khb 1700.7 revision c 45 sw hb s-100 august 19, 1999

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KHB 1700.7Revision C

45 SW HB S-100August 19, 1999

Space Shuttle

Payload Ground Safety Handbook

NASA USAFNational Aeronautics

and SpaceAdministration

Department of the Air ForceUnited States of America

Kennedy Space Center/Cape Canaveral Air Station


KHB 1700.7Revision C45 SW HB S-100August 19, 1999

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Responsible Office: EC/Director of Safety and MissionAssurance

* Preface

National Aeronautics and Space Administration (NASA)/Department of Defense (DoD) policy is to achieve a consistentlevel of safety by applying reasonable criteria, giving theSpace Shuttle Program (SSP) payload and ground supportequipment (GSE) designer, operator, processor, and user therequirements to develop effective, efficient ground processingprocedures usable at all SSP and cargo processing locations.This document aligns existing DoD and NASA ground safetycriteria and establishes requirements for ground processing ofSSP payloads and associated GSE. The requirements to assurepayload mission success are the responsibility of the payloadorganization and are not within the scope of this document.

This document replaces the regular John F. Kennedy Space Centerhandbook requirement for a preface signed at the directoratelevel and authorizes subordinate elements to implement thejoint safety policies established in the "Space Shuttle PayloadGround Safety Handbook."

The Director, Kennedy Space Center (KSC), and the Commander,45th Space Wing (45 SW), will assure compliance with thesepolicies and approve waivers to the provisions of thisHandbook.

The Handbook will be reviewed annually and changes incorporatedthat are mutually agreeable to the Director, KSC, and theCommander, 45 SW.

This Handbook supersedes SAMTO HB S-100/KHB 1700.7B,September 1, 1992.

/Original signed by/ /Original signed by/_______________________ _____________________________________ROY D. BRIDGES, JR. F. RANDALL STARBUCKDIRECTOR BRIG GEN, USAFKENNEDY SPACE CENTER COMMANDER, 45th SPACE WING

Distribution:Tech Doc Library



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Table of Contents

1.0 INTRODUCTION. . . . . . . . . . . . . . . . . . . 1-1

1.1 PURPOSE. . . . . . . . . . . . . . . . . . . . 1-1

1.2 SCOPE. . . . . . . . . . . . . . . . . . . . . 1-1

1.3 APPLICABILITY. . . . . . . . . . . . . . . . . 1-2

1.4 RESPONSIBILITY . . . . . . . . . . . . . . . . 1-2

1.4.1 DELEGATION. . . . . . . . . . . . . . . 1-3

1.5 CHANGES. . . . . . . . . . . . . . . . . . . . 1-3

2.0 PHASE SAFETY REVIEWS. . . . . . . . . . . . . . . . 2-1

3.0 DOCUMENTATION . . . . . . . . . . . . . . . . . . . 3-1

3.1 GENERAL. . . . . . . . . . . . . . . . . . . . 3-1

3.2 PHASE SAFETY REVIEW DOCUMENTATION. . . . . . . 3-1

3.3 LAUNCH SITE DOCUMENTATION. . . . . . . . . . . 3-2

3.3.1 PAYLOAD ORGANIZATION LAUNCH SITESAFETY PLAN . . . . . . . . . . . . . . 3-3

3.3.2 TECHNICAL OPERATING PROCEDURES (TOP's). 3-33.3.3 PAYLOAD SAFETY NONCOMPLIANCE

REPORTS . . . . . . . . . . . . . . . . 3-4

3.4 DOCUMENTATION CHANGES. . . . . . . . . . . . . 3-5

4.0 SAFETY REQUIREMENTS . . . . . . . . . . . . . . . . 4-1

4.1 OPERATIONAL CONSIDERATIONS . . . . . . . . . . 4-1

4.1.1 FAILURE TOLERANCE . . . . . . . . . . . 4-14.1.2 PERSONNEL POLICIES. . . . . . . . . . . 4-14.1.3 HAZARDOUS OPERATIONS. . . . . . . . . . 4-34.1.4 SAFETY INSPECTION . . . . . . . . . . . 4-44.1.5 SAFETY EQUIPMENT. . . . . . . . . . . . 4-44.1.6 TOOLS . . . . . . . . . . . . . . . . . 4-54.1.7 PHOTOGRAPHY . . . . . . . . . . . . . . 4-5



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Table of Contents (Cont.)

