams showing hardware data busses, hardware interfaces, software interfaces, data flow, and

power systems.

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A1.2.4.14.3. Logic diagrams, Software Design Descriptions (SDDs).

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A1.2.4.14.4. Operator user manuals and documentation.

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A1.2.4.14.5. List and description of all safety critical computer system functions, including interfaces.

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A1.2.4.14.6. Software hazard analyses.

Note: “Software hazard analysis” is a subsystem hazard analysis of a hazardous or safety-critical system and is synonymous

with the term “software safety analysis” covered in NASA-STD-8739.8 and NASA-GB-8719.13.

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A1.2.4.14.7. Software Test Plans (STPs), Software Test Descriptions (STDs), and Software Test Results (STRs) in accordance

with IEEE/EIA 12207, NPR 7150.2 NASA Software Engineering Requirements and NASA-STD-8739.8, NASA Software

Assurance and Software Safety Standard.

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A1.2.4.14.8. Software Development Plan (SDP) that includes discussions on conformance with applicable coding standards,

configuration control, PLCs, COTS, and software reuse. (for example, see Space and Missile Systems Center (SMC) Standard

SMC-S-012, Software Development)

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A1.2.4.14.9. Documentation describing Independent Validation & Verification (IV&V) process used to ensure safety

requirements have been correctly and completely implemented.

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A1.2.4.14.10. Software Safety Plan identifying software safety activities, data, and documentation created in development of

software in a safety-critical system.

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A1.2.5. Ground Support Systems

A1.2.5.1. At a minimum, the “ground support system” section shall include the following information and the specific data

requirements listed in A1.2.5.6 through A1.2.5.19 below:

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A1.2.5.1.1. Subsystem overview.

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A1.2.5.1.2. Nomenclature of major subsystems.

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A1.2.5.1.3. Function of the subsystem.

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A1.2.5.1.4. Location of the subsystem.

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A1.2.5.1.5. Operation of the subsystem.

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A1.2.5.1.6. Subsystem design parameters.

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A1.2.5.1.7. Subsystem test requirements.

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A1.2.5.1.8. Subsystem operating parameters.

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A1.2.5.1.9. Summaries of any PSWG and Range Safety required hazard analyses conducted.

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A1.2.5.2. Supporting data shall be included or summarized and referenced as appropriate with availability to Range Safety

upon request.

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A1.2.5.3. Tables, matrixes, and sketches are required for systems and component data. (See A1.2.4.7.2 and A1.2.4.7.3 for

suggestions.)

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A1.2.5.4. Required analyses, test plans, and test results may be included in the SDP (MSPSP) as appendixes or submitted

separately. At a minimum, analyses, test plans, and test reports shall be listed, referenced, and summarized in the SDP

(MSPSP).

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A1.2.5.5. A list of all PSWG and Range Safety approved noncompliances.

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Added PSWG

A1.2.5.6. Ground Support Material Handling Equipment. Design and test plan data for the following government payload

processing facility contractor and payload project furnished material handling equipment (MHE) shall be provided.

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A1.2.5.6.1. General Data. A detailed description of MHE shall be provided. The description shall include the information

identified in A1.2.5.1.

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A1.2.5.6.2. Ground Support Slings Used to Handle Critical Hardware. At a minimum, the following data is required:

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A1.2.5.6.2.1. SFP analysis.

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A1.2.5.6.2.2. NDE plan and test results for SFP components.

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A1.2.5.6.2.3. Initial proof load test plan and test results.

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A1.2.5.6.2.4. Stress analysis.

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A1.2.5.6.3. Ground Support Below-the-Hook Lifting Devices. At a minimum, the following documentation is required:

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A1.2.5.6.3.1. SFP analysis.

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A1.2.5.6.3.2. NDE plan and test results for SFP components.

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A1.2.5.6.3.3. Initial proof load test plan and test results.

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A1.2.5.6.3.4. Stress analysis.

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A1.2.5.6.4. Ground Support Handling Structures Used to Handle Critical Hardware. At a minimum, the following

documentation is required:

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A1.2.5.6.4.1. SFP analysis.

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A1.2.5.6.4.2. NDE plan and test results for SFP and non-SFP components and SFP and non-SFP welds.

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A1.2.5.6.4.3. Initial proof load test plan and test results.

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A1.2.5.6.4.4. Stress analysis for structures.

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A1.2.5.6.4.6. O&SHA and FMECA analyses for structural mechanisms like spin tables, rotating structures, and portable

launch support frames.

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A1.2.5.6.5. Support Structures Used to Handle Critical Hardware. At a minimum, the following documentation is required:

Select Status

A1.2.5.6.5.1. SFP analysis.

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A1.2.5.6.5.2. NDE plan and test results for SFP and non-SFP components and SFP and non-SFP welds.

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A1.2.5.6.5.3. Initial proof load test plan and test results.

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A1.2.5.6.5.4. Stress analysis for structures.

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A1.2.5.6.6. Ground Support LPDs and Load Measuring/Indicating Devices Used to Handle Critical Hardware. At a

minimum, the following documentation is required:

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A1.2.5.6.6.1. SFP analysis.

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A1.2.5.6.6.2. NDE plan and test results for SFP components and SFP welds.

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A1.2.5.6.6.3. Initial proof load test plan and test results.

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A1.2.5.6.6.4. Stress analysis.

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A1.2.5.6.7. Ground Support Rigging Hardware Used to Handle Critical Hardware. At a minimum, the following

documentation is required:

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A1.2.5.6.7.1. SFP analysis.

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A1.2.5.6.7.2. NDE plan and test results for SFP components.

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A1.2.5.6.7.3. Initial proof load test plan and test results.

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A1.2.5.6.8. Flight Hardware Used to Lift Critical Hardware. At a minimum, the following documentation is required:

Select Status

A1.2.5.6.8.1. SFP analysis.

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A1.2.5.6.8.2. NDE plan and test results for SFP components and SFP welds.

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A1.2.5.6.8.3. Initial proof test plan and test results.

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A1.2.5.6.8.4. Stress analysis.

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A1.2.5.6.9. MHE Used to Handle Non-Critical Hardware. At a minimum, the initial proof load test plan and results shall be

documented and be made available upon request.

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A1.2.5.8. Removable, Extendible, and Hinged Personnel Work Platforms. At a minimum, the following documentation is

required:

Select Status

A1.2.5.8.1. SFP analysis.

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A1.2.5.8.2. NDE plan and test results for SFP and non-SFP components and SFP and non-SFP welds.

Select Status

A1.2.5.8.3. Initial proof load test plan and test results.

Select Status

A1.2.5.8.4. Stress analysis.

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A1.2.5.9. Ground Support Pressure and Propellant Systems

A1.2.5.9.1. General Data. A detailed description of the pressure and propellant systems shall be provided. The description

shall include the information identified in A3.2.5.1, A3.2.4.7.1.1, A3.2.4.7.1.2, A3.2.4.7.1.3 as well as the in-service operating,

maintenance, and ISI plan.

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A1.2.5.9.2. Ground Support Pressure and Propellant System Data. The system data as identified in A3.2.4.7.2 shall be

submitted in addition to a copy of any DOT approved exemptions for mobile and portable hazardous pressure systems.

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A1.2.5.9.3. Ground Support Pressure and Propellant System Component Design Data. At a minimum, the information

identified in A1.2.4.7.3 shall be submitted for ground support pressure system components.

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A1.2.5.10. Ground Support Electrical and Electronic Subsystems

A1.2.5.10.1. General Data. A detailed description of electrical and electronic subsystems shall be provided. The description

shall include the information identified in A3.2.2.5.1.

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A1.2.5.10.2. EGSE Battery Design Data. At a minimum, the battery design data identified in A3.2.4.8.2 shall be provided

for EGSE batteries.

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A1.2.5.10.3. EGSE Design Data. The following EGSE design data is required:

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A1.2.5.10.3.1. Identification of EGSE and its use.

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A1.2.5.10.3.2. A description of how faults in the EGSE circuitry that can create a hazardous condition are prevented from

propagating into the flight system.

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A1.2.5.10.3.3. A description of how inadvertent commands that can cause a hazardous condition are prevented.

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A1.2.5.10.3.4. Identification of potential shock hazards.

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A1.2.5.10.3.5. A description of how the intent of the NFPA is met with respect to hazardous atmospheres.

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A1.2.5.10.3.6. Identification of all non-explosion proof equipment powered up during and after propellant loading.

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A1.2.5.10.3.7. For explosion proof and intrinsically safe equipment approved by a nationally recognized testing laboratory,

the following information shall be provided:

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A1.2.5.10.3.7.1. Manufacturer.

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A1.2.5.10.3.7.2. Model number.

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A1.2.5.10.3.7.3. Hazardous location class and group.

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A1.2.5.10.3.7.4. Operating temperature.

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A1.2.5.10.3.8. For any explosion proof equipment or components not having a fixed label from a nationally recognized testing

laboratory, the data and certification shall be available for inspection in the facility of use.

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A1.2.5.10.3.9. Test data and certification on custom or modified equipment that cannot be certified by a nationally recognized

testing laboratory for explosion proof equipment.

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A1.2.5.10.3.10. Test results for all payload project designed, built, or modified intrinsically safe apparatus as required by a

nationally recognized testing laboratory in accordance with UL 913.

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A1.2.5.10.3.11. A bent pin analysis for all connectors for safety critical or hazardous systems that have spare pins.

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A1.2.5.11. Ground Support Ordnance Subsystems

A1.2.5.11.1. General Data. A detailed description of ordnance subsystems shall be provided. The description shall include

the information identified in A1.2.5.1.

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A1.2.5.11.2. Ordnance Ground Systems Design Data. The following ordnance ground systems design data is required:

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A1.2.5.11.2.1. A complete description of the ground test equipment that will be used in the checkout of ordnance devices and

systems, including general specifications and schematics for all test equipment.

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A1.2.5.11.2.2. Specifications, schematics, and a complete functional description of the low voltage stray current monitor.

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A1.2.5.11.2.3. Schematics of all ordnance system monitor circuits from the ordnance component pick-off points to the PSC

termination.

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A1.2.5.11.2.4. Calibration data for all monitor circuit terminations that will be provided to the PSC.

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A1.2.5.11.2.5. A complete and detailed description of the airborne and ground ordnance telemetry system and how it

functions, including general specifications and schematics.

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A1.2.5.11.2.6. The following information is required for ordnance continuity and bridgewire resistance measurement devices:

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A1.2.5.11.2.6.1. Maximum safe no-fire energy of the ordnance being tested.

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A1.2.5.11.2.6.2. A declaration of any certification currently in effect for the instrument along with the manufacturer

specifications including:

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A1.2.5.11.2.6.2.1. Range.

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A1.2.5.11.2.6.2.2. Accuracy.

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A1.2.5.11.2.6.2.3. Power supply and recharge capability.

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A1.2.5.11.2.6.2.4. Self-test features.

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A1.2.5.11.2.6.2.5. Schematics.

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A1.2.5.11.2.6.3. Failure analysis including the outcome of the energy analysis (open circuit or maximum terminal voltage)

and current limit analysis (short circuit or maximum output current).

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A1.2.5.11.2.6.4. Instrument description including any modifications required for operational use and details of safety design

features such as interlocks.

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A1.2.5.11.2.6.5. Description of intended operations.

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A1.2.5.11.2.7. The following information is required for monitor circuit outputs:

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A1.2.5.11.2.7.1. Tolerances.

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A1.2.5.11.2.7.2. Maximum and minimum values.

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A1.2.5.11.2.8. For high voltage exploding bridgewires, the nominal gap breakdown voltage tolerance.

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A1.2.5.11.2.9. For laser initiated devices, the following information is required:

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A1.2.5.11.2.9.1. If modified secondary (composition) explosives are used, test requirements and reports.

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A1.2.5.11.2.9.2. Heat dissipation analysis.

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A1.2.5.11.2.10. Ordnance Hazard Classifications and Categories.

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A1.2.5.11.2.10.1. DoD/UN hazard classifications (class, division, and compatibility group) in accordance with DESR

6055.09_AFMAN 91-201, Explosive Safety Standards.

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A1.2.5.11.2.10.2. DOT classification.

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A1.2.5.11.2.10.3. The ordnance device and system hazard category for each ordnance item and system.

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A1.2.5.11.2.10.4. Test results and/or analysis used to classify the ordnance devices and systems.

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A1.2.5.11.2.11. A list and summary of test plans, test procedures, and test results, as required.

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A1.2.5.11.3. Ground Support Ordnance Handling and Storage Data. Specific requirements for handling and storing the

ground support ordnance shall be submitted.

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A1.2.5.12. Ground Support Non-Ionizing Radiation Source Data

A1.2.5.12.1. General Data. A detailed description of non-ionizing subsystems shall be provided. The description shall include

the information identified in A1.2.5.1.

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A1.2.5.12.2. Ground Support RF Emitter Data. The information identified in A1.2.4.10.2 shall be submitted for RF emitters.

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A1.2.5.12.3. Ground Support Laser Systems. At a minimum, the laser system data requirements identified in A1.2.4.10.3

shall be submitted.

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A1.2.5.13. Ground Support Ionizing Radiation Source Data

A1.2.5.13.1. General Data. A detailed description of ionizing subsystems shall be provided. The description shall include

the information identified in A1.2.5.1.

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A1.2.5.13.2. Ionizing Radiation Sources Data. At a minimum, the data identified in A1.2.4.11.3 shall be provided for all

ground radiation producing sources.

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A1.2.5.14. Ground Support Acoustic Hazards

A1.2.5.14.1. General Data. A detailed description of acoustical hazards and subsystems shall be provided. The description

shall include the information identified in A1.2.5.1.

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A1.2.5.14.2. Acoustic Hazards Data. The data identified in A1.2.4.12.2 shall be submitted for acoustic hazards.

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A1.2.5.15. Ground Support Hazardous Materials

A1.2.5.15.1. General Data. A detailed description of hazardous materials and subsystems shall be provided. The description

shall include the information identified in A1.2.5.1.

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A1.2.5.15.2. Ground Support Hazardous Materials Data. The hazardous materials data identified in A1.2.4.13.2 shall be

submitted.

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A1.2.5.17. Motor Vehicle Data. At a minimum, the following data shall be provided for motor vehicles:

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A1.2.5.17.1. General Vehicle Data

A1.2.5.17.1.1. Documentation certifying that vehicles used to transport bulk hazardous material on the range comply with

DOT requirements or are formally exempted by DOT.

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A1.2.5.17.1.2. If DOT certification or exemption documentation is not available, the following information is required:

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A1.2.5.17.1.2.1. Design, test, and inspection requirements.

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A1.2.5.17.1.2.2. Stress analysis.

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A1.2.5.17.1.2.3. SFP analysis.

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A1.2.5.17.1.2.4. FMECA.

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A1.2.5.17.1.2.5. Comparison analysis with similar DOT approved vehicle.

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A13.2.5.17.1.2.6. “Equivalent safety” (meets DOT intent) analysis.

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A1.2.5.17.2. Special-Purpose Trailer Data

A1.2.5.17.2.1. Stress analysis.

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A1.2.5.17.2.2. SFP analysis.

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A1.2.5.17.2.3. Initial proof load test plan and test results.

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A1.2.5.17.2.4. Initial road test plan and test results.

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A1.2.5.17.2.5. NDE plan and test results for SFPs.

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A1.2.5.17.3. Lift Trucks Data

A1.2.5.17.3.1. Certification that the lift truck meets applicable national standards such as ASME B56 Series Safety Standards.

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A1.2.5.17.3.2. For personnel platforms on lift trucks.

Select Status

A1.2.5.17.3.2.1. Stress analysis.

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A1.2.5.17.3.2.2. SFP analysis.

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A1.2.5.17.3.2.3. NDE plan and test results for SFP components and SFP welds.

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A1.2.5.17.3.2.4. Proof load test plan and test results.

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A.2.5.17.3.3. For lift trucks used to lift or move critical loads; maintenance plans shall be submitted for review an1d approval.

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A1.2.5.18. Computing Systems Data. The payload project shall provide the information identified in A1.2.4.14 to the

PSWG in conjunction with Range Safety in the SDP (MSPSP).

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A1.2.5.19. WR Seismic Data Requirements. The GSE data package shall identify the equipment and potential for seismic

hazard and risk and shall include:

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A1.2.5.19.1. GSE designation and applicable drawing numbers.

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A1.2.5.19.2. Whether the equipment is new or existing.

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A1.2.5.19.3. GSE description; for example, weight, materials, structural system.

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A1.2.5.19.4. How the GSE is used and where and how it is stored.

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A1.2.5.19.5. The length of time the GSE is used and stored.

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A1.2.5.19.6. Estimate of potential for seismic hazard (for example, propagation to catastrophic event, personnel injury,

blocking emergency egress routes, or hitting something) due to equipment failure or movement during a seismic event.

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A1.2.5.19.7. Whether the equipment is required to be designed to meet seismic design requirements.

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A1.2.5.19.8. Whether the equipment is required to be anchored.

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A1.2.5.19.9. Design margin of safety under seismic loading (if applicable).

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A1.2.5.19.10. Engineering analysis addressing how the launch vehicle, in typical configurations, will respond to a pre-defined

seismic event.

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A1.2.5.19.11. Risk analysis of items exempt from the seismic design requirements.

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A1.2.5.19.12. Detailed description of the “safe mode” for both safety-critical equipment and equipment whose failure could

result in a catastrophic event or a potential for endangering personnel.

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A1.2.6. Compliance Checklist. A compliance checklist of all design, test, analysis, and data submittal requirements in this

chapter shall be provided. The checklist shall indicate for each requirement if the proposed design is compliant, non-compliant

but meets intent, non-compliant (waiver required) or non-applicable.

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A1.2.6.1. Criteria/requirement.

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A1.2.6.2. System.

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A1.2.6.3. Compliance.

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A1.2.6.4. Noncompliance.

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A1.2.6.5. Not applicable.

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A1.2.6.6. Resolution.

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A1.2.6.7. Reference.

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A1.2.6.8. Copies of all Range Safety approved noncompliances including waivers and equivalent levels of safety

certifications.

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MODIFICATIONS TO THE SAFETY DATA PACKAGE (SDP)

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The change section contains a summary of all changes to the last edition of the SDP (MSPSP). All changes shall be

highlighted using change bars or similar means of identification.

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VOLUME 6 INTRODUCTION

Volume 6 contains NASA and Space Force Range Safety requirements for NASA Payload projects and related personnel and

equipment, systems, and material operations on NASA or NASA contracted facilities and on the Space Force Space Command

(AFSPC) ranges, including the Eastern Range (ER) and Western Range (WR). This volume, as does this publication, applies

to all NASA Payload projects, payload project related operations, payload project related personnel (NASA, contractors, or

persons with other agencies) whether involved directly on the project, a payload instrument, GSE or the facility. Like the rest

of this publication, this requires tailoring to accommodate NASA Payload projects processing and launching from Space Force

ranges. This publication may be tailored for other ranges and launch facilities however local range and safety requirements

must be included and coordinated in the tailoring.

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INTRODUCTION

Applicability

All NASA Payload projects are subject to the requirements of this volume to ensure that operations are conducted safely.

Organization of the Volume

1.2.1. Main Chapters. The main chapters of this volume include common requirements for all payload risk classifications.

Appendixes include additional requirements to supplement the main chapters.

1.2.2. Open Text. The open text contains the actual mandatory performance-based requirements. The only tailoring expected

for these requirements would be the deletion of non-applicable requirements. For example, solid rocket motor performance

requirements would be deleted for launch systems that do not use solid rocket motors.

1.2.3. Bordered Paragraphs

1.2.3.1. Bordered paragraphs are non-mandatory and are used to identify some of the potential detailed technical solutions

that meet the performance requirements. In addition, the bordered paragraphs contain lessons learned from previous

applications of the performance requirement, where a certain design may have been found successful, or have been tried and

failed to meet the requirement. These technical solutions are provided for the following reasons:

1.2.3.1.1. To aid the tailoring process between the PSWG, Range Safety and the payload project in evaluating a potential

system against all the performance requirements.

1.2.3.1.2. To aid the PSWG, Range Safety and the payload project in implementing lessons learned.

1.2.3.1.3. To provide benchmarks that demonstrate what the PSWG and Range Safety considers an acceptable technical

solution/implementation of the performance requirement and to help convey the level of safety the performance requirement

is intended to achieve.

1.2.3.2. The technical solutions in the bordered paragraphs may be adopted into the tailored version of the requirements for a

specific program when the payload project intends to use that solution to meet the performance requirement. At this point,

they become mandatory requirements to obtain the PSWG and Range Safety approval. This process is done to:

1.2.3.2.1. Provide an appropriate level of detail necessary for contractual efforts and to promote efficiency in the design

process.

1.2.3.2.2. Avoid contractual misunderstandings that experience has shown often occur if an appropriate level of detail is not

agreed to. The level of detail in the bordered paragraphs is necessary to avoid costly out-of-scope contractual changes and to

prevent inadvertently overlooking a critical technical requirement.

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1.2.3.3. The payload project always has the option to propose alternatives to the bordered paragraph solutions. Payload project

proposed solutions shall be evaluated against requirements in this standard. Payload project proposed alternative solutions

shall achieve an equivalent level of Safety and be approved by the PSWG and Range Safety. After meeting these two

requirements, the payload project proposed solutions become part of the tailored requirements from this publication for that

specific project.

1.2.3.4. The PSWG and Range Safety determines whether the payload project proposed detailed technical solutions meet the

intent of this document.

Compliance Documents

Occupational Safety and Health Administration (OSHA) (29 CFR), Environmental Protection Agency (EPA) (40 CFR),

Department of Transportation (DOT) (49 CFR), NASA procedural requirements (NPRs) documents including NPR 8715.7,

NASA Standards, Air Force and Space Force manuals, instructions, and directives along with industry standards are specified

as compliance documents throughout this volume. When there is a conflict between federal regulations, industry standards,

local requirements, and other requirements, the more stringent requirement shall be used.

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RESPONSIBILITIES AND AUTHORITIES

Payload Safety Working Group

The PSWG consists of safety engineers and personnel from the NASA payload project (NASA and contractor), NASA Launch

Services SMA as applicable, launch site range safety, the launch services provider contractor organization, the payload

processing facility safety representative, the payload or sample recovery organization (as needed), subject matter experts,

others as needed, and with participation from the Launch Site Integration Manager (LISM) as required. The PSWG is

responsible for ensuring the review and approval of all safety deliverables required by this document. Specific responsibilities

of the PSWG are provided in NPR 8715.7 and include the following:

2.1.1. Review and Approval

2.1.1.2. Ground Operations Plans (GOPs).

2.1.1.6. Other documents as specified in this publication and NPR 8715.7.

2.1.1.7. During the review and approval process, both the PSWG and the payload project shall assure timely coordination

with other authorities as appropriate. Other authorities include, but are not limited to, appropriate Radiation Officer (RPO),

Environmental Health, Institutional Safety, Pad Safety, Occupational Health/Medical, Civil Engineering, and the Fire

Department.

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2.1.2. General

2.1.2.1. Ensuring that hazardous and safety critical facilities are periodically inspected as required.

2.1.2.2. Monitoring hazardous and safety critical operations.

2.1.2.3. Defining the threat envelopes of all hazardous operations that may affect public safety or launch base safety and

establishing safety clearance zones.

2.1.3. Pad Safety. Although the following are not payload project requirements, it is intended that the payload project be

familiar with some of the key responsibilities of the Pad Safety function as they relate to the payload project's safety

requirements. Pad Safety functions are performed by the local launch pad Ground Safety organization, referred to as Pad

Safety.

Note: The payload project should also be familiar with the Payload Processing Facility (PPF) safety requirements, facility features and

facility personnel responsibilities and functions as they relate to the payload project’s operations and safety.

2.1.3.1. General Responsibilities. Pad Safety shall participate in meetings and events as directed by Range Safety, including

the following.

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2.1.3.1.1. All personnel shall observe, evaluate, and enforce compliance of Range Safety requirements within the launch

complexes, assembly and checkout areas, propellant and ordnance storage areas, and other areas as deemed appropriate by

Range Safety.

Note: Pad Safety personnel shall not be denied access to any range area where hazardous operations are conducted.

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2.1.3.1.2. Review and provide comments on hazardous procedures to Range Safety.

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2.1.3.1.3. Review and provide comments on system design data and operating procedures.

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2.1.3.1.4. Implement specified safety precautions and impose safety holds, when necessary, during ground operations, as

required by procedures or OSP.

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2.1.3.1.5. Assist in the resolution of safety problems in areas where Pad Safety has jurisdiction.

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2.1.3.1.6. Attend meetings and conferences that involve safety working groups and facility working groups, technical

interchange meetings, etc., as necessary.

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2.1.3.1.7. Coordinate with the RPO/RSO to ensure enforcement of the Radiation Control Program in all areas where launch

vehicles, payloads, and their related hazards are located.

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2.1.3.1.8. Coordinate with Bioenvironmental Engineering and Environmental Health (both Health Physics and Industrial

Hygiene) on environmental health hazards.

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2.1.3.1.9. Notify Environmental Health, Range Safety, Range Scheduling (SLD 30), and Cape Support (SLD 45), the

installation Fire Department and the Command Post immediately anytime an incident involves an environmental health hazard.

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2.1.3.1.10. When present, Pad Safety shall ensure the evacuation of personnel from launch complexes and facilities and

operations are halted when a lightning hazard is imminent in accordance with the various safety plans.

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2.1.3.1.11. Respond to mishaps and/or incidents in accordance with the SLD Installation Emergency Management Plan

(IEMP).and the AFI 10-2501, Emergency Management Program.

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2.1.3.1.12. Assist payload projects on safety related issues.

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2.1.3.2. Hazardous and Safety Critical Pad Support. Pad Safety shall provide oversight of the payload project when the

hazards of the activity are unique and not covered by OSHA, and when hazardous operations have the potential to endanger

beyond the boundaries of the launch complex, as follows:

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2.1.3.2.1. Ensure compliance with established directives and procedures during hazardous and safety critical operations.

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2.1.3.2.2. Assess procedure deviations and resolve with Range Safety, as necessary.

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2.1.3.2.3. Ensure the number of personnel is kept to a minimum in designated safety clearance zones in accordance with

Range Safety approved procedures.

Note: Pad Safety shall be included in the maximum allowable manning level, unless Range Safety determines that adequate

support can be provided from a remote location.

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2.1.3.2.4. Ensure a comprehensive safety briefing is conducted and understood by participants prior to the start of a hazardous

operation.

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2.1.3.2.5. Control personnel access into safety clearance zones during hazardous operations.

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2.1.3.2.6. Advise the operation control authority on whether or not to stop operations when a hazardous condition or a safety

compromise exists.

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2.1.3.2.7. Allow operations to resume only after the imminent danger no longer exists and safety requirements are met.

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2.1.3.3. Notifications

2.1.3.3.1. Immediately notify the appropriate agency (Command Post at the SLD 30 and Range Safety at SLD 45) of any

launch vehicle or payload mishap, hazard, handling malfunction, or other incident creating or contributing to an unsafe

condition for personnel or critical hardware.

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2.1.3.3.2. Verbally notify Range Safety of any violation of this document as soon as possible. If requested by Range Safety,

a written report shall be provided to Range Safety within five calendar days of the violation.

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2.1.3.4. Flight Termination System (FTS) Installation, Checkout, and Status. Monitor and verify the installation, checkout,

and status of the FTS in accordance with Range Safety instructions at locations designated by Range Safety.

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2.1.3.5. Inspections

2.1.3.5.1. Inspect all explosive areas and facilities at least annually to determine compliance with the requirements of this

document and DESR 6055.09_AFMAN 91-201, Explosives Safety Standards. These duties are performed by Weapons Safety

Office (SEW).

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2.1.3.5.2. Inspect critical facilities prior to the start of a hazardous operation or as directed by Range Safety.

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2.1.3.5.3. Inspect new and modified critical facilities prior to the initial startup operation, prepare inspection reports on these

facilities, and submit the reports to Range Safety within 15 calendar days of the inspection.

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2.1.3.5.4. Audit the execution of procedures for handling ordnance, propellant material, and high pressure gases performed

on CCSFS and VSFB at least quarterly.

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Payload Project Responsibilities

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Payload projects are responsible for the following:

2.2.1. Conduct of Operations

2.2.2.1. Planning and conducting hazardous and safety critical operations in accordance with procedures approved by the

appropriate local safety authority.

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2.2.2.2. Planning and conducting operations in accordance with the current edition of the applicable OSP for the launch

complex, facility, or area in use, including ordnance and propellant operations and areas.

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2.2.2.3. Planning and conducting other operations in accordance with the current edition of other safety plans, as applicable.

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2.2.3. Notification of Hazardous and Safety Critical Operations to Range Agencies

2.2.3.1. Notifying Cape Support (321-853-5211) for the ER and Range Scheduling (805-606-8825) for the WR at least 24

hours before the start of any hazardous system operation while on the Range. The following information shall be provided:

date, time, nature of the operation, location, and procedure or task number.

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2.2.3.2. Notifying Range Safety and Pad Safety of all hazardous and safety critical operations and tests that are planned to

take place at the Range.

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2.2.3.3. Notifying Range Safety and Pad Safety at least 30 calendar days before the scheduled erection of a launch vehicle

and/or payload.

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2.2.4. Document Preparation and Maintenance

2.2.4.1. Developing and implementing a Ground Operations Plan (GOP) in accordance with Attachment 1 of this volume to

cover operations conducted on the payload processing facility and launch site area.

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2.2.4.2. Developing and implementing procedures and general instructions to cover all operations conducted at the payload

processing facility and launch site area.

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2.2.4.3. Developing, obtaining appropriate safety approval as determined by the PSWG and Range Safety, and implementing

procedures related to hazardous and safety critical operations.

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The designation of a procedure as "Hazardous" or "Non-Hazardous" is evaluated on a case-by-case basis and does not

necessarily result in mandatory Pad Safety coverage of the operation. The requirements for hazardous procedures may be found

in Attachment 2 of this volume.

2.2.4.4. Obtaining appropriate safety authority approval of new procedures or revisions to previously approved procedures

when there is an impact to the safe conduct of the procedure.

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2.2.4.5. Developing and implementing a program to control hazardous energy sources by locking and tagging in accordance

with lockout/tagout approved procedures.

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2.2.4.6. Developing, obtaining appropriate safety approval as determined by the PSWG and Range Safety, and implementing

a propellant off-load plan and procedure.

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2.2.4.7. Developing, obtaining the PSWG and Range Safety approval, and implementing an Emergency Response Plan (ERP)

for graphite/epoxy composite overwrapped and Kevlar-wrapped pressure vessels.

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2.2.4.8. Developing, implementing, and maintaining records for an In-Service Inspection (ISI) Plan in accordance with the

requirements of this volume and Volume 3.

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2.2.4.9. Developing, implementing, and maintaining records for a Nondestructive Examination (NDE) Plan in accordance

with the requirements of this volume and Volume 3.

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2.2.4.14. Obtaining appropriate approval for procedures in accordance with KNPR 8715.3, Kennedy NASA Procedural

Requirements; AFI 40-201, 45TH Space Wing Supplement Radioactive Material (RAM) Management, AFMAN 91-110,

Nuclear Safety Review and Launch Approval for Space or Missile Use of Radioactive Material and Nuclear Systems; or other

local safety authorities and respective safety requirements, as required.

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2.2.4.17. Developing and implementing a training plan for all payload project personnel performing hazardous and safety

critical procedures and operations and submitting an outline of this training plan to the PSWG for the PSWG and Range Safety

for approval.

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The local safety authority responsible for review and approval of hazardous procedures should evaluate the training plan for

areas that could lead to a mishap caused by inadequate training and could affect workers of other employers, range assets, and

the general public.

2.2.4.18. Developing pathfinder requirements in coordination with the PSWG and Range Safety.

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2.2.4.19. At the WR, developing, obtaining SLD30/SE Range Safety approval and PSWG concurrence, and implementing a

SLD/SE 30 First Use Tag Program for lifting hardware at the WR.

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2.2.5. Operational Duties

2.2.5.1. Ensuring required support and emergency elements approved by the appropriate local safety authority have continuous

access to any area where hazardous conditions could occur.

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2.2.5.2. Obtaining concurrence to proceed from the appropriate local safety authority before starting any hazardous and safety

critical operations and before resuming any operation that has been interrupted resumes.

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Interruptions include such events as a safety hold, shift change, evacuation, or breaks.

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2.2.5.3. Before initiating hazardous or safety critical operations, the following shall be accomplished:

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2.2.5.3.1. Pre-operation and shift change briefings.

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2.2.5.3.2. Pre-operation and shift change inspections to verify proper system, facility, and area configuration; personnel and

equipment support; and use of an approved procedure.

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2.2.5.5. Observing, evaluating, and enforcing compliance with applicable safety requirements by all personnel within launch

complexes, assembly, and checkout areas, propellant and ordnance storage areas, and other areas as deemed appropriate by

Range Safety or the appropriate local safety authority.

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2.2.5.6. Reviewing and providing comments on hazardous and safety critical procedures to Range Safety or the appropriate

local safety authority.

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GROUND OPERATIONS POLICIES

Personnel Safety

3.1.1. All personnel shall be protected during the performance of operations.

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Stopping Unsafe Operations

3.2.1. All personnel shall have authority to stop immediately operations or practices that, if allowed to continue, could

reasonably be expected to result in death or serious physical harm to personnel or major system damage.

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3.2.2. All personnel are authorized to stop operations or practices when imminent danger cannot be eliminated through regular

channels. Personnel observing an unsafe operation or practice shall report their observations to a safety representative, an

operational supervisor, or any other appropriate authority.

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3.2.3. Notification of Action. Any action taken to stop an unsafe operation where imminent danger is involved shall be

followed by direct verbal, telephone, or radio communication and notification to the appropriate safety authority. For Space

Force Ranges notifications, include Pad Safety at the ER and Range Safety at the WR, the Squadron Commander, the Group

Commander, or their designated representative.

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3.2.4. Notification of Work Stoppage. The Contracting Officer or Administrator for an Space Force Construction Contract

shall be immediately notified of any work stoppage of their respective construction contract.

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DOCUMENTATION REQUIREMENTS

Ground Operations Plans

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GOPs shall be developed in accordance with the requirements in Attachment 1 of this volume and submitted to the PSWG

for PSWG and Range Safety review and approval.

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4.1.1. The GOP provides a detailed description of hazardous and safety critical operations for processing aerospace systems

and their associated ground support equipment (GSE). Along with the Safety Data Package (Missile System Prelaunch Safety

Package (MSPSP)), the GOP is the medium from which payload safety approval is obtained.

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4.1.2. A high level Ground Operations Flow Overview shall be provided at the Payload Safety Introduction Briefing. The

preliminary Draft GOP is due 30 days prior to project’s mission CDR for Safety Review II per NPR 8715.7. The Final GOP

shall be submitted 90 days prior to the payload shipment to the processing site per NPR 8715.7. The information from a GOP

may be part of the respective Safety Data Packages as an inclusion or may be a separate document. The level of detail provided

in the GOP data shall be commensurate with the level of data available at the time of submission.

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4.1.3. The final GOP shall be submitted no later than 60 days prior to the Safety Review III meeting and at least 90 days prior

to intended shipment of hardware to the prelaunch payload processing site per NPR 8715.7.

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4.1.4. The GOP shall be approved before the start of any hazardous operations.

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Test and Inspection Plans

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Test and inspection plans shall be developed to document the initial and recurring validation of component compliance and

assessment of hazards. Test and inspection plans shall be developed for the following items that include, but are not limited

to, material handling equipment, ground support pressure vessels, and ground support propellant systems. Specific

requirements for each of these systems are discussed in this volume.

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4.2.1. Equipment and System Logs and Test Records.

4.2.1.1. Unless otherwise specified in a separate part of this volume that addresses a particular class of system or equipment,

logs and test records shall be maintained on critical ground support systems and major fixed equipment. Logs and test records

shall comply with the following:

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4.2.1.1.1. Logs and test records shall contain chronological entries including:

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4.2.1.1.1.1. Records of use or running time.

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4.2.1.1.1.2. Maintenance.

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4.2.1.1.1.3. Modifications.

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4.2.1.1.1.4. Tests, inspections, acceptable parameters, and results.

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4.2.1.1.2. Discrepancies and out of specification results shall be clearly identified.

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4.2.1.1.3. Resolution of discrepancies and out of specification results shall be noted.

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4.2.1.2. Logs and test records shall be maintained for the life of the system/equipment.

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4.2.1.3. Logs and test records shall be available to the PSWG and Range Safety upon request.

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Safety and Emergency Plans

4.3.1. Operations Safety Plans and Danger Area Information Plans

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4.3.1.1. Payload project shall comply with and implement in their operations, applicable OSPs, and emergency plans.

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4.3.3. Emergency Evacuation Plans

4.3.3.1. EEPs detailing safety and emergency actions shall be developed by facility operators and posted in every building,

facility, and area.

4.3.3.2. EEPs shall include the following information:

4.3.3.2.1. Identification of exit/egress routes.

4.3.3.2.2. Identification of primary and alternate Emergency Evacuation Assembly Points (EEAPs); EEAPs shall be

designated by signs.

4.3.3.2.3. Responsibilities of supervisors and personnel for duties assigned in an emergency.

4.3.3.2.4. Actions to be taken to safe an operation.

4.3.3.2.5. Methods of communication including aural warning systems and public address (PA) announcements.

4.3.3.2.6. Location of fire alarm boxes and other emergency activation devices.

4.3.3.2.7. Required emergency equipment and PPE.

4.3.3.2.8. Required personnel training.

4.3.3.2.9. Reporting requirements such as, but not limited to, Squadron Commander or Command Post.

Procedures

4.4.1. General Requirements for Procedures

4.4.1.1. Procedures and general operating instructions for all operations shall be developed by the payload project and

reviewed by the appropriate local safety authority.

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4.4.1.2. All procedures shall be written in accordance with the requirements provided in Attachment 2 of this volume and

local safety requirements.

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When a procedure references another source (e.g., technical order, another procedure), it should be made available for review

upon request.

4.4.1.3. Brief summaries of all procedures shall be submitted as part of the GOP review and approval process. At that time,

the operating procedure summaries shall be designated as “Hazardous,” “Non-Hazardous,” or “Safety Critical.” These

designations shall be justified in the operating procedure summaries. Local safety authorities may designate additional

processes and operations as “Hazardous” or “Safety Critical.”

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4.4.1.4. Revisions to any procedures shall be submitted to the appropriate local safety authorities for review and approval

when there is a potential impact on the safe conduct of an operation.

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4.4.2. Hazardous and Safety Critical Procedures

4.4.2.1. Procedures for hazardous and safety critical operations shall be developed in accordance with the requirements in

Attachment 2 of this volume. Emergency actions shall be included in the procedures. Hazardous and safety critical procedures

shall be reviewed and approved by the appropriate local safety authority. Approval of hazardous and safety critical procedures

shall not be given until the pertinent data sections of the SDP (MSPSP) and GOP have been reviewed and approved.

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4.4.2.2. Disapproval of a formally submitted procedure may result in an additional 30 calendar day review time submittal and

possible delay of operations. The payload projects are encouraged to provide a draft of a typical procedure for early review by

all appropriate local safety authorities.

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Range User Training Plan

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A training plan listing all training courses used for personnel involved with hazardous or safety critical operations and

procedures shall be submitted to the PSWG in conjunction with Range Safety as part of the GOP.

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Mishap Reporting

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Mishap reporting shall be in accordance with NPR 8621.1, NASA Procedural Requirements for Mishap and Close Call

Reporting, and in accordance with local safety authorities’ procedures.

4.6.1. Mishaps Involving Space Force Personnel and Property. Reporting criteria for mishaps involving Space Force

personnel and property are established in AFI 91-204, Safety Investigations and Reports. Mishaps involving radioactive

materials shall be reported in accordance with AFMAN 91-110, Nuclear Safety Review and Launch Approval for Space or

Missile Use of Radioactive Material and Nuclear Systems.

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4.6.2. Accident Notification Plan. An Accident Notification Process complying with NPR 8621.1 and the Project’s Mishap

Preparedness and Contingency Plan, as well as local requirements, shall be included in the GOP to ensure proper notification

of personnel at the various stages and locations of payload processing. The PSWG Chairperson shall be notified immediately

of any payload project mishap (accident) or close call.

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4.6.3. Support to Investigations. The payload project will provide reasonable support for mishap investigations, including

providing access to all pertinent documents and personnel who may have relevant information.

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Safety for Return-to Earth Payloads or Sample Returns

4.7.1. Payload or Sample Return Recovery Safety Plan

4.7.1.1. The payload project shall prepare and implement a comprehensive Payload or Sample Return Recovery Safety

Plan to ensure safety during return-to-Earth payload or sample recovery.

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4.7.1.2. The Payload or Sample Return Recovery Safety Plan shall:

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4.7.1.2.1. Identify each organizational unit involved in the payload or sample recovery operations.

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4.7.1.2.2. Define in detail the roles, responsibilities, and authorities of each organizational unit, field team, and key

personnel for each task.

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4.7.1.2.3. Describe interfaces and communications between all organizational units and field teams to be used in payload

or sample recovery and transportation for both nominal and off-nominal recovery scenarios.

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4.7.1.3. A Recovery Command System similar to the Incident Command System process used by departments, agencies,

and private sector organizations shall be used in the execution of recovery operations.

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4.7.1.4. The local safety authority's plan for safe recovery operations shall be reviewed for adequacy as applicable.

Modifications for a particular mission or for a set of planned missions will be jointly coordinated and approved before the

scheduled launch date.

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4.7.1.5. Changes to the Recovery Safety Plan subsequent to the "final" edition will be expediently coordinated with the local

safety authorities.

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4.7.2. Recovery Hazard Analysis

4.7.2.1. The payload project shall perform and document an operations hazard analysis identifying and assessing hazards

associated with payload or sample recovery operations, nominal and off-nominal.

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4.7.2.2. Hazards identified shall be documented on the NF 1825 NASA Payload Safety Hazard Report found on the NASA

Payload Safety Program website at https://kscsma.ksc.nasa.gov/PayloadSafety or an equivalent form that contains all

information required on NF 1825.

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4.7.2.3. Hazard controls or elimination activities shall be incorporated into the payload, operations involving payload or

sample recovery, and related support equipment.

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4.7.3. Recovery Hazardous Operations

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4.7.3.1. Hazardous recovery operations shall be performed in accordance with existing institutional and local safety

standards, national consensus standards (e.g., ANSI, NFPA), or special supplemental alternative standards when there are

no known suitable existing standards.

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4.7.3.2. Written procedures approved by the local safety authorities shall be provided in accordance with Attachment 2,

Hazardous and Safety Critical Procedures, of this Volume.

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4.7.4. Payload or Sample Return Recovery Operations Safety Training

4.7.4.1. The payload project shall develop safety training courses for personnel involved with hazardous or safety critical

operations during the payload or sample recovery operations. The training shall cover applicable local requirements,

various roles, responsibilities, and authorities.

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4.7.4.2. Safety training courses shall include information on hazards and preventing injury during payload or sample

recovery operations.

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4.7.5. Mishap Preparedness and Contingency Plan. The payload project is required by NPR 8621.1, NASA Procedural

Requirements for Mishap and Close Call Reporting, Investigating, and Recordkeeping, to ensure the project’s Mishap

Preparedness and Contingency Plan includes payload return or sample return contingencies.

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4.7.6. Safety Data Submittal, Schedule, Review, and Approval

4.7.6.1. Payload or Sample Recovery Safety Plan.

4.7.6.1.1. A draft Payload or Sample Recovery Safety Plan shall be submitted to appropriate local safety authorities and

the NASA project safety management for review prior to the project’s Preliminary Design Review (PDR).

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4.7.6.1.2. A baselined Payload or Sample Recovery Safety Plan shall be submitted to appropriate local safety authorities

and the NASA project safety management for review and approval prior to the project’s Critical Design Review (CDR).

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4.7.6.1.3. The Payload or Sample Recovery Safety Plan is a living document and shall be updated as design or operational

changes impact recovery operations.

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4.7.6.1.4. The final Payload or Sample Recovery Safety Plan shall be submitted for review and approval to the appropriate

local safety authorities and the NASA project safety management at least 180 days prior to payload or sample recovery.

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4.7.6.2. Recovery Hazard Reports

4.7.6.2.1. Preliminary Hazard Reports shall be submitted for review and approval to the appropriate local safety authorities

and the NASA project safety management prior to the project’s PDR.

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4.7.6.2.2. Updated Hazard Reports shall be submitted for review and approval to the local safety authorities and the NASA

project safety management prior to the project’s CDR.

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4.7.6.2.3. Updated Hazard Reports shall be submitted to the appropriate local safety authorities and the NASA project

safety management for review and approval prior to the project’s Operational Readiness Review (ORR).

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4.7.6.2.4. Final Hazard Reports shall be submitted for review and approval to the local safety authorities and the NASA

project safety management at least 180 days prior to payload or sample recovery.

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4.7.6.3. Hazardous Operations

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4.7.6.3.1. Documented procedures for all hazardous operations shall be provided to the appropriate local safety authorities

and NASA project safety management for review and approval at least 180 days prior to payload or sample recovery.

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4.7.6.3.2. Finalized documented procedures for hazardous operations shall be made available to the local safety authorities,

the Recovery System Incident Commander, and all those performing and managing hazardous operations during payload

or sample recovery at least 60 days prior to payload or sample recovery.

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GROUND OPERATIONS SAFETY REQUIREMENTS

Ground Operations Personnel Requirements

5.1.1. Personnel Training, Certification and Experience. A list of personnel training, certification, and experience

requirements shall be available as part of the payload project’s training plan.

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5.1.2. Ground Operations Safety Orientation and Training

5.1.2.1. All payload projects shall ensure that their personnel receive formal safety, fire prevention, medical surveillance, and

occupational health orientation and training before receiving a controlled area badge. The employer is responsible to ensure

the training is adequate and complete.

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5.1.2.2. Unique personnel training and certification requirements for hazardous operations such as ordnance, crane operations,

forklift operations, PPE, and SCAPE shall be specified in the appropriate procedures.

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5.1.3. Personnel Conduct

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5.1.3.1. Food, Beverage, and Cigarette Consumption. The payload project shall ensure that eating, drinking, or smoking,

including the use of e-cigarettes, is authorized only in designated areas.

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5.1.3.2. Alcoholic Beverages and Narcotics

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5.1.3.2.1. The payload project shall ensure that the use of alcoholic beverages and narcotics while on duty is prohibited.

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5.1.3.2.2. The payload project shall require that their personnel taking prescription or non-prescription medications that could

affect performance notify their supervisor.

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5.1.3.3. Mischief. The payload project shall ensure that their personnel are prevented from indulgence in practical jokes,

horseplay, scuffling, and wrestling.

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5.1.4. Work Time Restrictions

5.1.4.1. The payload project supervisors at all levels shall ensure their personnel will not be assigned to, and will not participate

in, critical operations if it is evident that their physiological or psychological wellbeing is, or is likely to be, adversely affected

by immunizations, fatigue, blood donations, use of drugs, illness, consumption of alcohol, or other stress conditions. For

payload operations on NASA or NASA contracted facilities, the payload project or contractor shall adhere to the requirements

in NPR 1800.1, paragraph 2.14, and their Center’s or organizations maximum work time policies and requirements but in no

case shall an employee work in excess of 16 consecutive hours. For payload and launch operations on Space Force property

the following shall apply:

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5.1.4.2. Each duty period for mission ready (Category A) and mission support (Category B) personnel, including participation

in a launch or launch attempt activity, shall be preceded by an available rest period.

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5.1.4.3. Planned duty for personnel in either mission ready or mission support should normally be 8 hours, starting when the

individual reports for duty. Those personnel identified to support operational tests shall not be scheduled for duty during the

planned rest period.

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5.1.4.4. Hazardous Operations and Prelaunch Attempts. The following criteria shall be used for determining hours worked

versus rest time for all personnel who work with hazardous systems, materials, or components, or who accomplish prelaunch

functions that require a high degree of concentration:

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5.1.4.4.1. Maximum 12-hour shift, unless approved by Range Safety or a USAF Squadron Commander, with at least 8 hours

of rest after 12 hours of work.

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5.1.4.4.2. A maximum of 60 hours per week.

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5.1.4.4.3. A maximum of 14 consecutive days.

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5.1.4.5. Consecutive Launch Attempts

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5.1.4.5.1. When 12-hour shifts are required and launches are rescheduled on a 24-hour basis, consideration shall be given for

a 48-hour launch delay after 3 consecutive back-to-back launch attempts.

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5.1.4.5.2. In the event mission impacts or operational requirements necessitate 12-hour shifts, mission ready personnel shall

not be scheduled for more than 5 consecutive shifts without a 48-hour break and mission support personnel shall not be

scheduled for more than 6 consecutive shifts without a 24-hour break.

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5.1.4.6. SLD 30 Additional Work Restrictions

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5.1.4.6.1. In the event of a missile accident, emergency, or operational necessity, the duty time limits defined in this volume

may be exceeded with the expressed knowledge of the SLD 30 Commander or Vice Commander, commanders of tenant

organizations, or the SLD 30 Chief of Safety for personnel under their respective control.

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5.1.4.6.2. When mission requirements dictate, the duty period may be extended to 12 hours by the first level supervisor. Rest

periods and break periods shall be provided according to appropriate regulations and negotiated agreements.

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5.1.4.6.3. If, after a complete evaluation of the potential hazards involved, mission requirements dictate a duty period in excess

of 12 hours, the following criteria shall apply:

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5.1.4.6.3.1. For mission ready (Category A) personnel, the duty periods may be increased to 14 hours or rest periods may be

waived with the express knowledge of the SLD 30 Commander or Vice Commander, WR Commander, Operations Groups

Commander, or the Chief of Safety.

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5.1.4.6.3.2. For mission support (Category B) personnel, the duty period may be increased to 14 hours with the expressed

knowledge of the applicable division chief or equivalent level supervisor.

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Hazardous Ground Operations General Requirements

5.2.1. Pathfinder Requirements

5.2.1.1. The PSWG, Range Safety and payload project shall determine which procedures require a pathfinder and its necessary

fidelity.

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5.2.1.2. Before the first use of applicable hazardous procedures, including contingency, such as operations with live ordnance,

pressure systems, or propellant, pathfinder operations shall be conducted at the payload processing facility and launch site area

in a nonhazardous fashion by using inert or dummy ordnance, non-pressurized systems, or non-fueled systems.

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5.2.1.2.1. Handling operations shall be performed with inert or dummy equipment that simulates the flight unit in form, fit,

function, weight, and center of gravity.

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5.2.1.2.2. Pressure and propellant system operations shall be performed with equipment that simulates flight equipment valve

connections and operations.

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5.2.1.2.3. Pathfinder operations shall use GSE that will be used for flight operations.

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5.2.1.2.4. The project shall work with the local safety authority (who is responsible for the safety operations in the area) to

develop acceptance criteria for pathfinder operations and evaluate whether the acceptance criteria have been met.

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5.2.2. Control of Access to Hazardous Operations. A control area shall be established for each hazardous operation in

accordance with local safety requirements for the hazard(s). Man-loading shall be determined and implemented for each

hazardous control area. The appropriate safety authority as identified by the PSWG and Range Safety shall establish personnel

limits, entry control, and control areas for all hazardous operations.

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5.2.2.1. Personnel Limits for Hazardous Ground Operations

5.2.2.1.1. Personnel limits shall be established for all hazardous operations and tasks. Deviation from approved access list

numbers requires approval from the local safety authority.

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5.2.2.1.2. The supervisor in charge of the building or operation is responsible for maintaining personnel load limits for that

building or operation.

5.2.2.2. Control of Access to All Hazardous Operations

5.2.2.2.1. Hazardous areas shall be fenced, barricaded, or cordoned off and personnel access control maintained at a central

control point.

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5.2.2.2.2. Access roads shall be closed by barricades, guards, or signs during hazardous operations for positive control of

personnel and vehicles. Emergency vehicles shall not traverse the controlled area if another route is available.

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5.2.2.2.3. When hazardous operations are covered by Pad Safety, Pad Safety shall control access. When hazardous operations

are not covered by Pad Safety, the operation test conductor shall control access.

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5.2.2.3. Personnel Restrictions for Hazardous Ground Operations

5.2.2.3.1. Non-essential personnel shall leave hazardous areas (safety clearance zones) before the start of operations.

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5.2.2.3.2. Whenever a warning light status is changed or an audible signal is sounded, a PA announcement shall precede it

and identify the reason for the change.

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5.2.2.3.3. Each facility and/or area shall have instruction signs informing personnel of the area aural and warning light scheme

before entry.

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5.2.2.3.4. The buddy system shall be used in all hazardous operations.

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5.2.2.3.5. Area Warning Lights. Personnel with the appropriate badge and security clearance have access to areas in

accordance with the following:

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5.2.2.3.5.1. A flashing green light indicates the controlled area is open to normal work. Hazardous commodities may be

present in the area, but no hazardous operations are in progress. Access is controlled by Security/Hazardous Support

Operations (HOS).

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5.2.2.3.5.2. A flashing amber light indicates a hazardous operation is in progress in the controlled area. Non-essential

personnel shall be cleared from the controlled area. Personnel shall not enter without permission from Pad Safety or, in the

absence of Pad Safety, the entry control authority.

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5.2.2.3.5.3. A flashing red light indicates an emergency situation in the controlled area. All personnel shall evacuate the

controlled area to the EEAP. This signal shall be accompanied by the sounding of an audible alarm and a PA announcement.

This signal is also used to clear all personnel from a launch complex before a launch or for a hazardous operation that requires

clearing the complex, such as wet dress rehearsal or static fire. At the WR, a flashing red light also designates a dangerous

operation for ballistic missile operations [e.g., follow-on test and evaluation (FOT&E) where work is performed under the

strict control of technical orders (TOs)].

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5.2.3. Hot Work Operations

5.2.3.1. Hot Work Operating Standards. Hot work (open flame) operations including welding, soldering, cutting, brazing,

grinding, or heating of materials in such a manner as to cause a source of ignition shall be conducted in accordance with 29

CFR 1910.252, (Subpart Q, Welding, Cutting and Brazing), General Requirements, and American National Standards Institute

(ANSI) Z49.1, Safety in Welding, Cutting, and Allied Processes as well as local safety requirements. AFMAN 91-203

(Chapter 27, Welding, Cutting, and Brazing) applies for hot work operations on USAF properties.

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5.2.3.2. Hot Work Operations Training and Certification. All welders shall be trained and certified by competent authority to

standards no less than those established by the American Welding Society (AWS).

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5.2.3.3. Hot Work General Operating Requirements

5.2.3.3.1. A written permit shall be obtained from the Fire Marshall before performing hot work.

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5.2.3.3.2. Locations where hot work will be routinely performed may operate on an indefinite permit if that area is subject to

periodic Fire Department inspections.

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5.2.3.3.3. A fire watch shall be maintained during and after the hot work until such time the fire watch determines that the

combustion hazard no longer exists.

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5.2.3.3.4. The requirement for the Fire Department to perform the fire watch shall be determined on a case-by-case basis by

the Fire Marshall and the appropriate local safety authority.

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5.2.3.3.5. Proper housekeeping and protective shields and barriers shall be used to prevent inadvertent combustion.

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5.2.3.3.6. Combustibles shall be kept at least 35 feet away from the operation.

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5.2.3.3.7. A suitable fire extinguisher shall be available.

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5.2.3.4. Hot Work Within Ordnance or Propellant Areas. Hot work within ordnance or propellant areas shall be

coordinated with the local safety authority as well as the range Fire Department.

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Normally, fire watches are conducted by the Range User; however, there may be instances when, after consultation

with Range Safety on any unique hazards or operating environment considerations (such as a nearby fueled

spacecraft, ordnance, hypergolic propellants), the Fire Marshall determines a Fire Department engine crew on-site

is warranted.

5.2.3.3.5. Proper housekeeping and protective shields and barriers shall be used to prevent inadvertent combustion.

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5.2.3.3.6. Combustibles shall be kept at least 35 feet away from the operation.

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5.2.3.3.7. A suitable fire extinguisher shall be available.

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5.2.3.5. Hot Work on Containers and Lines That May Have Contained Explosives or Flammables. Hot work shall not

be performed on containers and lines that may have contained explosives or flammables and that have not been properly

cleaned and purged.

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5.2.4. Control of Hazardous Energy Sources

5.2.4.1. Hazardous energy sources shall be controlled through a lockout/tagout program that complies with the requirements

of 29 CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout), AFMAN 91-203 (Chapter 21, Hazardous Energy

Control), and ANSI Z244.1, Control of Hazardous Energy Lockout/Tagout and Alternative Methods, as well as local safety

requirements.

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5.2.4.2. Lockout/tagout procedures shall be developed by the payload project and approved by the appropriate local safety

authority.

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5.2.5. Confined Space, Tank Entry, and Tank Cleaning

5.2.5.1. Personnel who enter and work within permit-required confined spaces shall comply with appropriate controls as

defined in 29 CFR 1910.146, Permit-Required Confined Spaces; ANSI Z117.1, Safety Requirements for Entering Confined

Spaces, AFMAN 91-203 (Chapter 23, Confined Spaces), and local safety requirements.

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5.2.5.2. The payload projects, contractors, and subcontractors who will be entering confined spaces other than the contractor’s

equipment and flight hardware shall contact the appropriate local safety authority at the start of the project to obtain information

about the confined space.

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5.2.6. Tethering of Equipment

5.2.6.1. Hand-held tools, equipment, and personal belongings shall be tethered in any area where dropped objects could pose

a hazard to personnel.

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5.2.6.2. Falling Object Hazards to be considered in determining tethering requirements include direct contact with personnel

or the consequences of damaging critical hardware providing the potential of latent or immediate hazards to personnel from

damaged hardware.

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Personal Protective Equipment

5.3.1. Payload Project Responsibilities. The payload project shall provide the applicable PPE required for the work location

that meets the requirements established by 29 CFR 1910.132, (Subpart I-Personal Protective Equipment), General

Requirements; 29 CFR 1910.133, Eye and Face Protection; 29 CFR 1910.134, Respiratory Protection; 29 CFR 1910.135,

Head Protection; 29 CFR 1910.136, Foot Protection; California Occupational Safety and Health (CAL-OSHA) (WR only);

ANSI; and National Institute of Occupational Safety and Health (NIOSH). The PPE selected shall have been approved for

the planned usage by the appropriate local safety authorities, occupational health authorities, and other applicable approving

authorities as identified by the PSWG and Range Safety.

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5.3.2. PPE Compatibility. All PPE shall be compatible with the hazardous materials involved and shall be subject to approval

by the safety and occupational health authorities and other applicable approving authorities as identified by the PSWG and

Range Safety.

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5.3.2.1. Protective gear including coveralls shall be compatible with propellants involved and shall be fire resistant and non-

static producing as well.

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5.3.3. Clothing Requirements in Payload Processing Facility and Launch Site Areas

5.3.3.1. Complete upper and lower body attire shall be worn in industrial and missile operating areas. Lower arms, hands,

and head do not have to be covered unless otherwise stated.

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5.3.3.2. Open-toed and high-heeled shoes are prohibited.

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5.3.3.3. Canvas shoes are not permitted where liquid propellants or cryogenics are handled.

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5.3.3.4. Dresses and shorts shall not be worn on towers.

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5.3.3.5. The appropriate attire for hazardous and safety critical operations shall be identified in the operating procedure.

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5.3.3.6. Coveralls or other work clothes designated to be worn in toxic propellant areas shall not be worn in eating areas or

other facilities off site.

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5.3.3.7. Expended work clothes shall be clearly segregated from work clothes ready for use.

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5.3.3.8. Work clothes exposed to an oxygen-rich atmosphere shall be thoroughly aired before smoking is allowed.

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5.3.4. The operating procedure shall include a check for PPE training.

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Fall Protection

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The payload project shall observe and implement fall protection requirements in accordance with 29 CFR 1910.28 and NPR

8715.1, NASA Safety and Health Programs. Specific criteria for the equipment listed above can be found in ANSI Z359.1,

Personnel Fall Arrest Systems, Subsystems, and Components; (such as guard rails, lanyard anchorages, lanyards, snap hooks,

ladders, inspections) and 29 CFR 1910 Sub Part D.

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Fall Hazards: All open-sided floors or fall hazards 4 feet above the next lower level or any height where falls into hazards such as moving

machinery, impaling, or drowning hazards exist should be guarded by standard guard rails with mid-rails and toe boards.

Fall protective PPE should be used when installing guardrails, safety nets, and other fall protection.

Hazard Guards: If standard guard rails are not installed, PPE, in the order of preference listed below, should be used to protect personnel if

they are within 6 feet of the hazard:

(1) Full body harness (ANSI Class III).

(2) Chest harness (ANSI Class II).

(3) Safety nets (29 CFR 1926.105).

PPE Lanyards: PPE should be attached to anchorages by a lanyard that limits the length of a fall to no more than 6 feet. The order of

preference is as follows:

(1) Self-retracting lanyard (inertia reel).

(2) Shock absorbing lanyard.

(3) Nylon rope lanyard.

(4) Wire rope lanyard (for welders).

Lanyard Anchorages:

(1) Handrails should not be used for anchorages or lanyard tie-off points.

(2) Life-line (dog-run) style anchorages for lanyards require appropriate justification with analysis to be submitted and specific approval by

the PSWG, Range Safety or local safety authority for each application. Dog-runs are not an acceptable alternative to installed platforms

or walkways.

Installation of Permanent Anchorage Connectors:

(1) Visual inspection of installed permanently fixed anchorage connections and dog-runs should be accomplished annually by the payload

project. Documentation should be available for review by the PSWG and Range Safety.

(2) Suspect connections or anchorages should receive NDE as determined by the PSWG, Range Safety or local safety authority and should

be repaired or replaced as required.

Fall Protection Snap Hooks. Fall protection snap hooks used in fall protection systems should be sized to ensure proper connection.

Fall Protection Equipment Inspections:

(1) Each article of PPE should be visually inspected by the user before use.

(2) All PPE should be thoroughly inspected at least twice a year by a qualified person of the organization that owns the PPE.

Inspection Tags: Each piece of PPE should have a visible tag or other indication of inspection permanently attached with the following

information:

(1) The date inspected.

(2) The next inspection due date.

(3) The stamp or signature of the quality inspector.

Ladder Fall Protection:

(1) Ladder fall protection should be installed on all fixed ladders with a fall hazard of 20 feet or more.

Ladder safety devices with a full body harnesses shall be the preferred method of fall protection.

Smoking Areas

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5.5.1. The payload project shall observe and use applicable industry standards for smoking areas. No smoking signs shall be

posted as directed by the local safety authority or Fire Department.

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Selection of designated smoking areas, their ash receptacles, and ventilation systems is subject to the review and approval of the

Fire Department. No smoking and smoking areas in the complex should be clearly designated by lines painted on the concrete

or asphalt surfaces and appropriately marked by signs.

5.5.2. Designated Non-Smoking Areas. Smoking, matches, open flames, e-cigarettes and spark-producing devices shall be

prohibited at all times within the following areas:

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5.5.2.1. Within 100 feet of any propellant storage tank.

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5.5.2.2. On gantries or service towers.

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5.5.2.3. Within 100 feet of the test stand while propellants are being transferred or during the time propellants are aboard the

launch vehicle and/or payload.

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5.5.2.4. Within 50Ft of the launch vehicle and/or payload during and after ordnance installation.

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5.5.2.5. In missile impact areas where radioactive contamination, ordnance, or fuels are present.

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5.5.2.6. In any area displaying NO SMOKING signs.

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5.5.2.7. In all propellant operating and storage areas except in specifically designated smoking areas.

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Operating Restrictions Due to Adverse Weather

5.6.1. General. Local adverse weather requirements for NASA, NASA contractors, Space Force Range Safety, and other

facilities where payload project operations take place shall be adhered to and specified in the OSP. The payload project shall

comply with OSP. Adverse weather conditions include but are not limited to lightning and thunderstorms, hurricanes, and

high wind conditions.

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5.6.2. ER Lightning Hazard Watches and Hazard Warnings

5.6.2.1. Operations that will be allowed during lightning watches and warnings shall be coordinated, reviewed, and approved

by SLD 45/SEA and documented in the specific OSP.

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5.6.2.2. Phase I Lightning Watch. For the five nautical miles lightning watch (Forecast for lightning within five nautical miles

of centroid of a specific lightning alert area, [Space Launch Complex (SLC) and/or facility], expected within some time,

usually 30 minutes), the following actions shall be taken:

5.6.2.2.1. SCAPE operations, propellant tanking and de-tanking, hoisting hazardous materials or 1.1 to 1.4 class ordnance,

and other hazardous operations that take 30 minutes or longer to secure shall not be started.

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5.6.2.2.2. If an operation is in progress, personnel shall begin safing the system so as to have the area secured and evacuated,

if required, before the forecasted five nautical miles lightning warning start time.

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5.6.2.3. Phase II Lightning Warning. For the lightning warning, lightning is imminent or occurring within the five nautical

mile boundary of a centroid of a specific lightning alert area (SLC and/or facility), the following actions shall be taken:

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5.6.2.3.1. All operations shall cease unless they are performed remotely and have been approved by either Range Safety or

are authorized in the specific OSP.

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5.6.2.3.2. If the Phase I lightning watch has not been previously announced or the five nautical mile lightning warning start

time is earlier than forecast, the operation shall be terminated at the safest step and the area secured and evacuated in accordance

with the specific OSP.

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5.6.2.4. Due to the differences between launch vehicle configurations and SLCs, evacuation requirements shall be specified

in each specific OSP. In general, the complex shall be cleared before the 5 nautical mile lightning warning start time whenever

a launch vehicle with payload, propellants, solid rocket motors, or Class 1.1 to 1.4 ordnance is present or EEDs are electrically

connected.

5.6.2.5. Additional information regarding lightning hazard watches and warnings may be found in the 45 SWI 15-101,

Weather Support instruction.

5.6.3. WR Lightning/Thunderstorm Watches and Warnings. The 30th Force Support Squadron (FSS) issues two

messages related to lightning/thunderstorms: A watch and a warning.

5.6.3.1. A Lightning/Thunderstorm Watch is a forecast issued when the potential for lightning/thunderstorms is expected to

occur within ten nautical miles of any location on VSFB. The desired lead time for this watch is two hours. The watch is

forecast for a period of time (valid time) that lightning/ thunderstorms are expected to be within ten nautical miles.

5.6.3.2. A Lightning/Thunderstorm Warning is issued when lightning is observed within 10 nautical miles of VSFB.

5.6.3.3. Meteorological and weather warning notification procedures are provided in 30SWI 15-101, Weather Support

instruction.

5.6.3.4. Upon issuance of the Lightning/Thunderstorm Watch, all operations involving propellant or ordnance activities shall

be completed before the start of the Lightning/Thunderstorm Watch “valid time.” All propellant or ordnance activities not

completed before the watch “valid time,” may continue if the facility has a certified lightning protection system and the

organization’s commander grants approval to continue. All other non-propellant or non-ordnance activities may continue in

the facility during the Lightning/Thunderstorm Watch.

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5.6.3.5. Upon issuance of the Lightning/Thunderstorm Warning, a space launch complex, explosive/missile processing

facility, launch facility, storage facility, or any other hazardous operating location that has a certified lightning protection

system does not require evacuation; and all non-propellant or non-ordnance activities may continue in the facility during the

Lightning/Thunderstorm Warning.

Exception: If either of the following conditions apply, all personnel shall evacuate to at least the public transportation route (PTR)

distance regardless of the lightning protection system: Condition 1: There is exposed solid propellant. Condition 2: There is an explosive

initiation device that cannot be placed in a safe configuration.

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The intent of 5.6.3.4 and 5.6.3.5 is to allow all non-ordnance and non-propellant activities to continue in facilities with certified

lightning protection systems during a Lightning/ Thunderstorm Watch or Warning. A ”certified” lightning protection system is

inspected and maintained in accordance with the National Fire Protection Association Standard 780. These are the minimum

lightning protection requirements imposed by SLD 30 Safety, Payload projects may be more conservative at their own discretion.

5.6.3.6. Upon issuance of the Lightning/Thunderstorm Warning, any operation involving propellant or ordnance activities in

a space launch complex, explosive/missile processing facility, launch facility, storage facility, or any other hazardous operating

location that does not have a certified lightning protection system shall evacuate to at least the PTR distance.

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5.6.3.7. If a Lightning/Thunderstorm Watch or Warning has not been previously issued or the Lightning/Thunderstorm Watch

or Warning “valid time” is earlier than forecast, the propellant or ordnance activities shall be terminated at the safest point and

the area secured.

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5.6.3.8. Lightning/Thunderstorm Watch and Warning notifications and payload project action requirements for propellant or

ordnance activities apply to both day-to-day and day-of-launch operations.

5.6.3.9. Range Users working an approved operation involving propellant or ordnance activities during a Lightning/

Thunderstorm Watch can call 30 WS (x6-8022) to get an update of the status of the watch. To ensure the consistent and

accurate relay of information, payload projects should designate a single point of contact to make these calls, preferably the

individual in charge of the operation.

Examples of approved activities are installation of electrical cables, mechanical components, flight hardware, stud standoff, and

wing installation. Examples of unapproved activities are handling of rocket motors or launch vehicles by lifting, mating, or roll

transfer; fuel transfer and pressurization; and ordnance installation and connection.

Operating Restrictions Due to High Winds

5.7.1. For Winds of 18-29 Knots as Measured on or Closest to Specific Facilities. No work shall be performed on the

exterior surface of umbilical or mobile service towers or other tall structures unless spider staging, or similar suspended work

devices are safely secured to the structure.

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5.7.2. For Winds of 30 Knots or More as Measured on or Closest to Specific Facilities

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5.7.2.1. No work shall be performed on the exterior surfaces of umbilical or mobile service towers or other tall structures

except for emergency tasks.

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5.7.2.2. Work performed during emergency conditions shall be approved by Pad Safety or Range Safety and all suspended

work devices shall be secured to the structure.

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Facility Use

5.8.1. Facility Use General Requirements

5.8.1.1. Facilities shall be used within the limits of their design. If facilities are leased from the USAF, the payload project

shall coordinate with Range Safety and Civil Engineering for proper use within the limits of their design.

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5.8.1.2. Only those operations that are consistent with facility design, materials, equipment, and personnel shall be performed

in the facility.

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5.8.2. Hazardous Facility Use General Requirements

5.8.2.1. The use of facilities for hazardous storage or processing operations shall be approved by the appropriate local safety

authority.

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5.8.2.2. The OSP shall be developed by the facility operator in coordination with the appropriate safety authorities. Payload

projects will review and be familiar with the OSP as needed.

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5.8.2.3. Facilities used for hazardous activities shall have an FEOP and an Evacuation Plan developed by facility operators.

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5.8.2.4. Simultaneous hazardous operations within the same control area are prohibited.

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5.8.2.5. Non-hazardous operations within the same control area as an ongoing hazardous operation are prohibited unless a

safe distance approved by the appropriate safety authority can be maintained.

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5.8.3. Hazardous Facility Inspection

5.8.3.1. Facility Inspections

Note: These requirements are for the facility personnel and owners that potentially impact and involve the payload project.

5.8.3.1.1. Facilities shall be inspected before first use, upon modification, before operations, and at least annually, as

determined by the payload project and local safety authorities.

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5.8.3.1.2. Inspection reports shall be maintained in accordance with local safety requirements (NPR 8715.1 NASA Safety and

Health Programs for NASA facilities or for Space Force facilities in accordance with DESR 6055.09_AFMAN 91-201,

Explosive Safety Standards, and AFI 91-202.

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5.8.3.1.3. Actions shall be taken to correct discrepancies identified during inspections. Records of discrepancies and

discrepancy corrections shall be maintained for three years.

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5.8.3.1.4. A verbal report shall be made to the appropriate local authority within the same day of the inspection if discrepancies

are found that may delay a planned operation or endanger personnel or material handling equipment (MHE) used to handle

critical hardware, or the critical hardware itself.

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5.8.3.1.5. Written reports describing actions taken to correct discrepancies identified during inspections shall be submitted to

the local safety authority within 15 calendar days or less if deemed necessary by either group.

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5.8.3.2. Operations Safety Facility, Complex, and Area Inspections

5.8.3.2.1. A systematic visual examination of facilities, related GSE, and any work in progress that could cause accidental

damage to property or injury to people or affect the launch schedule shall be performed by the appropriate safety authority.

This inspection deals primarily with aerospace ground equipment (AGE), launch critical associated equipment, maintenance,

associated hardware, fire hazards, fall protection, and equipment on the complex.

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5.8.3.2.2. A safety inspection shall be performed on launch complexes, explosives storage and processing facilities and areas,

and in hazardous processing and checkout facilities according to the following schedule:

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5.8.3.2.2.1. At least two weeks before a launch vehicle or payload being brought to the pad or facility.

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5.8.3.2.2.2. Within 48 hours of the pad erection day.

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5.8.3.2.2.3. Immediately before the start of any hazardous or safety critical operation.

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5.8.3.2.2.4. After any major or safety-related modification has been made to facilities or equipment.

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5.8.3.2.3. Explosives storage and operating areas and facilities shall be inspected by the appropriate authority at least annually

to ensure compliance with explosives safety criteria. Area monthly records shall be reviewed during the annual inspection.

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5.8.3.3. Facility Operator Inspections. The facility operator shall inspect explosive storage and operating areas and facilities

at least once a month.

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5.8.3.4. Facility Spot-Checks. Spot-checks of processing facilities shall be performed to ensure compliance with this

publication.

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Hazardous Operation Support Requirements

5.9.1. Communication and Television Support

5.9.1.1. All hazardous operations shall require primary and backup communications between the operation’s control point

and the operation.

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5.9.1.2. Recorded voice communication and Operation Television (OTV) coverage shall be used for Self-Contained

Atmospheric Protective Ensemble (SCAPE) operations and whenever required by the safety authority or local safety

authorities.

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5.9.2. Safety Radio Net

5.9.2.1. Emergency forces supporting hazardous operations shall be required to maintain continuous monitoring on a safety

radio net. Verification of operational status shall be accomplished prior to each hazardous operation. Use of RT (Radio

Telephone) devices on USAF property shall conform to the requirements of DESR 6055.09_AFMAN 91-201, Explosive

Safety Standards, Volume 3, Chapter 8 and Volume 6, Chapter 8 of this standard.

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5.9.2.2. Safety Net shall be used during transit and when SCAPE personnel are off Operational Intercommunications System

(OIS).

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5.9.2.3. Telephones or other means of radio communications shall be available for summoning assistance in emergencies in

areas where hazardous operation are conducted.

5.9.3. Loss of support and equipment during any phase of the operation shall be reported immediately to the appropriate

payload project office authorities for assessment of necessary actions.

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MATERIAL HANDLING EQUIPMENT, CRANE, HOIST, PERSONNEL

PLATFORM, POWERED INDUSTRIAL TRUCK, AND ELEVATOR

OPERATIONS

This chapter is applicable to the equipment that falls under the payload project’s responsibility. In addition to the requirements

listed herein, the requirements of NASA-STD-8719.9, Lifting Standard, apply in their entirety. Any local lifting equipment

requirements shall be adhered to when operating material handling equipment (MHE) related to or involving payload testing,

processing or integration. This chapter is divided into the following: 6.1. Material Handling Equipment (MHE) Operations;

6.2. Crane and Hoist Operations; 6.3. Personnel Platform Operations; 6.4. Powered Industrial Trucks (see ASME B56); and 6.5.

Elevator Usage. Requirements for vehicles used to transport hardware onto and off of NASA facilities or ranges are not governed

by this chapter.

Material Handling Equipment Operations

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The operations requirements for material handling equipment (MHE) used for handling (lifting, supporting, or manipulating)

critical and non-critical hardware are described below. These requirements are applicable to new or modified MHE. The

requirements are also applicable to permanent or short-term use MHE and apply whether the equipment is owned, rented, or

leased by the government, contractors, or commercial operators.

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MHE is comprised of below-the-hook lifting devices (BTHLD), handling structures, support structures, slings, load cells, (Hydra

Sets ®), load indicating devices (LID), and rigging hardware. Slings, BTHLDs, lifting assemblies, rigging hardware, and LIDs

are governed by industry standards, e.g., OSHA, ASME.

6.1.1. MHE Operating Standards

6.1.1.1. Existing equipment shall not be used in operations unless it meets all the requirements in Volume 3, Chapter 6 unless

otherwise agreed to by the appropriate local safety authority.

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6.1.1.2. All MHE shall be operated, tested, and maintained in accordance with the requirements of this publication, NASA-

STD-8719.9, Lifting Standard; OSHA; AFMAN 91-203; and applicable military and industry standards including, but not

limited to, ANSI, the American Society of Mechanical Engineers (ASME), and the National Fire Protection Association

(NFPA).

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6.1.1.4. All users of MHE used to handle the critical hardware covered in this publication shall have written and approved

procedures that cover selection, operation, maintenance, and testing of the MHE used.

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Operations that include maintenance of the MHE and use of these items with no safety critical or hazardous loads shall not be

considered safety critical operations. Those operations that involve MHE and safety critical or hazardous loads including direct

contact, such as supporting the load, or within the immediate vicinity, such as moving the MHE without a load over a hazardous

commodity, shall be considered hazardous operations. Moving or parking an empty hook over a hazardous/critical commodity

shall not be considered a hazardous operation.

6.1.2. MHE Operator Qualification and Training

6.1.2.1. MHE Operator Qualification Requirements

6.1.2.1.1. Operators shall be mentally and physically capable of safely operating the MHE.

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6.1.2.1.2. Operators shall be physically tested for vision and hearing before being assigned to operator duty and annually

thereafter.

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6.1.2.2. MHE Operator Training and Certification

6.1.2.2.1. Operators shall be trained in the safe operation of the MHE used and the hazards to which they are exposed.

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6.1.2.2.2. Operator training shall include, but not be limited to, the following topics:

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6.1.2.2.2.1. The requirements of the operator manual.

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6.1.2.2.2.2. The requirements of NASA-STD-8719.9, Lifting Standard; applicable parts of AFMAN 91-203, and ASME B30

series, Material Handling Equipment.

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6.1.2.2.2.3. The parts of 29 CFR 1910, Subpart N, Material Handling and Storage.

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6.1.2.2.2.4. The parts of ASME B30 and other industry standards.

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6.1.3. MHE Periodic Test and Inspection Requirements

6.1.3.1. MHE Test and Inspection General Requirements

6.1.3.1.1. MHE shall be tested initially and periodically in accordance with Volume 3, 6.2.1.3.

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6.1.3.1.2. All damaged MHE shall be removed from service until all discrepancies are corrected.

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6.1.3.1.3. All MHE shall be marked with the due date of next inspection.

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6.1.3.2. MHE General Data Requirements. All MHE data requirements and documentation (inspection, test, maintenance,

and modification reports, commercial-off-the-shelf (COTS) operating and maintenance manuals, etc.) shall be provided in

accordance with requirements of AFSPCMAN 91-710, Volume 3, Chapter 4, and Volume 3, Attachment A3.1 of this

publication and other standards referenced herein. This documentation shall be made available to PSWG and Range Safety

for audit upon request.

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6.1.4. MHE General Operations

6.1.4.1. All MHE to be used for hazardous operations and/or safety critical operations shall be identified to the appropriate

local safety authority as determined by the PSWG, Range Safety, and the center LDEM (NASA only).

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6.1.4.2. All MHE shall be verified as safe for its intended use by the payload project.

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6.1.4.3. MHE documentation (inspections, tests, maintenance, and modifications) shall be maintained by the payload project

for the life of the MHE. This documentation shall be made available to the PSWG, Range Safety, and local safety authority.

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6.1.5. Sling Operations

6.1.5.1. Sling Operating Standards. The NASA-STD-8719.9, Lifting Standard, requires all slings shall be operated,

maintained, and tested in accordance with; ASME B30.9, Slings; and ASME B30.26, Rigging Hardware.

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Synthetic web/rope slings should have an overload indicating device when used for safety critical operations.