4.2 PERSONNEL SAFETY . . . . . . . . . . . . . . . 4-5

4.2.1 HUMAN FACTORS . . . . . . . . . . . . . 4-6

4.3 PAYLOADS AND GROUND SUPPORT EQUIPMENT (GSE). . 4-8

4.3.1 BIOMEDICAL SUBSYSTEMS . . . . . . . . . 4-84.3.2 ELECTRICAL. . . . . . . . . . . . . . . 4-84.3.3 PRESSURE/VACUUM SYSTEMS . . . . . . . . 4-124.3.4 RADIATION . . . . . . . . . . . . . . . 4-224.3.5 ORDNANCE. . . . . . . . . . . . . . . . 4-304.3.6 MECHANICAL, ELECTROMECHANICAL DEVICES . 4-354.3.7 PROPELLANTS . . . . . . . . . . . . . . 4-354.3.8 CRYOGENICS. . . . . . . . . . . . . . . 4-414.3.9 GSE MATERIALS . . . . . . . . . . . . . 4-434.3.10 INDUSTRIAL HYGIENE. . . . . . . . . . . 4-444.3.11 OXYGEN. . . . . . . . . . . . . . . . . 4-46

4.4 ENVIRONMENTAL. . . . . . . . . . . . . . . . . 4-46

4.4.1 METEOROLOGICAL REQUIREMENTS . . . . . . 4-464.4.2 HAZARDOUS ATMOSPHERE. . . . . . . . . . 4-474.4.3 HUMIDITY. . . . . . . . . . . . . . . . 4-494.4.4 TOXIC MATERIALS . . . . . . . . . . . . 4-50

4.5 HANDLING AND TRANSPORTS. . . . . . . . . . . . 4-50

4.5.1 HOISTING AND HANDLING . . . . . . . . . 4-514.5.2 TRANSPORTERS. . . . . . . . . . . . . . 4-58

5.0 MISHAP INVESTIGATION AND REPORTING. . . . . . . . . 5-1

5.1 NASA MISHAP INVESTIGATION CONTROL. . . . . . . 5-1

5.2 USAF MISHAP INVESTIGATION CONTROL. . . . . . . 5-1

5.3 MISHAP REPORTING . . . . . . . . . . . . . . . 5-1

5.3.1 MISHAP CONTACTS . . . . . . . . . . . . 5-15.3.2 PAYLOAD ORGANIZATION INVOLVEMENT. . . . 5-25.3.3 PAYLOAD ORGANIZATION RESPONSIBILITIES . 5-25.3.4 INVESTIGATION BOARDS. . . . . . . . . . 5-35.3.5 MISHAP SCENE. . . . . . . . . . . . . . 5-3



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Table of Contents (Cont.)

APPENDIX A - ACRONYMS, ABBREVIATIONS, ANDGLOSSARY OF TERMS . . . . . . . . . . . . . A-1

APPENDIX B - COMPLIANCE AND REFERENCE DOCUMENTS. . . . . B-1

APPENDIX C - GUIDELINES FOR THE PREPARATION OFTECHNICAL OPERATING PROCEDURES (TOP's). . . C-1

APPENDIX D - ORDNANCE STORAGE AND HANDLING DATAREQUIREMENTS. . . . . . . . . . . . . . . . D-1

APPENDIX E - PAYLOAD RELATED EMERGENCY PROCEDURESDOCUMENTS AND FACILITY SAFETY PLANS . . . . E-1

Tables

TABLE 4-1 SLING REQUIREMENTS. . . . . . . . . . . . . . 4-54



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* 1.0 INTRODUCTION

1.1 PURPOSE

The purpose of this Handbook is to present the SSPpayload ground safety policy and the criteriaapplicable to payload/GSE design and to groundprocessing from arrival to liftoff and duringpostlanding activities to qualify SSP payloads andassociated GSE for safety certification by thepayload organization to the Launch Site Safety Office(LSSO). It establishes SSP payload ground safetyrequirements by providing a single, commoninterpretation of Eastern and Western Range (EWR)127-1, "Range Safety Requirements," for the 45thSpace Wing (45 SW) and Kennedy Space Center (KSC)safety policies and requirements. This allowsreciprocal operations at the Eastern Range (ER) afterjointly acceptable safety certification is achieved.ER consists of the SSP and the payload processingfacilities at KSC and Cape Canaveral Air Station(CCAS).

1.2 SCOPE

This document establishes the minimum NASA/DoD groundprocessing safety policy, criteria, and requirementsfor SSP payloads and associated payload organization-provided portable GSE. It provides the detailedsafety requirements for ground operations andpayload/GSE design not contained in NASA Handbook,NSTS 1700.7 and Addendum, "Safety Policy andRequirements for Payloads Using the SpaceTransportation System." This document does notaddress facility GSE, non-SSP program elements, orflight safety. Specific implementation of designrequirements is sometimes omitted to allow thepayload organization flexibility in developingpayload/GSE design. The payload organization'simplementation of design requirements shall becoordinated with the LSSO. Associated OccupationalMedicine and Environmental Health requirements havebeen selected and included in this document.