6.1.5.1.1. For identification and onsite assurance purposes, sling assemblies shall have a periodic recertification tag containing

equipment identification, next required test date, and quality control stamp.

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6.1.5.1.2. Sling assemblies which have components that are normally disassembled shall be either marked, coded, or tethered

to assure proper assembly of verified hardware.

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6.1.5.1.3. Removable lifting lugs used on flight hardware or GSE shall be identified to ensure the lugs can be reinstalled in

the proper location if necessary.

Note: Components not marked, coded, or tethered will invalidate the proof or periodic load/certification of the whole

assembly.

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6.1.5.2. Sling Periodic Test and Inspection Requirements.

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6.1.5.2.1 Periodic Test Requirements. Slings used to support critical operations shall be Periodic Load tested to 100% of the

manufacturer’s rated load within one year of intended use, unless the range user has proposed, with supporting risk analysis,

in accordance with PSWG and Range Safety approval, an alternate test interval. Following modifications and repairs, critical

slings shall be Proof load tested to the same level as new slings, in accordance with this standard Volume 3, Table 6.1, ASME

B30.9 and 29 CFR 1910.184. NDE shall be performed on load tested critical slings per, Volume 3, paragraph 6.2.1.3.2. MHE

NDE, requirements following a PSWG and Range Safety approved NDE plan.

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6.1.5.2.2 Periodic and Frequent Inspection Requirements. Sling assemblies used for critical lifts shall be periodically inspected

and inspected before each use. Sling assembly inspection shall be in accordance with periodic and frequent inspection

methodologies described in ASME B30.9 and ASME B30.26. Any sling or rigging hardware shall be removed from service

if any conditions are present, that are listed in ASME B30.9/ASME B30.26 Removal Criteria, for each sling/rigging hardware

type. Slings and rigging hardware shall not be returned to service until approved by a qualified person, the PSWG and Range

Safety.

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6.1.5.3. Sling Recurring Data Requirements. Recurring data is required in accordance with Volume 3, Chapter 4.

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6.1.6. Load Positioning and Load Measuring/Indicating Device Operations

6.1.6.1. Operator Training. LPD and LID operators shall be trained and certified in accordance with manufacturer

recommendations and NASA-STD-8719.9, Lifting Standard.

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6.1.6.2. LPD and LID Operating Standards. LPD and LID shall be operated, maintained, and tested in accordance with the

manufacturer instructions; NASA-STD-8719.9, Lifting Standard; and the additional requirements described below.

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6.1.6.3. LPD and LID Inspection and Periodic Test Requirements. LPD and LID shall be inspected and tested in accordance

with Volume 3, Section 6.2.6.2 of this publication and NASA-STD-8719.9, Lifting Standard.

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6.1.6.4. LPD and Recurring Data Requirements. Recurring data is required in accordance with Volume 3, Chapter 4.

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6.1.6.4.1. Before every use, LPDs and LIDs shall be inspected. LPDs and LIDs showing evidence of damage or rejectable

criteria shall not be used in operations.

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6.1.6.4.2. LIDs used to support critical operations shall be properly calibrated before use. If a wireless remote readout control

is used with the LID, it shall be calibrated and display the same weight as the LID.

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Remote control display devices are often used with LIDs when the LID is too high off the ground to be able to read its weight

display.

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6.1.6.4.3. LPDs and LIDs used to support critical operations shall be inspected and periodic load tested to 100% of the rated

load within one year of intended use, unless the payload project has proposed, with supporting risk analysis, and PSWG and

Range Safety has approved, an alternate test interval. Following any modifications or repairs, critical LPDs and LIDs shall be

proof load tested to the same level as new LPDs or LIDs, to include calibration in accordance with manufacturer instructions.

After the proof load test, NDE shall be performed on critical LPDs or LIDs per a PSWG and Range Safety approved NDE

plan.

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6.1.7. Handling Structure Operations

6.1.7.1. Handling Structure Operating Standards. All structural lifting beam operations shall meet NASA-STD-8719.9 and

ASME B30.20, Below Hook Lifting Devices, for range operations.

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6.1.7.2. Handling Structure Inspection and Periodic Test Requirements. Handling structures shall be inspected and tested

in accordance with Volume 3, 6.2.4.2.

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6.1.7.2.1. Before every use, handling structures shall be visually inspected in accordance with applicable industry

methodology and the PSWG and Range Safety approved NDE plan. Structures showing evidence of damage or rejectable

criteria shall not be used in operations

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6.1.7.2.2. Handling structures used to support critical operations shall be inspected and load tested to 100% of the rated load

within one year of intended use, unless the payload project has proposed, with supporting risk analysis, and the PSWG and

Range Safety has approved, an alternate test interval. Following any modifications or repairs, critical handling structures shall

be proof load tested to the same level as new handling structures. After the proof load test, NDE shall be performed on critical

handling structures in accordance with a PSWG and Range Safety approved NDE plan.

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6.1.7.2.3. Handling structures fabricated (including fittings and attachment hardware) of ductile materials and exhibiting

ductile failure mode at the operating environmental conditions may be exempted by the PSWG and Range Safety from periodic

load testing on a case-by-case basis. Subject to PSWG and Range Safety review and approval, such structures may be verified

using an alternate approach, based on fracture mechanics and proof-test logic.

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6.1.7.3. Handling Structure Recurring Data Requirements. Recurring data is required in accordance with Volume 3, Chapter

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6.1.8. BTHLD Operations.

6.1.8.1. BTHLD Operating Standards. BTHLDs shall be inspected, operated, maintained, and tested in accordance with

NASA-STD-8719.9, NASA Lifting Standard, ASME B30.20 and 29 CFR 1910.

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6.1.8.2. BTHLD Periodic Test and Inspection Requirements.

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6.1.8.2.1. BTHLDs shall be visually inspected in accordance with frequent and periodic inspection methodologies described

in ASME B30.20 and shall follow the PSWG and Range Safety approved NDE plan. See volume 3 of this standard, paragraph

4.4.1 Nondestructive Examination Plan test requirements. BTHLDs showing evidence of damage or rejectable criteria shall

be removed from operational use.

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6.1.8.2.2. BTHLD’s, and associated rigging hardware, used to support critical operations shall be inspected and Periodic Load

tested to 100% of the rated load within one year of intended use in accordance with V3, Table 6.1 (5) and Note 2.

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6.1.8.2.3. BTHLD’s Proof Load tested to 125% of the rated load performed after modification or repairs, in accordance with

ASME B30.20 methodology, shall satisfy the Periodic Load test requirement for that interval periodic load test cycle in

accordance with V3, Table 6.1. After the Proof Load test, volumetric and surface NDE shall be performed on all SFP

components and welds on critical BTHLDs in accordance with a PSWG and Range Safety approved NDE plan.

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6.1.8.2.4. BTHLDs fabricated (including fittings and attachment hardware) of ductile materials and exhibiting ductile failure

mode at the operating environmental conditions may be exempted from periodic load testing by the LDEM (when on center),

the PSWG and Range Safety. on a case-by-case basis. Subject to PSWG and Range Safety review and approval, such structures

may be verified using an alternate approach based on fracture mechanics and proof-test logic.

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6.1.8.2.5. Periodic load test intervals may be extended by no more than 90 days from the original lifting device expiration

date due to programmatic or institutional needs, subject to the center LDEM, PSWG and Range approval. To extend the

periodic load test interval, the following conditions shall be met: a. The payload project provides documented rationale to the

LDEM, PSWG and Range Safety. b. The LDEM, PSWG and Range Safety determines there is no increase in risk.

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6.1.8.2.6. The payload project can implement, with supporting risk analysis, an alternate test interval plan for critical

BHTLD’s, and associated rigging hardware, performed in accordance with test criteria in V3, Table 6.1, with the center

LDEM, the PSWG and Range Safety concurrence.

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6.1.9. Support Structure Operations

6.1.9.1. Support Structure Periodic Test and Inspection Requirements.

6.1.9.1.1. Before every use, support structures shall be visually inspected in accordance with applicable industry methodology

and the PSWG and Range Safety approved NDE plan. Structures showing evidence of damage or rejectable criteria shall not

be used in operations.

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6.1.9.1.2. Support structures used to support critical operations shall be inspected and tested to 100% of the rated load within

one year of intended use, unless the payload project has proposed, with supporting risk analysis, and PSWG and Range Safety

has approved, an alternate test interval. Following any modifications or repairs, critical support structures shall be proof load

tested to the same levels as new critical support structures. After the proof load test, NDE shall be performed on critical support

structures in accordance with a PSWG and Range Safety approved NDE plan.

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6.1.9.1.3. Support structures fabricated (including fittings and attachment hardware) of ductile materials at the operating

environmental conditions may be exempted by the PSWG and Safety from periodic load testing on a case-by-case basis.

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6.1.10. Rigging Hardware Operations.

6.1.10.1. Rigging Hardware Operating Standards. All rigging hardware shall be operated, maintained, and tested in

accordance with ASME B30.26.

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6.1.10.2. Rigging Hardware Periodic Test and Inspection Requirements.

6.1.10.2.1. Before every use, rigging hardware shall be visually inspected in accordance with ASME B30.26. Any rigging

hardware showing evidence of damage and meeting removal criteria as outlined in ASME B30.26 shall be removed from

service.

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6.1.10.2.2. Rigging hardware used to support critical operations shall be inspected and load tested to 100% of the rated load

within one year of use. Following any modifications or repairs, critical rigging hardware shall be proof load tested to the same

level as new critical rigging hardware in accordance with ASME B30.26. After the proof load test, NDE shall be performed

on critical rigging hardware in accordance with a PSWG and Range Safety approved NDE plan.

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Crane and Hoist Operations

6.2.1. Crane and Hoist Operating Standards. In addition to the requirements in 6.1, all cranes and hoists shall be operated

in accordance with ASME B30 series, CMAA 70, Specifications for Electric Overhead Traveling Cranes; and CMAA 74,

Specifications for Top Running and Under Running Single Girder Electric Overhead Traveling Cranes Utilizing Under

Running Trolley Hoist, MHI Standards, NASA-STD-8719.9, Lifting Standard; and NFPA 70, National Electric Code; and

AFMAN 91-203. The requirements are also applicable to permanent or short-term use equipment and apply whether the

equipment is owned, rented, or leased by the government, contractors, or commercial operators.

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At VSFB, cranes not on VSFB exclusive federal jurisdiction property also require inspection, testing, and certification in

accordance with CAL-OSHA requirements.

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6.2.2. Crane Operator Training and Certification

6.2.2.1. All operators of cranes shall be trained in accordance with NASA-STD-8719.9, Lifting Standard; Materials Handling

and Storage Equipment; AFMAN 91-203 (Chapter 12, Material Handling Equipment) and the qualifications stated in the

ASME B30 series, 29 CFR 1910.179, and 29 CFR 1910.180, as applicable.

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6.2.2.2. All operators of hoisting apparatus of over 1,000 pound capacity [hoists (fixed or traveling) or cranes (overhead or

mobile)] shall be trained and certified.

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6.2.2.3. All operators of cranes that are used to lift critical loads are subject to the requirements stated in ASME B30 series.

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6.2.2.4. Annual Crane Operator Certification. Annual crane operator certification is required and shall be conducted in

three parts:

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6.2.2.4.1. Classroom Training and Testing. Employers shall ensure their personnel receive classroom training as evidenced

by testing. Employers shall maintain records for each operator they employ. For the WR, the requirements in 6.2.2.1, 6.2.2.2,

and 6.2.2.3 apply.

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6.2.2.4.2. Physical Examination. The employer is responsible for obtaining a physical examination of the operator as required

by NPR 1800.1 NASA Occupational Health Program Procedures, AFMAN 91-203, ASME B30 series, and the local

requirements of the crane owner.

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6.2.2.4.3. Hands-On Training and Certification. The employer shall document hands-on training, evaluation, and certification

in the form of a card that includes the following:

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6.2.2.4.3.1. Name of operator.

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6.2.2.4.3.2. Certifying agency and certification expiration date.

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6.2.2.4.3.3. Other pertinent information such as the types of equipment the operator is certified to operate.

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6.2.2.5. Types of Operator Certification

6.2.2.5.1. Critical load (except for proof load) hands-on training and certification shall be conducted on the specific device to

be used for the lift.

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6.2.2.5.2. Non-critical load hands-on training and certification shall be conducted on a crane of the same type for which

personnel are to be certified such as mobile hydraulic, mobile mechanical (friction), overhead bridge, and overhead monorail.

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6.2.3. Crane and Hoist Inspection and Periodic Test Requirements

6.2.3.1. Daily Inspections

6.2.3.1.1. Using a pre-operational checklist, daily, or otherwise before first use, inspections shall be conducted as required by

OSHA and recommended by the manufacturer on the equipment to be used at the beginning of each shift.

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6.2.3.1.2. Daily inspections shall cover the following items:

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6.2.3.1.2.1. The function of all controls, brakes, and operating mechanisms for maladjustment interfering with proper

operations.

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6.2.3.1.2.2. The condition of all components that can be inspected without major disassembly and whose failure would cause

a safety hazard. This includes the deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or

hydraulic systems; hooks with deformation or cracks; hoist chains and end connections for excessive wear, twist, distorted

links interfering with proper function, or stretch beyond manufacturer’s recommendations; control mechanisms; all chords

and lacing; tension in guys; and plumb of mast.

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6.2.3.2. Slack Rope Inspections. If a slack rope condition has occurred, inspectors shall be positioned to observe the rope

seating in the drum and sheave grooves as the load is reapplied, and concurrently inspect the rope for damage.

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6.2.5. Crane and Hoist Retest and Reinspection

6.2.5.3. If an accidental overload condition occurs, the equipment user shall notify the facility manager, the Center Lifting

Devices and Equipment Manager, payload project, and PSWG chairperson and follow up by submitting a written report.

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6.2.6. Dual Crane Lift Operating Requirements. Dual crane lifts are considered hazardous operations without regard to

the load. The following is required:

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6.2.6.1. The load shall be restricted to no more than 75 percent of rated capacity for each crane for non-critical lifts. The load

shall be restricted to no more than 50% of rated capacity for each crane for critical lifts.

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6.2.6.2. All mobile crane dual lifts shall require load cells and cab-installed load indicators.

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6.2.6.3. A dry run with a geometric/mass simulator shall be required for all critical hardware lifts.

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6.2.6.4. A Dual Crane Lift Plan addressing the following information shall be submitted to Range Safety for review and

approval:

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6.2.6.4.1. The exact weight (+/- 1 percent) of the total load including spreader bar/beam, hoist attachments, fixtures, and

slings.

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6.2.6.4.2. Any dynamic forces that affect the load.

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6.2.6.4.3. All crane movements, including trolley, bridge, boom up, down, extension, and swing, and crane travel.

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6.2.6.4.4. Center of gravity throughout the complete lift.

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6.2.6.4.5. Certification of cranes and crane operators.

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6.2.6.4.6. Operating surface capacity compatibility with mobile cranes (paved areas).

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6.2.6.4.7. Soil compaction compatibility with mobile cranes (unpaved areas).

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6.2.6.4.8. Provisions for a lift director, two-ways communication, and spotter(s).

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6.2.6.5. Operations involving offset lifts shall not exceed the crane's capability.

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6.2.7. WR First Use Tag Program

6.2.7.1. Payload projects requesting approval of a program in which specific equipment certification expiration date and time

do not start until the item is issued or installed or first used shall provide the following documentation to Range Safety for

review and approval with PSWG concurrence:

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6.2.7.1.1. A complete list of all items by nomenclature with identifying part numbers, rated load, maximum test load, and

operation where normally tested.

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6.2.7.1.2. An approved quality assurance program identifying controls, inspection points, and complete First Use Tag

information.

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6.2.7.1.3. Identification of shelf-life criteria.

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The shelf-life shall not exceed 5 years in an environmentally controlled location without retest.

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6.2.7.2. Range Safety shall withdraw approval upon any infraction of the program.

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6.2.8. Mobile Cranes. All mobile cranes to be used shall be properly inspected, functionally validated, and maintained

according to 29 CFR 1910; 29 CFR 1926; NASA-STD-8719.9, Lifting Standard; applicable ASME standards; applicable state

OSHA plans; and the requirements identified below. These requirements apply whether the equipment is government, payload

project, or contractor owned, rented, or leased.

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6.2.8.1. Mobile cranes shall be certified for operational use by the appropriate authorizing agency.

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6.2.8.2. Dual crane lift operations require Range Safety approved lift plans (See 6.2.6.4).

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6.2.8.3. The use of mobile cranes to lift critical hardware shall be justified to and approved by the PSWG and Range Safety

on a case-by-case basis.

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6.2.8.4. Prior to conducting a critical lift with a mobile crane, the upper limit switch shall be tested for proper functioning by

raising an empty hook to the upper limit, activating the upper limit switch, and verifying that the hoist stops. After the load is

hoisted a small distance, the load shall be left hanging for approximately three minutes (i.e., a holding brake test) to ensure the

winch holding brakes functions properly and that there is no load slippage.

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6.2.8.5. Mobile cranes used for critical lifts shall be de-rated to 50% of their original load capacity. The total weight of the

load shall not exceed 50% of the crane rated capacity for the given lift radius and load line reeving configuration of the crane.

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6.2.8.6. Load charts shall be used as the primary means for determining safe loads for various boom angles. Crane computers

shall not be used as a sole means for this determination.

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6.2.8.7. Evolutions that actually involve man-rated lifts shall also comply with operational requirements in this chapter and

ASME B30.23, Personnel Lifting Systems. For man-rated lifts, the total weight of the loaded personnel platform and related

rigging shall not exceed 50% of the rated capacity for the radius and configuration of the crane or derrick.

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6.2.8.8. Inspection and Test Requirements. Payload projects utilizing mobile cranes shall submit a data package to the

PSWG and Range Safety for review and approval that provides evidence that the mobile crane meets the following

requirements:

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6.2.8.8.1. Current maintenance documentation.

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6.2.8.8.2. Operator qualifications and certification documentation.

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6.2.8.8.3. Proof that operators have performed similar type lifts within one year of planned lift.

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6.2.9. Lifting Operations

6.2.9.1. Pre-Operational Lifting Requirements. The person responsible for supervising lifting operations shall ensure the

following:

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6.2.9.1.1. The crane has met all of its maintenance, test, and inspection requirements and is operated within its rated capacity.

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6.2.9.1.2. The operator is properly certified.

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6.2.9.1.3. The operator remains at the controls the entire time a load is suspended.

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Exceptions may be approved by the PSWG and Range Safety in the interest of operational efficiency to allow lifting hardware

such as slings, spreader bars, BTHLDs, load cells, and LPDs to remain suspended while unattended provided all of the

following conditions are met:

6.2.9.1.3.1. A procedure documenting such exceptions has been approved by the appropriate local safety authority as

determined by the PSWG and Range Safety.

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6.2.9.1.3.2. The lifting hardware suspended is connected to but not supporting the weight of the objective load (e.g., the launch

vehicle stage, motor segment, or payload).

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6.2.9.1.3.3. The load is scheduled to be lifted within 24 hours.

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6.2.9.1.3.4. The load and immediate vicinity are roped off or otherwise identified to prohibit unauthorized personnel entry.

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6.2.9.1.3.5. The crane controls are locked in the off position.

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6.2.9.1.3.6. The restrictions against people being under the suspended lifting hardware are enforced.

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6.2.9.1.4. The vicinity of the lift is controlled so that:

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6.2.9.1.4.1. Unauthorized personnel entry is precluded.

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6.2.9.1.4.2. Personnel or any part of their bodies are prevented from being under or in the way of the load.

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6.2.9.1.4.3. For cranes equipped with booms, the area is defined by the swing radius of the crane and includes all of the

rotating superstructure.

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6.2.9.1.4.4. A large enough area is cleared so as to protect against flying debris from a dropped object.

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6.2.9.1.5. All personnel within the controlled hoisting area wear suitable head and foot protection.

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6.2.9.1.6. Previously announced lightning advisories and lightning warnings will not cause the load to be in jeopardy.

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6.2.9.1.7. All personnel are knowledgeable of the operation to be performed, tasks to be done, route to be traveled, and safety

considerations.

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6.2.9.1.8. If using a mobile crane, the crane shall be level and the following criteria shall be met:

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6.2.9.1.8.1. The area shall be set up so that the lift is made within the shortest possible radius.

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6.2.9.1.8.2. The lift shall be made over the rear of the crane, if possible.

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6.2.9.1.8.3. When the load to be handled and the operating radius require the use of outriggers, or any time when outriggers

are used, the outrigger beams shall be fully extended or deployed per load rating chart specifications. Blocking under outrigger

beams is not permitted. Blocking under outrigger floats, when used, shall be strong enough to prevent crushing, bending, or

shear failure and of sufficient thickness, width, and length as to completely support the float, transmit the load to the supporting

surface, and prevent shifting or topping under load. Outrigger floats shall be made of 4 x 4 inch or cross-hatched 2 x 4 inch

lumber, a minimum of 4 x 4 feet square or equivalent support.

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6.2.9.1.8.4. When using outriggers, they shall be fully extended and raise the crane so that the wheels are off the ground unless

the crane is designed for partial outrigger use and has appropriate load rating charts.

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6.2.9.1.8.5. No part of the crane or load shall pass within 10 feet of an electrical power line unless the line is de-energized and

visibly grounded on both sides of the area of possible contact.

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6.2.9.1.8.6. Outriggers and outrigger floats shall be used on flat hard/compacted surfaces.

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6.2.9.1.8.7. Outrigger floats or cribbing is required in areas that do not have a hard surface such as concrete.

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6.2.9.1.8.8. Operators shall not exceed inclination angles specified by the mobile crane manufacturer when locating, then

leveling the mobile crane prior to lifting operations.

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6.2.9.1.8.9. Operators shall not operate mobile cranes upon unapproved, temporary foundations at unimproved surfaces or on

road bearing surfaces not rated for the lifting load.

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6.2.9.1.9. Systems shall have sufficient assistant operators or spotters to make sure that all sides of the system are clear for

operation.

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6.2.9.1.10. All operators or spotters shall have aural communications for coordination between themselves when power is on

the system.

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6.2.9.1.11. Tag lines shall be used when there is potential for load sway that could damage the article lifted, high value

equipment, or flight hardware.

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6.2.9.1.12. Tag line personnel shall not impart undesirable motion to the load.

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6.2.9.1.13. If the weight of the load to be lifted is not known, the weight shall be estimated with a reasonable degree of

accuracy before attempting to lift the load.

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6.2.9.1.14. Unattended suspended loads require local safety authority approval.

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6.2.9.2. Attaching the Load. To attach the load, the crane hook shall be positioned directly over the center of gravity of the

load before attachment unless authorized in a written procedure approved by the appropriate local safety authority.

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6.2.9.3. Lifting the Load

6.2.9.3.1. On the first lift of the day or shift, or on a critical lift, the load shall be raised a few inches, then held in place

momentarily, to verify that the brakes operate normally.

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6.2.9.3.2. The load shall be lifted to a height sufficient to clear all obstacles in its intended path.

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6.2.9.3.3. For hoist angles, cranes are designed to function with the load raised perpendicular with respect to the ground.

Cranes are normally designed for vertical lifts. Side angle pull lifts should not be attempted unless the crane is specifically

designed for this purpose in accordance with the requirements in Volume 3.

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6.2.9.3.3.1. Fleet (side) angles shall be kept as close to zero as possible. The appropriate local safety authority’s approval is

required for all anticipated fleet angles.

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Pulling the rope with a load component perpendicular to the drum or sheave grooves (fleet or side angle) may cause the rope to

jump out of the groove and become entangled on the drum or caught between the sheave and its mounting with possible

catastrophic results.

6.2.9.3.3.2. Lead (in-line) angles shall be kept as close to zero as possible. The appropriate local safety authority approval is

required for anticipated lead angles exceeding 5 degrees unless the hoist is specifically designed for greater angles. Increasing

the lead (in-line) angle increases the strain on the load line, brakes, bearings, sheaves, and other crane parts.

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6.2.9.3.3.3. When lifting a load, load lines shall not contact load girts, structural members, or any other obstructions.

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6.2.9.3.4. Loads may be lifted with the load line off-perpendicular for the purpose of rotating large pieces of hardware if all

of the following conditions are met:

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6.2.9.3.4.1. There is no safer way to accomplish the rotation.

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6.2.9.3.4.2. The angle on the load line shall not exceed five degrees unless the hoist was specifically designed for a greater

angle.

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This angle is sometimes referred to as the lead or draft angle; it is not to be confused with the fleet angle.

6.2.9.3.4.3. On an installed crane, the angle is pulled in line with the rotation of the rope onto the drum (lead angle) unless the

crane is equipped with a level wind device.

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6.2.9.3.4.4. The crane is inspected to ensure that the load line does not engage the load girts, structural members, or any other

obstructions at the angle to be used.

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6.2.9.3.4.5. Before the lift, the crane is checked to ensure that all rope parts are properly seated in the grooves of the drums or

sheaves.

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6.2.9.3.4.6. The load is prevented from swinging or otherwise inducing dynamic loads on the hoisting system.

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6.2.9.3.5. Mobile or boom-equipped cranes shall not be used for off-perpendicular lifting due to the severe hazard of tipping

the crane over or of collapsing the boom.

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6.2.9.3.6. Crane maintenance instructions or checklists shall include directions to look for evidence of apparent offset lift

damage during inspections.

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6.2.10. Suspended Load Operations

6.2.10.1. Moving a Suspended Load

6.2.10.1.1. Crane operations involving lifting of hazardous or explosive materials shall be limited to only those personnel

required to perform the task.

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6.2.10.1.2. A safety clearance zone shall be established in the vicinity around the load and all non-essential personnel cleared

to a safe distance.

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6.2.10.1.3. Horizontal and vertical travel speeds shall be kept at a safe level and shall be addressed, as appropriate, in

procedures.

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6.2.10.1.4. Each lift shall be planned so that the load is suspended for a minimum amount of time.

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6.2.10.1.5. The load shall not be lifted until immediately before intended travel.

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6.2.10.1.6. The most direct route of travel shall be used.

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6.2.10.1.7. Loads shall not be carried over critical hardware except when that load is being mated to the critical hardware.

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6.2.10.1.8. The landing area shall be prepared so that the load may be set down immediately at the end of travel.

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6.2.10.1.9. If the load remains suspended for any length of time, the safety clearance zone shall remain in force.

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6.2.10.1.10. The load shall not be carried over personnel nor shall personnel be allowed to place any part of their bodies under

any part of the load.

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6.2.10.1.11. The load shall be transported as low as possible but at a height sufficient to clear all obstacles that may be in its

path.

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6.2.10.1.12. Alarm device or spotter personnel accompanying the load shall be used to clear other persons out of the load

path.

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6.2.10.1.13. Tag lines shall be used to control movement of the load and not impart undesirable motion to the load.

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6.2.10.1.14. Tag lines shall be long enough to protect personnel from being struck by the load.

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6.2.10.1.15. Tag lines shall be used when there is potential for a load swing that could damage flight hardware, property, or

cause injury or death.

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6.2.10.1.16. Crane operators shall be instructed to stop motion should anyone be in the path of the load or if anyone signals

to stop.

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6.2.10.1.17. Two-way communication between the test conductor and crane operator shall be maintained.

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6.2.10.2. Crane-Suspended Personnel Platforms. Operations involving lifting suspended personnel platforms are

prohibited except as provided by NASA-STD-8719.9, Lifting Standard, AFMAN 91-203, and 29 CFR 1926.1431, Crane, or

Derrick Suspended Personnel Platforms, and specifically authorized by the appropriate local safety authority.

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6.2.10.3. Man-Rated Crane Criteria. All cranes used to suspend personnel platforms and work baskets shall meet the

following requirements:

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6.2.10.3.1. Crane free-fall features shall be deactivated.

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6.2.10.3.2. Load testing of the current configuration shall have been performed within past 12 months.

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6.2.10.3.3. Two-way communication shall be maintained between the crane operator and the person in the basket.

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6.2.10.3.4. The crane operator shall be appropriately qualified.

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6.2.10.3.5. The total weight of the loaded personnel platform and related rigging shall not exceed 50 percent of the crane

capacity rating.

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Personnel Work Platform Operations

6.3.1. Removable, Extendible, or Hinged Personnel Work Platforms

6.3.1.1. Removable, Extendible, or Hinged Work Platform Operating Standards. Personnel work platforms shall be

operated, maintained, and tested in accordance with the manufacturer instructions and the additional requirements listed

below.

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6.3.1.2. Removable, Extendible, or Hinged Work Platform Periodic Test Requirements. At a minimum, periodic tests

shall be performed on all personnel work platforms annually in accordance with Volume 3, 6.3.3.

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6.3.1.3. Removable, Extendible, or Hinged Work Platform Recurring Data Requirements. At a minimum, recurring data is

required in accordance with Volume 3, Chapter 4.

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6.3.2. Aerial Work Platforms

Aerial work platforms are commercial (whether or not modified) vehicle-mounted elevating and rotating aerial devices, manually

propelled elevating aerial platforms, boom-supported elevating work platforms, self-propelled elevating work platforms, and

airline ground support vehicle-mounted vertical-lift devices.

6.3.2.1. Aerial Work Platform Operating Standards. All aerial work platforms shall be verified to meet the design and

construction standards of NASA-STD-8719.9, Lifting Standard; ANSI/SIA A92.2, Vehicle Mounted Elevating and Rotating

Aerial Devices; A92.3, Manually Propelled Elevating Aerial Platforms; A92.5, Boom Supported Elevating Work Platforms;

and A92.6, Self-Propelled Elevating Work Platforms, and bear identifying mark(s) evidencing the same.

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6.3.2.2. Aerial Work Platform Designations. All aerial work platforms operated in a hazardous environment as defined by

NFPA 505, Fire Safety Standard for Powered Industrial Trucks Including Type Designations, Areas of Use, Conversions,

Maintenance, and Operation, shall be approved for fire safety purposes by a nationally recognized testing laboratory [for

example, Underwriters Laboratories, Inc. (UL), Factory Mutual Engineering Corp (FM)] using nationally recognized testing

standards, bear mark(s) evidencing testing, and bear the appropriate designation (i.e., D, DS, DY, E, ES, EE, EX, G, GS, LP,

LPS).

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6.3.2.3. Aerial Work Platform Operations

6.3.2.3.1. Only qualified and trained personnel shall operate aerial work platforms.

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6.3.2.3.2. Aerial work platforms shall be operated in accordance to this section, the manufacturer’s recommendations and the

applicable ANSI/SIA standard and with the safety rules and practices of NASA-STD-8719.9, Lifting Standard; ASME B56.2

Type Designated Area, Use Maintenance, Operator, and ASME B56.3, Electric Battery-Powered Industrial Trucks, safety

standards.

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6.3.2.3.3. Usage in NFPA 505 Hazardous Area Classifications shall be restricted to aerial work platforms with the appropriate

designation per UL 558, Standard for Safety, Industrial Trucks, Internal Combustion Engine Powered; UL 583, Standard for

Safety, Battery Powered Industrial Trucks; or comparable nationally recognized testing laboratory.

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6.3.2.3.4. Aerial work platforms shall not be used in proximity of critical hardware where inadvertent operation could result

in damage of same.

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6.3.2.3.5. Before each use, the operator shall perform a pre-operational check to demonstrate operational readiness, including

all limit switches and outrigger drift switches, if applicable, but excluding the tilt alarm/shutoff. If controls do not operate

properly, the operator is responsible for notifying the supervisor. Repairs and adjustments shall be made before operations

begin. The operator shall adhere to all tags on the controls.

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6.3.2.3.6. Before each use, the operator shall survey the area for applicable hazards such as overhead obstructions and high-

voltage conductors, debris, bumps and loose obstructions, drop-offs and holes, ditches, untamped earth fills, obstructed path

of travel, unstable footing, and other possible hazardous conditions. The operator shall establish appropriate safety zones

before initiating operations.

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In some cases, aerial work platforms are intentionally used in close proximity to critical hardware [e.g., to

disconnect the rigging from the top of solid rocket motor upgrade (SRMU) segments when they are placed vertically

in the stands]. A hazard analysis should be conducted on such aerial platforms and identified hazards mitigated.

Examples of mitigation include padded platform handrails, elimination of single point failures from the hydraulic

control system, and stabilization of the chassis to prevent sudden shifting of the platform in case of tire failure.

Lessons learned from the SRMU program are listed below:

(1) Do not use worn or dry rotted tires on aerial platform vehicles. Sudden tire failure may cause platform

translation and impact against sensitive flight hardware.

(2) Keep the hydraulic system clean and ensure adequate hydraulic hose chafing guards are installed in the boom

articulated joint areas. At least one hydraulic hose failure

occurred

on the SRMU program, spraying the entire

lift with hydraulic oil.

(3) Ensure that the hydraulic system components have no unacceptable failure modes. In case of an SRMU aerial

platform, reverse command resulted in the vehicle lurching forward and the platform impacting the doorframe.

This malfunction was attributed to contamination in the hydraulic system.

Powered Industrial Trucks

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Powered industrial trucks are commercial (whether or not modified) fork trucks, platform lift trucks, crane trucks, tow tractors,

personnel and burden carriers, and other specialized industrial trucks powered by electric motors or internal combustion engines.

6.4.1. Powered Industrial Truck Standards. All powered industrial trucks shall be verified to meet the design and

construction standards of ASME B56 series safety standards and bear identifying mark(s) evidencing the same.

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6.4.2. Powered Industrial Truck Designations. All powered industrial trucks shall be approved for fire safety purposes by

a nationally recognized testing laboratory (for example, UL, FM) using nationally recognized testing standards, bear mark(s)

evidencing testing, and bear the appropriate designation (i.e., D, DS, DY, E, ES, EE, EX, G, GS, LP, LPS).

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6.4.3. Powered Industrial Truck Operations

6.4.3.1. Only qualified and trained personnel shall operate powered industrial trucks.

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6.4.3.2. Operations of all powered industrial trucks shall be operated in accordance with the safety rules and practices of

NASA-STD-8719.9, Lifting Standard; and ASME B56 series safety standards.

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6.4.3.3. Use in NFPA 505 Hazardous Area Classifications shall be restricted to powered industrial trucks with the appropriate

designation per UL 558, UL 583, or a comparable nationally recognized testing laboratory.

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6.4.3.4. Powered industrial trucks shall not be used in the proximity of critical hardware where inadvertent operation could

result in damage of the hardware.

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6.4.3.5. If external attachments, such as special lifting adaptors, are attached to the forks for lifting, the attachment components

shall have the proper load rating and meet the appropriate testing requirements in this publication.

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6.4.3.6. Lift trucks shall be de-rated to 75 percent of rated capacity for critical loads.

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Elevator Usage

6.5.1. Passenger elevators not designed in accordance with Volume 5 criteria for freight shall not be used for propellant or

other hazardous materials.

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6.5.2. Freight elevators used for the movement of ordnance that has been removed from the original shipping containers, toxic

propellants, or other hazardous materials shall be controlled remotely.

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6.5.3. Personnel shall not ride in elevators during movement of the materials listed in 6.5.2.

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ACOUSTIC HAZARD OPERATIONS

Acoustic Hazard Operating Standards

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Acoustic (noise) protection shall be provided in accordance with the requirements in NPR 1800.1, Occupational Health

Program Procedures, latest revision, Hearing Conservation Section. (See Volume 3, Section 7.1 for noise exposure limits and

related requirements.)

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Acoustic Hazard Operations Personnel Protection Requirements

7.2.1. Unprotected personnel shall not be exposed to hazardous noise levels.

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7.2.2. Approved hearing protection devices shall be worn as required.

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Acoustic Operations

7.3.1. All potential hazardous noise sources in the work environment that could expose personnel shall be identified to the

Bioenvironmental Engineer or approving authority (as determined by the PSWG and Range Safety) for hearing conservation.

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7.3.2. Identified noise sources shall be surveyed by the Bioenvironmental Engineer or a designated representative.

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7.3.3. A means of warning personnel before entering the noise hazard area shall be provided. A description of the hazard and

what measures are necessary to ensure the safety of personnel shall be included.

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1. Warning signs should be posted in a manner to be visible before entering the noise hazard area.

2. Warning signs should warn of the hazardous noise and indicate the requirement for hearing protection.

3. Any posting of hazardous noise areas should be coordinated with and approved by the Bioenvironmental

Engineer or the approving authority (as determined by the PSWG and Range Safety) for hearing conservation.

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NON-IONIZING RADIATION OPERATIONS

Non-Ionizing Radiation Operating Standards

8.1.1. Personnel and electroexplosive devices (EEDs) shall not be exposed to hazardous levels of non-ionizing radiation.

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8.1.2. All non-ionizing radiation operation shall be conducted in accordance with the requirements of the following standards:

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8.1.2.1. NASA and NASA contractor personnel performing operations that utilize, transport, or dispose of, non-ionizing

radiation generating equipment, associated with payload processing, shall comply with NPR 1800.1, NASA Occupational

Health Program Procedures, Chapter 4.13, for operations on all NASA centers; and AFMAN 40-201, Radioactive Materials

(RAM) Management, and any SLD-specific supplements for personnel during payload processing and operations on USSF or

launch service providers facilities.

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8.1.2.2. NASA-STD-8719.12, Safety Standard for Explosives, Propellants, and Pyrotechnics; DESR 6055.09_AFMAN 91-

201, Explosive Safety Standards, and American Institute of Aeronautics and Astronautics (AIAA)-S-113, Criteria for

Explosive Systems and Devices on Space and Launch Vehicles for radiation limits for ordnance exposure.

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8.1.2.3. NASA-STD-8719.12, Safety Standard for Explosives, Propellants, and Pyrotechnics; DESR 6055.09/AFMAN 91-

201, Explosive Safety Standard; and American Institute of Aeronautics and Astronautics (AIAA)-S-113, Criteria for

Explosive Systems and Devices on Space and Launch Vehicles for guidance with respect to siting ordnance.

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Note: While Range Users do not site ordnance, they participate in the process and both design/operations may be

influenced by siting considerations.

8.1.3. The use and operating location of non-ionizing radiation producing devices shall be approved by the appropriate safety

authority and the RPO/RSO.

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Radio Frequency Procedures

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All Electromagnetic Frequency Radiation (EMFR) transmitters shall be operated using the appropriate safety authority and

RPO/RSO approved procedures with the appropriate controls established. The RPO/RSO shall specify minimum power

levels below which EMFR transmitters are exempt from controls.

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EMFR Operations

8.3.1. RF EMFR Operations General Requirements

Non-ionizing radiation operations involve EMFR transmitters in the range of 3 kHz to 300 GHz and optical devices

such as lasers.

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8.3.1.1. Before transmitting, areas in which power density levels exceed permissible exposure limits shall be controlled to

restrict access.

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Area control may be accomplished using appropriate warning signs, lights, and access barriers.

8.3.1.2. The RPO/RSO shall survey EMFR transmitting devices as required.

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8.3.1.2.1. The payload project shall comply with the survey recommendations.

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8.3.1.2.2. Where applicable all safety devices shall be checked by site personnel before operation to ensure proper function.

If transmission is required while performing these checks, the tests shall be performed at low output power or with a dummy

load. Steps for performing these verifications shall be incorporated into procedures.

Note: A safety device (or feature) is levied on the system design to control the cause of an identified hazard or to mitigate the

effect of a hazard once the cause has been satisfied. As a result, the probability and/or severity of a hazard can be reduced to

an acceptable level. Safety devices (or features) can take numerous forms in a design. No matter what form a safety device (or

feature) takes, its purpose is to prevent an undesirable (hazardous) event from occurring. Safety devices (or features) may be

wholly or partly mechanical, electrical, or software in nature. A safety device (or feature) may inherently be part of the system

or be specifically added to a system. Safety devices (or features) may include the following:

1. Barriers - a physical means to keep personnel away from hazardous energy or to contain/deflect hazardous

energy if it were released.

2. Fail-safe design - a design feature in which a system reacts to a failure by switching to or maintaining a safe

operating mode that may include system shutdown.

3. Inhibit - a device that prevents system operation if a predetermined condition is not satisfied.

4. Interlock - a device that may be inserted into the system to prevent system operation (often used in

maintenance).

5. Interrupt - a device that disrupts system operation if a predetermined condition is violated.

6. Redundancy/failure tolerance - the built-in ability of a system to provide continued correct operation in the

presence of a specific number of failures.

7. Special system features - systems or devices, such as fire suppression and hazardous gas detection, that control

and/or warn of system hazards.

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8.3.1.3. All new, modified, or relocated EMFR transmitters shall be reported to the appropriate safety authority and the

RPO/RSO at least 30 days prior to hardware installation so that potential hazards can be evaluated.

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8.3.2. EMFR Transmission Operations for EEDs and Open Grain Solid Propellant

8.3.2.1. As determined by analyses and tests, local or range-wide EMFR silence is required during periods of EED installation,

removal, and electrical connection or disconnection. At a minimum, EMFR silence within the complex or area shall be

required.

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8.3.2.2. Radio transmitters shall be kept away from systems with installed EEDs in accordance with the guidance found in

AFI 91-208, Hazards of Electromagnetic Radiation to Ordnance (HERO) Certification and Management and NASA-STD-

8719.12, Safety Standard for Explosives, Propellants, and Pyrotechnics.

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The 25-foot radio transmission distance requirement is the minimum requirement; however, this requirement does not consider

situations where EEDs are EMFR sensitive and leads are unshielded. Based on the specific radio, ordnance, and area involved,

an EMFR analysis performed in accordance with (AIAA)-S-113, Criteria for Explosive Systems and Devices on Space and

Launch Vehicles, for radiation limits may be provided to the appropriate safety authority for consideration to reduce this

requirement.

8.3.2.3. Transmitting devices shall be kept a minimum of 50 feet from a fueling area unless they are intrinsically safe.

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Class 1M, 2M, 3B, and 4 Optical/Laser Operations

8.4.1. Optical/Laser Operating Standards. NASA and NASA contractor personnel performing operations that utilize,

transport, or dispose of, Laser and non-Laser optical generating equipment, associated with payload processing, shall do so

in accordance with NPR 1800.1, NASA Occupational Health Program Procedures, Chapter 4.16, for operations on all NASA

centers; and AFI 48-139, Laser and Optical Radiation Protection Program, and any SLD-specific supplements for personnel

during payload processing and operations on USSF or launch service providers facilities.

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8.4.2. Optical/Laser Operation Personnel Protection Requirements

8.4.2.1. NASA and NASA contractor personnel performing operations that utilize, transport, or dispose of laser and non-laser

optical generating equipment shall be appropriately trained in work practices commensurate with the degree of potential laser

hazards, both from laser radiation and non-beam hazards, in accordance with NPR 1800.1, NASA Occupational Health

Program Procedures, Chapter 4.16 paragraph 4.16.3.2. NASA and NASA contractor personnel performing optical/laser

operations on USSF property shall be trained and certified in accordance with AFMAN 40-201, Radioactive Materials (RAM)

Management, as applicable.

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8.4.2.2. Approved protective eye wear and other PPE shall be worn as required.

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8.4.3. Optical/Laser Procedures. All optical devices and lasers capable of exceeding allowable energy levels, as determined

by the appropriate local safety authority, shall be operated using the appropriate local safety authority and LSO, RPO/RSO

approved procedures with the appropriate controls established.

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8.4.4. Optical/Laser Inspection

8.4.4.1. Periodic inspections shall be conducted to ensure the laser and controls are in safe working condition and are properly

protected from potential damage.

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Conditions of concern include dangerous light radiation, temperature extremes, shatterable materials, contaminating gases,

cryogenics, high voltage, and X-rays.

8.4.4.2. Inspection records shall be maintained for the life of the program.

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8.4.4.3. Inspection records shall be available at the request of the appropriate local safety authority.

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8.4.5. Optical/Laser Operations

8.4.5.1. Alignment of targets, optics, filters, and other optical/laser items shall be accomplished following written procedures

and using non-hazardous low power (Class 1 or Class 2) lasers.

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8.4.5.2. Active beam or target viewing shall be accomplished with closed circuit television or an optical comparator with an

appropriate filter.

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8.4.5.3. Laser beams directed toward flammable or explosive materials, pressurized systems, any other system that may

become hazardous due to laser energy or directed toward sensitive components of FTSs shall not exceed allowable limits as

determined by the appropriate local safety authority.

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8.4.5.4. Activated lasers shall not be left unattended.

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8.4.5.5. Unattended lasers shall be locked out and otherwise safed.

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8.4.5.6. Operations involving laser systems with hazardous materials shall follow the requirements for hazardous materials

described in Chapter 10 of this volume.

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8.4.5.7. Operations involving laser systems with pressurized subsystems such as cryogenic fluids shall follow the requirements

described in Chapter 11 of this volume.

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8.4.5.8. Operations involving lasers with high voltage or capacitance shall follow the requirements in Chapter 14 of this

volume.

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8.4.5.9. All electrical and mechanical azimuth and elevation stops, and other safety devices shall be verified before performing

each laser operation. (See the bordered paragraph immediately after 8.3.1.2.2 for examples of safety devices.)

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8.4.5.10. Laser platforms shall comply with the requirements for mechanical ground support equipment used to handle critical

hardware as described in Chapter 6 of this volume.

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8.4.5.11. Laser operation conforms to the principles and requirements set forth in ANSI Z136.1, American National Standard

for Safe Use of Laser, and ANSI Z136.2, Safe Use of Optical Fiber Communication Systems Utilizing Laser Diode and LED

Sources.

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8.4.5.12. Requirements for the procurement and manufacture of laser products are provided in 21 CFR Part 1040.10, Laser

Products, and 21 CFR Part 1040.11, Specific Purpose Laser Products.

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8.4.5.13. All nominal hazardous procedural items shall be accomplished including, but not limited to, the following:

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8.4.5.13.1. 24-hour notification of Pad Safety.

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8.4.5.13.2. Pre-operational PA announcements.

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8.4.5.13.3. Clearance of safety clearance zones.

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8.4.5.13.4. Posting of applicable warning signs and operation of area warning lights.

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8.4.5.13.5. Pad Safety permission prior to start of the hazardous lasing activity.

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RADIOACTIVE (IONIZING) RADIATION SOURCES OPERATIONS

Launch approval of radioactive (ionizing radiation) sources is addressed in Volume 3, Chapter 9 of this publication.

9.1. Payload projects shall comply with NPR 1800.1, NASA Occupational Health Program Procedures, Chapter 4.13, General

Radiation Requirements and AFMAN 40-201, Radioactive Materials (RAM) Management, and any SLD specific supplements

or instructions, as applicable.

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9.2. All ionizing operations shall be planned and conducted in accordance with written procedures, approved by the

appropriate safety authority, or RPO/RSO, so that personnel exposure is as low as reasonably achievable (ALARA), but in no

case shall exceeded the maximum dose and exposure limits in 10 CFR 20, Standards for Protection Against Radiation, be

exceeded.

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9.3. Local safety authorities and the RPO/RSO shall be notified of the location of radioactive material spills, releases, and

incidents. Local radiation safety requirements shall be followed. CCSFS Cape Support (ER 321-853-5211) or VSFB

Command Post (WR 805-606-9961), Range Safety, and the RPO/RSO shall be notified of the location of radioactive material

if spilled, released, or dispensed either by design or accident when on Air Force and Space Force property. KNPR 1860.1

shall be followed for releases and spill on KSC property.

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9.4. Flight radioactive sources shall be installed as late in the countdown as practical.

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9.5. Mishaps involving radioactive materials shall be reported in accordance with NPR 8621.1, NASA Procedural

Requirements for Mishap and Close Call Reporting, Investigating, and Recordkeeping and appropriate local safety

organizations requirements as required above. AFMAN 91-110 and AFI 91-204 shall also apply for mishaps on Air Force

and Space Force property.

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HAZARDOUS MATERIALS OPERATIONS

Hazardous Materials Operating Standards

10.1.1. Hazardous materials shall be selected in accordance with 10.1 of Volume 3 of this publication and NPR 1800.1,

Chapter 4.

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10.1.2. An operation or process task that includes a solid, liquid, or gaseous material that, under foreseeable conditions, are

toxic, carcinogenic, cryogenic, explosive, flammable, pyrophoric, water-reactive, corrosive, an oxidizer, a compressed gas, a

combustible liquid, or are chemically unstable shall be conducted as a Hazardous Operation and performed in accordance with

the NASA-STD-8719.11, Fire Protection, NASA-STD-8719.12 Safety Standard for Explosives, Propellants, and

Pyrotechnics, NPR 8715.1, NASA Safety and Health Programs, AFI 90-821, Hazard Communication (HAZCOM) Program,

AFMAN 91-203, and any Wing-specific supplements or instructions, as directed by the PSWG and Range Safety for process

safety management (PSM) and risk management plan (RMP). See Attachment V6 A.23 Classification of Hazardous

Procedures.

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10.1.3. When threshold quantities of toxic chemicals as defined by OSHA, NASA, or Space Force requirements are being

used, the payload project shall comply with any local process safety requirements, the appropriate local safety and health

authorities, as identified by the PSWG and Range Safety, and the local Biomedical/Bioenvironmental Office, concerning

hazardous material selection, operation, storage, and disposal. At the ER the payload project shall comply with applicable ER

Requirements are the 45 SWI 91-101, Process Safety Management. The SLD 45 point of contact for process safety

management is System Safety (SLD 45/SE).

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Hazardous Materials Operations Personal Protective Equipment (PPE)

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Proper head, eye, hand, body, and respiratory protection shall be worn as required in accordance with 29 CFR 1910, NPR

1800.1, Chapter 4, and local requirements. The PPE shall be approved by the approved local safety/occupational health

authority and is subject to the approval of the Bioenvironmental Engineer as required.

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Hazardous Materials Procedures

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Hazardous materials procedures shall be established per local requirements. For operations taking place on Air Force or

Space Force property, hazardous material procedures shall be established per AFMAN 32-4013. Hazardous materials

procedures shall include, but not be limited to, the following topics:

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10.3.1. Emergency actions for unplanned events such as spills, fires, and personnel contamination.

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10.3.2. Actions for decontamination, neutralization, cleanup, and disposal.

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Hazardous Materials Operations

10.4.1. The use of any hazardous material is subject to the appropriate local safety and bioenvironmental authority’s approval.

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10.4.2. Appropriate control measures shall be established for the use of hazardous materials based on known properties. If

properties are unknown, testing shall be performed subject to approval by the appropriate local safety and bioenvironmental

authorities.

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10.4.3. Control measures for hazardous liquids include, but are not limited to, the following criteria:

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10.4.3.1. Approved containers shall be used.

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10.4.3.2. Containers shall remain capped (covered) when not in use.

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10.4.3.3. Quantities shall be limited as approved by the Fire Authority Having Jurisdiction (AHJ).

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10.4.3.4. Work areas shall contain no more than the quantity required for a single shift.

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10.4.3.5. Work areas shall not be used for storage unless approved storage cabinets and lockers are available.

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10.4.3.6. Local or general exhaust ventilation shall be used to control solvent vapors from reaching toxic levels or explosive

levels.

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10.4.3.7. Materials that are themselves not hazardous, but that can be hazardous in conjunction with other materials, shall be

controlled.

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10.4.3.8. The location and/or facility shall be compatible with the type and quantity of hazardous material.

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10.4.3.9. When personnel are in confined spaces, hazardous materials and chemicals shall only be used in accordance with

29 CFR 1910.146, Permit-Required Confined Spaces, compliant program. Proper ventilation shall be used to prevent buildup

and/or pocketing of hazardous materials and chemicals to hazardous levels. Due consideration shall be given to all potential

sources of toxic buildup, such as chemicals employed by workers within the confined space, from venting of systems, and

from off-gassing.

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10.4.3.10. Materials prone to electrostatic charge buildup shall not be used in the vicinity of ordnance or propellants.

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10.4.3.11. Glass containers shall not be used in the immediate vicinity of flight hardware or in elevated locations so that they

could fall and shattered pieces of glass strike hardware or personnel. In general, use of glass containers is discouraged.

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10.4.4. In the event of an unplanned toxic release local emergency response plans shall be followed.

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The following documents applicable at Space Force Ranges: IEMP, AFI 10-2501, Air Force Emergency Management Program,

and any SLD-specific supplements, instructions, or plans. At KSC: KNPR 8715.2, Comprehensive Emergency Management

Plan.

Restrictions on the Use of Plastic Films, Foams, and Adhesive Tapes (PFAs) and other

Static-Producing and Flammable Materials

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10.5.1. General. The use of plastic films, foams, and adhesive tapes (PFAs) shall be kept to a minimum in all payload

processing and testing areas. Materials prone to electrostatic charge buildup shall not be used on or near ordnance items or in

the vicinity of flammable liquids or commodities such as propellants.

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10.5.1.1. Compliance with the restriction on static-producing materials is handled on a case-by-case basis; however, the

following criteria shall be used as a guideline:

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10.5.1.1.1. Materials shall not come into contact with a system having an installed EED or other ordnance.

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10.5.1.1.2. Materials shall not come within 10 feet of exposed solid propellant grain, which is defined as when the grain is

visible with no nozzle plug or cover.

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10.5.1.1.3. Materials shall not come within 50 feet of exposed flammable liquids.

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10.5.1.2. Compliance with the use of materials that could be flammable is handled on a case-by-case basis; however, all

materials that are used in the vicinity of ordnance or flammable liquids, such as hypergolic propellants, shall pass the material

tests described below.

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10.5.2. Material Tests

10.5.2.1. Materials such as contamination covers, thermal blankets, splash shields, Velcro, tape, and any other material located

in the vicinity of liquid propellant areas or ordnance areas shall be evaluated for compatibility with their intended use.

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10.5.2.2. The payload project shall supply a sample of materials to KSC testing laboratory or other approved laboratory for

testing, and the results shall be forwarded to the appropriate local safety authority. Materials passing KSC or approved

equivalent tests may be deemed acceptable by the appropriate local safety authority.

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Material properties may be obtained through NASA MAPTIS (Material and Process Technical Information System), from KSC

Materials Testing Labs, or other approved material database.

10.5.2.3. Testing shall consider the following material characteristics:

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10.5.2.3.1. Ability to build up a charge (triboelectric test).

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10.5.2.3.2. Ability of that charge to decay (triboelectric test).

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A material is considered to have good electrostatic dissipation properties if it can dissipate voltage down to 350 volts in 5 seconds

using the triboelectric test.

10.5.2.3.3. Flammability

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10.5.2.3.4. Compatibility with other materials and liquids the material may come into contact with.

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10.5.2.4. Material restrictions may also arise from other limitations such as being humidity dependent (for charge dissipation)

or degradable in sunlight (ultraviolet).

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10.5.2.5. The appropriate local safety authority shall approve the use of materials based on the test results.

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Materials that do not meet these criteria may be acceptable for a particular usage as determined by the appropriate local safety

authority.

10.5.2.6. Material deficiencies shall result in operational restrictions.

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Hazardous Commodity Lockers

10.6.1. Positioning and Use of Hazardous Commodity Lockers. Hazardous commodity lockers or cabinets shall be

positioned and used for the purpose of storing flammable and combustible liquids in accordance with 29 CFR 1910.106, NFPA

30, Flammable and Combustible Liquids Code; NASA-STD-8719.11, NASA Standard for Fire Protection; and local fire safety

requirements as applicable.

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10.6.2. Hazardous Commodity Locker Inspection. The payload project shall inspect hazardous commodity lockers at least

weekly.

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Disposal of Contaminated Liquid Propellant, Gas, or Other Regulated Wastes

10.7.1. On Space Force Ranges, the payload project shall notify CCSFS Cape Support (ER) (321-853-5211) or Range

Scheduling (WR) (805-606-8825) of any hazardous material requiring disposal on the respective Range location. For other

locations the payload project shall follow local policies.

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If required, additional guidance shall be obtained from Civil Engineering (Environmental Coordinator) or their designated

representative and Range Safety.

10.7.2. Disposal of toxic or contaminated liquid propellants, gases, or other wastes shall be performed using methods and

techniques approved by the safety and other local authorities, as well as all applicable federal, state, and local regulations.

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On USSF, the approval authority is Range Safety and Civil Engineering (Environmental Coordinator). Follow 45 and 30

Space Wing Operations Plan (SWOP) 19-14, Petroleum Products and Hazardous Waste Management Program.

10.7.3. Payload project shall notify the appropriate local safety authorities to obtain proper clearance and support to dispose

of wastes before the generation of such wastes. For Space Force Ranges, Civil Engineering shall be notified.

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10.7.4. As needed, those operations involving toxic propellants shall be conducted under the surveillance of Environmental

Health and Pad Safety for operations on the AF Range to ensure the safety of personnel involved in the operation and personnel

located in adjacent or downwind areas.

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10.7.5. Records of management and identification of wastes shall be maintained by the organization generating the waste.

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10.7.7. All spills or releases of hazardous substances, including petroleum products, shall be reported to the local authority

responsible for emergency response, in accordance with the facility safety plan and local requirements. For CCSFS Cape

Support (ER) (321-853-5211) or Range Scheduling (WR) (805-606-8825) and Pad Safety immediately and for KSC dial 911

(or 321-867-7911 from a cell phone).

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GROUND SUPPORT AND FLIGHT HARDWARE PRESSURE SYSTEMS

OPERATIONS

The minimum operational requirements for both ground support and flight hardware pressure systems operations

are described below. Operational requirements unique to either category are identified.

Pressure Systems Operating Standards

The degree of hazard in pressure systems is proportional to the amount of energy stored, which is a function of both the pressure

and the volume stored. As a result, low-pressure, high-volume systems can be as hazardous to personnel as high-pressure

systems.

11.1.1. Only pressure systems that meet the design requirements of Volume 3 as tailored for each specific project (mission)

shall be used.

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11.1.2. The handling and storage of propellants shall be in accordance with NASA-STD-8719.12, Safety Standard for

Explosive, Propellants, and Pyrotechnics; CPIA 394, Chemical Propulsion Information Agency-Hazards of Chemical Rockets

and Propellants; and DESR 6055.09_AFMAN 91-201, Explosive Safety Standards and NAVSEA OP 5, Ammunition and

Explosives Ashore: Safety Regulations for Handling, Storing, Production, Renovation and Shipping.

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11.1.3. Propellants shall be used and stored only in facilities designed and suited for that purpose and approved for specified

time periods of use by the appropriate local safety authorities.

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11.1.4. Propellants shall be used and stored only in systems that meet the design requirements of Volume 3, Chapter 11 and

Chapter 12 and shall be approved by the appropriate local safety authorities.

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11.1.5. Portable or mobile vessels and packaging used for transportation of pressurized or hazardous commodities shall be

maintained and recertified in accordance with applicable Department of Transportation (DOT) 49 CFR.

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Pressure Systems Personnel Requirements

11.2.1. Pressure Systems Training and Certification. All personnel who operate, test, and maintain pressure systems

shall be trained and certified.

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11.2.2. Pressure Systems PPE

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11.2.2.1. Selection of PPE. The PPE selected shall have been approved for the planned usage by the appropriate local safety

authorities, occupational health authorities, and other applicable approving authorities as identified by the PSWG and Range

Safety (see section 5.3).

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11.2.2.1.1. Approval shall be limited to a particular model number of protective equipment and a particular operation.

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11.2.2.1.2. Approval of PPE for an operation depends on the type and volume of propellants involved, the size of the lines,

flow rate, pressure, capability to deal with emergencies, and egress accessibility.

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11.2.2.1.3. Approvals are not transferable; approvals for similar operations require a reevaluation of the parameters stated

above.

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11.2.2.1.4. Protective gear shall be compatible with the propellants involved, shall be fire resistant, non-static producing, and

shall have been approved for the planned usage by the appropriate local safety authorities, occupational health authorities, and

other applicable approving authorities as identified by the PSWG and Range Safety (see section 5.3).

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11.2.2.1.5. If the protective gear has limitations, these limitations and subsequent protective actions shall be identified in the

operating procedure.

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For example, splash suits are not to be used when hydrazine concentrations can exceed 100 ppm.

11.2.2.2. SCAPE, Category I or IV

11.2.2.2.1. SCAPE, Category I or IV shall be used for propellant flow and pressurization during the following operations:

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11.2.2.2.1.1. Connection and disconnection of wet lines or contaminated (not purged and flushed) dry lines.

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11.2.2.2.1.2. Sampling operations.

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11.2.2.2.1.3. During propellant flow.

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11.2.2.2.1.4. During initial pressurization with propellants until system integrity has been verified (no leaks).

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11.2.2.2.1.5. Connections and disconnections of tanker load/off-load lines.

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11.2.2.2.1.6. Removal and replacement of components in a liquid line.

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11.2.2.2.1.7. Opening any liquid system that has not been drained, purged, and flushed with referee fluid.

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11.2.2.2.1.8. When the condition of the system is uncertain or unknown.

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11.2.2.2.2. The maximum operating time in a Category I SCAPE suit is 110 minutes; however, the appropriate local safety

authorities (including Pad Safety for AF Range facilities) can authorize on-station time not to exceed 120 minutes. In

extreme temperatures, the appropriate local safety authorities can restrict on-station times in Category I SCAPE suits to

less than 110 minutes. (ER Only). Personnel using Category I SCAPE suits shall observe a 60-minute rest period between

consecutive SCAPE operations: for example, no double-packing. All personnel required to wear Category 1 and Category

lV Self-Contained Atmospheric Protective Ensemble (SCAPE) shall be certified in accordance with KTI-1202, Propellant

Handlers Ensemble User’s Manual.

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SCAPE categories are defined as:

Category I - Propellant Handlers Ensemble (PHE) with environmental control unit (ECU).

Category IV - Propellant Handlers Ensemble (PHE) using remote breathing air supplied by hardline hose.

Category VI - 'Chemturion' Chemical Protection Suit (CPS) "blue suit" with hardline breathing hose.

Please refer to KTI-1202, Propellant Handlers Ensemble User’s Manual for Propellant Handlers Ensemble user requirements

and further explanation of categories.

11.2.2.2.3. For physiological purposes, the maximum operating time in a Category IV or VI SCAPE suit shall not exceed four

consecutive hours.

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11.2.2.3. Splash Suits. Splash suits, with self-contained breathing apparatus, shall only be used with systems that contain

residual vapors and only after the appropriate local safety authority’s approval. If any liquid is in the system, splash suits shall

not be used.

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11.2.2.3.1. Removal of full protective gear after system integrity verification shall require approval by the appropriate local

safety authorities.

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11.2.2.3.2. Emergency protective gear shall be available throughout operations to the crew and other personnel who might be

affected in the event of a spill.

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11.2.2.3.3. The following non-liquid operations shall require splash suits:

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11.2.2.3.3.1. Removal and replacement of components on purged and isolated liquid lines.

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11.2.2.3.3.2. Removal and replacement of components on vent lines.

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11.2.2.3.3.3. Connections and disconnections of drained, purged, and isolated lines.

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11.2.2.3.3.4. Pressure leak checks when required by procedure.

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11.2.2.3.4. With the appropriate local safety authority concurrence, the use of splash suits during propellant flow after integrity

has been established may be allowed at the WR.

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11.2.2.4. PPE for Cryogenic Systems

11.2.2.4.1. All personnel performing liquid oxygen and liquid hydrogen transfer operations, repairs, or adjustments to the

system shall wear PPE (flame-resistant treated, non-static producing overalls of liquid resistant material, cryogenic service

gloves, hoods or face shields, and non-absorbent shoes) in accordance with 29 CFR 1910, NPR 1800.1, Chapter 4, and local

requirements. The PPE shall be approved by the approved local safety/occupational health authority and is subject to the

approval of the Bioenvironmental Engineer as required.

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11.2.2.4.2. Personnel performing operations on other cryogenic systems shall be similarly protected, except that flame-

resistant treating of coveralls is not required for non-flammable commodities.

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11.2.2.5. PPE for Hydrogen Peroxide Transfers. Hydrogen peroxide transfers shall require PPE (boots, gloves, and face

shields) in accordance with 29 CFR 1910, NPR 1800.1, Chapter 4, and local requirements. The PPE shall be approved by the

approved local safety/occupational health authority and is subject to the approval of the Bioenvironmental Engineer as

required.

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11.2.2.6. If a DOT vessel is installed on a permanent basis, it shall fall under the recertification requirements for a fixed

system.

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Pressure Systems Procedures

11.3.1. Procedures shall be prepared governing the safe operation, testing, maintenance, and installation of pressurized systems

by the agency performing the specific task.

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11.3.2. Procedures shall be developed for all operations involving propellants and the checkout of propulsion systems.

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11.3.3. Off-loading procedures for payloads shall be made available at any time propellant is loaded in flight hardware. Off-

loading design as outlined in Volume 3, Chapter 11 and Chapter 12 of this publication addresses the complete system during

the complete processing flow. The off-loading procedures shall include integration of the following:

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11.3.3.1. Hardware:

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11.3.3.1.1. Launch vehicle.

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11.3.3.1.2. Launch vehicle fairing.

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11.3.3.1.3. Spacecraft.

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11.3.3.1.4. Launch complex.

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11.3.3.1.5. Process facility.

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11.3.3.1.6. Transport vehicle.

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11.3.3.1.7. Fixed GSE.

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11.3.3.1.8. Portable GSE.

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11.3.3.2. Software Command Capability:

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11.3.3.2.1. Flight Hardware.

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11.3.3.2.2. GSE:

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11.3.3.3. Personnel Capability:

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11.3.3.3.1. Remote.

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11.3.3.3.2. SCAPE.

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11.3.3.3.3. Combination of both.

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Pressure Systems Test, Inspection, and Maintenance Requirements

11.4.1. General Test Requirements

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11.4.1.1. Pressure systems shall be initially tested in accordance with Volume 3, Chapter 11 or Chapter 12.

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11.4.1.2. Any system that has been opened shall be leak tested at 100 percent maximum operating pressure (MOP) with an

inert medium.

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11.4.1.3. Pressure relief valves and flex hoses shall be retested within one year of intended use.

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11.4.1.4. Pressure gauges and transducers shall be calibrated annually.

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11.4.1.5. After any disconnection, modification, or repair of a system, the affected part of the system shall be leak tested.

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11.4.1.6. Any component that has been damaged, potentially damaged, repaired, replaced, or modified shall be proof tested

in accordance with Volume 3.

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11.4.1.7. After the component proof test, the system or subsystem shall be proof tested, functionally tested, and leak tested.

The determination for system proof testing shall be made on a case-by-case basis.

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11.4.1.8. New, modified, or repaired propellant systems shall be tested in accordance with Volume 3, Chapter 11, or Chapter

12.

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11.4.1.9. A log shall be kept on propellant systems to keep track of use, maintenance, modification, testing, and inspection.

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11.4.2. Ground Support Pressure Systems General Inspection Requirements

11.4.2.1. Before use and each operation, facilities and equipment shall be inspected by the payload project and the appropriate

local safety authority to ensure a safe configuration for the facilities, equipment, and propellants involved.

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11.4.2.2. Propellant transfer and storage areas shall be spot checked by the appropriate local safety authority, the Fire

Department, and Environmental Health. The appropriate area supervisor shall be advised of any discrepancies noted.

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11.4.2.3. Periodic inspections shall be performed on all ground pressure systems in accordance with applicable procedures.

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11.4.2.4. Periodic inspections shall be performed on ground based pressure vessels and liquid holding tanks in accordance

with the ISI Plan in Volume 3. These inspections shall be performed during the following periods:

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11.4.2.4.1. Certification Period. Period from the initial operational use of the vessel and/or system until the vessel and/or

system requires recertification.

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11.4.2.4.2. First Certification Period. Period from the first recertification effort until second recertification.

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11.4.2.4.3. All subsequent Recertification Periods.

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11.4.2.4.4. The hazardous pressure system operator shall retain all documentation generated as a result of the recertification

effort and place this documentation in the system ISI certification and recertification file.

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11.4.3. Pressure Systems General Maintenance

11.4.3.1. Before replacement, storage, or repair of hypergolic or toxic propellant or fluid system components, the system shall

be purged and flushed of all residual contaminants. System connections and removed components shall be appropriately

capped, bagged, and labeled before moving the component.

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11.4.3.2. A record shall be kept on the certification of system and component cleanliness.

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11.4.3.3. When it is necessary to remove flight hardware components from the system, all broken connections shall be bagged

and tagged to prevent moisture or particle contamination from outside sources.

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11.4.3.4. If DOT vessels are used in portable GSE, maintenance and operating procedures for periodic hydrostatic tests shall

be in accordance with DOT regulations.

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11.4.3.5. All maintenance procedures and training shall ensure that personnel performing visual inspections or other checks

shall not walk in front of any National Pipe Thread (NPT)-connected components but shall inspect/observe the NPT

connections from a side position to prevent exposure to possible high pressure projectiles.

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11.4.3.6. All rupture discs installed in hazardous fluid systems shall be replaced every two years.

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11.4.4. Pressure Systems Tests. Tests performed shall meet the requirements as outlined in Volume 3, Chapter 11 and

Chapter 12. The following requirements apply unless the payload project has proposed, with supporting risk analysis, and

PSWG and Range Safety has approved an alternative test interval for components:

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11.4.4.1. Periodic Test Requirements for Pressure System Components:

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11.4.4.1.1. Uninstalled Flexible Hose. Uninstalled flexible hoses shall be hydrostatically proof tested to 1.5 times their MAWP

within one year before use, or pneumatically tested to 1.1 times MAWP once every two years unless otherwise approved by

the PSWG or Range Safety.

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11.4.4.1.2. Installed Flexible Hose. Installed flexible hoses in functional use shall be hydrostatically tested to 1.5 times their

MAWP once a year. Exception: This requirement does not apply to flexible hoses that are permanently installed, located, and

operated in an environment that does not exceed the rated temperature, pressure, and shelf life of the hose.

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11.4.4.1.3. Prior to project use and at least annually, all flexible hoses shall be visually inspected over their entire length.

Those with damaged fittings, broken braid, kinks, flattened areas, or other evidence of degradation shall be removed from

service. A flexible hose exhibiting major defects as classified in SAE ARP 1658, shall be removed from service.

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Exception: This requirement does not apply to flexible hoses that are permanently installed, located, and operated in an

environment that does not exceed the rated temperature, pressure, and shelf life of the hose.

11.4.4.1.4. Pressure gauges and transducers shall be calibrated once a year.

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Hazardous pressure operations begin at 150 psig.

11.4.4.1.5. Pressure relief valves shall be tested for proper setting and operation once a year.

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11.4.4.2. Testing Modified and Repaired Pressure Systems. Tests performed shall meet the requirements as outlined in

Volume 3, Chapter 11, and Chapter 12.

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11.4.4.3. Pressure Systems Tagging

11.4.4.3.1. Post testing and inspection, pressure system components shall be tagged.

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11.4.4.3.2. Tags shall provide the date of the last inspection and proof-load test and the component MAWP.

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11.4.5. Ground Support Pressure Vessels and Liquid Holding Tanks Recertification. Recertification data shall be

submitted as part of the SDP (MSPSP) as required in Volume 3, Chapter 11, and Chapter 12.

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11.4.6. Pressure Vessel and Liquid Holding Tank Recertification Documentation. Documentation shall be recorded and

maintained in accordance with Volume 3. Chapter 11.

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Pressure Systems Operating Requirements

11.5.1. General Operating Requirements. Only pressure systems approved by the appropriate local safety authority shall

be used.

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11.5.1.1. Pressure Systems Marking

11.5.1.1.1. Warning signs shall be posted to keep personnel out of areas where pressurization is taking place.

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11.5.1.1.2. High and ultra-high pressure systems (systems equal to or greater than 3,000 psig) shall be marked with danger

signs indicating the maximum pressure that could be involved.

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11.5.1.1.3. Pressure relief valves that present a noise hazard on activation shall be marked with danger signs.

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11.5.1.2. Pressure Systems Remote Pressurization. Exception. For the, remote pressurization can be waived provided the

following is provided: (1) The assembled system has been proof tested at a pressure equal to 1.5 times the system MEOP/MOP

or to an agreed-upon level for tanks with less than 2:1 safety factor for burst; (2) system configuration has not been modified

or repaired before the above testing. Unwelded relief or sensing devices may be replaced after system proof testing; and (3)

Inspection of the pressure system at the launch site verifying damage has not been sustained during transportation or handling

before the above testing.

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11.5.1.2.1. Remote pressurization is required for the following conditions:

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11.5.1.2.1.1. Initial pressurization of any vessel or system with an inert medium.

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For metallic vessels/tanks or systems, initial pressurization at the ranges does not have to be done remotely and/or use blast

protection if initial pressurization was performed at off-range sites, such as factory acceptance testing, and followed-up by

acceptable post-test inspection.

11.5.1.2.1.2. Any pressurization that will exceed MOP/MEOP.

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11.5.1.2.1.3. Any system or vessel whose design or condition is considered unknown or questionable by the appropriate local

safety authority.

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11.5.1.2.2. All personnel shall be evacuated whenever pressure exceeds the MAWP.

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11.5.1.2.3. Suitable barriers shall be used to protect personnel. The payload project and the appropriate local safety authority

shall determine the adequacy of the blast shield for the pressure and volume of the system.

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11.5.1.3. Pressure Systems Pressurization Operations

11.5.1.3.1. Pressure systems shall be inspected upon arrival on the ranges or before first operation.

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11.5.1.3.1.1. Where there is evidence that systems have been damaged or overstressed, replacement or, at a minimum, remote

initial pressurization shall be required.

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11.5.1.3.1.2. Payload projects who do not perform initial pressurization remotely shall certify to the appropriate safety

authority that no evidence of damage or overstress exists.

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11.5.1.3.2. A system and/or facility check shall be made before the start of the pressurization operation.

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11.5.1.3.3. Personnel present during any pressurization shall be limited to those in direct support of the operation. During

dynamic pressurization of flight pressure vessels/tanks, personnel shall not be exposed any time vessel/tank pressure exceeds

50% of the vessel/tank’s design burst rating. Once the flight vessel/tank is in a static condition and verified to not leak,

personnel may return to the area as long as vessel/tank pressure does not exceed MOP.

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11.5.1.3.4. Personnel may be present in the area of ground pressure vessels/tanks at all times when pressurized to no greater

than MAWP.

Exception: During initial pressurization of ASME/DOT compliant vessels, personnel must evacuate when pressure exceeds

50% of MAWP during dynamic pressurization activity. After initial pressurization of a ground pressure vessel/tank, it is

acceptable for personnel to be present during subsequent pressurizations (static and dynamic states) provided the vessel is still

within its design and cycle life.

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11.5.1.3.5. If a leak occurs during pressurization, the system and/or subsystem shall be depressurized before adjusting any

fittings.

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11.5.1.3.6. Unless otherwise specified, hoses over 2 feet (0.6 meters) in length, and pressurized above 100 psig (1.03 MPa),

shall meet the following restraint requirements:

1) the flexible hose shall be properly secured at each end, unions, and every 6 feet along the length of the hose by an approved

stainless resistant device by securely attaching to the structure in a manner that in no way interferes with the hose flexibility.

2) If the hose cannot be securely attached to the structure every 6 feet, weighted bags (minimum of 50 pounds) sand or shot

bags (with approval of range safety), ingots, or other suitable weights shall be used as flexible hose anchors or anchoring

attach points at a minimum of 6 foot intervals.

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11.5.1.3.7. Bolts and fittings shall not be loosened or torqued while the system is under pressure.

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11.5.1.3.8. Any system that requires devices such as pressure regulators, pressure-reducing valves, safety valves, or pressure

relief valves shall not be activated unless the devices are in place and in operable condition. Only qualified and authorized

personnel shall change the setting of these valves and regulators.

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11.5.1.3.9. Flight hardware pressure vessels that exhibit a brittle fracture or hazardous leak-before-burst (LBB) failure mode

shall maintain a minimum safety factor of 1.5:1 during transport or ground handling operations unless otherwise specified and

approved by the PSWG and Range Safety.

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11.5.1.3.10. Flight hardware pressure vessels that have a non-hazardous LBB failure mode shall maintain a minimum safety

factor of 1.5:1 during transport or ground handling operations.

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11.5.1.4. Pressure Systems Entry, Maintenance, and Repair

11.5.1.4.1. Pressure Systems Entry and Repair Requirements

11.5.1.4.1.1. Before entry into or repair of a pressurized system, depressurization of that portion of the system is mandatory.

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11.5.1.4.1.2. The steps listed below shall be followed:

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11.5.1.4.1.2.1. A minimum of two block valves shall be closed between the portion of the system to be opened and the source

of pressure.

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11.5.1.4.1.2.2. The section of line to be opened and the section between the block valves in series shall be vented

(depressurized) to atmospheric pressure before the start of work and remain vented (depressurized) during all phases of work.

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11.5.1.4.1.2.3. Whenever operations permit, the entire system shall be depressurized before a portion of the system is isolated,

vented, and opened.

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11.5.1.4.1.2.4. Venting a pressure system shall be accomplished through vent valves. Regardless of pressure, venting shall

never be accomplished by loosening or removing a fitting.

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11.5.1.4.1.2.5. Lockout devices and warning tags shall be attached to the valves that are isolating the area where system entry

will be made.

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11.5.1.4.1.2.6. The isolated area shall be verified as being depressurized before opening.

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11.5.1.4.2. Open System Work Precautions

11.5.1.4.2.1. Whenever a depressurized section of a pressurized system is to be entered or there is disassembly of any system

components, it is considered open system work and the following precautions shall be observed:

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11.5.1.4.2.1.1. Authorization for entry or disassembly of any system components, is required from the responsible complex

or area supervisor.

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11.5.1.4.2.1.2. Personnel limits shall be established in a local safety authority approved procedure.

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11.5.1.4.2.2. When it is necessary to remove components from the system, due care shall be exercised to prevent moisture or

particle contamination from outside sources.

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11.5.1.4.2.3. Lockout devices and tagging shall be used to ensure systems or subsystems are not operated while work is being

performed on the system.

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11.5.1.4.2.4. Work requiring lockout and tagging includes the following:

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11.5.1.4.2.4.1. The system is depressurized for maintenance.

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11.5.1.4.2.4.2. The work to be performed extends to another shift, either same crew next day or a different crew the same day.

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11.5.1.4.2.4.3. The work site is left unattended.

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11.5.1.4.2.4.4. The valve is not visible at all times.

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11.5.1.4.2.4.5. Valves shall be rendered inoperative with a lockout device compatible with the valve material and the lockout

devices shall be approved by Range Safety or the local safety authority.

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Range Safety Approved Lockout Devices:

1. Passing a metal chain through the hand wheel and the valve yoke or around the bottom of the valve body or pipe, and then

locking the chain.

2. Making the valve inaccessible by locking the housing that encloses the valve, locking the cover of a valve pit, or removing or

locking the hand wheel extension of an underground valve or a valve that can- not be reached from the ground or a valve

platform.

3. Locking and tagging electrical controls of valves with electric motor actuators.

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11.5.1.4.2.5. The following criteria shall be observed when removing locks and tags and returning the system to service:

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11.5.1.4.2.5.1. Lockout devices used to render a valve inoperative shall be removed only by an authorized work crew after all

work has been accomplished and, when applicable, approved by the proper authority.

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11.5.1.4.2.5.2. Tags shall be removed only by the crew placing the tag.

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11.5.1.4.2.5.3. Removed tags shall be returned to the crew office and mated with the tear off portion of the tag.

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11.5.1.4.2.5.4. Both tag and tear off portion shall be filed or disposed of in accordance with current practice.

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11.5.2. Pressure Systems Containing Liquid Propellant. In addition to the requirements noted above, the following

requirements shall be adhered to when operating, testing, and maintaining pressure systems containing liquid propellants.

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11.5.2.1. General Operating Requirements for Pressure Systems Containing Liquid Propellants

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11.5.2.1.1. The Fire Department shall be notified of the presence of propellants in any facility as well as any specific

firefighting and spill handling support requirements.

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11.5.2.1.2. During Any Mishap or Incident. At the ER, the designated Operations Controller is the on-scene commander until

relieved by the 45MSG/DET 1 Commander or Fire Chief. Pad Safety advises, ensures control, and supports, as necessary, in

accordance with SLD 45 IEMP 10-2. At the WR, the Support Group Commander or Fire Chief serves as the incident

commander and Pad Safety advises, ensures control, and supports, as necessary. At KSC the Fire Chief serves as the incident

commander during any mishap or incident. For NASA contracted processing facilities, off of government property follow the

local processing facilities safety procedures.