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1.3 APPLICABILITY

This document applies to:

a. All organizations processing SSP payloads orexperiments at the ER. This includes allgovernment organizations (e.g., NASA, DoD, otherdomestic or foreign government, or allianceorganizations) and independent foreign ordomestic enterprises.

b. Contractors in direct support of the above

organizations. c. Other organizations or agencies providing direct

personnel and equipment interface to payload orpayload GSE support.

d. Any of the above organizations required to

support SSP payload postlanding operations atany landing site.

1.4 RESPONSIBILITY

The KSC Director and the 45 SW Commander have beenassigned overall authority for safety for all SSPpayload activities conducted at their respectiveCenters.

a. The officials of the LSSO responsible forimplementing the safety policy and criteria forSSP payload activities are identified below:

(1) For KSC, Director of Safety and MissionAssurance (EC).

(2) For CCAS, 45 SW Director of Safety (SE).

b. The Chiefs, Biomedical and BioenvironmentalEngineering Offices, are responsible for certainactivities as identified in this Handbook.Office contacts are identified below:

(1) For KSC, Biomedical Office (JJ).



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(2) For CCAS, Bioenvironmental EngineeringOffice (45 AMDS/SGPB, Patrick AFB).

1.4.1 Delegation

The Launch Site Safety Representative (LSSR) is thedesignated representative of the LSSO and has beendelegated the following authorities:

a. Monitors LSSO-selected operations and has safetyapproval authority for procedural deviations.

b. Gives concurrence to start these selected

operations. c. May halt any operation deemed unsafe.

1.5 CHANGES

This Handbook will be reviewed annually in accordancewith appropriate directives or as required byreference document changes. Changes to this Handbookshall be directed to and require joint agreementbetween the KSC Director and the 45 SW Commander.

All documents referenced in the text of this documentare by the basic number. The revision level and dateof the referenced document are identified in AppendixB and are updated by the required review process.



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2.0 PHASE SAFETY REVIEWS

* The payload organization personnel are responsiblefor the safety of their own systems and personnel.They are also responsible to the SSP operator and thelaunch site operator not to compromise the safety ofthe other SSP payloads, the Orbiter, launch sitefacilities, and personnel. To implement this safetyeffort, the NASA and DoD programs of phase safetyreviews are implemented by Johnson Space Center (JSC)document, NSTS 13830, "Implementation Procedure forNSTS Payloads System Safety Requirements.” Thisprocedure provides for an early safety interface tobe established between the payload organization andthe launch site.

The phase safety reviews are conducted by a team ofrepresentatives from many different backgrounds toprovide a broad spectrum of knowledge on the subjectof safety. It is their task to advise payloadorganizations on matters of system safety. Includedin this team are representatives of the processingsites. It is their task, in addition to the above,to verify that the payload and its support equipmentcomply with the requirements of this document.

NASA normally conducts flight safety reviews for thepayload at JSC and a separate ground safety review onground operations and GSE design at KSC. They may,however, be held concurrently at either site or at asite jointly agreed on by JSC and KSC. DoD normallyconducts their reviews concurrently at thecontractor's facility but may select an alternatesite. These reviews provide for the delivery ofsafety documentation required by the launch siteprior to delivery of the payload to that site. Thisdocumentation is further discussed in Paragraph 3.0of this document. In the past, some payloadorganizations have not fully understood the extent ofthese data requirements, and this has createdproblems. The procedures explained and outlined inthis text preclude these problems and bring about asmooth transition from the factory to the launchsite, through the launch and, if applicable, throughrecovery.

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The documentation requirements of this document andthe phase safety reviews will be based upon thehazardous nature and degree of complexity of thepayload systems. When flight payload safety reviewsand ground payload reviews are separate reviews, anassessment shall be made by the payload organizationto assure hazards identified in each package areassessed for applicability to the other; e.g., if aground safety hazard report on inadvertent thrusterfiring does not exist, the flight safety hazardreport must be referenced in the ground safetypackage and it must contain a discussion of theapplicability of the flight safety controls on groundsafety.



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3.0 DOCUMENTATION

* 3.1 GENERAL

The LSSO requires documentation to assure safetycompliance of payload/GSE design and safe groundoperations for the SSP payloads. Identification,submittal, and approval of the documentation requiredby NSTS is accomplished by the phase safety reviewprocess. Documentation submitted shall be consistentwith the phase level under review and be approvedprior to completion of the Phase III Safety Review.