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11.5.2.1.3. Simultaneous tanking of fuels and oxidizers aboard a launch vehicle/payload is prohibited.

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11.5.2.1.4. Vessels, lines, and propellant loading systems shall be properly bonded and commonly grounded.

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11.5.2.1.5. Vapor monitoring equipment shall be used for leak (sniff) checks and general atmosphere monitoring to determine

the necessity for PPE. Vapor monitoring equipment shall be approved by the appropriate local safety authority and is subject

to approval by Bioenvironmental Engineering.

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11.5.2.1.6. A toxic vapor check shall be conducted by the operations control authority when personnel are in a facility that

has toxic propellants contained in flight hardware and GSE at the start of each 8-hour shift and before entering a facility in

which toxic propellant has been left unattended for 8 hours or more.

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11.5.2.1.7. In locations where liquid propellants will be handled, water shall be available in the area in sufficient quantities

for fire, spill, and medical use. Skin or eye contact with toxic propellants shall be flushed with copious amounts of water. For

specified flush periods, consult the Safety Data Sheet (SDS) for the product being used. Appropriate medical attention shall

be sought as early as possible (during flushing if possible).

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11.5.2.1.8. The supervisor shall notify the appropriate local safety authority a Bioenvironmental Engineering of any injury

involving toxic or non-toxic propellants.

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11.5.2.1.9. Transport of more than five gallons of hypergolic propellants. in non-DOT approved containers, shall require a

Security or HOS escort as described in Chapter 16 of this volume. Transport of any quantity of hazardous commodities in

DOT approved containers does not require escort.

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11.5.2.2. Pre-Operational Requirements for Pressure Systems Containing Liquid Propellants

11.5.2.2.1. The payload project procedures, approved by the appropriate local safety authority, shall be used for all propellant

operations and the checkout of propulsion systems.

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11.5.2.2.2. As required by procedure, the appropriate local safety authority (Pad Safety on Space Force property) and other

required support shall be on hand before the conduct of operations.

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11.5.2.2.3. Appropriate local safety authority concurrence to proceed shall be obtained by the payload project before the

conduct of operations.

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11.5.2.2.4. Personnel qualification and training shall be verified by the respective supervisors.

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11.5.2.2.5. Before starting operations, the payload project and the appropriate local safety authority shall verify that the facility

and equipment are ready by performing the following checks:

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11.5.2.2.5.1. Wet check of safety showers and water lines before propellant transfer.

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11.5.2.2.5.2. Accessibility and operability of emergency exit doors.

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11.5.2.2.5.3. Operability of drain and sump systems and their capability for handling a worst case spill and wash down.

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11.5.2.2.5.4. Operability of vent systems.

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11.5.2.2.5.5. Availability of fire protection.

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11.5.2.2.5.6. Proper configuration and grounding of propellant systems.

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11.5.2.2.5.7. Weather conditions.

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11.5.2.2.5.8. PA announcements, warning lights, and barriers.

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11.5.2.2.5.9. Implementation of access control.

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11.5.2.2.5.10. All required support on hand.

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11.5.2.2.5.11. Availability of approved operating procedures and emergency procedures.

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11.5.2.2.5.12. Removal of ignition sources from the area.

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11.5.2.2.6. The appropriate local safety authority or security authority shall inform the Test/Launch Conductor that the

appropriate roadblocks have been established, the hazard area cleared, and propellant tanking can begin.

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11.5.2.2.7. Propellant transfer shall not start when the passage of an electrical storm is imminent (within 5 nautical miles). A

propellant transfer operation already in progress shall be interrupted or expeditiously concluded at the discretion of the

appropriate local safety authority or the supervisor in charge of the operation. The OSP for each facility shall detail the

procedure for this situation. At the WR, propellant operations shall not start when lightning is within 10 nautical miles. At

the WR, the guidance provided in 5.6.3 shall be followed.

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11.5.2.2.8. Emergency protective equipment shall be provided as required by the appropriate local safety authority.

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11.5.2.2.9. The payload project shall provide the maximum source strength based on quantity (gallon or pound) and surface

area. The worst case credible spill (quantity) shall be based on a failure analysis provided to the appropriate local safety

authority before the operation. This information shall be used to determine the downwind sector that shall be evacuated if a

large spill occurs.

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11.5.2.2.10. Where feasible, the payload project shall develop a means to minimize the surface area of spills by providing a

dike or other means of containment.

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11.5.2.3. Controls

Leaks, spills, and venting of toxic propellants may create a toxic cloud. This toxic cloud will diffuse through the atmosphere at

a rate that varies with meteorological conditions and spill size. The establishment of clearance zone controls helps mitigate

exposure to this hazard.

11.5.2.3.1. A localized safety clearance zone that limits personnel access to those individuals directly involved with the

operation and who have the proper protective equipment shall be established.

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11.5.2.3.2. A larger safety clearance zone that limits personnel access to those individuals directly or indirectly involved in

the operation or mission shall be established. The determination of the larger safety clearance zone shall include consideration

of the availability of fencing and Security or HOS check points and the TNT equivalency of the propellants involved.

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11.5.2.3.3. The minimum downwind sector that must be immediately evacuated in the event of a major spill shall be provided

to all personnel involved in the operation, and controls shall be in place to implement the control of this sector. The downwind

sector shall be defined in the OSP.

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11.5.2.4. Operating Requirements for Pressure Systems Containing Liquid Propellants

11.5.2.4.1. Concurrence from the appropriate local safety authorities (Pad Safety on Space Force property) shall be obtained

before starting propellant transfer operations and before pressurization.

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11.5.2.4.2. Portable vessels and systems containing incompatible fuels and oxidizers shall not be brought into closer proximity

than allowed for permanent systems unless otherwise agreed to in advance by the appropriate local safety authority.

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11.5.2.4.3. Fire Protection and Environmental Health shall be available as required by procedure.

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11.5.2.4.4. All persons and vehicles not absolutely essential to the operation shall be evacuated.

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11.5.2.4.5. Before opening a contaminated or toxic propellant system, the system shall be flushed or purged to concentration

levels coordinated with Bioenvironmental Engineering and approved by the appropriate local safety authority. At the ER,

Environmental Health shall monitor and report any levels exceeding health standard criteria to the Pad Safety Office. At the

WR, Bioenvironmental Engineering and Environmental Health monitor for AF operations only. Contractors are responsible

for monitoring their own systems.

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11.5.2.4.6. The handling and transfer of toxic materials and propellants shall be monitored by the appropriate local safety

authority to ensure the safety of personnel involved in the operation and personnel downwind of the operation.

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11.5.2.4.7. Vapor monitoring shall be continuous whenever personnel are in enclosed areas having toxic propellants present.

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11.5.2.4.8. At KSC and the ER, in the case of a lightning warning (lightning within 5 nautical miles), the system shall be

secured; the complex, storage, or operating area shall be cleared; and the required actions called for in procedures and OSPs

shall be taken (see Attachments 3, 4, and 5 of this volume). At the WR, work stop’s and systems shall be secured when

lightning is within 10 nautical miles. Buildings are evacuated when lightning approaches 5 miles.

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11.5.2.4.9. Reentry into the area of a launch vehicle and/or payload with fuel and oxidizer aboard shall be held to a minimum

and shall be subject to approval by the appropriate local safety authority.

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11.5.2.4.10. Reentry into the area of a launch vehicle and/or payload with only fuel aboard shall also be held to a minimum

and shall be subject to the approval of the task or area supervisor and local safety authorities.

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11.5.2.4.11. Tanking of toxic or cryogenic liquids aboard a launch vehicle or payload during launch countdown shall be

performed as late as possible. If tanking is required during launch processing before the countdown, tanking shall be performed

as late in the processing as is practical.

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11.5.2.4.12. The appropriate actions and evacuations shall take place in the event of an emergency such as a propellant spill.

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11.5.2.4.13. All appropriate local safety authorities including Cape Support (ER), Range Safety (WR), and Pad Safety (WR),

as well as the PSWG Chairperson, shall be notified of any propellant mishap and incidents, including near misses.

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11.5.3. Releases of Toxic Vapors

11.5.3.1. All releases of toxic vapors shall comply with NPR 8715.2, NASA Emergency Preparedness Plan Procedural

Requirements, and any local response requirements KNPR 8715.2, Comprehensive Emergency Management Plan for KSC;

SLD IEMP, AFI 10-2501, and any SLD-specific supplements, instructions, or plans.

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11.5.3.2. Any plans to vent toxic vapors shall be coordinated with the appropriate local safety authority and any other

approving authorities. At the ER, any plans to vent toxic vapors shall require coordination with the Civil Engineer –

Environmental Flight, Bioenvironmental Engineering, and Environmental Health and Range Safety approval. At the WR,

venting operations shall be conducted in accordance with 30SWI 91-106 and the applicable facility or operations plan.

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11.5.3.3. The actual venting operation shall not start without approval from the appropriate local safety authority.

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11.5.3.4. Venting restrictions and controls shall be identified in the appropriate OSP or operating procedure.

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11.5.3.5. Venting operations require that the appropriate downwind sector be evacuated.

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11.5.3.6. The operations control authority shall verify that Environmental Health or the local equivalent authority is present

to verify concentration levels at the control area boundary.

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11.5.3.7. The operations control authority shall verify that Security Police or HOS maintain the appropriate roadblocks.

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11.5.3.8. Planned releases shall be in accordance with permits maintained by the appropriate local safety authority (e.g., Civil

Engineering for Space Force Range Safety locations).

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11.5.4. Emergency Decontamination of Facilities and Personnel. Emergency decontamination of facilities and personnel

shall be accomplished under the direction of the appropriate local safety authority (Pad Safety on Space Force property) with

Environmental Health and the Fire Department performing the decontamination, if required.

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11.5.5. Handling Leaks and Spills of Liquid Propellant

11.5.5.1. PPE for Treating Spills. Personnel treating or flushing major spills of toxic and corrosive propellants shall wear

the proper protective clothing and equipment.

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11.5.5.2. Leak and Spill Procedures

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11.5.5.2.1. The payload project and supporting agencies shall develop procedures for handling major and minor leaks and

spills. Notification shall be provided to the appropriate local hazardous spill response personnel, local safety authority, the

PSWG Chairperson, and others per NPR 8621.1. Additionally, CCSFS Cape Support (ER 321-853-5211) or VSFB Command

Post (WR 805-606-9961) shall be notified of any spill or release of hazardous material on their respective range and when the

spill takes place on KSC property dial 911 (or 321-867-7911 from a cell phone) to notify the Protective Services Control

Center and receive spill response assistance as needed.

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11.5.5.2.2. Each area that contains liquid propellants shall have a plan approved by the appropriate local safety authority for

evacuation based on spill size (quantity and surface area). At the ER, an evacuation zone for a small spill (for example, a

gallon of hypergolic propellant) is typically 700 feet downwind or more and approximately 200 feet radially if the spill is

allowed to spread out on a flat surface. At the WR, required evacuations are 2,000 feet upwind or as published in the OSPs

and Toxic Hazard Zones (THZs).

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11.5.5.2.2.1. The approved evacuation plan shall describe the localized safety clearance zone, the general support (larger)

safety clearance zone, and the minimum downwind sector to be evacuated in the case of a large spill.

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11.5.5.2.2.2. The downwind sector shall be based on the following factors:

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11.5.5.2.2.2.1. Maximum source strength based on quantity (gallon or pound) and surface area. The payload project shall

determine a worst case spill (quantity) based on a failure analysis.

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11.5.5.2.2.2.2. Maximum vapor concentration acceptable for personnel exposure.

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11.5.5.2.2.2.3. Average weather criteria, such as wind direction, wind speed, temperature, temperature lapse rate.

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Weather variables can be obtained from the local Weather Officer.

11.5.5.2.3. These procedures shall be in accordance with the applicable OSP and shall be submitted to the appropriate local

safety authority for review and approval.

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11.5.5.2.4. Procedures shall address the topics covered in 10.7.

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11.5.5.3. Handling Minor Leaks or Spills

11.5.5.3.1. Minor leaks or spills shall be cleaned up with absorbent material where possible.

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For safety and hardware protection reasons, certain spills may require the spill to be washed or flushed with water into collecting

tanks or holding basins and disposed of properly to prevent ecological or health hazards. See CPIA 394 for information on

treating spills.

11.5.5.3.2. The appropriate local safety authority shall be notified of minor leaks and spills and subsequent actions.

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See CPIA 394 and Range Safety for guidance on disposal of toxic or corrosive propellants.

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11.5.5.4. Handling Major Leaks or Spills

11.5.5.4.1. Major leaks or spills shall be handled according to the situation with the objective of minimizing injury to personnel

and damage to facilities and equipment in accordance with local procedures (KNPR 8715.2, Comprehensive Emergency

Management Plan; SLD IEMP, AFI 10-2501, and any SLD-specific supplements, instructions, or plans). If the requirements

described below are in conflict with these OPLANS, the OPLANS shall take precedence.

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11.5.5.4.2. The following actions shall be taken:

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11.5.5.4.2.1. Time and the situation permitting, the source of the propellant flow and pressure source shall be shut down.

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11.5.5.4.2.2. All personnel shall be evacuated out of the area including the minimum downwind sector. Travel shall be upwind

or crosswind to the minimum evacuation radius as defined in the Facility Operating Plan, Operations Safety and Area Safety

Plan, or the payload project emergency procedure, and away from the downwind sector.

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11.5.5.4.2.3. Injured or trapped personnel shall be rescued. Appropriate PPE shall be used.

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11.5.5.4.2.4. Adjacent areas shall be alerted.

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11.5.5.4.2.5. Personnel shall be available to direct emergency crews and to provide information to assist them.

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11.5.5.4.2.6. All personnel shall report to the supervisor at the designated assembly point for head count.

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11.5.5.5. Handling Cryogenic or Toxic Liquid Spills

11.5.5.5.1. Spills of cryogenic liquids shall be flushed with large amounts of water into the surrounding ground surface or a

holding basin.

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11.5.5.5.2. Spills of toxic or corrosive propellant, or those that could affect the public health or ecology, shall be flushed with

water or another neutralizing agent into a collecting tank to be disposed of in accordance with approved procedures.

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Refer to CPIA 394 Volume III, Liquid Propellants, the Medical Department, and the Florida Department of Environmental

Protection (ER) or the California Department of Environmental Protection (WR) for guidance.

11.5.5.6. Flight Graphite Epoxy Composite Overwrapped Pressure Vessel Operations. Only composite overwrapped

pressure vessels (COPVs) that meet the design, test, and inspection requirements described in Volume 3 of this publication

shall be used.

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11.5.5.6.1. If COPVs that contain inert pressurant are in close proximity to propellant tanks, the payload project office shall

provide test data proving that the composite overwrap is compatible with the propellant in terms of strength degradation,

flammability, and ignition/combustion requirements, when personnel are at risk. If this data is not available, the following

actions shall be accomplished:

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11.5.5.6.1.1. Verification that the COPV is not in a credible "drip zone" for liquid propellants during ground processing

operations.

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11.5.5.6.1.2. If the COPV is in a credible "drip zone," the COPV shall be protected with a coating and/or covers and/or splash

shields to guard against contact with potentially incompatible liquids.

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11.5.5.6.1.3. Hazardous vapor detectors shall be used to monitor the propellant tanks.

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11.5.5.6.2. If COPVs on AFSPC ranges will be pressurized to pressures greater than 1/3 of the COPV design burst pressure,

the pressurization shall be performed remotely, or a blast shield shall be used to protect personnel. If the vessel is to remain

pressurized, personnel access shall not be permitted for a minimum of 10 minutes after the pressurization is completed.

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11.5.5.6.3. Personnel limits for each operation on or near a pressurized COPV/spacecraft shall be established to minimize

personnel exposure to pressurized COPVs.

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11.5.5.6.4. The transport of pressurized COPVs shall only occur on routes approved by the local safety authority and that

minimize personnel and facility exposure. In addition, pressurized COPV transport shall utilize escorts and shall only occur

during time periods designated and approved by the appropriate local safety authority.

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11.5.5.6.5. COPVS shall be protected from damage due to impacts during manufacturing, handling, transportation, assembly,

and integration of COPVs into the payload project’s system(s).

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11.5.5.6.6. Except for the pressure test requirements of Volume 3 of this publication, pressure testing of systems with COPVs

shall not exceed the manufacturer MOP pressure limit without the manufacturer's approval and the PSWG and Range Safety's

agreement.

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11.5.5.6.7. The payload projects shall develop and provide to the appropriate local safety authority the Emergency Response

Plans (ERPs). These ERPs shall include contingency safing and back out plans for COPVs (taking into consideration leaks,

impacts, and exposure to incompatible chemical agents). If implemented, a real time assessment shall be accomplished and

contingency operations taken, as required. The ERP shall be approved by the appropriate local safety authority.

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11.5.5.6.7.1. The payload project shall provide the ERP to Range Safety at least 45 calendar days prior to the start of hazardous

operations involving COPVs.

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11.5.5.6.7.2. The payload project shall obtain approval by the by the appropriate local safety authority prior to the start of

hazardous operations.

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11.5.5.6.8. Prior to the first pressurization of Graphite/Epoxy (Gr/Ep) COPVs at the payload processing launch site, an

inspection of the vessel for visible damage shall be performed by a trained inspector. The trained inspector’s skills shall be

comparable to a Level II visual inspector, per the American Society of Nondestructive Testing (ASNT) Recommended Practice

No. SNT-TC-1A (see ANSI/AIAA-081). If this inspection is not possible at the payload processing launch site area (i.e., the

Gr/Ep COPV is not accessible), then it shall be conducted the last time the Gr/Ep COPV is accessible for inspection.

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11.5.5.6.9. After completing the visual inspection and determining that there is no evidence of critical damage to the Gr/Ep

COPV, initial pressurization of a COPV at the launch site COPVs shall be pressure tested to 100% of the maximum ground

operating pressure. The minimum hold time for this pressure test shall be 5 minutes. This pressurization shall be conducted

remotely, or a blast shield shall be used to protect personnel. Personnel will not approach the COPV for a minimum of 10

minutes following the pressurization.

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11.5.5.6.10. If Gr/Ep COPVs are to be pressurized to pressures greater than 1/3 of the Gr/Ep COPVs design burst pressure,

the pressurizations shall be performed remotely, or a blast shield shall be used to protect personnel. If the vessel is to remain

pressurized, personnel access shall not be permitted to the area for at least 10 minutes after pressurization is completed.

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11.5.5.6.11. Personnel limits for each operation on or near the Gr/Ep COPV/Spacecraft shall be established to minimize

personnel exposure to the pressurized tank when at pressures greater than one third design burst pressure.

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11.5.5.6.12. The transport of pressurized Gr/Ep COPVs at pressures greater than one third design burst pressure shall be along

routes that minimize exposure to personnel and facilities with escort during designated “off-shift” time periods.

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11.5.5.6.13. The Mechanical Damage Control Plan (MDCP) for the Gr/Ep COPVs shall be provided by the design agency

and made available for review by the applicable safety organization.

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11.6.13. COPV Test Data Requirements.

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11.6.13.1. Prelaunch inspection and pressure test reports.

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11.6.13.2. In-service inspection and recertification test reports for reusable flight COPVS.

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11.6.14. Testing Flight Hardware Pneumatic and Hydraulic Components. Pressure gauges and transducers shall be periodically

calibrated.

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11.6.15. COPVs with Brittle Fracture or Hazardous LBB Failure Mode Safe-Life Demonstration Requirements. The initial

report that documented the fracture mechanics safe-life analysis (for metal liners only) or safe-life testing shall be periodically

revised and updated during the life of the program.

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11.6.16. Flight Hardware Cryostats or Dewars with Brittle Fracture Failure Mode Safe-Life Demonstration Requirements. The

initial report that documented the fracture mechanics safe-life analysis or safe-life testing shall be periodically revised and

updated during the life of the program.

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RESERVED

ORDNANCE OPERATIONS

Ordnance Operations Procedure Requirements

13.1.1. All ordnance operations shall be covered by an appropriate local safety authority approved operating procedure.

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13.1.2. All operations conducted in ordnance facilities shall be specified in procedures and/or operating instructions approved

by the appropriate local safety authority.

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13.1.3. Procedures shall include transportation activity on-Center, all on-base or facility transportation.

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Ordnance Transportation, Receipt, and Storage

13.2.1. Ordnance Transportation, Receipt, and Storage Standards

13.2.1.1. All ordnance transportation, receipt, and storage shall be performed in accordance with, AFMAN 24-204, Preparing

Hazardous Materials for Military Air Shipments; NASA-STD-8719.12, Safety Standard for Explosives, Propellants, and

Pyrotechnics; 49 CFR, Transportation; DESR 6055.09_AFMAN 91-201, Explosive Safety Standards , and any Range/SLD-

specific supplements or instructions, as applicable.

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13.2.1.2. The transportation and shipment of explosives by rail, air, vessel, and public highway shall comply with the

Department of Transportation (DOT) Code of Federal Regulation (CFR) Title 49 Parts 172 through 179.

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Receipt inspection requires DOT violations to be reported (see 13.2.4).

13.2.1.3. To be acceptable for transportation by any mode, explosives shall have the following items provided to the PSWG

and Range Safety and verified by the payload project before shipment:

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13.2.1.3.1. Proper DOT classification for transport. For air transport, refer to AFMAN 24-204.

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13.2.1.3.2. An assigned hazard classification hazard class and/or division; storage compatibility group; DOT class, markings,

shipping name and label; and the United Nations (UN) serial number.

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13.2.1.3.3. The availability confirmation of adequate and suitable storage at the payload processing facility and on the launch

site area.

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Note: Availability of adequate and suitable storage space depends on the hazard classification, the size of the storage containers,

and temperature and humidity requirements.

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13.2.1.3.4. The availability of proper connectors and cabling for ordnance checkout if local facilities and equipment are to be

used.

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For all hazardous ordnance, the presence of a convoy may be required.

13.2.2. Ordnance Transportation General Requirements

13.2.2.1. Transportation Restrictions. Payloads shall not be shipped to the payload processing facility and launch site area

with ordnance such as EEDs installed unless prior written approval has been obtained from the appropriate local safety

authority.

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13.2.2.2. Ordnance Services Coordination. Plans for shipment of ordnance to the payload processing facility and launch

site area must be coordinated with the local ordnance support entity.

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Note: Plans for shipment of ordnance to CCSFS shall be coordinated with CCSFS Ordnance Services. Plans for shipment of

ordnance to VSFB shall be coordinated with SLD30 /SEGW.

13.2.2.3. Ordnance Transportation Address for Space Force Range Deliveries. All ordnance shipments, including

EEDs, shall be addressed as shown in 13.2.2.3.1 or 132.2.3.2:

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13.2.2.3.1 Ordnance Transportation Address for Eastern Range Deliveries:

To: Transportation Officer

Patrick Space Force Base, FL 32925

Marked for: Manager, Ordnance Services

Bldg.72910 (Munitions Storage Area #2)

Cape Canaveral Air Force Station, FL

Special Markings: Name of Program

Name of Project Monitor or Office

Complete Address

From: Sender's Name and Address

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13.2.2.3.2 Ordnance Transportation Address for Western Range Deliveries:

13.2.3. ER Ordnance Delivery and Receipt

13.2.3.1. The Range User must schedule ordnance deliveries by calling CCSFS Cape Support (321-853-5211). Once CCSFS

Ordnance Services has received an ordnance delivery, they are the only authorized transport service on the base. Ordnance

Services will only deliver to locations that have been licensed or sited for ordnance.

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13.2.3.2. The Range User shall notify Pad Safety of ordnance deliveries on CCSFS.

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13.2.3.3. After receipt at Munitions Storage Area #2 at CCSFS, all ordnance transportation shall be performed by CCSFS

Ordnance Services unless specifically approved by SLD45/SE Safety.

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13.2.4. Ordnance Shipment Inspection

13.2.4.1. As soon as possible after receipt, a receiving inspection shall be conducted by ER Contractor Ordnance Services or

30 LRS (WR), the appropriate local safety authority and the payload project to ensure that no damage has occurred during

shipment.

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13.2.4.2. Any shipment discrepancy or DOT violation shall be reported to the Ordnance Services (ER) or 30 LRS (WR) and

appropriate local safety authority.

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13.2.5. Ordnance Storage

13.2.5.1. Payload projects operating on the ER and WR shall store ordnance and propellants in facilities specifically designed

for that purpose and approved by PSWG, Range Safety and/or the Department of Defense Explosive Safety Board (DDESB)

and/or local safety authority. Processing facilities shall not be used for the storage of ordnance.

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13.2.5.2. The payload project shall plan to remove ordnance from the ranges when it is no longer needed or becomes defective.

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13.2.5.3. The payload project shall furnish instructions for the disposition of stored ordnance items to the storage provider

upon project termination or when ordnance items are no longer required.

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To: Transportation Officer

Vandenberg Space Force Base, CA 93437

Marked for: 30 LRS/LGRDDC

2010 New Mexico Street

Vandenberg Space Force Base, CA 93437

Name of Project Monitor and Office

Complete Address

From: Sender's Name and Address

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Ordnance Systems Grounding

13.3.1. Ordnance Systems Grounding PPE

13.3.1.1. Personnel handling, installing, or electrically connecting ordnance or working within ten feet of exposed, solid

propellant grain shall wear appropriate local safety authority approved, flame-retardant, non-static producing, long-sleeve,

cuffless, full-body garments (coveralls, not smocks) with leg stats, or safety shoes with a Conductive (CD) or Static Dissipating

(SD) rating, and/or wrist stats. If required, the payload project shall submit a sample of the garment for testing.

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Note: The following is guidance for Ordnance Systems Grounding PPE Criteria:

(1) The two primary concerns in selecting garments to be worn by personnel handling, installing, or electrically connecting ordnance or working

within 10 feet of exposed, solid propellant grain are static and fire. The static concern is self-explanatory. Anti-static smocks may be approved by

the appropriate local safety authority if there is no significant fire hazard. Fire is a primary concern because of the potential for solid/liquid

propellant fires. This concern dates back to the X-248 solid motor mishap in the spin test facility at the ER in 1964. Although the most probable

cause for this mishap was static electricity, it was observed the survivors of the mishap would have fared much better had they been wearing full-

body protection, in other words, coveralls, rather than smocks. Another key piece of information is the fact that the inadvertent motor initiation

occurred during a non-hazardous operation.

(2) With the transition of the Space Force and NASA expendable launch programs to the Space Shuttle Program in the early 1980s, many activities

involved both agencies from a launch vehicle, facility, or personnel point of view. It became increasingly more difficult for safety personnel to

ascertain the acceptability of the coveralls being used, particularly with respect to Space Force operations in the Payload Changeout (clean) Room

on NASA/KSC's shuttle launch pad. For that reason, the ER Safety Office joined forces with the KSC Safety Office to develop common standards

and specifications for coveralls for both non-cleanroom and cleanroom environments. The standardized requirements were documented in the

KSC Ground Operations Safety Plan GP 1098, a publication that has since been superseded by other documents. The following guidance on the

selection of coveralls is provided for the payload projects:

(3) General Criteria for Coveralls:

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a. Flame Retardant. Cotton garments meeting the appropriate local safety authority flame retardant requirements should meet the requirements

of MIL-C-43122G, Cloth, Sateen, Cotton, Flame Retardant Treated: "finished cloth shall have an average time of after-flame of not more than

2.0 seconds, and not more than 40 percent consumed both initially and following 15 launderings.

b. Thermal Protection. Garments used in solid rocket motor open grain and Category A ordnance operations should provide a measure of radiant

heat and flame contact protection where practical. See Aerospace Medicine, Volume 40, Number 11, Method and Rating System for Evaluation

of Thermal Protection, November 1969. NASA/KSC blue-collar garments have been tested for thermal protection (Naval Space Development

Center technical memorandum, 6 March 1979) and provide greater than 14 seconds radiation protection before skin blister at a brightness

temperature of 1900oC and greater than 3 seconds flame contact protection before skin blister at a flame temperature of 1220oC.

c. Static Dissipation. Garments meet the appropriate local safety authority static dissipation requirement when voltage drops below 350 volts in

5 seconds at 45 plus 5 percent relative humidity (maximum) and 75oF temperature (maximum). See NFPA 77, Recommended Practices on

Static Electricity or NASA KSC Materials Testing Branch Report MMA-1985-79, Standard Test Method for Evaluating Triboelectric Charge

Generation and Decay.

d. Rescue. Consideration should be given to rescue of personnel during hazardous operations. Rescue aids can usually be applied external to the

garments in general use applications. However, because of frequent confining work, rescue straps are mandatory for cleanroom garments used

for hazardous operations.

e. Sleeves/Legs. Coveralls should contain full-length sleeves and legs; frocks should contain full-length sleeves.

f. Pockets. Pockets, if any, should be lattice type, arranged not to trap hazardous fluids.

g. Cuffs. Garments should not have cuffs (hazardous fluids must not be trapped).

h. Fasteners. Fasteners should be protected from contact (burning) with the skin.

i. Color. Garments should be white or natural in color to take advantage of flame/heat reflectivity.

(4) Detailed Criteria for Non-Cleanroom Coveralls. In addition to meeting general criteria, non-cleanroom coveralls used in ordnance

facilities/operations should meet the following:

a. Garments should be readily identifiable as meeting the appropriate local safety authority requirements:

(1) Approved general-use, NASA/KSC hazardous operation coveralls are identified by blue collars.

(2) Aramid (NOMEX) garments containing 1 percent (minimum) filament wire "Brunsmet" or "Bekinox" or carbon thread in one-quarter

inch raised grid pattern (carbon grid suits) are approved (carbon thread garments are identified by green rescue straps per Paragraph.

2.16.1.3.d in MIL-C-43122F.).

(3) Aramid (NOMEX) garments (non-carbon grid suits) dipped with an appropriate local safety authority approved anti-static solution, such

as Ethoquad, subject to periodic checks to ensure the anti-static solution remains active, can be used and should be stenciled "KSC Safety

Approved." The payload project should acquire white blue-collar coveralls per the KSC specification because the coveralls are known to meet

requirements and are readily recognizable. Often the available data on other coveralls is insufficient to determine static resistant and/or fire

retardant acceptability. In these cases, a sample set of coveralls needs to be provided to the appropriate local safety authority for testing by the

KSC Materials Laboratory.

b. Coveralls should be properly cleaned to comply with the manufacturer instructions.

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(5) Detailed Criteria for Cleanroom Coveralls. In addition to meeting the general criteria, cleanroom coveralls used in ordnance facilities/operations

should meet the following:

a. The maximum permissible concentration of particles and fibers should not exceed 2,000 particles per square foot of 5 microns and larger, with a

maximum of 25 fibers. See ASTM F51-68, Standard Method for Sizing and Counting Particulate Contaminant In and On Cleanroom Garments,

(1984), U.S. Air Force Technical Order T.O.-00-25-203, Contamination Control of Aerospace Facilities, and Johnson Space Center JSCM 5322,

Contamination Control Requirements Manual.

Blue-collar garments should not be used for cleanroom use.

b. Garments should be readily identifiable as meeting appropriate local safety authority requirements.

(1) Approved cleanroom coveralls used in hazardous operations are identifiable in that they are 99 percent continuous filament NOMEX with

approximately 1 percent conductive nylon filament yarn (carbon impregnated)arranged in a one-quarter inch raised grid pattern (carbon grid

suits).

(2) Continuous filament Aramid (NOMEX) garments dipped with an appropriate local safety authority approved anti-static solution such as

Ethoquad, subject to periodic checks to ensure the anti-static solution remains active, are approved by the appropriate local safety authority

and should be stenciled stating that the garments have been approved and by which appropriate local safety authority.

c. Non-metallic ("Delrin©" or equal) zippers should be used on garments in lieu of buttons/snaps in the vicinity of flight hardware where the loss

of a button/snap is a concern.

d. When rescue provisions are applicable, green NOMEX parachute grab straps suitable for rescue purposes should be provided on the legs,

shoulders, torso, and back of the garment. Straps should withstand a pull of 200 pounds. Grab straps should be tacked down by breakaway

stitching at the center of the strap length to prevent the strap catching on objects while the garment is being worn.

In NASA and Space Force contractor-operated cleanroom facilities, facility users are expected to use cleanroom coveralls

provided by the NASA facility operator, Space Force facility operator or Launch Site Integration Manager (LSIM). Besides the

fact that (1) it took a long time to develop the currently approved (carbon-grid) cleanroom coveralls and (2) gaining approval for

a new type of coverall could be difficult, logistical considerations are involved. For example, a facility evacuation typically

requires the facility user to exit the facility to the outside thereby invalidating the cleanroom garments that are worn. Additionally,

it is easier for a facility operator to maintain the necessary inventory for replacement garments rather than a facility user. It is

strongly recommended that non- NASA and Space Force contractor-managed cleanroom facilities use cleanroom garments that

meet the NASA/KSC specifications.

The appropriate local safety authority has the option to invoke more stringent controls regarding PPE when necessary to

enforce Range Safety policy. For example, all personnel entering a particular control area may be required to wear the

proper coveralls.

13.3.2. Ordnance Processing Restrictions on the Use of Static-Producing Materials

13.3.2.1. Materials prone to electrostatic charge buildup shall not be used in the vicinity of ordnance and propellants.

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13.3.2.2. Compliance with the restriction on static-producing materials is handled on a case-by-case basis; however, the

following criteria shall serve as a guideline:

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13.3.2.2.1. Static-producing materials shall not come into contact with a system having an installed EED or other ordnance.

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13.3.2.2.2. Static-producing materials shall not come within 10 feet of exposed solid propellant grain; for example, no nozzle

plug or cover.

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13.3.2.3. Further restrictions and testing requirements are provided in 10.5.

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13.3.3. Ordnance System Static Ground Point Test. Static ground points in all ordnance and propellant operating and

storage facilities shall be tested according to 14.4.1 of this volume.

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13.3.4. Ordnance Systems Grounding Operations

13.3.4.1. Ordnance Systems Grounding Operations General Requirements

13.3.4.1.1. Ordnance associated equipment such as handling fixtures and missile structures shall be connected to a common

ground to ensure that an electrostatic charge cannot build up to levels that can cause ignition of the ordnance.

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13.3.4.1.2. Platforms and ladders shall be grounded when used in conjunction with vehicles and/or payloads containing

ordnance.

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13.3.4.1.3. Launch complex service tower platforms are not necessarily good electrical conductors due to corrosion, paint,

and questionable bonding of work platforms to ground. Conductive mats that are grounded to the service tower ground shall

be used if proper grounds cannot be achieved by other means. Wrists stats shall be required if proper grounding cannot be

attained.

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13.3.4.1.4. Grounding system, Megger high-voltage checks shall not be performed after initiators are installed or electrically

connected unless proper fault protection is provided, as approved by the appropriate local safety authority.

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Proper fault protection for grounding system Megger high voltage checks can include fuses placed in the leads or other

measures, as approved by the appropriate local safety authority.

13.3.4.2. Ordnance Systems Grounding Pre-Operational Checks

13.3.4.2.1. When leg stats or conductive shoes, either CD or SD, are required, grounding of personnel shall be verified using

a conductive shoe tester before the start of an ordnance operation. Leg stat or conductive shoe resistance shall not exceed 1

megohm.

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13.3.4.2.2. When wrist stats are required, grounding of personnel shall be checked with an ohmmeter. Wrist stats are required

to have a resistance between 0.8 and 1.2 megaohms, in accordance with ANSI/Electrostatic Discharge (ESD) S1.1, The

Protection of Electrostatic Discharge Susceptible Items Wrist Straps.

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13.3.4.2.3. To ensure grounding of personnel, conductive floors shall be verified in all ordnance and propellant operating

facilities before operations.

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13.3.4.2.4. Conductive floors and terminals shall be verified to be electrically bonded to a grounding system common to the

ordnance device before operations.

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13.3.4.2.5. Static ground points shall be tested in accordance with AFI 32-1065, Grounding Systems.

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13.3.4.3. Ordnance Systems Grounding Operating Requirements

13.3.4.3.1. Touching a grounded surface is required before handling an EED or other static-sensitive ordnance device.

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13.3.4.3.2. When hoisting ordnance systems with a crane, a trailing ground connection to the facility ground shall be

maintained during the hoist.

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13.3.4.3.3. Metal shipping containers shall be grounded before opening the containers.

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13.3.4.3.4. Before removing an ordnance item from a shipping container, the specific ordnance item shall be grounded.

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13.3.4.3.5. When hoisting ordnance with a crane, the ordnance and/or container and the hook shall be commonly grounded

before connecting the hook to the ordnance and/or container.

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Ordnance Operations

13.4.1. Ordnance Operating Standards and Procedures Guidance

13.4.1.1. Ordnance operations performed on Space Force property shall be conducted in accordance with DESR

6055.09_AFMAN 91-201, Explosive Safety Standard. Ordnance operations on NASA property, shall be conducted in

accordance with the following general guidance from NASA STD 8719.12, Safety Standard for Explosives, Propellants, and

Pyrotechnics.

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13.4.1.2. All initiators are considered hazardous unless range safety concurs with a downgraded designation.

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13.4.2 Ordnance Facility Inspection

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13.4.2.1. All new or modified explosives and propellant facilities shall be inspected and approved by the PSWG and Range

Safety before first use.

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13.4.2.2 Range users shall support an annual explosive safety inspection by Range Safety to determine compliance with

explosives safety criteria as defined in this publication, other DoD, and USAF standards (for example, DESR

6055.09/AFMAN 91-201, Explosives Safety Standard, and the provisions of the Explosives Safety Plan.

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13.4.2.3.The annual inspection shall include, but not be limited to, the following explosives storage and operating areas:

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13.4.2.3.1. Launch complexes.

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13.4.2.3.2. Assembly area processing facilities.

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13.4.2.3.3. Support facilities.

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13.4.2.3.4. Solid and liquid propellant storage areas.

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13.4.2.4. The results of the annual explosives safety inspection shall be reported under the provisions of ESP 1.

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13.4.2.5. Ordnance facilities shall be inspected monthly by the facility manager.

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13.4.3. Ordnance Operations General Requirements

13.4.3.1. All hazardous ordnance operations on the ranges shall be monitored and approved by Pad Safety. Hazard division

1.4S ordnance and ordnance systems are not required to meet the design requirements of AFSPCMAN 91-710 Volume 3,

Chapter 13; however, all ordnance and ordnance systems shall comply with the operations requirements of this volume.

Examples of Pad Safety coverage during ordnance operations are as follows:

1. The receipt of ordnance at the assembly and/or processing area.

2. Resistance and continuity checks.

3. "No voltage" (stray voltage) checks.

4. Hazardous ordnance installation and electrical connection.

5. Solid propellant work involving open grain.

6. Handling of liquid and solid propellant motors, segments, stages, or payloads.

7. Cycling and checkout of safe and arm (S&A) or other safety devices.

8. Destruct system checks.

9. Any render-safe operations.

10. Ordnance removal.

11. Launch operations.

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13.4.3.2. Testing of any ordnance circuit or device that could result in personnel injury or death (if the ordnance should fire)

shall be conducted with no personnel exposed (remotely, in a test cell, or behind a barricade or shield). An appropriate local

safety authority (Pad Safety on Air Force or Space Force property) shall be present during on-site ordnance activities.

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13.4.3.3. An appropriate local safety representative (Pad Safety on Air Force or Space Force property) shall be present to

monitor all ordnance operations designated by the appropriate local safety authority and shall spot check all other ordnance

operations.

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13.4.3.4. Ordnance electrical continuity and resistance checkout shall not be conducted at a launch complex or vehicle or

payload assembly area without the written approval of the appropriate local safety authority.

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13.4.3.5. All test equipment used on the range or processing facility to check out ordnance shall be approved by the appropriate

local safety authority (on Air Force or Space Force property, Range Safety) before use. Maximum available applied current

shall not exceed 10 percent of the no-fire current of any EED in the circuit, or 50 mA, whichever is less. On Space Force

property, a list of currently approved instruments shall be maintained by the Range Safety offices.

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13.4.3.6. No current, voltage, power, energy, or other type of energy source shall be applied to any ordnance device outside

of an approved test facility or with personnel in the immediate vicinity of the ordnance device except under the following

conditions:

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13.4.3.6.1. The operation is covered by an approved procedure.

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13.4.3.6.2. Approved equipment is used.

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13.4.3.6.3. The system or subsystem is approved.

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13.4.3.7. Based upon the RF and EED susceptibility, RF silence is required during periods of ordnance installation, removal,

and electrical connection and disconnection aboard a payload and/or vehicle. Where practical, the RF control area shall include

the entire facility and/or complex. The periods of RF silence shall be requested by the payload project. The periods of RF

silence shall be identified by an approved Standard Operating Procedure (SOP). Radiating payloads are handled on an

individual basis.

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13.4.3.8. The appropriate local safety authority, with the assistance of the payload project, shall provide the local authority in

charge of explosive ordnance disposal with familiarization training on the payload ordnance systems upon request. Training

will entail (1) launch pad walkdown and (2) payload and launch vehicle familiarization that includes descriptions, locations,

and hazards associated with any ordnance. Additionally, payload project shall provide 8 x 10 inch color photographs of all

ordnance items. The photographs should be of sufficient detail to identify individual ordnance items as well as to show the

ordnance items in installed configurations on the payload and launch vehicle.

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13.4.3.9. For each electrically initiated ordnance device installed on the payload, the following tools and equipment shall be

supplied to the local authority (EOD for Space Force property) in the event of a malfunction that requires render-safe actions

or a mishap recovery effort:

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13.4.3.9.1. One complete set of shielding caps (current design).

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13.4.3.9.2. One set of safety pins.

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13.4.3.9.3. Special tools used in installing, removing, and safing the ordnance.

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13.4.4. Ordnance Operations Pre-Operational Requirements

13.4.4.1. Coordination between the Appropriate Local Safety Authority and the Payload Project. Before giving

concurrence for any ordnance operations to begin, the appropriate local safety authority and the payload project shall ensure

the following:

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13.4.4.1.1. All necessary controls are established.

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13.4.4.1.2. Test equipment and the system conform to a configuration approved by the appropriate local safety authority.

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13.4.4.1.3. For RF susceptible ordnance distance separation requirements, refer to DESR 6055.09_AFMAN 91-201,

Explosive Safety Standard and NASA-STD-8719.12, Safety Standard for Explosives, Propellants, and Pyrotechnics.

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13.4.4.1.4. All ordnance circuit control switches and firing line interrupt switches are in the off (open) position before electrical

connection of ordnance and thereafter when pad access is required.

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13.4.4.1.5. Personnel and explosives limits are enforced.

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13.4.4.1.6. Proper safety clearance zone has been established and cleared before starting the hazardous operation.

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13.4.4.1.7. Proper signs are posted, warning lights are operating, barricades are established, and Security/HOS is posted.

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13.4.4.1.8. Proper aural warnings and announcements have been made.

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13.4.4.1.9. All serial numbers, calibration dates, proof test dates, and other equipment requirements have been verified before

operations.

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13.4.4.2. Pre-Installation Checkout of Ordnance Items

13.4.4.2.1. The pre-installation checkout of all ordnance items shall be performed only at the appropriate local safety authority

approved test facilities.

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13.4.4.2.2. Requests to use alternate facilities shall be submitted in writing to the appropriate local safety authority.

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13.4.4.3. Ordnance No Voltage Checks

13.4.4.3.1. Before any ordnance electrical connection, no voltage (stray voltage) checks shall be performed on all launch

vehicle and payload ordnance electrical connectors.

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13.4.4.3.2. These checks shall be made first with power on, then with power off, and include all pin-to-pin and pin-to-case

combinations.

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13.4.4.3.3. The power on configuration requires the launch vehicle to be powered up in launch configuration. This

configuration also requires the payload and upper stage to be powered (along with the launch vehicle) unless the payload does

not have any electrical interfaces with the upper stage.

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13.4.4.3.4. The power on check shall be performed anytime in the launch.

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13.4.4.3.5. The power off configuration requires the launch vehicle and payload to be powered down.

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13.4.4.3.6. Power off checks shall be made immediately before ordnance electrical connection.

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13.4.4.3.7. If a number of connections must be made in the same general area of the launch vehicle and payload, power off

checks shall be made on all of the connectors before ordnance electrical connection. These connections shall be made before

any electrical configuration or system changes such as bringing power back up occur.

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13.4.4.3.8. Shielding caps shall not be removed from EEDs until electrical connection to the ordnance is to be made.

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13.4.4.3.9. The resulting measured signal (current, voltage, power, energy) from a no voltage check shall not be capable of

producing a current greater than 20 dB below the no-fire current of the EED. The no voltage test procedure shall specify the

maximum acceptable reading.

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13.4.4.3.10. Meters that are used for no voltage checks shall have a valid calibration seal.

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13.4.4.3.11. The integrity of the meter and test leads shall be verified before use. Fixed- or facility-test instrumentation that

is used in place of portable GSE shall have a procedure that verifies the integrity of the system. A copy of the completed

procedure shall be provided to the appropriate local safety authority.

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13.4.4.3.12. The use of computerized no-voltage meters is acceptable if proper current-limiting can be demonstrated.

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13.4.5. Ordnance Operating Requirements

13.4.5.1. Ordnance operations shall not be conducted when the relative humidity is less than 35 percent. Payload project shall

ensure relative humidity in the operational area is determined and recorded prior to the start and every 4 hours during operations

involving open grain, open flammable/combustible fluid systems, and Category A EEDs (when the Faraday cap is removed

or firing circuits to EEDs are exposed).

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13.4.5.1.1. At or below 50 percent relative humidity the following shall take place: (1) Bonding, grounding, nonconductive

materials, and personnel grounding devices shall be verified at less than 350 volts potential. (2) Electrostatic scanning, not to

exceed 1 hour intervals, shall be performed during the operation and at any time additional personnel, equipment, or hardware

are introduced into the immediate area, the relative humidity goes lower, or the handling of nonconductive materials is

required.

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Static Charge Risk Assessment. The static charge risk assessment should address the extent of low humidity conditions, any plastic or other

materials being used such as contamination covers, the propellant/ordnance that is part of the planned task, and the potential of the activity to

build up static electricity and create a hazardous electrostatic discharge situation. The risk assessment should also include a discussion of the

hazard controls used, such as equipment grounding, personnel grounding, static meter scans, and static dissipation methods. It should be noted

that "approved" plastic materials are considered "anti-static" based on testing at 30 percent humidity; therefore, the use of such materials where

the humidity is less than 30 percent is cause for concern.

13.4.5.2. Ordnance operations shall be conducted in facilities and/or locations specifically approved by the DDESB

(Department of Defense Explosive Safety Board) as applicable, and the appropriate local safety authority. Such approvals

shall be accomplished by explosives site plans or facility licenses.

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13.4.5.3. At the ER, ordnance items shall not be handled, installed, or electrically connected when the passage of an electrical

storm is imminent (within 5 nautical miles). Operations Safety Plans shall identify the procedures to be followed for different

configurations. At the WR, the guidance provided in 5.6.3 shall be followed.

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13.4.5.4. Ordnance items, particularly Category A initiators, shall be installed and electrically connected as late in processing

flow as practical.

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13.4.5.5. A rotation test shall be performed on all launch vehicle and/or payload safe and arm devices (S&As) after installation

and erection on the launch pad but before final connection to the ordnance train. This test shall be performed using the launch

day system configuration for cycling the S&A.

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Launch day system configuration for performing a rotation test on S&As includes items such as monitor circuitry, power sources,

and circuits for cycling the S&A.

13.4.5.6. The ordnance train shall be disconnected from the S&A output during all checkout operations except during the

following circumstances:

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13.4.5.6.1. Single complete rotation test (safe to arm to safe).

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13.4.5.6.2. Final rotation to arm on the last day of the count.

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13.4.5.7. When the S&A is rotated on the pad, all personnel shall be cleared to an area designated in the OSP.

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13.4.5.8. EMI testing shall not be conducted with initiators installed on the vehicle or payload without the appropriate local

safety authority’s approval.

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13.4.5.9. Launch day system configuration for performing a power-on-self-test (POST) on electronic safe-and-arm-devices

(ESADs) includes items such as monitor circuitry, power sources, and circuits for cycling the ESAD.

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13.4.5.10. The ordnance train shall be disconnected from the ESAD output during all checkout operations, except during final

arm on the last day of the count.

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13.4.5.11. When the ESAD is armed on the pad, all personnel shall be cleared to an area designated in the OSP.

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13.4.6. Laser Initiated Ordnance Operations Personnel Access Criteria

13.4.6.1. For laser initiated ordnance (LIO) systems, the following personnel access criteria are required:

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13.4.6.1.1. For unlimited personnel exposure during LIO tests - the system shall contain three independent verifiable circuit

inhibits (dual-failure tolerance).

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13.4.6.1.2. For essential personnel exposure during LIO tests - the system shall contain two independent circuit inhibits

(single-failure tolerance).

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13.4.6.1.3. For no personnel exposure during LIO tests - the system shall contain one circuit inhibit.

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13.4.6.2. One inhibit shall be a disconnection of the ordnance train at the LIO or the destruct charge/solid rocket motor igniter

(other ordnance end item).

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Explosive Ordnance Disposal

13.5.1. Rendered Safe Ordnance. All damaged ordnance shall be rendered safe by the local EOD (Explosive Ordnance

Disposal) Team unless otherwise approved by the appropriate local safety authority.

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13.5.2. Obtaining AF EOD Services. AF EOD services may be obtained by calling Cape Support (321-853-5211) or

PAFB Command Post (321-494-7001) on the ER or Range Scheduling (805-606-8825) on the WR.

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13.5.3. Appropriate Local Safety Authority Approval for Shipment of Damaged or Rendered Safe Ordnance

13.5.3.1. Shipments of damaged or rendered safe ordnance from the processing facility, ranges or the downrange stations

shall be approved in writing by the appropriate local safety authority.

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13.5.3.2. This approval and/or certification shall accompany the shipment.

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13.5.3.3. A DOT exception shall normally be obtained by the payload project before local explosive ordnance disposal team

will release damaged ordnance.

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Ordnance Facilities Operations

13.6.1. Ordnance items shall not be delivered to, placed in, or processed through facilities or locations on the ranges, or

downrange stations unless the facility or area has been approved for such operations by the appropriate local safety authority.

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13.6.2. Ordnance deliveries from storage to the payload project shall be coordinated with the appropriate local safety authority.

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13.6.3. All facilities in which ordnance operations are conducted or stored shall be properly equipped, display the correct

explosive safety markings, and otherwise meet the minimum explosives safety standards cited in NASA-STD-8719.12, Safety

Standard for Explosives, Propellants, and Pyrotechnics, and for Space Force facilities, DESR 6055.09_AFMAN 91-201,

Explosive Safety Standards , sub tier documents, and this publication.

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13.6.4. All operations and activities within an explosives sited facility shall be related and require the appropriate local

safety authority approval.

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ELECTRICAL SYSTEMS OPERATIONS

Electrical Systems Operating Standards and Definitions

14.1.1. Electrical Systems Operating Standards

14.1.1.1. ANSI C2, National Electric Safety Code, shall be followed in the conduct of electrical systems operations and

maintenance.

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14.1.1.2. Workplace electrical safety shall be in accordance with NFPA 70E, Electrical Safety Requirements for Employee

Workplaces; and AFI 32-1064, Electrical Safe Practices.

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14.1.1.3. Maintenance of AF owned electric power systems shall be in accordance with AFI 32-1062, Electrical Systems,

Power Plants and Generators. Non AF-owned electric power systems shall be maintained per relevant provisions found in 40

CFR, 29 CFR, National Electrical Code (NEC), NFPA, etc., and manufacturer’s written instructions or procedures.

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14.1.1.4. Maintenance of grounding systems for AF facilities or facilities regulated by the DDESB shall be in accordance

with AFI 32-1065, Grounding Systems. Maintenance of grounding systems for non-AF facilities shall be in accordance with

relevant provisions found in 7 CFR, 14 CFR, 29 CFR, NEC, NFPA, etc., and manufacturer’s written instructions or procedures.

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14.1.2. Electrical Equipment Operations in Hazardous (Classified) Locations

14.1.2.1. Definition of Hazardous (Classified) Locations for Electrical Equipment Operations. Hazardous (Classified)

locations are defined in NEC Article 500, Hazardous (Classified) Locations.

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14.1.2.2. Explosives and Propellants Not Covered in NEC Article 500. For government installations, the following

paragraphs define the minimum requirements to be applied in the definitions of locations in which explosives, pyrotechnics,

or propellants are present or are expected to be present. These requirements shall be followed unless less stringent

classifications are justified and approved as part of the design data submittal process. The responsible facility safety

organization and the local Fire Authority Having Jurisdiction (AHJ) or Fire Marshal shall approve all potential critical facility

hazardous location designations.

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14.1.2.2.1. Class I, Division 1. Complete definitions of classified locations are found in NFPA 70. These include the

following locations:

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14.1.2.2.1.1. Within 25 feet of any vent opening unless the discharge is normally incinerated or scrubbed to nonflammable

conditions [less than 25 percent of Lower Explosive Limit (LEL)]. This distance may be increased if the vent flow rate creates

a flammability concern at a distance greater than 25 feet.

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14.1.2.2.1.2. Below grade locations in a Class I, Division 2 area.

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14.1.2.2.1.3. Locations in which flammable liquids, vapors, or gases may be present in the air during normal operations.

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14.1.2.2.1.4. Locations in which there is a credible risk that ignitable concentrations of vapors or gases may be present in the

air during abnormal operations due to a failure, leakage, or maintenance/repair.

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14.1.2.2.2. Class I, Division 2. Complete definitions of classified locations are found in NFPA 70. These include the

following locations:

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Class I, Division 2 usually includes locations where volatile flammable liquids or flammable gases or vapors are used but, in the

judgment of the appropriate safety authority and the local AHJ or Fire Marshal, would become hazardous only in case of an

accident or of some unusual operating condition. The quantity of flammable material that might escape in case of an accident,

the adequacy of ventilating equipment, and the total area involved are all factors that merit consideration in determining the

classification and extent of each location.

14.1.2.2.2.1. Piping without valves, checks, meters, and similar devices would not ordinarily introduce a hazardous condition

even though used for flammable liquids or gases. Locations used for the storage of flammable liquids or of liquefied or

compressed gases in sealed containers would not normally be considered hazardous unless also subject to other hazardous

conditions.

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14.1.2.2.2.2. As determined by the appropriate safety authority and the AHJ or local Fire Marshal, locations may actively

change classification depending on the flammable fluid system activity and configuration. For these types of locations, fixed

or permanently installed electrical equipment shall be designed for the worst case hazardous environment.

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14.1.2.2.2.3. Portable electrical equipment shall be designed for the worst case hazardous environment in which it will be

used. Portable equipment that is not designed for use in a particular hazardous environment is not allowed in that environment.

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14.1.2.2.2.4. Class I, Division 2 locations include the following equipment or areas:

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14.1.2.2.2.4.1. Storage vessels (including carts and drums). 25 feet horizontally and below to grade and 4 feet vertically above

the vessel (25 feet in any direction for hydrogen).

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14.1.2.2.2.4.2. Transfer lines. 25 feet horizontally and below to grade and 4 feet above the line (25 feet in any direction for

hydrogen).

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14.1.2.2.2.4.3. Launch vehicle (liquid fueled vehicle, stage, or payload). 100 foot radius horizontally from and 25 feet

vertically above (100 feet for hydrogen) the highest leak or vent source and below the vehicle to grade.

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14.1.2.2.2.4.4. Enclosed locations such as rooms, work bays, and launch complex cleanrooms that are used to store and handle

flammable and combustible propellants when the concentration of vapors inside the room resulting from a release of all fluids

stored and handled equals or exceeds the LEL. The quantity of fluids used in the analysis to determine vapor concentration

shall be the maximum amount allowed in the explosives site plan.

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14.1.2.2.2.4.5. Locations adjacent to a Class I, Division 1 location into which ignitable concentrations of gases or vapors

might occasionally be communicated, unless communication is prevented by adequate positive pressure ventilation from a

source of clean air and effective safeguards against ventilation failure are provided.

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14.1.2.2.3. Hazardous Commodity Groups. Hazardous commodities are grouped by similar characteristics.

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14.1.2.2.3.1. These fuels shall be considered ignitable regardless of the ambient temperature.

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14.1.2.2.3.2. The following fuels shall be categorized as follows:

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14.1.2.2.3.2.1. Group B: Liquid or gaseous hydrogen.

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14.1.2.2.3.2.2. Group C: Hypergolic fuels such as N

, MMH, UDMH, A50.

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14.1.2.2.3.2.3. Group D: Hydrocarbon fuels (RP and JP).

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14.1.2.2.3.2.4. Group D: Oxidizers. Oxidizers shall be considered Group D hazardous substances in addition to the fluids

listed in NFPA 497, Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and Hazardous

(Classified) Locations for Electrical Installations in Chemical Process Areas.

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14.1.2.2.3.2.5. Group D: Exposed Solid Propellants. The atmosphere within 10 feet horizontally and directly overhead of

exposed solid propellant shall be classified as a Class I, Division 2, Group D location. Solid rocket motors are considered

exposed in the following situations:

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14.1.2.2.3.2.5.1. The motor nozzle is not attached, and the aft end of the motor does not have a cover.

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14.1.2.2.3.2.5.2. The motor nozzle is attached but does not have a nozzle plug.

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14.1.2.2.3.2.5.3. The unassembled motor segments do not have front and rear covers.

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14.1.2.2.3.2.5.4. The igniter is removed from the motor and cover is not provided.

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14.1.2.3. Personnel wearing conductive grounding devices shall not operate electrically powered devices which could result

in a shock hazard.

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14.1.3. Photography

14.1.3.1. Photography General Requirements

14.1.3.1.1. Manual (with a photographer) photography shall not be allowed in a hazardous (Class I, Division 1) environment.

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14.1.3.1.2. Remotely operated, hazard-proofed cameras and UL listed lighting sources shall be used for Class I, Division 1

environments as well as for Class I, Division 2 environments that cannot be verified as non-hazardous.

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14.1.3.2. Class I, Division 2 Photography Requirements. Requirements for the use of cameras and camera flash attachments

in areas containing solid and liquid propellants that would normally be classified as Class I, Division 2 are listed below:

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14.1.3.2.1. Before and during the use of photography equipment within 100 feet of a flight vehicle propellant system or within

25 feet of propellant storage vessels, the operating environment of the photography equipment shall be verified to be free of

hazardous vapors.

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14.1.3.2.2. Before bringing photography equipment into an area, all ordnance installation and/or connection operations and

liquid propellant system operations that affect propellant systems within 100 feet of the photography equipment shall cease.

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14.1.3.2.3. The user of the photography equipment shall certify to the appropriate safety authority in writing that the camera

and/or flash attachments have no sparking/arcing capability. Information, including vendor specifications, shall be made

available to the appropriate safety authority upon request. The portable battery operated electrical equipment shall have a UL

certification or be purged in accordance with NFPA requirements, meet explosion proof requirements, or demonstrate by

analysis to be intrinsically safe. The details of the method of compliance shall be included in a safety assessment report.

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14.1.3.2.4. Camera batteries shall be securely installed in the camera or in a protective case. Battery replacement shall occur

outside the Class I, Division 2 area. No battery charging shall take place in a hazardous area.

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14.1.3.2.5. All equipment that is brought into the hazardous area and poses a drop hazard shall remain in the tethered

possession of the photographer or his/her assistant(s).

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14.1.3.2.6. The camera shall be tethered to the photographer.

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14.1.3.2.7. Photography using heat-producing, expendable flash bulbs such as flash cubes and sun guns shall not be used with

photography equipment and not permitted within 100 feet of hazardous liquid propellant systems or solid propellant grain.

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14.1.3.2.8. Cameras and/or flash attachments shall be enclosed or otherwise contained to prevent parts from falling into or

contacting flight hardware.

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14.1.3.2.9. The maximum operating temperature of the camera and/or flash attachment and portable battery operated electrical

equipment shall not exceed 80 percent of the ignition temperature for any vapor that may occur in the operating environment

of the photography equipment.

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14.1.3.2.10. Cameras and/or flash attachments to be used inside solid rocket motor bores shall be designed and specified for

that particular use.

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14.1.3.2.11. Photo equipment and portable battery operated electrical equipment shall not be stored in the Class I, Division 2

area.

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14.1.3.2.12. Photo equipment and portable battery operated electrical equipment shall be removed from the Class I, Division

2 area before any operation that could cause an increase in the hazardous environment.

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Electrical Systems Operations Personnel and Special Insulated Equipment

14.2.1. If live electrical maintenance or repair work must be performed, special insulated equipment shall be provided.

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14.2.2. Special insulated equipment includes, but is not limited to, the following:

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14.2.2.1. Insulated hook sticks for opening and closing disconnect switches.

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14.2.2.2. Insulated fuse sticks for removing and installing cartridge-type fuses.

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14.2.2.3. Rubber insulating sleeves and gloves.

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14.2.2.4. Rubber insulation floor mats.

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14.2.2.5. Rubber insulating line conductor hose.

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14.2.2.6. Dielectric hard hats.

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Electrical Systems Procedures

14.3.1. Procedures shall be written for all electrical maintenance and repair work.

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14.3.2. Procedures shall include, but not be limited to, the following topics:

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14.3.2.1. Tagging and locking out control switches.

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14.3.2.2. Use of approved non-conductive fuse pullers.

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14.3.2.3. Provision and use of PPE.

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14.3.2.4. Grounding of equipment and personnel.

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14.3.2.5. Use of the buddy system (mandatory when working on energized equipment and circuits).

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14.3.2.6. Safety precautions to be followed when working on energized equipment and circuits.

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14.3.2.7. Fire protection and equipment.

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14.3.2.8. Knowledge of resuscitation procedures.

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Electrical Equipment and Systems Test, Inspection, and Maintenance Requirements

14.4.1. Grounding Systems Tests

14.4.1.1. Grounding Systems General Test Requirements

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14.4.1.1.1. Grounding system tests for lightning protection, electrical fault protection, and static protection systems shall be

performed for all facilities and/or locations (including launch complexes and integrated rocket checkout facilities) used to

store, handle, or process ordnance or liquid propellants.

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14.4.1.1.2. Facility operators and payload projects shall inspect their portable and movable equipment connections to ground

before starting operations each day the equipment is to be used.

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14.4.1.2. Ground Systems Test Plan and Test Frequency Criteria

14.4.1.2.1. A floor plan layout showing all grounding system test points shall be developed by the facility operator and/or the

payload project.

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14.4.1.2.2. Lightning and grounding systems shall be tested in accordance with the responsible facility’s approved procedure

and for Air Force facilities with AFI 32-1065.

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14.4.1.2.3. Based on the floor plan, the following tests shall be conducted:

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14.4.1.2.3.1. Lightning protection system resistance to ground shall be tested annually to the following criteria:

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14.4.1.2.3.1.1. Ten ohms or less for the counterpoise system.

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14.4.1.2.3.1.2. Ten milliohms from the terminal to the counterpoise system.

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14.4.1.2.3.2. The lightning protection system shall be inspected visually and mechanically twice a year.

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14.4.1.2.3.3. The facility static/electrical ground system resistance shall be tested annually to a criterion of 10 ohms or less

using the methods of measuring resistance to earth described in ANSI/IEEE-142.

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14.4.1.2.3.4. Portable and movable facility equipment connections to the facility ground system shall be visually inspected

before each use and tested every two months to a criterion of one ohm or less.

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Grounding Test Preparations. During the grounding test, ground support equipment and flight hardware containing

hazardous commodities may be disconnected but do not have to be removed from the facility.

14.4.1.2.3.5. Conductive floors shall be visually inspected and tested twice a year to the requirements of AFI 32-1065,

Paragraph 13.4. Hazardous commodities shall be removed before testing.

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14.4.1.2.3.6. All resistance measurements shall be taken with a currently calibrated instrument in accordance with a Range

Safety approved procedure.

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14.4.1.2.3.7. Measuring devices such as megohm meters (Megger’s) shall be current-limited by the use of fuses or equivalent

devices when the facility contains electrically connected EEDs.

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14.4.1.2.3.8. Test and inspection results shall be provided to the facility custodian and be available at the facility.

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14.4.2. Electrical Equipment Inspection. Before first use or first use after repair, electrical distribution equipment shall be

inspected for compliance with NFPA 70 and NFPA 70E.

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14.4.3. Electrical Equipment Maintenance and Testing

14.4.3.1. Electrical equipment shall be maintained in accordance with AFJMAN 32-1083, Facilities Engineering - Electrical

Interior Facilities, and NFPA 70E.

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14.4.3.2. Conductors with worn, abraded, or defective insulating material shall be repaired or replaced before the circuit being

energized.

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14.4.3.3. In addition to maintenance requirements in AFJMAN 32-1083, Chapter 15, electric motors shall be properly

maintained, and excess dust and oil shall be removed from motors by vacuum cleaning or wiping.

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14.4.3.4. Electrical system interior inspection and testing of wiring, power circuit breakers, and protective relaying shall be

accomplished in accordance with the NEC.

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Electrical Systems Operating Requirements

14.5.1. Electrical Systems General Operating Requirements. Personnel working with electrical equipment shall comply

with NFPA 70E; NPR 8715.1, NASA Safety and Health Program Requirements; and AFI 32-1064. Particular attention shall

be given to the following:

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Excessive humidity, wet areas, lack of protective matting, or equipment with exposed contacts to ground may require low or

lesser voltage to be designated as high voltage. If these conditions exist, they increase the hazards of the operation.

14.5.1.1. Personnel working with high voltage equipment shall wear appropriate non-conductive PPE.

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14.5.1.2. Supervisors shall be responsible for ensuring that safe working conditions are provided; the work is done in a safe

manner; and frequent inspections of equipment, materials, and the work site are conducted.

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14.5.1.3. Whenever maintenance or repair work is performed on potentially hazardous energized electrical equipment or

circuits, a minimum of two people shall be present (buddy system).

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14.5.1.4. Rescue and first aid equipment shall be readily available in areas where electrical maintenance and repair work is

being performed.

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14.5.1.5. Personnel exposed to energized electrical circuits shall not wear loose clothing, rings, watches, or other metallic

objects that can act as conductors of electricity.

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14.5.1.6. Only a nationally recognized testing laboratory such as UL or FM, or those accredited by OSHA under the Nationally

Recognized Testing Laboratory (NRTL) accreditation program, 29 CFR 1910.7, Definition and Requirements for a Nationally

Recognized Testing Laboratory, weather proof or water-tight test and maintenance equipment shall be used in areas subject to

excessive moisture.

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14.5.1.7. Only listed explosion and/or hazard-proofed test and maintenance equipment shall be used in potentially hazardous

atmospheres , unless otherwise approved on a case-by-case basis by the PSWG and Range Safety and documented in a safety

assessment report.

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14.5.1.8. Before working on capacitor circuitry, external power and short terminals shall be disconnected and discharged to

ground.

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14.5.1.9. If temporary power lines are required to extend across outside work areas, they shall be protected by a non-

conductive cover or elevated so as not to interfere with personnel, vehicles, or equipment traffic.

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14.5.1.10. Electrical equipment cords shall have an equipment grounding conductor and shall be grounded when in use.

Unless double insulated, the equipment exterior shall be securely bonded and grounded.

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14.5.1.11. Dead-end wires shall be completely insulated.

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14.5.1.12. Energized equipment will be manned or connected to the manned facility emergency power shut-off system. The

electrical equipment will be powered down during non-working hours.

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14.5.1.13. All electrical equipment located outside a hazardous processing area will be inhibited from supplying power to

electrical equipment located within the hazardous processing area during non-working hours.

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14.5.1.14. Electrical equipment that must remain energized for hazardous operations (i.e., maintaining spacecraft thruster’s

solenoid valves in an opened or closed state) shall be equipped with an uninterrupted power source such as a battery backup.

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14.5.2. Electrical Systems Pre-Operational Requirements

14.5.2.1. With the exception of test and checkout, all electrical equipment and circuits shall be de-energized before any work

is started on these circuits or equipment through a scheduled power outage.

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14.5.2.2. Power outages in facilities shall be coordinated with the affected parties.

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14.5.2.3. When work is being done on circuits, the line switch shall be locked out and tagged in accordance with NFPA 70E,

Part II.

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14.5.2.4. Electrical conductors shall be routed to eliminate tripping hazards or contact with energized lines.

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14.5.3. Electrical Systems Operating Requirements

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14.5.3.1. During repair or maintenance, if panel covers are removed and panels left open to obtain power where none is

available, a DANGER HIGH VOLTAGE sign shall be placed next to the open panel and a temporary cover manufactured and

installed. When cable connections are made that require the removal of the panel cover, a suitable temporary cover with

openings to accommodate the temporary cables shall be used.

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14.5.3.2. Insulated fuse pullers shall be used for removal of fuses. Only fuses of proper rating shall be used in circuits. No

other material shall be used in place of a fuse.

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14.5.3.3. Personnel who are exposed to energized circuits for electrical activities such as troubleshooting, maintaining, or

repairing electrical equipment energized with 50 volts or more shall stand on non-conductive matting.

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14.5.3.4. Grounding or shorting sticks (or cables) shall be used on potentially “hot” circuits and shall not be removed until

repairs are completed.

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Battery Operations

14.6.1. Battery Operating Standards

14.6.1.1. An approved means of disposal or transportation to an off-site approved disposal site shall be in place before receipt

of the batteries on the ranges.

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14.6.1.2. The means of disposal shall be in accordance with DOT and EPA requirements and carry DOT and EPA approvals.

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14.6.2. Battery Operations Personnel Requirements

14.6.2.1. Battery Operations Training and Certification. A training program shall be generated and approved by the

payload project for all personnel handling batteries not listed or not intended for public use.

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14.6.2.2. Emergency First Aid and PPE Requirements

14.6.2.2.1. Emergency First Aid

14.6.2.2.1.1. An emergency eye wash and shower shall be provided in locations where batteries are present/installed and

serviced. They shall be installed in accordance with AFMAN 91-203, ANSI/International Safety Equipment Association

(ISEA) Z358.1, Emergency Eyewash and Shower Equipment, or 29 CFR 1910.151 as applicable.

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14.6.2.2.1.2. An emergency first aid kit, containing a burn neutralizer shall be provided.

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14.6.2.2.2. PPE

14.6.2.2.2.1. The following PPE shall be provided when servicing or handling batteries in accordance with the battery safety

data sheet (SDS), AFMAN 91-203, or ANSI/ISEA Z87.1, Occupational and Educational Personal Eye and Face Protection

Devices, as applicable:

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14.6.2.2.2.1.1. Front and side face and eye protection.

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14.6.2.2.2.1.2. Rubber gloves.

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14.6.2.2.2.1.3. Rubber apron.

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14.6.2.2.2.1.4. Foot protection.

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14.6.2.2.2.2. In addition, electrolyte/chemical spill containment/adsorption material shall be provided in the close vicinity of

the battery(s) for use by operating personnel in the event of an electrolyte spill.

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14.6.3. Battery Procedures

14.6.3.1. Procedures for battery receipt, transportation, checkout, handling, installation, safing, packing, storage, and disposal

shall be developed and submitted to the appropriate safety authority for review and approval.

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14.6.3.2. Specific safing operations of batteries shall be in battery handling and checkout procedures.

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14.6.3.3. Battery handling and checkout procedures shall include the following topics:

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14.6.3.3.1. A list of proper handling equipment.

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14.6.3.3.2. Identification of specific personnel qualified to safe batteries if in an unsafe condition.

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14.6.3.3.3. Identification of the exact location of the storage site of depleted or unsafe batteries.

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14.6.4. Lithium Batteries Special Requirements

Batteries that have a UL listing and are intended for public use are exempt from these requirements.

Lithium batteries are thermal batteries, also called molten salt batteries. Lithium batteries are different from lithium-ion

batteries, even though they both contain the element lithium. Lithium batteries are primary cell batteries, that is, batteries

where the electrochemical reaction is not reversible.

14.6.4.1. The appropriate safety authority shall approve temporary lithium battery storage and handling facilities. These

facilities shall be used only for lithium batteries and shall not be used for other purposes. Lithium batteries shall not be stored

permanently on the ranges.

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14.6.4.2. The payload project shall provide certification of lithium battery(s) conforming with all safety critical steps and

processes agreed to by the appropriate safety authority during the battery development phase.

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14.6.4.3. Before delivery of lithium batteries to the ranges, an approved off-site disposal contract shall be in place for the

batteries in any condition.

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14.6.5. Lithium Ion Battery/Cell Special Requirements.

14.6.5.1. Storage of the batteries (when not installed in GSE or the spacecraft) shall be in approved battery storage locations.

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14.6.5.2. Battery and cells shall be treated as always having a voltage potential; therefore, connection or disconnection of a

battery shall be considered an electrical personnel hazard and a ‘spark’ potential.

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14.6.5.3. Range users shall have an operational plan for battery/cell handling that includes emergency contingency operations

for physical abuse incident and battery installation/removal.

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14.6.5.4. Support equipment (ground or airborne) shall be verified to operate correctly prior to first operational use on the

range, including all fault tolerant devices or subsystems, prior to connecting battery. Verification shall include inducing

overvoltage/undervoltage/temperature extremes to the monitoring devices as intended when in use prior to connecting of the

battery.

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14.6.5.5. On-base transportation to the launch site should meet DOT requirements. Evidence of compliance with DOT

requirements for transportation shall be provided.

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14.6.5.6. External heating sources for battery/cell maintenance shall be dual fault tolerant and provide feedback monitoring

capability or be analyzed for failure modes on cell/battery heating.

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14.6.5.7. Charging and Discharging.

14.6.5.7.1. GSE/Flight hardware used for charging (shall prevent each cell from exceeding 4.4 volts) and discharging (driving

cells to less than 0 volts) shall be dual fault tolerant. Individual cells that have an internal design which provides high rate

discharge protection (e.g., positive temperature coefficient devices and internal fuses) may be considered to already have one

inhibit. The GSE shall provide at a minimum one inhibit for charging/discharging control.

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14.6.5.7.2. Discharging shall not take place below -20° C or above 60° C.

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14.6.5.8. Battery/Cell Monitoring.

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14.6.5.8.1. Battery/cell monitoring and recording is required during charging and discharging.

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14.6.5.8.2. Voltages shall be recorded at least every minute for charge rates that exceed the battery capacity (e.g., if capacity

is 1 amp-hour and charger is supplying greater than 1 amp of current). Record voltages every 10 seconds for charge rates

between 1 and 2 times battery capacity. Record voltages every second for charge rates that exceed 2 times battery capacity.

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14.6.5.8.3. Charging data shall be reviewed for anomalies and verification of voltage limits.

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14.6.5.8.4. Provisions shall be made for charging, monitoring, and recording each cell/cell pack with electronic ground support

equipment that prevents high heat, sparking and high charge/discharge current rates.

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14.6.6. Battery Maintenance, Storage, and Operations

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14.6.6.1. Rechargeable storage batteries and batteries requiring activation shall be handled only in PSWG and Range Safety

approved, and designated battery shops and areas equipped for servicing and recharging.

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14.6.6.2. Separate areas shall be provided for servicing of batteries that have incompatible electrolytic solutions, for example,

acid and alkaline.

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MOTOR VEHICLE OPERATIONS

Motor Vehicle Operating Standards

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15.1.1. Motor vehicles that do not meet DOT public transportation requirements shall not be permitted to transport hazardous

materials on the range unless the vehicle is covered by a formal DOT exemption and is approved by PSWG and Range Safety.

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15.1.2. Special-purpose trailers for range use only shall conform to operational requirements in DESR

6055.09/AFMAN 91-201, Explosives Safety Standard.

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15.1.3. All vehicle operations shall comply with federal and state laws, and Space Force and range regulations, including, but

not limited to, the following criteria:

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15.1.3.1. Proper licensing of operators.

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15.1.3.2. The use of vehicle restraint devices such as seat belts.

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15.1.3.3. Restrictions on wearing headphones or ear speaker type radios while operating a vehicle.

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15.1.3.4. The use of spotters when backing with restricted rear vision vehicles.

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Motor Vehicle Operating Requirements

15.2.1. Operator Instructions

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15.2.1.1. Maneuvering in the vicinity of hazardous commodities requires the use of a spotter.

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15.2.1.2. When backing, chocks shall be used to prevent contact.

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15.2.2. Indoor Operations. Gasoline or diesel vehicle operations in buildings shall require the approval of the Industrial

Hygiene and/or Bioenvironmental Engineer.

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15.2.3. Ordnance and Propellant Area Parking

15.2.3.1. General Parking Requirements

15.2.3.1.1. Vehicle parking in areas sited and used for ordnance or propellants shall be in accordance with the applicable OSP.

(See Attachments 3, 4, and 5 of this volume.)

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15.2.3.1.2. These OSPs shall be developed using the criteria found in this document and shall also take into consideration the

criteria from NPR 8715.1, NASA Safety and Health Program Requirements; DESR 6055.09_AFMAN 91-201, Explosive

Safety Standards.

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15.2.3.2. General Parking Restrictions

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15.2.3.2.1. Designated parking areas shall be used.

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15.2.3.2.2. Privately owned vehicles shall not be parked within the fenced-in area of hazardous processing facilities.

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15.2.3.2.3. No vehicle shall be parked within 25 feet of lines containing liquid propellants.

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15.2.3.2.4. No vehicle shall be parked within 50 feet of storage tanks containing liquid propellants.

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15.2.3.2.5. When required, delivery vehicles are exempt from the preceding requirements during loading and off-loading but

they shall be removed immediately afterwards.

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15.2.3.2.6. While parked, the parking brake shall be engaged, and wheels shall be chocked.

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15.2.3.3. Restricted Parking Areas. All non-essential vehicles are prohibited from parking in the following areas under the

following conditions:

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15.2.3.3.1. Within the flight hazard area (FHA) once the FHA has been established.

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15.2.3.3.2. In the blast danger area (BDA) during wet dress rehearsal (cryogen tanking).

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15.2.3.3.3. Within the FHA during core vehicle tanking (other than cryogens that are tanked) after the BDA/FHA is

established.

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15.2.3.3.4. Within the launch complex fence line during fueled spacecraft/upper stage mating operations.

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15.2.4. Internal Combustion Engine Vehicles. Motor vehicles or equipment having internal combustion engines shall be

equipped with spark arresters and carburetor flame arresters as applicable:

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15.2.4.1. When transporting explosives that have exposed grain, scrap, waste or items visibly contaminated with explosives.

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15.2.4.2. When operating within the control area during propellant transfer operations or continuously within propellant off-

loading and/or propellant storage areas.

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15.2.5. Hazardous Commodities Vehicle Transportation Standards. Vehicles transporting hazardous commodities shall

meet DOT and DoD (for example, DESR 6055.09_AFMAN 91-201, Explosive Safety Standards) regulations unless

exempted or approved for use by Range Safety or for non-USSF, the appropriate local safety authority.

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15.2.6. Hazardous Location Restrictions. Vehicles shall not be operated in locations classified as hazardous by NEC Article

500 without the appropriate local safety authority approval.

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Special-Purpose Trailers Used to Transport Critical or Hazardous Loads.

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15.3.1. Periodic Tests. A periodic road/load test at 100% rated load shall be performed at least every 4 years on trailers used

to transport hazardous hardware, with single failure point (SFP) weld inspection limited to surface NDE. Unless otherwise

agreed to by Range Safety, a road/load test shall also be performed after a trailer has experienced structural modification or

repair.

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15.3.2. Data Requirements. Recurring data requirements shall be submitted in accordance with AFSPCMAN 91-710 Volume

3, Attachment 1. Maintenance records shall be maintained by the operator and made available upon request.

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CONVOY OPERATIONS

General

16.1.1. A convoy is required for all transportation considered hazardous operations unless exempted by the appropriate local

safety authority. Convoy operations shall be conducted in accordance with federal, state, and any SLD-specific regulations or

policy memorandums.

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16.1.2. All transportation of over-sized loads (larger than 12 feet in width, 13.5 feet in height, or 55 feet in length); transport

of hypergolic fuels in non-DOT approved containers; transport operations that go against flow of traffic or that take up more

than one lane is considered a hazardous operation.

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16.1.3. All convoys shall be conducted in accordance with AFMAN 24-306, Operation of AF Government Motor Vehicles.

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16.1.4. All convoy and convoy operations shall be in accordance with DOT requirements.

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Convoy Operations Procedures

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A procedure for hazardous convoy operations shall be submitted to the appropriate local safety authority for review and

approval. This procedure should include a description of a pre-route survey.

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Convoy Operations Requirements

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The payload project and/or the agencies responsible for the transportation of a load shall ensure the following items are

performed:

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16.3.1. The hazardous load or commodity to be transported shall be identified.

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16.3.2. The convoy shall be scheduled through the appropriate local safety authority [CCSFS Cape Support (321-853-5211)

at the ER and through Range Scheduling (805-606-8825) at the WR].

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16.3.3. A convoy commander shall be designated.

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16.3.4. If flight hardware or hazardous commodities are involved, a Security/HOS escort shall be arranged.

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16.3.5. The appropriate local safety authority approval shall be obtained before the start of the convoy if hazardous

commodities or flight hardware are involved.

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16.3.6. When transporting hazardous commodities, the transfer route shall be chosen to minimize exposure to populated areas

and critical facilities. Transfer should occur during off-peak traffic and population hours.

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16.3.7. The selected route shall be identified, and the following items noted/documented:

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16.3.7.1. Horizontal and vertical clearances (i.e., bridges, construction, power lines, trees, signs, walls, railings, barriers, etc.).

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16.3.7.2. The hazardous commodity transported.

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16.3.7.3. Population along the route.

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16.3.7.4. Traffic that may be encountered.

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16.3.7.5. Condition of surface being traveled upon.

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16.3.7.6. Distance of route.

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16.3.8. Radio contact shall be maintained with the convoy commander for all elements of the convoy.

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16.3.9. At a minimum, the following items of equipment are required:

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16.3.9.1. Flashlights if transport occurs during periods of darkness.

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16.3.9.2. Emergency apparatus such as fire extinguishing equipment, reflectors, and flares.

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16.3.10. Proper environmental health required by the commodity transported shall be ensured.

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16.3.11. Areas shall be cordoned off as required by the appropriate local safety authority.

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16.3.12. Emergency actions shall be taken to secure the item being transported in the event of a mishap.

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16.3.13. A pre-operational check of the loaded vehicle and trailer shall be conducted.

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The prescribed tire air pressure should be verified.

16.3.14. A convoy commander pre-departure briefing guide and requirements shall be prepared and conducted. The briefing

guide includes such information as hazards, communication checks, and stop points.

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16.3.15. Convoys carrying liquid fuel, solid motors, or installed ordnance shall not commence when a local electrical storm

lightning watch or warning is in effect.

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LAUNCH OPERATIONS

To view Launch Operations criteria, please see USSF 91-710.

SOLID ROCKET MOTORS AND ROCKET, ROCKET MOTOR SEGMENTS, AND

ROCKET MOTOR OPERATIONS

Solid Rocket Motors and Rocket Motor Segments Operations General Requirements

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In addition to the requirements of Chapter 3 and Chapter 13 of this volume, the payload project shall comply with the

following requirements for operations involving solid rocket motors and rocket motor segments.

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Solid Rocket Motor and Rocket Motor Segment Transportation

18.2.1. Operational hazard analyses should be performed for all aspects of solid rocket segment and/or motor handling and

buildup.

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18.2.2. Solid rocket motor segments/motors transported on trailers or railroad cars shall be properly restrained to the trailer or

railroad car support structures to minimize possibility of loss of load in an accident scenario.

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18.2.3. For solid rocket motor/segment transporting trailers or railroad cars that use internal combustion engine powered

generators for the environmental control units, gasoline or liquid propane gas powered engines shall not be used. If internal

combustion engine generator equipped trailers or rail- road cars loaded with solid rocket motors/segments are brought inside

processing facilities, care shall be taken to minimize the quantity of fuel in the generator tanks. The fuel tanks shall be

reinforced and equipped with a protective shield to minimize possibility of tank rupture and fuel ignition during transport. An

insulation barrier shall be provided between the environmental control unit and the solid rocket motor or motor segment to

protect the motor from heat or possible fuel fire.

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Diesel powered generators are preferred due to much lower flammability of the diesel fuel.

18.2.4. If forced air heaters are used for environmental control on covered railroad cars or trailers transporting solid rocket

motors/segments, liquid propane gas heaters or gasoline heaters shall not be used. The effects of heater failures on the

trailer/railroad car shall be analyzed and reported in an analysis as required by Volume 3, 18.3.

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18.2.5. Canvas covers for solid rocket motor/segment transporting trailers or railroad cars shall not be used. If their use cannot

be avoided, the rubberized canvas material shall be subjected to triboelectric testing and meet the test requirements for plastic

materials used in solid rocket motor/segment processing. An operational hazard analysis shall be performed to demonstrate

that under the worst case conditions (for example, broken or loose canvas tie downs and canvas flapping and rubbing on the

segment or motor case), not enough static can be accumulated to cause a catastrophic event, such as propellant ignition).

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18.2.6. Solid rocket motor/segment transport trailers or railroad cars containing solid rocket motors/ segments shall be secured

to prevent inadvertent motion when parked; in other words, brakes set and wheels chocked.

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18.2.7. Locomotives and tractors that transport solid rocket motor/segment cars and trailers shall be removed from processing

facilities as soon as possible.

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18.2.8. If air pallets are used for transport of solid rocket motors/segments inside processing facilities, the structure of the air

pallet shall be rigid enough to minimize elastic deformation of the pallet under load and, thus, minimize stresses transferred to

the solid rocket motor/segment.

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Due to the strict requirements for floor surfaces required for such air pallet operation and the fact that such surfaces are easily

damaged, extensive use of air pallets for solid rocket motor/segment transport is not recommended.

Solid Rocket Motor and Rocket Motor Segment Inspections

18.3.1. Periodic NDE should be performed for all aerospace ground equipment used to handle rocket motors and segments,

in accordance with NDE plans.

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18.3.2. If wetting of a solid rocket motor/segment with water is required for ultrasonic inspections, adequate water intrusion

barriers shall be provided to prevent the propellant from getting wet.

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The wetting of propellant surfaces with water could result in precipitation of ammonium perchlorate crystals on the propellant

surface and possibly increase propellant sensitivity.

18.3.3. Solid rocket motors/segments with graphite epoxy casings, which are very sensitive to external damage, shall be

visually inspected for case damage at each major stage of processing and upon arrival at the launch pad.

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Protective measures, such as blankets, should be used to shield solid rocket motors/segments from damage during transport

and storage where practical.

18.3.4. For igniter uncrating and inspection operations of separately shipped igniters, corrosion protection coatings shall be

removed from the igniter metal flange before special lifting adapters are attached to the flange.

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Failure to remove the coatings may cause the lifting adapter to stick to the igniter flange, possibly resulting in the igniter being

lifted after the adaptor bolts have been removed when attempting to remove the unsecured adaptor. This may result in the

igniter being raised and dropped into its crate.

18.3.5. Extreme care shall be taken when inspecting and handling igniters.

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Igniter propellant may contain a higher percentage of oxidizer and have a higher burn rate than regular motor propellant and

may be very energetic.

18.3.6. Fixtures using cradles for the storage and handling of solid rocket motors/segments shall be inspected for cleanliness

and the absence of any objects that could damage the sensitive solid rocket motor/segment cases when they are lowered into

the cradles.

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18.3.7. For open grain inspections, wrist stats shall be used within five feet of the open grain.

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Solid Rocket Motor and Rocket Motor Segment Processing and Handling

18.4.1. Solid Rocket Motor and Rocket Motor Segment Processing and Handling General Requirements

18.4.1.1. Pathfinder operations using size and weight representative of inert solid rocket motors/ segments shall be conducted

before live/operational solid rocket motor/segment processing operations are conducted.

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18.4.1.2. For solid rocket motor/segment lifting operations, main processing facility overhead doors shall be kept at least

partially open, weather permitting, to provide additional exit routes, unless the doors are required to be closed to reduce

exposure of additional personnel.

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18.4.1.3. If rotating fixtures are used to rotate solid rocket motors/segments (for purposes of cork installation, for example),

the rotating fixture cradles shall be equipped with a means to restrain the solid rocket motors/segments during rotation.

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A hydraulic powered rotating mechanism is preferred.

18.4.1.4. If internal combustion powered vehicles, such as forklifts or man lifts, are required for support of solid rocket

motor/segment handling operations and are operated in close proximity of the solid rocket motors/segments, gasoline and

liquid propane gas powered equipment shall not be used. The equipment shall be located no less than 25 feet from the solid

rocket motors/segments and at least 100 feet away when being refueled. If a forklift is used as a hoist in close proximity of a

solid rocket motor/segment, OSHA approved fork lifting adapters shall be used.

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Battery powered equipment is preferred.

18.4.1.5. All tapes and plastic materials used around open grain areas of a solid rocket motor/segment shall be subjected to

triboelectric and flammability testing and be listed on NASA-STD-6001, Flammability, Offgassing, and Compatibility

Requirements and Test Procedures, and/or KTI-5212, Material Selection List for Plastic Films, Foams, and Adhesive Tapes.

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18.4.1.6. For joint cleaning operations where solid rocket motors/segments are placed on elevated adaptors, extreme care shall

be taken to ensure that such adaptors are properly attached to the support structures. If solid rocket motors/segments are

suspended from a crane during such operations, at least 50 percent of the solid rocket motor/segment weight shall be supported

by the crane.

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18.4.1.7. An operations safety plan shall be written for each solid rocket motor/segment processing facility. This plan shall

define the required clearance areas for all hazardous operations.

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18.4.1.8. Solid rocket motor/segment processing facilities shall be kept clean and uncluttered at all times. Separate facilities

for storage of support equipment and receiving and uncrating of flight hardware shall be used, as necessary, to maintain

unobstructed access to exit’s at all times. Shipping containers shall be removed from the processing facility immediately as

soon as possible after unpacking the hardware.

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18.4.1.9. Solid rocket motor/segment processing facilities shall not be used for storage of ground support equipment or flight

hardware belonging to other programs or not related or not needed for the solid rocket motor/segment handling operations.

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18.4.1.10. Solid rocket motor/segment processing and storage facilities containing ordnance shall not be used as emergency

garage facilities for motor vehicles; for example, storing these vehicles next to stored solid rocket motors/segments before an

earthquake, tropical storm, or a hurricane.

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18.4.1.11. An unobstructed access to at least two exits in the processing facility shall be maintained at all times during solid

rocket motor/segment handling operations.

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18.4.1.12. Breakout gates shall be provided in the processing facility perimeter fence to enable speedy evacuation in case of

emergency. The number and location of the gates shall be based on worst case conditions (facility population, facility

configuration, and meteorological conditions) and shall be approved by the appropriate local safety authority.

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18.4.1.13. Waste collection dumpsters shall not be located inside solid rocket motor/segment processing and storage facilities.

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18.4.1.14. Combustible materials, such as lumber and dunnage used in support of rocket segment/ motor handling operations,

shall be treated with flame retardant paint. Bulk stacks of combustible materials shall be no closer than 100 feet from the solid

rocket motors/segments and removed from the facility as soon as possible.

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18.4.1.15. Flammable materials needed for processing of solid rocket motors/segments shall be stored in appropriate local

safety authority approved lockers and used in minimum necessary quantities around the solid rocket motors/segments. Waste,

such as degreaser or oil soaked rags, shall be placed in closed appropriate local safety authority approved metal containers and

the containers shall be emptied at the end of every shift. Due to the possibility of spontaneous fires, contaminated waste

material shall be removed from the facility as soon as possible and, in no case, left unattended overnight. Waste collection

metal containers shall be placed no closer than 25 feet from the solid rocket motor segments/motors.

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18.4.1.16. Complete solid rocket motors that are capable of unguided flight upon ignition (as determined by analysis) that are

stored vertically or horizontally shall be restrained or thrust termination devices shall be provided to prevent fly-away.

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Vertical storage of built-up rocket motors is undesirable unless they are mated to the core vehicle.

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18.4.1.17. When built-up solid rocket motors must be stored vertically in the stands, provisions shall be made to protect the

motor nozzles from external facility fires. The motors shall be restrained in the stands to ensure that they will not topple in

case of an earthquake, tornado, high winds, or a hurricane impacting the facility, or some other mishap in the facility.

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For example, a separation wall could be built between the processing area and the stand.

18.4.1.18. If desiccant cartridges are used in the stored solid rocket motor/segment covers, provisions shall be made for their

periodic replacement.

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18.4.1.19. For large vertically stacked solid rocket motor igniter installations, the bore opening on top of the motor shall be

guarded to prevent personnel from falling into the motor bore.

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18.4.2. Grounding and Open Grain Work

18.4.2.1. All solid rocket motors/segments and built-up motors shall be grounded at all times. When solid rocket motor

segments and built-up motors are in storage stands or fixtures, the resistance to ground shall not exceed 10 ohms. When

moving the solid rocket motors/segments, make-before-break technique shall be applied. The new ground wire shall be

connected to ground and the resistance verified.

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18.4.2.2. If a solid rocket motor/segment and/or built-up motor is found ungrounded for any reason (for example, the

grounding wire is disconnected), the ground wire shall be immediately reconnected, the ground verified, and a static meter

shall be used to measure the voltage on the case surface. The voltage shall be 1,000 V or less before the solid rocket

motor/segment can be worked on or moved from its storage stand or fixture. Grounding shall be accomplished in the manner

that attaches the grounding wire to the ordnance item first and then to the facility ground (away from the ordnance) last.

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18.4.2.3. For open grain work, wrist stats shall be used within five feet of the open grain. Electrically powered equipment

used within ten feet of the open grain shall be explosion proof or designed to be intrinsically safe.

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18.4.3. Solid Rocket Motor and Rocket Motor Segment Processing and Handling Crane Operations

18.4.3.1. If lifting of a rocket motor/segment with a crane is required, the height of such a lift shall be kept to the absolute

minimum required to accomplish the mission.

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18.4.3.1.1. The propellant ignition threshold shall be determined for each lift (i.e., the height from which if dropped, the

propellant would ignite upon impact with the ground or other surface).

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18.4.3.1.2. For each lift where the lift height must exceed the propellant ignition threshold, detailed justification data shall be

submitted to the appropriate local safety authority for review and approval.

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18.4.3.2. A clear area shall be established around each lift to ensure that the solid rocket motor/segment will not impact any

objects in case of crane or rigging failure.

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Sharp object impalement may reduce the ignition threshold of propellant by a factor of two.

18.4.3.3. Lifting of solid rocket motors/segments over other motors or flight hardware shall be avoided except where necessary

for stacking or storing operations.

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18.4.3.4. The number of spotters and personnel required to support the solid rocket motor/segment lift operations shall be

kept to the absolute minimum required. Remote cameras or similar devices shall be used in locations where NFPA 101, Life

Safety Code, requirements for evacuation of personnel from high hazard facilities cannot be met.

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18.4.3.5. Proposed breakover operations of solid rocket motors/segments shall be submitted to the appropriate local safety

authority with substantiation that there is no other practical means to accomplish the task. The data shall illustrate how risks

are minimized and managed. A detailed operational hazard analysis is required.

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The cranes shall be designed for breakover operations in accordance with section 3.6 and the heights of the lift kept to the

absolute minimum required.

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18.4.3.6. Crane hoisting operations that involve lifting large stacked solid rocket motors are not recommended due to the

extreme hazards involved. A detailed operational hazard analysis is required. Lifting heights shall be kept to the absolute

minimum required.

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Stacking on a transporter or on the launch pad is always a safer alternative.

18.4.3.7. If a crane operational fault occurs during a solid rocket motor/segment lifting operation that leaves the load

suspended, the crane power shall not be recycled to clear the fault until crane troubleshooting determines the nature of the

fault.

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ATTACHMENT 1 GROUND OPERATIONS PLAN

INTRODUCTION

A1.1.1. Purpose. The Ground Operations Plan (GOP) provides a detailed description of the hazardous and safety critical

operations associated with a payload (spacecraft) and its associated ground support equipment. It is the medium from which

payload safety approval is obtained from the PSWG in conjunction with Range Safety, along with the Safety Data Packages

[Missile Systems Prelaunch Safety Package (MSPSP)] required in NPR 8715.7 and Volume 3 of this document. The GOP

may be a stand-alone document or part of the Safety Data Package (MSPSP).

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A1.1.2. Content. This attachment contains the content preparation instructions for the data generated by the requirements

delineated in Volume 6.

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A1.1.3. Applicability. The requirements in this attachment are applicable to the payload projects activities in the payload

processing facility and the launch site.

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A1.1.4. Submittal Process. The GOP submittal periods are delineated in NPR 8715.7 and 4.1 of Volume 6.

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A1.1.5. Final Approval. The GOP shall be approved by the PSWG and Range Safety as delineated for Safety Data Packages

in NPR 8715.7 and in 4.1 and 4.1.4 of this volume.

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PREPARATION INSTRUCTIONS

A1.2.1. Content. This attachment contains the content preparation instructions for the data generated by the requirements

delineated in Volume 6. The GOP contains a description of planned operations (including back out) and the associated hazard

analysis of those operations. Where applicable, previously approved documentation may be referenced throughout the

package. The high level Ground Operations Flow Overview presented at the Payload Safety Introduction Briefing shall

provide an overview of the major payload activities and tasks, where these activities and tasks take place, and an operations

flow timeline for these activities and conform to Volume 6 and this Attachment. The Draft GOP is due 30 days prior to

project’s mission CDR for Safety Review II per NPR 8715.7. The Final GOP shall be submitted 90 days prior to the payload

shipment to the processing site per NPR 8715.7. The information from a GOP may be part of the respective Safety Data

Packages as an inclusion or may be a separate document. The level of detail provided in the GOP data shall be commensurate

with the level of data available at the time of submission.

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A1.2.2. Format. Payload project format is acceptable provided the information described below is provided.

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A1.2.2.1. Table of Contents and Glossary. The GOP shall contain a table of contents and a glossary.

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A1.2.2.2. Introduction. The “introduction” section shall address the purpose and scope of the GOP.

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A1.2.2.3. General Description. The “general description” section shall present an overview of the system and the general

processing flow as a prologue to the hazardous and safety critical operation descriptions. The following items are included in

this section:

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A1.2.2.3.1. General flow of system integration and testing.

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A1.2.2.3.2. Facilities to be used.

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A1.2.2.3.3. Generic timeline with sufficient granularity to identify the major hazardous and/or FTS operations.

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A1.2.2.4. Ground Operations. The “ground operations” section shall identify the ground processing flow including all

hazardous and safety critical operations. The following items are included in this section:

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A1.2.2.4.1. List of all non-hazardous, hazardous, and safety critical procedures by title and numerical designation with an

indication as to which have been designated as hazardous or related to FTS operation.

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A1.2.2.4.2. Procedure Descriptions. Procedure descriptions shall include separate listing of tasks so that hazardous tasks

within each procedure can be identified.

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A1.2.2.4.3. Procedure Task Summaries. Task summaries for each procedure shall include the following information:

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A1.2.2.4.3.1. Each separate task.

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A1.2.2.4.3.2. Responsible agency.

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A1.2.2.4.3.3. Objective.

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A1.2.2.4.3.4. Initial and final configuration.

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A1.2.2.4.3.5. Equipment and support required.

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A1.2.2.4.3.6. Description.

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A1.2.2.4.3.7. Hazards and precautions.

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A1.2.2.4.3.8. List of approved PPE and detection equipment used in ground operations.

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A1.2.2.4.4. Flow Chart Task Summary. A flow chart indicating expected time sequence and location of each individual

procedure and task shall be included. Each flow chart block used shall be assigned a maximum of one procedure and include

the following information:

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A1.2.2.4.4.1. Identifier for each procedure.

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A1.2.2.4.4.2. Procedure number.

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A1.2.2.4.4.3. Hazardous, non-hazardous, or safety critical designation.

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A1.2.2.4.4.4. Task summary number(s).

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A1.2.2.4.5. Identification of emergency and abort/back-out actions.

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A1.2.2.4.6. A list of personnel training certifications, medical certification examination (e.g., crane, propellant, ordnance) as

per NPR 1800.1, NASA, Occupational Health Procedures, and experience requirements for each type of hazardous operation

such as ordnance, crane, and propellant operations.

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A1.2.2.5. Off-Site Processing. The “off-site processing” section shall include the following information:

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A1.2.2.5.1. A detailed description of the off-site build-up and transport configuration of the payload that will be transported

to the Range or launch area.

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A1.2.2.5.2. A description of the tests performed on hazardous and safety critical systems such as rotation of S&A devices, no

voltage checks on ordnance systems, pressure checks of pressure and propellant vessels, RF radiation measurements, and

preliminary FTS checks.

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A1.2.2.6. Operating and Support Hazard Analysis. An Operating and Support Hazard Analysis (O&SHA) shall be performed

for each procedure and the results summarized in the GOP.

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A1.2.2.6.1. The O&SHA shall identify and evaluate the safety considerations associated with environments, personnel,

procedures, and equipment involved throughout the operational phase of the program and shall meet the intent of Volume 1,

Attachment 2, O&SHA requirements.

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A1.2.2.6.2. O&SHAs shall be conducted for activities such as testing, installation, maintenance, support, transportation,

storage, operations, and training.

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A1.2.2.6.3. O&SHAs shall coincide with the flow chart task summaries in A1.2.2.4.

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A1.2.2.6.4. O&SHAs shall incorporate a worksheet associated with each specific flow block in the flow chart and shall include

the following information:

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A1.2.2.6.4.1. The general hazard group.

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A1.2.2.6.4.2. The specific hazard condition.

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A1.2.2.6.4.3. The effect if the hazard is not controlled.

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A1.2.2.6.4.4. Hazard control hardware.

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A1.2.2.6.4.5. The hazard control procedure.

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A1.2.2.6.4.6. Hazard control personnel.

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A1.2.2.6.4.7. Reference to the flow block task number.

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NF 1825 The NASA Payload Safety Hazard Report Form found on the Payload Safety Program's website at:

https://kscsma.ksc.nasa.gov/PayloadSafety under the Payload Safety Forms button should be used to record all identified

hazards.

A1.2.2.7. Payload Project Plans. Payload project plans that include, but are not limited to, the following, shall be submitted

in or added as appendixes to the GOP as identified in 4.5 and 4.6.2 of this volume.

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A1.2.2.7.1. Payload Project Training Plan.

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A1.2.2.7.2. Accident Notification Plan.

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A1.2.2.7.3. Emergency Response Plans for Graphite Epoxy Composite Overwrapped Pressure Vessels.

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A1.2.2.8. Changes. The “change” section contains a summary of all changes to the latest edition of the GOP. All changes

shall be highlighted using change bars or similar means of identification.

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ATTACHMENT 2 HAZARDOUS AND SAFETY CRITICAL PROCEDURES

INTRODUCTION

A2.1.1. Determination of Non-Hazardous, Hazardous and Safety Critical Documented Procedures. The Ground

Operations Plan (GOP) (Attachment 1 of this volume) is the basic document used to initially determine the classification of a

procedure. Specifically, all documented procedures description and task summaries along with the associated Operating &

Support Hazard Analyses (O&SHAs) are reviewed. This review validates the payload project’s determination of documented

procedures as non-hazardous, hazardous, or safety critical. Once the classification of hazardous, non-hazardous, and safety

critical is determined, hazardous or safety critical procedures are submitted to the local safety authority for review and

approval. The PSWG and Range Safety shall determine if select local safety authority notification or attendance shall be

required during review of the initial draft of hazardous or safety critical documented procedures. During review of the initial

documented procedures draft that will take place on an Space Force range, Range Safety shall determine if Pad Safety

notification or attendance shall be required. The review of the draft documented procedure allows a second opportunity to

ensure the classification is appropriate.

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A2.1.2. Purpose. All documented procedures identified as hazardous or safety critical shall provide a detailed, step-by-step

description of the manner in which hazardous and safety critical operations will be accomplished. The procedures are the

medium from which approval to start any hazardous or safety critical operation is obtained from the appropriate safety

authority.

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A2.1.3. Content. This attachment contains the content preparation instructions for the data generated by the requirements

delineated in Volume 6.

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A2.1.4. Applicability. This attachment is applicable to the following:

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A2.1.4.1. All launch vehicle, payload, or service contractors performing hazardous or safety critical operations at the payload

processing facility and launch site area.

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A2.1.4.2. Construction and management contracts for hazardous facilities.

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A2.1.5. Submittal Process. All hazardous documented operational procedures submittal, review, and approval process is in

accordance with the safety requirements and processes of the specific operating location. For operations in areas under KSC

jurisdiction KNPR 8715.3 shall be followed. For Space Force Ranges, the hazardous procedure submittal process is as follows:

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A2.1.5.1. For operations on Space Force Ranges, one copy of the procedures shall be submitted to Range Safety and one copy

to Pad Safety for review and approval 55 days prior to the operation. The payload project shall review, approve, and sign the

final procedures to be submitted to Range Safety or the appropriate local safety authority for approval.

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A2.1.5.2. Final Pad Safety and Range Safety comments, reviews, and approvals shall be provided to the Range User 45

calendar days after receipt of all documented operational procedures.

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A2.1.6. Final Approval. Hazardous and safety critical documented operational procedures shall be approved before

starting any hazardous or safety critical operations at the payload processing facility and launch site area.

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PREPARATION INSTRUCTIONS

A2.2.1. Documented Procedures. Documented Procedures are a written communication that identifies, directs and

authorizes work to be performed and provides the detailed instructions necessary to successfully accomplish and verify task

completion.

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A2.2.2. Content. Documented procedural instructions of non-hazardous and hazardous documents shall consist of a set of

numerically listed steps, ranked sequentially, in the order of importance, to ensure the safe performance of task that involve

ground support equipment used to store, transport, handle, check-out, and control aircraft, launch vehicles, spacecraft, or

payloads, payload systems and facilities and processes used for servicing, operating, or test operations. Hazardous or safety

critical procedures shall be written in a logical format with clear instructions as to the tasks to be performed and hazards and

precautions involved. A decimal numbering system shall be used.

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A2.2.3. Criteria for Hazardous Documented Procedures. Any servicing, operation or test activity that has a high potential

to result in loss of life, serious injury to personnel or public, or damage to property due to the material or equipment involved

or the nature of the operation/activity itself shall be identified as Hazardous (Safety Critical). At a minimum, documented

procedures shall be classified as hazardous for activities listed in Attachment A2.3, Classification of Hazardous Operations.

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A2.2.4. Cover Page

A2.2.4.1. A cover page with the procedure title and required approval signatures, to include the Payload Organization Safety

Engineer date and revision level shall be provided. The signature page shall contain a block for signature approval by the

appropriate safety authority.

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A2.2.4.2. The words Draft or Preliminary shall appear on any signed procedure that does not have the required safety approval.

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A2.2.4.3. The cover sheet shall state, “This Document Does Not Contain Hazardous Operations” for non-hazardous

documented procedures and state “WARNING: This Procedure Contains Hazardous (or Safety Critical) Operations” and shall

be outlined with a border and marked in bold print for hazardous or safety critical operations or equivalent for electronic

documented procedures).

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A2.2.4.4. The cover sheet shall indicate revision level and date.

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A2.2.5. Purpose Section

A2.2.5.1. The “purpose” section shall provide a brief synopsis of all major tasks in each operating procedure.

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A2.2.5.2. The synopsis shall include the following information:

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A2.2.5.2.1. A brief description of the tasks, operations, tests, or checkouts to be performed. For hazardous or safety critical

task, all conditions that cause the documented procedure to be classified as hazardous or safety critical shall be identified.

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A2.2.5.2.2. The facility and area where the procedure is to take place.

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A2.2.5.2.3. The departure and arrival locations if transportation is required.

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A2.2.5.2.4. For launch vehicle and payload tests, when the test is normally performed in relation to launch day (for example,

L-5).

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A2.2.5.3. Revision Log

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A2.2.5.3.1. A revision log shall be maintained and used to identify the date, the step in the procedure where corrections,

technical modifications or changes made to previously submitted hazardous procedures. This would not apply to grammatical

changes unless it alters critical procedural steps or increases or reduces the hazard level of the documented procedure.

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A2.2.5.3.2. Changes to previously submitted hazardous procedures shall list the specific procedural steps revised in the

revision log and be noted with change bars or a similar method of marking.

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A2.2.6. Identification of Specific Hazards. The following specific hazards shall be identified in each procedure:

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A2.2.6.1. The quantity and hazard classification of ordnance and propellants involved.

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A2.2.6.2. The hazardous and non-hazardous configurations of the system before, during, and upon completion of the

operation.

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A2.2.7. Safety Precautions. As applicable, the following precautions shall be incorporated in each procedure at the beginning

of the procedure as well as at the applicable step in the body of the procedure:

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A2.2.7.1. Warnings: Warnings shall consist of (a) the word "WARNING" in upper case letters, enclosed in a border, and

centered on the page, and (b) the text of the warning shall include (a) a brief description of the hazard, (b) the likely result if

the warning is ignored, and (c) specific steps to take to avoid the hazard. Warnings shall precede the information to which they

apply.

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A2.2.7.2. Cautions: Cautions shall consist of (a) the word "CAUTION" in upper case letters and centered on the page, and

(b) the text of the caution shall include (a) a brief description of the hazard, (b) the likely result if the hazard is ignored, and

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A2.2.7.3. Note inhibits.

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A2.2.7.4. Safety devices.

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A2.2.7.5. Control areas.

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A2.2.8. Facility Configuration Inspections. The procedure shall indicate the specific facility and safety clearance zone

control area to be used.

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A2.2.8.1. The requirements for the performance of facility configuration inspections shall be incorporated in the procedures.

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A2.2.8.2. The facility configuration inspection requirements shall address verification of the following:

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A2.2.8.2.1. Facility explosive limits.

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A2.2.8.2.2. Facility personnel limits.

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A2.2.8.3. Posting of fire symbols when ordnance and propellants are moved into or out of a facility.

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A2.2.9. PPE and Emergency Equipment

A2.2.9.1. PPE, fit testing, and emergency equipment requirements for each operation shall be incorporated in hazardous

procedures.

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A2.2.9.2. The PPE and emergency equipment shall address the following:

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A2.2.9.2.1. PPE requirements according to the manufacturer model number, MIL-SPEC, or standard for compliance.

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A2.2.9.2.2. The occasions for the use of PPE.

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A2.2.9.2.3. Types of emergency equipment required.

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A2.2.9.2.4. Location of the emergency equipment during the operation.

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A2.2.9.2.5. The number of emergency equipment units required. No substitution or configuration alteration of PPE shall be

allowed without specific appropriate local safety approval.

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A2.2.10. Pre-Operational Checklist of Required Tools and Equipment

A2.2.10.1. A pre-operational checklist of all tools and equipment required for safe operations shall be incorporated in the

procedures.

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A2.2.10.2. For safety critical equipment, the following information shall be included:

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A2.2.10.2.1. Manufacturer, model, and serial number.

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A2.2.10.2.2. Location of the equipment during the operation.

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A2.2.10.2.3. The number of units required.

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A2.2.10.2.4. The required monitoring devices and their alarm settings.

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A2.2.10.2.5. Proof test requirements.

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A2.2.10.2.6. Nondestructive examination requirements.

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A2.2.10.2.7. Calibration requirements.

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A2.2.11. Support Personnel Requirements

A2.2.11.1. Payload project and any support personnel requirements such as Pad Safety, Fire, Medical, and Security/HOS

personnel shall be incorporated in the procedures. In a multi-task procedure, the times these support personnel are needed

shall be stipulated.

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A2.2.11.2. The following support personnel requirements shall be addressed:

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A2.2.11.2.1. The hazardous periods when personnel limits shall be enforced.

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A2.2.11.2.2. The minimum essential personnel by functional title and number required.

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A2.2.11.2.3. The Pad Safety or local safety authority notification in all cases. In accordance with local safety requirements,

local safety authority or Pad Safety presence and concurrence is required before beginning all hazardous operations.

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A2.2.11.2.4. Special training, certifications, or experience requirements.

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A2.2.12. References to Applicable Documents

A2.2.12.1. All applicable documents, drawings, and specifications shall be referenced in the procedures.

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A2.2.12.2. If a specific operations safety plan or other safety plans apply to the procedure, they shall be listed in the procedure

reference section.

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A2.2.12.3. This document and USSF 91-710 shall be listed in the procedures.

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A2.2.12.4. Procedures shall not use excessive second tier references.

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NOTE: Use of excessive second tier references to incorporate references in such volume that the meaning is lost and use of the

procedure becomes confusing, unnecessarily complex, or irrelevant.

A2.2.13. CCSFS Cape Support and WR Range Scheduling Notification. Notification of the local safety authority at least

24 hours before the planned start of an operation is required to ensure appropriate support is provided and shall be incorporated

in the procedures. The PSWG shall provide the notification information. CCSFS Cape Support (321-853-5211) and Range

Scheduling (321-853-5941) on the ER and Range Scheduling (805-606-8825) on the WR.

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A2.2.14. Pre-Task Briefing

A2.2.14.1. A step for the conduct of a pre-task briefing shall be incorporated in the procedures.

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A2.2.14.2. The following topics shall be addressed:

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A2.2.14.2.1. Operational hazards.

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A2.2.14.2.2. Precautions.

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A2.2.14.2.3. Emergency actions.

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A2.2.14.2.4. Critical task items.

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A2.2.14.2.5. Procedure flow.

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A2.2.14.2.6. Operational discipline.

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A2.2.14.2.7. Communication discipline.

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A2.2.14.3 Specification that when a change of shift/personnel occurs the pre-task briefing shall be repeated.

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A2.2.15. Step-by-Step Directions

A2.2.15.1. A set of numerically listed, step-by-step directions, written in clear language, with sufficient detail to allow a

qualified technician or mechanic to clearly understand the tasks to be performed and hazards and precautions involved, shall

be incorporated.

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A2.2.15.2. The procedure shall contain applicable data sheets, figures, and schematics to document or clarify system

parameters and connect points.

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A2.2.16. Identification of Hazardous and Safety Critical Portions of Procedures

A2.2.16.1. The beginning and end of a hazardous or safety critical portion of a procedure shall be incorporated according to

the following criteria:

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A2.2.16.1.1. A “Warning” shall be used to identify hazards to personnel.

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A2.2.16.1.2. A “Caution” shall be used to identify hazards to equipment.

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A2.2.16.1.3. A “Note” shall be used to indicate an operating procedure of such importance that it must be emphasized.

Select Status

A2.2.16.2. The activation of warning lights, Public Address (PA) announcements, and notification to Security/HOS of any

controlled areas, if not accomplished as a pre-task item, shall be incorporated.

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A2.2.16.3. Safety highlights such as evacuations, safety clearance zones, clearances, activation of aural and visual warnings

shall be detailed before the hazardous sequence and in the applicable section of the procedure.

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A2.2.17. Emergency Shutdown and Backout Steps. Emergency shutdown and backout procedures or steps necessary to safe

the system or facility in the event of a mishap, incident, or abort shall be incorporated.

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A2.2.18. Transmittal of Procedures. For payloads launched via NASA’s Launch Services Program procedures shall be

forwarded to the NASA Launch Site Integration Manager (LSIM) unless otherwise agreed to go to the local safety authority.

The PSWG Chairperson is responsible for all safety coordination and the LSIM is responsible for all launch site coordination

and Launch Services Program coordination. Transmittal of procedures shall be made with a transmittal letter containing the

following information:

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A2.2.18.1. Need Date (minimum of 55 calendar days review time required).

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NOTE: Prior to use, final version of any new, changed, or revised hazardous procedure shall be reviewed and approved by the

appropriate safety authority.

A2.2.18.2. Procedure title and number.

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A2.2.18.3. Program identified or other identifier to ensure that the proper safety point of contact receives the procedure.

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A2.2.18.4. Special instructions for such items as review and comment and final copy for filing.

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A2.2.18.5. Pertinent information such as “procedure is non-hazardous,” “procedure change does not affect the hazardous

portion of the procedure nor otherwise have a safety impact,” or “all previous comments have been incorporated.”

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A2.2.18.6. If the procedure has been previously submitted as a draft or with a different revision number, clarification of the

extent of the changes shall be noted in the document revision log.

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CLASSIFICATION OF HAZARDOUS PROCEDURES

A2.3.1. Hazardous Operation (Hazardous Tasks): Documented Procedures that should be classified as hazardous include

but are not limited to operations involving or controlling activities that:

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A2.3.1.1. Require personnel to enter a work area with atmospheric conditions that could exceed occupational exposure

limits or contain an oxygen deficient or enriched environment, but which does not meet the NPR 8715.1, NASA Safety

and Health Programs, definition of a “confined space.”

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A2.3.1.2. Involve the handling, receipt, storage, transportation, installation, removal, checkout, or closeout of explosives

including solid propellants.

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A2.3.1.3. Involve liquid propellant loading, unloading or flow, venting, sampling, connecting, or disconnecting, moving

or storing of loaded storage units, or opening of contaminated systems.

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A2.3.1.4. Involve cryogenic loading, unloading or flow, venting, sampling, connecting, or disconnecting, moving, or

storing of loaded storage units, or repairing of a system containing cryogenics.

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A2.3.1.5. Involve the handling or transfer of hazardous fluids, hazardous gases, combustible/corrosive liquids, or other

hazardous materials when the given quantity of the gas/vapor or liquid, when mixed or unmixed with air, could result in

death or serious physical injury.

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A2.3.1.6. Involve “critical lift operations” as defined in NASA-STD-8719.9, Lifting Standard. The PSWG or Range Safety.

Select Status

A2.3.1.7. Involve the use of ionizing or non-ionizing radiation sources that have hazard controls specified in the approved

Radiation Use Authorization for that source as issued by the facility Radiation Safety Officer.

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A2.3.1.8. Involve energized electrical systems that may expose personnel to injury and/or death. Exposure to energized

electrical systems operating at voltages of less than 30 volts alternating current (AC) or 50 volts direct current (DC) may

be considered non-hazardous if an assessment has been performed to verify the current levels will not result in a shock.

Select Status

A2.3.1.9. Call up hazardous step(s) of subtask Documented Procedures. The controlling documented procedure shall be

classified as hazardous.

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A2.3.1.10. Involve the pressurization of systems or components and include at least one of the following cases:

Select Status

A2.3.1.10.1. Flight system pressure vessels controlled by fracture mechanics.

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A2.3.1.10.1.1. Any pressurization that exceeds any previously recorded pressurization in the pressure vessel operational

time/cycle log.

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A2.3.1.10.1.2. Any pressurization above the Maximum Allowable Working Pressure (MAWP).

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A2.3.1.10.1.3. Any pressurization greater than 25 percent of the MAWP when the vessel contains hazardous fluids.

Select Status

A2.3.1.10.2. Flight system pressure vessels not controlled by fracture mechanics with:

Select Status

A2.3.1.10.2.1. Any pressurization greater than 25 percent of the MAWP that exceeds any previously recorded

pressurization in the pressure vessel operational time/cycle record log.

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A2.3.1.10.2.2. Any pressurization above MAWP.

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A2.3.1.10.2.3. Any pressurization greater than 25 percent of the MAWP when the vessel contains hazardous fluids.

Select Status

A2.3.1.11. Involve the pressurization of ground-based pressure vessels/systems that include at least one of the following

cases:

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A2.3.1.11.1. Any pressurization above the MAWP/Design Pressure.

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A2.3.1.11.2. First time pressurization to rated pressure of any new vessel/system or the modified portion of an existing

vessel/system. This excludes pressurization after removal or replacement of a component with a like item that has been

pressure tested prior to installation. This also excludes pressurization of Flexible hoses up to rated operating pressure,

provided hose restraints IAW KSC specification 80K51846 Flexible Hose Handling and Installation Requirements are in

place.

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A2.3.1.11.3. In-place calibration at more than 80 percent of full scale for pressure gauges with scale range over 200 pounds

per square inch gauge (psig) unless the gauge has a solid front case with pressure relief back.

Select Status

A2.3.1.11.4. Involve procedures that manually control pressurization of systems where MAWP/Design Pressure can be

reached.

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A2.3.1.12. Involve the pressurization of Composite Overwrapped Pressure Vessel (COPV) to pressures greater than one-

third of the COPV design burst pressure.

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EASTERN AND WESTERN RANGE OPERATIONS/AREAS SAFETY PLANS

A2.4.1 Eastern and Western Range Operations Safety Plans for base or launch complex and payload processing facilities

covering launch vehicle and payload processing operations, may be requested by the PSWG, the eastern or western range

safety organizations or the launch vehicle service provider upon request.

Note: Additional plans shall be developed for facilities, systems, and operations as needed.

LAUNCH COMMIT CRITERIA

Note: To view Range Safety Launch Commit Criteria see USSF 91-710

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VOLUME 7: INDEX OF APPLICABLE AND REFERENCE

DOCUMENTATION, TERMS AND SUPPORTING INFORMATION

Applicable Documents

Code of Federal Regulations (CFR)

10 CFR Energy

21 CFR 1040 Performance Standards for Light Emitting Products

29 CFR 1910 Occupational Safety and Health Standards – General Industry

29 CFR 1910, Subpart N Material Handling and Storage

29 CFR 1910.7 Definition and Requirements for a Nationally Recognized Testing Laboratory

29 CFR 1910.23 Guarding Floor and Wall Openings and Holes

29 CFR 1910.27 Fixed Ladders

29 CFR 1910, Subpart F Powered Platforms, Manlifts, and Vehicle-Mounted Work Platforms

29 CFR 1910.106 Flammable and Combustible liquids

29 CFR 1910.109 Explosives and Blasting Agents

29 CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals

29 CFR 1910.132, Subpart I Personal Protective Equipment, General Requirements

29 CFR 1910.133 Eye and Face Protection

29 CFR 1910.134 Respiratory Protection

29 CFR 1910.135 Head Protection

29 CFR 1910.136 Foot Protection

29 CFR 1910.146 Permit-Required Confined Spaces

29 CFR 1910.147 The Control of Hazardous Energy (Lockout/Tagout)

29 CFR 1910.151 Medical Services and First Aid

29 CFR 1910.179 Overhead and Gantry Cranes

29 CFR 1910.180 Crawler Locomotive and Truck Cranes

29 CFR 1910.184 Slings

29 CFR 1910.252, Subpart Q Welding, Cutting and Brazing, General Requirements

29 CFR 1910.301, Subpart S Electrical

29 CFR 1926 Safety and Health Regulations for Construction

29 CFR 1926.550 Cranes and Derricks

29 CFR 1926.550 (g) Crane or Derrick Suspended Personnel Platforms

29 CFR 1926.1427 Operator Training, Certification, and Evaluation for All Lifts of Personnel

29 CFR 1926.1431 Crane or Derrick Suspended Personnel Platforms

40 CFR 68 Chemical Accident Prevention Provisions, Subpart G, Risk Management Plan

49 CFR 173.56 New Explosives – Definitions and Procedures for Classification and Approval

49 CFR 173.185 Lithium Batteries and Cells

49 CFR, Subpart 6 Surface Transportation Board, Department of Transportation, Parts 1000 through

1199

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BAnnex to NASA-STD-8719.24 VOLUME 7 Revision Basic

NASA Directives, Programs, Standards and Requirements

NASA NPR 1800.1 Occupational Health Program Procedures

NASA NPR 7120.5 Space Flight Program and Project Management Processes and Requirements

NASA NPR 7150.2 Software Engineering Requirements

NASA NPR 8000.4 Risk Management Procedural Requirements

NASA NPR 8621.1 Procedures and Guidelines for Mishap Reporting, Investigating and

Recordkeeping

NASA NPR 8715.1 Safety and Health Programs

NASA NPR 8715.2 NASA Emergency Preparedness Plan Procedural Requirements

NASA NPR 8715.3 General Safety Program Requirements

NASA NPR 8715.7 Payload Safety Program

NASA NPR 8715.26 Nuclear Flight Safety

NASA-STD-5005 Standard for the Design and Fabrication of Ground Support Equipment

NASA-STD-5006 General Fusion Welding Requirements for Aerospace Material Used in Flight

Hardware

NASA-STD-5008 Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch

Structures, Facilities, And Ground Support Equipment

NASA-STD-5009 Nondestructive Evaluation Requirements for Fracture Critical Metallic

Components

NASA-STD-6001 Flammability, Offgassing, and Compatibility Requirements and Test Procedures

NASA-STD-6016 Standard Materials and Processes Requirements for Spacecraft

NASA-STD-7001 Payload Vibroacoustic Test Criteria

NASA-STD-7002 Payload Test Requirements

NASA-STD-8719.9 Lifting Standard

NASA-STD-8719.11 Safety Standard for Fire Protection

NASA-STD-8719.12 Safety Standard for Explosives, Propellants, and Pyrotechnics

NASA-GB-8719.13 Software Safety Guidebook

NASA-STD-8719.14 Process for Limiting Orbital Debris

NASA-STD-8719.17 Requirements for Ground-based Pressure Vessels and Pressurized Systems (PV/S)

NASA-STD-8739.8 Software Assurance and Software Safety Standard

NASA-KNPR-1860.1 KSC Ionizing Radiation Protection Program

NASA-KNPR-1860.2 KSC Nonionizing Radiation Protection Program

NASA-KNPR-8715.2 Comprehensive Emergency Management Plan

NASA-KNPR-8715.3 KSC Safety Procedural Requirements

NASA KSC-C-123 Specification for Surface Cleanliness of Ground Support Equipment Fluid System

NASA KSC-DE-512-SM Facility, System and Equipment General Design Requirements

NASA KSC-GP-425 Fluid Engineering Standards

NASA KSC/MMA-1985-79 Standard Test Method for Evaluating Triboelectric Charge Generation and Decay

NASA KSC/MTB-175-88 Procedure for Casual Exposure of Materials to Hypergolic Fluids: Exothermic

Reaction Test Method

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BAnnex to NASA-STD-8719.24 VOLUME 7 Revision Basic

NASA KSC-SPEC-Z-0008 Fabrication and Installation of Flared Tube Assemblies and Installation of Fittings

and Fitting Assemblies

NASA KSC Specification

80K51846 Facility and GSE Flex Hose Handling and Installation Requirements

NASA FLAGRO JSC-22267 NASA Fatigue Crack Growth Computer Program

MSFC-STD-3029 NASA/MSFC Guidelines for the Selection of Metallic Materials for Stress

Corrosion Cracking Resistance in Sodium Chloride Environments

MSFC-SPEC-3746 Flow-Induced Vibration Assessment Requirements for Metal Bellows and

Flexible Hoses

NASA JPR 5322.1 Contamination Control Requirements Manual

PD/NSC 25 Presidential Directive/National Security Council 25Scientific or Technological

Experiments with possible Large-Scale Adverse Environmental Effects and

Launch of Nuclear Systems into Space

United States Air Force

AFPD 91-1 Nuclear Weapons and Systems Surety

AFPD 91-2 Safety Programs

USAF AFSPCI 91-701 Launch and Range Safety Program Policy and Requirements

USAF AFSPCMAN 91-710 Volume 1, Range Safety User Requirements Manual – Air Force Command

Range Safety Policies and Procedures

USAF AFSPCMAN 91-710 Volume 3, Range Safety User Requirements Manual – Launch Vehicles,

Payloads, and Ground Support Systems Requirements

AFJMAN 32-1083 Facilities Engineering - Electrical Interior Facilities

AFMAN 24-306 Operation of Air Force Government Vehicles

AFMAN 40-201 Radioactive Materials (RAM) Management

AFMAN 91-110 Nuclear Safety Review and Launch Approval for Space or Missile Use of

Radioactive Material and Nuclear Systems

AFMAN 91-203 Air Force Occupational Safety, Fire and Health Standards

DESR 6055.09_AFMAN 91-201 Explosives Safety Standards

AFI 40-201 45TH Space Wing Supplement Radioactive Materials Management (RAM)

AFI 48-109 Electromagnetic Field Radiation (EMFR) Occupational and Environmental Health

Program

AFI 48-139 Laser and Optical Radiation Protection Program

AFI 91-204 Safety Investigations and Reports

AFI 91-208 Hazards of Electromagnetic Radiation to Ordnance (HERO) Certification and

Management

30 SWI 10-119 Western Range Emergency Procedures Responsibilities

30 SWI 15-101 Weather Support

30 SWI 91-201 Launch Support Team Process

45 SWI 15-101 Weather Support

45 SWI 91-203 Process Safety Management (PSM) Plan

45 SW IEMP 10-2 Installation Emergency Management Plan

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BAnnex to NASA-STD-8719.24 VOLUME 7 Revision Basic

30/45 SWOP P19-14 Space Wing Operations Plan Petroleum Products and Hazardous Waste

Management Program

United States Space Force Space

USSF SPFCMAN 91-710 Volume 6 - Range Safety User Requirements Manual – Ground and Launch

Personnel, Equipment, Systems, and Material Operations Safety Requirements

USSF SPFCMAN 91-710 Volume 7 - Range Safety User Requirements Manual – Glossary of References,

Abbreviations and Acronyms, and Terms.

USSF Space Launch Delta Instructions (SLDI)

SLD30I91-106 Toxic Hazard Assessment

Department of Defense (DOD) Directives, Programs, Standards and Requirements

DODD 3100.10 Department of Defense Directive 3100.10 Space Policy

DOD (no designator) Joint Software Systems Safety Engineering Handbook

DOD JS-SSA Software System Safety Implementation Process and Tasks Supporting MIL-STD-

882

DOD T.O. 11A-1-47 DoD Ammunition and Explosives Hazard Classification Procedures

MIL-C-43122G Cloth, Sateen, Cotton, Flame Retardant Treated

MIL-HDBK-5 Metallic Materials and Elements for Aerospace Vehicle Structures

MIL-HDBK-454 Standard General Requirements for Electrical Equipment

MIL-HDBK-6870 Inspection Program Requirements Nondestructive for Aircraft and Missile

Materials and Parts

MIL-HDBK-729 Corrosion and Corrosion Prevention Metals

MIL-PRF-25567 Leak Detection Compound, Oxygen Systems

MIL-STD-461 Requirements for the Control of Electromagnetic Interference Characteristics of

Subsystems and Equipment

MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems

MIL-STD-810 Environmental Engineering Considerations and Laboratory Testing

MIL-STD-882 Standard for System Safety

ST/SG/AC.10/1 Recommendations on the Transport of Dangerous Goods - Model Regulations

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BAnnex to NASA-STD-8719.24 VOLUME 7 Revision Basic

Consensus Standards and Requirements

AIA/NAS 1514 Radiographic Standard for Classification of Fusion Weld Discontinuities

AIAA S-113A-2016 Criteria for Explosive Systems and Devices on Space and Launch Vehicles

ANSI/AIAA S-080-2018 Space Systems – Metallic Pressure Vessels, Pressurized Structures, and Pressure

Components

ANSI/AIAA S-081-2018 Space Systems Composite Overwrapped Pressure Vessels (COPVs)

ANSI/SIA A92.2 Vehicle Mounted Elevating and Rotating Aerial Devices

ANSI A10.14 Construction and Demolition Operations - Requirements for Safety Belts,

Harnesses, Lanyards and Lifelines for Construction and Demolition Use

ASME B30 Cranes, Hoists, and Lifting Devices

ASME B30.9 Slings

ASME B30.20 Below Hook Lifting Devices

ASME B30.23 Personnel Lifting Systems

ASME B56.2 Type Designated Area, Use Maintenance, Operator

ANSI C84.1 Electric Power Systems and Equipment - Voltage Ratings (60 Hz)

ANSI/ISEA Z87.1 Occupational and Educational Personal Eye and Face Protection Devices

ANSI Z117.1 Safety Requirements for Confined Spaces

ANSI Z136.1 Safe Use of Lasers

ANSI Z136.2 Safe Use of Optical Fiber Communication Systems Utilizing Laser Diode and

LED Sources

ANSI Z244.1 Safety Requirements for the Lockout/Tagout of Energy Sources

ASME B1.1 Unified Inch Screw Threads

ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flange

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings

ASME B18.2.1 Square and Hex Bolts and Screw Inch Series

ASME B18.2.2 Square and Hex Nuts (Inch Series)

ASME B31.3 Process Piping

ASME B36.10M Welded and Seamless Wrought Steel Pipe

ASME B40.1 Gauges, Pressure Indicating Dial Type

ANSI/IEEE C95.1 Safety Levels with Respect to Human Exposure to Radio Frequency

Electromagnetic Fields, 3 Khz. to 300 Ghz.

ANSI Y32.2-1975 Graphic Symbols for Electrical & Electronics Diagrams

ASCE/SEI 7-10 Minimum Design Loads for Buildings and Other Structures

ASME-BPVC Section VIII, Pressure Vessels, Division 1 Appendix M, Installation and

Operations

ASTM A182 Forged or Rolled Alloy-Steel Pipe Flanges, Forged

ASTM A312 Standard Specifications for Seamless and Welding Austenitic Stainless-Steel Pipes

ASTM A403 Standard Specification for Wrought Austenitic Stainless-Steel Piping Fittings

ASTM E1417 Standard Practice for Liquid Penetrant Inspection

ASTM E1742 Radiographic Inspection

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ASTM MNL 36 Safe Use of Oxygen and Oxygen Systems: Guidelines for Oxygen System Design,

Materials Selection, Operations, Storage, and Transportation

ASTM F51-68 Standard Method for Sizing and Counting Particulate Contaminant in and on

Clean- room Garments

AWS D17.1 Specification for Fusion Welding for Aerospace Applications

CPIA 394 Chemical Propulsion Information Agency, Hazards of Chemical Rockets and

Propellants

CPIA 394, Volume III Liquid Propellants

CMAA 70 Specifications for Electric Overhead Traveling Cranes

CMAA 74 Specifications for Top Running and Under Running Single Girder Electric

Overhead Traveling Cranes Utilizing Under Running Trolley Hoist

FEMA 74 Reducing the Risks of Nonstructural Earthquake Damage, A Practical Guide

Global Information Grid Technical Guidance Federation

International Civil Aviation

Organization (ICAO) Technical Instructions for the Safe Transport of Dangerous Goods by Air

International Air Transport

Association (IATA) Dangerous Goods Regulations

IEEE/EIA 12207 Standard for Information Technology

Consensus Standards

NEC Article 250-102 Bonding Jumpers

NEC Article 500 Hazardous (Classified) Locations

NEC Article 504 Intrinsically Safe Systems

NFPA 30 Flammable and Combustible Liquids Code

NFPA 70 National Electric Code

NFPA 70E Electrical Safety Requirements for Employee Workplaces

NFPA 77 Recommended Practices on Static Electricity

NFPA 101 Life Safety Code

NFPA 496 Purges and Pressurized Enclosures for Electrical Equipment

NFPA 497 Recommended Practice for the Classification of Flammable Liquids, Gases, or

Vapors and Hazardous Locations (Classified) for Electrical Installations in

Chemical Process Areas

NFPA 505 Fire Safety Standard for Powered Industrial Trucks Including Type Designations,

Areas of Use, Conversions, Maintenance, and Operation

RTCA DO-311 Minimum Operational Performance Standards for Rechargeable Lithium Batteries

and Battery Systems

SAE AS4330 Design Standard - Standard Dimensions for Flared Tubing

SVFISP MSS-SP-6 Standard Finishes for Contact Faces of Pipe Flanges and Connecting End Flanges

of Valves and Fittings

UL 558 Standard for Safety, Industrial Trucks, Internal Combustion Engine Powered

UL 583 Standard for Safety, Battery Powered Industrial Trucks

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UL 913 Standard for Safety, Intrinsically Safe Apparatus and Associated Apparatus for

Use in Class I, II, and III, Divisions 1, Hazardous Areas

Reference Documents

29 CFR 1910.106 Flammable and Combustible liquids

29 CFR 1910.1200 Hazard Communication

29 CFR 1910, Subpart F Powered Platforms, Manlifts, and Vehicle-Mounted Work Platforms

30 SLD 30/SE Space Launch Delta 30/Chief of Safety

3008DOT/FAA/AR MMPDS Metallic Materials Properties Development and Standardization

30 SW OPLAN 32-40020A Hazardous Materials (HAZMAT) Emergency Response Plan

45 SWI 15-101 Weather Support

45 SWI 91-203 Process Safety Management (PSM) Plan

45 SPW/JOP 15E-3-50 Transportation of Oversized Loads

45 SW Range SOR 19 Range Safety Operations Requirements (SOR), Number 19, Toxic Hazard Control

Daily and Launch Operations

49 CFR Department of Transportation, Chapter 49, Code of Federal Regulation

ADA 086259 Joint Services Safety and Performance Manual for Qualification of Explosives for

Military Use

AFI 10-2501 Air Force Emergency Management Program

AFI 91-110 Nuclear Safety Review and Launch Approval for Space or Missile Use of

Radioactive Material and Nuclear Systems

AFI 91-202 The US Air Force Mishap Prevention Program

API 579-1/ASME FFS-1 Fitness-For-Service

ASME B1. Unified Inch Screw Threads

ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flange

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings

ASME B56.3 Electric Battery-Powered Industrial Trucks

ASME-BPVC Section VIII, Pressure Vessels Division 1, Pressure Vessel Rules

ASME-BPVC Section VIII, Pressure Vessels, Division 1 Appendix G, Suggested Good Practice

Regarding Piping Reactions and Design of Supports and Attachments

ASME BPVC Section VIII, Pressure Vessels Division 2, Alternative Rules

ASME BPVC Section X, (ASME S001100), Fiber-Reinforced Plastic Pressure Vessels

ASTM A182 Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe

Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ANSI/SIA A92.3 Manually Propelled Elevating Aerial Platforms

ANSI/SIA A92.5 Boom Supported Elevating Work Platforms

ANSI/SIA A92.6 Self-Propelled Elevating Work Platforms

ANSI/ASCE 7 Minimum Design Loads for Buildings and Other Structures

ANSI Z49.1 Safety in Welding and Cutting

ANSI Z358.1 Emergency Eyewash and Shower Equipment

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ANSI Z359.1 Personnel Fall Arrest Systems, Subsystems, and Components

ASNT - SNT-TC-1A Recommended Practices for Personnel Qualifications and Certification in

Nondestructive Testing

CCEMP/JHB 2000 Cape Canaveral Spaceport Consolidated Comprehensive Emergency Management

Plan

CMH-17 Composite Materials Handbook

KNPR 1820.3 KSC Hearing Loss Prevention Program

KTI-5212 NASA/KSC Material Selection List for Plastic Films, Foams, and Adhesive Tapes

MIL-STD-1751 Safety and Performance Tests for Qualification of Explosives

NACE RP0285-95 Corrosion Control of Underground Storage Tank Systems by Cathodic Protection

NASA-STD-4003 Electrical Bonding for NASA Launch Vehicles, Spacecraft, Payloads, and Flight

Equipment

NASA-SPEC-5022 NASA Manufacturing and Test Requirements for Normally Closed Pyrovalves for

Hazardous Flight Systems Applications

NASA-KNPR-8715.3-1 Safety Procedural Requirements for Civil Servants NASA Contractors

NASA-KNPR-8715.3-2 Safety Procedural Requirements for Partner Orgs Operating in Joint use Facilities

NASA-KNPR-8715.3-3 Safety Procedural Requirements for Partners Operating in Exclusive Use Facilities

NASA-KSC-KTI-5212 NASA/KSC Material Selection List for Plastic Films, Foams, and Adhesive Tapes

NASA-KSC-KTI-1202 Propellant Handlers Ensemble User’s Manual

NASA/FLAGRO (JSC-22267) NASA Fatigue Crack Growth Computer Program

NEPA National Environmental Policy Act

NFPA 70 Article 501 Class I Locations

NFPA 70 Article 700 Emergency Systems

NFPA 70 Article 702 Optional Standby Systems

NPR 1800.1 NASA Occupational Health Program Procedures

T.O. 00-25-203 Contamination Control of Aerospace Facilities

T.O. 31Z-10-4 Electromagnetic Radiation Hazards

T.O. 42C-1-11 Cleaning and Inspection Procedures for Ballistic Missile Systems

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Abbreviations and Acronyms

A-50 Aerozine 50 (UDMH)

AC Alternate Current

AF Air Force

AFI Air Force Instruction

AFJMAN Air Force Joint Manual

AFMAN Air Force Manual

AFPD Air Force Policy Directive

AFSPC Air Force Space Command

AFSPCI Air Force Space Command Instruction

AFSPCMAN Air Force Space Command Manual

AGE aerospace ground equipment

AHJ Authority Having Jurisdiction

AIA Aerospace Industries Association

AISC American Institute of Steel Construction

ANSI American National Standards Institute

ASIC Application Specific Integrated Circuit

ASME American Society of Mechanical Engineers

ASNT American Society for Nondestructive Testing

ASTM American Society for Testing and Materials

AVE aerospace vehicle equipment

BDA blast danger area

BPVC boiler and pressure vessel code

BTHLD below-the-hook-lifting-device

CAD cartridge-activated device

CAL-OSHA California Occupational Safety and Health Administration

CCSFS Cape Canaveral Space Force Station

CCCV constant current constant voltage

CDR critical design review (Note: Throughout this document, “CDR” refer to the project’s mission CDR).

CD ROM compact disc read only memory

CFR Code of Federal Regulations

CMAA Crane Manufacturers Association of America

COPV composite overwrapped pressure vessel

COTS commercial-off-the-shelf

CPIA Chemical Propulsion Information Agency

CPLD Complex Programmable Logic Devices

CPU central processing unit

CPS cycles per second

CW continuous wave

DAFMAN department of the air force manual

dB decibel

dBA decibels on the A scale

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DFMR Design for Minimum Risk

DoD Department of Defense

DP Documented Procedure

DOT Department of Transportation

EBW exploding bridgewire

EBW-FU exploding bridgewire firing unit

ECP Engineering Change Proposal

EED electroexplosive device

EGSE electrical and electronic ground support equipment

ELS equivalent level of safety

ELV expendable launch vehicle

EMC electromagnetic compatibility

EMFR electromagnetic field radiation; electromagnetic frequency radiation

EMI electromagnetic interference

EOD explosive ordnance disposal

EPA Environmental Protection Agency

EPROM erasable programmable read only memory

ER Eastern Range

ERP emergency response plan

ESO explosives safety officer

ETA explosive transfer assembly

ETS explosive transfer system

FAA Federal Aviation Administration

FCDC flexible confined detonation cord

FHA flight hazard area

FM (1) Factory Mutual; (2) frequency modulation

FMECA failure modes, effects, and criticality analysis

FOC fiber optic cable

FPGA Field Programmable Gate Array

FSS Force Support Squadron

FTS flight termination system

gaseous hydrogen

GHe gaseous helium

GHz gigahertz

GOP Ground Operations Plan

GOTS government off-the-shelf

GOX cryogenic oxygen

Gr/Ep graphite epoxy

GSE ground support equipment

GSS ground support system

HA Hazard Analysis

HAZMAT hazardous materials

HDBK handbook

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HIF Horizontal Integration Facility

HMS Hazard Monitor System

HMX cyclotetramethylenetetranitramine

HNS hexanitrostilbene

HOS Hazardous Operations Support

Hz hertz

I importance factor

IATA International Air Transport Association

IAW in accordance with

IBC International Building Code

ICAO International Civil Aviation Organization

IEEE Institute of Electrical and Electronics Engineers

INSRB Interagency Nuclear Safety Review Board

IPF Integration Processing Facility

IRSO Installation Radiation Safety Officer

ISI in-service inspection

JP jet propellant

JTA Joint Technical Architecture

KHz kilohertz

KNPR Kennedy NASA Procedural Requirements

K1 stress intensity

KIc plane-strain fracture toughness

K Ie surface-crack tension specimen fracture toughness

KISCC stress-corrosion cracking threshold

Kmax maximum stress intensity factor

KSC Kennedy Space Center

KTI Kennedy Technical Instruction

kV kilovolts

LBB leak before burst

LED light emitting diode

LEL lower explosive limit

LFU laser firing unit

liquid hydrogen

LHe liquid helium

LID laser initiated device

Li-Ion Lithium Ion

LIO laser initiated ordnance

LIOS laser initiated ordnance system

liquid nitrogen

liquid oxygen

LOX liquid oxygen

LSIM Launch Site Integration Manager

LSO Laser Safety Officer

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LSRRR Launch Safety Requirements Relief Request

mA milliamps

MAC maximum allowable concentration

MAPTIS Material and Process Technical Information System

MAWP maximum allowable working pressure

MDCP Mechanical Damage Control Plan

MEOP Maximum Expected Operating Pressure

MHE material handling equipment

MIL-HDBK military handbook

Mil-Spec military specification

MIL-STD military standard

mm millimeters

MMH mono-methyl hydrazine

MOP maximum operating pressure

MPE maximum predicted environment; maximum permissible exposure

MRB Material Review Board

MSA Mine Safety Appliances

hydrazine

nitrogen tetroxide

NACE National Association of Corrosion Engineers

NASA/FLAGRO NASA Fatigue Crack Growth Computer Program

NDE nondestructive examination

NDI nondestructive inspection

NEC National Electric Code

NEI non-explosive initiator

NFPA National Fire Prevention Association

NFSO NASA Nuclear Flight Safety Officer

NIOSH National Institute of Occupational Safety and Health

NPT National Pipe Thread

NRC Nuclear Regulatory Commission

NRTL Nationally Recognized Testing Laboratory

O&M operating and maintenance

O&SHA operating and support hazard analysis

OIS Operational Information System

OPLAN operations plan

OSC Operations Safety Console

OSHA Occupational Safety and Health Administration

OSP operations safety plan

OTV Operation Television

PA public address

PAD percussion-activated device

PD Presidential Directive

PDR preliminary design review (Note: Throughout this document, “PDR” refer to the project’s mission PDR.)

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PETN Pentaerythritol tetranitrate

PFA plastic films, foams, and adhesive tapes

PHA preliminary hazard analysis

PHE propellant handlers’ ensemble

PLC programmable logic controller

PLD Programmable Logic Devices

PM project manager

PPE personal protective equipment

PPF payload processing facility

PSI payload safety introduction

PSIB payload safety introduction briefing

psi pounds per square inch

psig pounds per square inch gauge

PSM process safety management

PSWG payload safety working group

PTFE polytetrafluoroethylene

PTR program trouble report; public traffic route

PV/S pressurized vessels and pressurized systems

QA quality assurance

RADSAFCOM Radiation Safety Committee (Western Range)

RDX cyclotrimethylenetrinitramine

RF radio frequency

RLV reusable launch vehicle

RMP risk management plan

RP rocket propellant

RPO Radiation Protection Officer

RSC Radiation Safety Committee (Eastern Range)

RSO Radiation Safety Officer

RT radiographic testing

S&A (1) safe and arm device; (2) status and alert

SAS Safety Analysis Summary

SCAPE self-contained atmospheric protective ensemble

SCCB Software Configuration Control Board

SCCSF safety critical computer system function

SCM software configuration management

SCN specification change notice

SDP safety data package formerly MSPSP

SDS Safety Data Sheet

sec second, seconds

SEE single event effects

SEU single event upset

SEW Weapons Safety Office

SFP single failure point

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SGI service group I

SHA system hazard analysis

SLC space launch complex

SLD space launch delta

SLD30 space launch delta 30 (Formerly the 30

Space Wing)

SLD30/SE space launch delta 30 Safety (Formerly 30

Wing Safety)

SLD30I space launch delta 45 instruction (Formerly 30th Space Wing Instruction, SWI)

SLD45 space launch delta 45 (Formerly the 45

Space Wing)

SLD45/SE space launch delta 45 Safety (Formerly 45th Wing Safety)

SLD45I space launch delta 45 instruction (Formerly 45th Space Wing Instruction, SWI)

SMA safety and mission assurance

SNT-TC Society for Nondestructive Testing-Testing Certification

SNS space nuclear systems

SOC System on Chip

SOP standard operating procedures

SPFCMAN Space Force Command Manual

SPR software problem report

SR safety review

SSC United States Space Force Space Systems Command

SSHA subsystem hazard analysis

SSP System Safety Plan

STD software test description

STD Standard

STP standard temperature and pressure

STR software trouble reports

SVFISP Society of the Valve and Fittings Industry Standard Practice

SW Space Wing

SWI Space Wing Instruction

SWOP Space Wing Operation Plan

T.O. technical order

TBI through bulkhead initiator

THZ toxic hazard zone

TIM technical interchange meeting

TLV threshold limit value

TMO Transportation Management Office

TNT trinitrotoluene

TWA time weighted average

UDMH unsymmetrical dimethylhydrazine

UDS Universal Documentation System

UL Underwriters Laboratories

UN United Nations

UNO united nations organizations

US United States

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USAF United States Air Force

USSF United States Space Force

UT ultrasonic test

VSFB Vandenberg Space Force Base

V Volt

Vac volts, alternating current

Vdc volts, direct current

Vrms volts, root mean square

WOCC Wing Operations Control Center

WR Western Range

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Definitions

“A” Basis Allowables. The minimum mechanical strength values guaranteed by the material producers or suppliers

such that at least 99% of the material they produce, or supply will meet or exceed the specified values with a 95%

confidence level.

“B” Basis Allowables. The mechanical strength values specified by material producers and suppliers such that at

least 90% of the materials they produce, or supply will meet or exceed the specified values with a 95% confidence

level.

Abort. An action used to cut short or break-off an action, procedures or operation, in order to preserve the mission

for a future attempt. Aborts can fall into two categories: (1) Contingency abort: re-direction of vehicle flight during

ascent or descent in a manner that does not jeopardize public health and safety and the safety of property, in accordance

with mission rules and procedures. Contingency abort includes landing at an alternative location that has been

designated as a contingency abort location in advance of vehicle flight. (2) Emergency abort: redirection of vehicle

flight during ascent or descent in a manner that minimizes risk to public health and safety and the safety of property.

Emergency abort involves failure of a vehicle, safety-critical system, or flight safety system such that contingency

abort is not possible.

Acceptable hazard. Determination of the acceptability of any hazard imposed by a launch vehicle/missile or orbital

vehicle launched from or onto the range is solely the responsibility of the USSF SLD Commander; the acceptability

varies with operational requirements and/or national need and is determined by the USSF SLD Commander on a case-

by-case basis.

Acceptable launch risk. The allowable collective risk to the general public, without higher management review and

approval, is an aggregated (all hazards, all people including personnel on ships) expectation of casualty (Ec) of ≤ 100

x 10-6. The allowable individual public risk criterion is an aggregated Ec of ≤ 1 x 10-6.

Acceptance tests. The required formal tests conducted on hardware to ascertain that the materials, manufacturing

processes, and workmanship meet specifications and that the hardware is acceptable for its intended use; also the formal

required tests conducted on software to ascertain that the code meets specifications and is acceptable for its intended use.

Acceptable risk. A residual hazard that has been accepted by the Program Manager and the Space Wing Commander.

Accumulated risk. The combined collective risk to all individuals exposed to a particular hazard through all phases

of an operation.

Aggregated risk. The accumulated risk due to all hazards associated with a flight; see also accumulated risk.

Aerozine 50. A 50-50 blend of hydrazine and unsymmetrical dimethylhydrazine.

All-fire level. The minimum direct current or radio frequency energy that causes initiation of an electroexplosive initiator

or exploding bridgewire initiator or laser initiated device with a reliability of 0.999 at a confidence level of 95% as

determined by a Bruceton test. Recommended operating level is all-fire current, as determined by test, at ambient

temperature plus 150%of the minimum all-fire current.

Allowable load (stress). The maximum load (stress) that can be allowed in a material for a given operating environment

to prevent rupture or collapse or detrimental deformation; allowable load (stress) in these cases are ultimate load (stress),

buckling load (stress), or yield load (stress), respectively.

Allowable strength. The ratio of material strength to the specified factor of safety.

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Antenna. A device capable of radiating or receiving radio frequency energy.

Apogee. The point of an object’s greatest distance from the center of the Earth, where the object’s velocity is lowest.

The apogee altitude is the distance of the apogee point above the surface of the Earth.

Applied load. The static or dynamic load applied to a structure, excluding load amplification factors.

Applied load (stress). The actual load (stress) imposed on the structure in the service environment.

Arm/Disarm device. An electrically or mechanically actuated switch that can make or break one or more ordnance

firing circuits; operate in a manner similar to safe and arm devices except they do not physically interrupt the explosive

train.

Arming plug. A removable device that provides electrical continuity when inserted in a firing circuit.

Automatic flight termination (destruct) system. A flight safety system that is installed on each propulsion system on

the launch vehicle, including stages, upper stages, and payload systems; this system functions autonomously during flight

to render the powered stage non-propulsive in the event of the inadvertent breakup of a vehicle.

Autonomous flight safety system. An onboard system that includes all hardware and software needed to make a

flight termination decision (or other safety decision) and initiate actions that end vehicle flight (or otherwise restrict

vehicle flight) without ground-based intervention. An Autonomous Flight Termination System (AFTS) is a type of

AFSS.

Auxiliary payload. A small satellite (e.g., CubeSats, Nanosatellites, Picosatellites) that does not interfere with the

primary payload mission.

Azimuth. The initial launch direction measured clockwise from zero degrees north.

Battery capacity. (1) Rated capacity: the capacity assigned by the battery manufacturer based on a set of specific

conditions such as discharge temperature, discharge current, end of discharge voltage, and state of charge at start of

discharge; (2) measured capacity: the capacity determined by the specific qualification tests, including any time the

battery is under load during qualification; the end of discharge voltage is the minimum voltage that flight termination

system components have been qualified to.

Below-the-hook lifting device. Structural and mechanical lifting devices and equipment (except for slings, load

positioning devices, and load cells) used to connect a crane/hoist hook and a load being lifted, including lifting beams

(and arms) and attachment hardware such as bolts and pins (lifting assemblies).

Blast danger area. A hazardous clear area; clearance prior to establishment of a major explosive hazard such as

vehicle fuel/oxidizer load and pressurization; the area subject to fragment and direct overpressure resulting from the

explosion of the booster/payload.

Brittle fracture. (1) A type of failure mode in structural materials that usually occurs without prior plastic

deformation and at extremely high speed, (2) a type of failure mode such that burst of the vessel is possible during

cycling [normally this mode of failure is a concern when cycling to the maximum expected operating pressure (MEOP)

or when the vessel is under sustained load at MEOP], and (3) a type of fracture that is characterized by a flat fracture

surface with little or no shear lips (slant fracture surface) and at average stress levels below those of general yielding.

Bruceton Test Method. A statistical method for determining the all-fire and no-fire characteristics of an electro-

explosive device using a small sample size, but with high reliability.

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Burst factor. A multiplying factor applied to the MEOP to obtain the design burst pressure; synonymous with ultimate

pressure factor.

Casualty. A serious injury or worse, including death, to a human.

Casualty area. The area on the ground about the impact point of a fragment within which an exposed person would be

expected to become a casualty.

Catastrophic hazard. A hazardous condition causing a mishap that could result in one or more of the following: death,

permanent total disability, irreversible significant environmental impact or facility, ground, or flight equipment loss

greater than $10,000,000.00.

Cell. A single electrical energy or electrical charge-storing unit described by minimum voltage and minimum capacity.

Certified inspector. A person qualified and certified in nondestructive examination inspection techniques according

to the American Society for Nondestructive Testing, recommended practices (SNT-TC-1A).

Collective risk. The total combined risk to all individuals within a category (for example, launch-essential personnel,

general public) exposed to any hazard from an operation. Unless otherwise noted, collective risk is the mean number of

casualties (Ec) predicted to result from all hazards associated with an operation. Collective risk is specified as either for

a mission or per year. The collective risk should include the aggregated and accumulated risk.

Collision avoidance. A process designed to prevent collisions between on-orbit tracked objects or to prevent

collisions between on-orbit tracked objects and launched vehicles (including spent stages)/payloads by determining

and implementing courses of action through careful analysis of validated conjunction assessments and satellite health

and mission requirements. The process includes establishing launch wait periods in either the launch window or

spacecraft thrust firings based on validated conjunction assessments and accounts for uncertainties in spatial

dispersions, arrival time of orbiting objects and/or the launch vehicle/payload, and modeling accuracy.

Command control system. The portion of a flight safety system that includes all components needed to send a flight

termination control signal to an onboard vehicle flight termination system; a command control system starts with flight

termination activation switches at the mission flight control console and ends at each command-transmitting antenna;

it includes all intermediate equipment, linkages, and software and any auxiliary transmitter stations that ensure a

command signal will reach the onboard vehicle flight termination system from liftoff until the launch vehicle achieves

orbit or can no longer reach a populated or other protected area.

Command destruct. The process in which a sequence of commands are issued from a ground station or center that,

when executed by the flight system, causes the launch vehicle to be destroyed.

Command destruct system. A portion of a flight termination system that includes all components on board a launch

vehicle that receive a flight termination control signal and achieve destruction of the launch vehicle; a command

destruct system includes all receiving antennas, receiver decoders, explosive initiating and transmission devices, safe

and arm devices and ordnance necessary to achieving destruction of the launch vehicle upon receipt of a destruct

command; a command destruct system is one type of a command terminate system.

Command system. The portion of the flight safety system consisting of the airborne flight termination system and

the ground flight termination system command transmitter system that sends arm and terminate commands.

Command terminate system. A portion of a flight termination system that includes all components on board a launch

vehicle that receive a flight termination control signal and achieve termination of the flight of a launch vehicle; a

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command terminate system includes all receiving antennas, receiver decoders, explosive initiating and transmission

devices, safe and arm devices and ordnance necessary to achieving destruction of the launch vehicle or other devices

to stop propulsion or otherwise terminate flight upon receipt of a terminate command.

Commercial/FAA-licensed launch. Activity licensed by the FAA. This includes activity required to prepare,

conduct, or recover from a launch action (to include such activity as a static fire, engine test, booster assembly, launch,

etc.) when requesting services, commodities, or resources from USSF under the provisions of 51 USC and/or 10 USC

§ 2276.

Compatibility. The ability of two or more materials or substances to come in contact without altering their structure or

causing an unwanted reaction in terms such as permeability, flammability, ignition, combustion, functional or material

degradation, contamination, toxicity, pressure, temperature, shock, oxidation, or corrosion.

Composite material. The combinations of materials differing in composition or form on macro scale. The

constituents retain their identities in the composite; normally, the constituents can be physically identified, and there is

an interface between them.

Composite material. The combinations of materials differing in composition or form on macro scale. The

constituents retain their identities in the composite; normally, the constituents can be physically identified, and there is

an interface between them.

Conflagration. A destructive fire, usually an extensive one.

Conjunction assessment. The process of determining the point of closest approach of two orbiting objects, or

between a launch vehicle and an orbiting object, in association with a specified miss-distance screening criterion or

the corresponding probability of collision. Associated with the closest approach assessment is the closest approach

distance, the times of launch or orbital firing that would result in the closest approach and meeting the miss-distance

or collision probability criteria.

Contamination. The introduction of impurities, undesirable material, suspect material, or material potentially out of

specification that may render the system or equipment unusable for its intended purpose or in such a state that special

measures need to be taken before the equipment or system can be restored to normal service.

Control area clears. A hazardous clear area: clearance of defined areas to protect personnel from hazardous

operations.

Conventional facility or structure. Office buildings, libraries, auditoriums, warehouses, cafeterias, utility buildings,

and other facilities whose structures are characterized by well-established design precedents and loading conditions

and whose function is non-hazardous.

Control authority. A single commercial user on-site director and/or manager, a full time government tenant director

and/or commander, or United States Space Force squadron/detachment commander responsible for the implementation

of launch complex safety requirements.

Countdown. The timed sequence of events that must take place to initiate flight of a launch vehicle.

Crew rest. That period of time immediately prior to the beginning of duty as assigned; for launch-essential personnel,

it is mandatory that the rest period include the time necessary for meals, transportation, and 8 hours of uninterrupted

rest prior to reporting for duty. In preparation for launch operations, rest periods start no earlier than 2 hours after the

assigned personnel are released from an earlier launch or range operation. Only the Chief of Safety or USSF SLD

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Commander has the authority to waive the safety rest period requirements for Mission Ready (Category A) personnel;