3.2 PHASE SAFETY REVIEW DOCUMENTATION

Phase safety reviews allow the participating partiesto put into perspective the safety impact that thedesign concepts presented by the payload organizationwill have on the Shuttle, other payloads, and launchsite processing facilities. The payload organizationmust demonstrate to the LSSO that hazards noteliminated by design exist for valid technicalreasons and are not for operational convenience orcost savings. These hazards can cause operationalrestrictions that could limit personnel numbers,require a specific sequence of operations, or limitoperations to specific facilities. The LSSO willcommunicate to the payload organization the rationalefor any restrictions imposed as early as possible andwill assist the payload organization in determiningthe course of action which can best serve operationalefficiency.

* The payload organization shall, in accordance withNSTS 13830, provide the Safety Review Panel thefollowing data consistent with the program phase:

a. Block diagrams, schematics, and descriptions ofsafety-critical subsystems. This includestables of design and operating parameters forsuch items as lifting equipment, pressuresystems, ordnance, and batteries.

b. Launch site processing plan including timelines

for handling, storage, assembly, servicing, andcheckout operations.

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c. List of Technical Operating Procedures (TOP's),a synopsis of each procedure, and theirpreliminary classifications; i.e., hazardous ornonhazardous.

d. Documentation certifying compliance with

ionizing and nonionizing radiation controlrequirements.

e. Hazard reports addressing both design and

operations. f. Failure/accident summary reports. g. Copies of all noncompliance reports. h. Ordnance storage and handling data requirements

in accordance with Appendix D. i. A list of all hazardous materials and physical

agents. Material Safety Data Sheets (MSDS's)(CFR 1910.1200) shall be provided to the LSSOfor all material and agents brought to the ELSby the payload organization.

j. A list of all plastic films, quantity, and

location of use. k. List of the payload T-O Umbilical functions. l. Critical software commands must be identified

and managed. These critical software commandsinclude commands which, if executed or executedout of sequence, would create a hazardouscondition or would remove a safety inhibit.

3.3 LAUNCH SITE DOCUMENTATION

The LSSO requires assurance, in the form of detaileddocumentation, that the payload organization iscognizant of and has the means to implement thesafety and health policies and requirements of thelaunch sites. For example, Facility Safety Plans andEmergency Procedure Documents (EPD's) developed by



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the launch sites contain specific requirements forspecific hazardous processing facilities/areas andare mandatory for all facility/area users. (SeeAppendix E for a listing of Facility Safety Plans andEPD's.)

3.3.1 Payload Organization Launch Site Safety Plan

The payload organization Launch Site Safety Plan willdemonstrate the means by which the organizationmanages and interfaces safety within its organizationand how it applies the launch site safetyrequirements. For DoD and DoD-sponsored payloads,the format and content of the plan shall comply withthe requirements of the payload organization's LaunchBase Test Plan, Section 7 (ELS). For NASA and NASA-sponsored payloads, the specifics of the plancontents will be identified to the payloadorganization early in the phase safety reviewprocess. All plans shall be tailored to thecomplexity of the payload element and be provided tothe LSSO for review and approval at least 30 daysprior to first hardware delivery to the launch site.

* 3.3.2 Technical Operating Procedures (TOP's)

In order to be accomplished in a safe and orderlymanner, payload ground operations must be conductedusing detailed step-by-step instructions in TOP's.All TOP's designated hazardous by the LSSO or by thepayload organization are required to be approved bythe LSSO and published and "on the shelf" 10 daysprior to use (7 days prior to use for revisions).For TOP's which are performed on CCAS, an additional30 days must be allowed for 45 SW review. Draft orpreliminary procedures should be submitted to theLSSO when available. Where procedures are used tocontrol hazards identified in the hazard reports, alisting of those procedures and the applicable stepnumbers which control the hazard shall be identifiedin the Phase III data package. Guidelines forhazardous classification of procedures are providedin Paragraph 4.l.3. LSSO guidelines and requirementsfor the preparation of TOP's can be found in AppendixC.

* Denotes Change



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* 3.3.3 Payload Safety Noncompliance Reports

The payload organization must comply with all therequirements of this Handbook and of NSTS l700.7 orobtain an approved waiver/deviation for each case ofinability to comply with a specific safetyrequirement. Waiver/Deviation requests shall bedocumented in accordance with requirements referencedin Paragraph 3.l. The LSSO will coordinate therequests and provide rationale for approval ordisapproval to the appropriate authority. Launchsite waivers/deviations shall be granted only byauthority of the KSC Director or 45 SW Commander andare not transferable between Centers or payloadactivities. Payload organizations will be formallynotified of the disposition of the waiver/deviationrequest.

3.3.3.1 Waivers - Each waiver request shall be limited to aspecific subsystem or component in a specificapplication.

The payload organization is responsible forcorrecting the waived condition prior to the reflightof the payload on another Space Shuttle mission orthe flight of subsequent payloads of the same series.If the waived condition is not corrected, a newwaiver request is required. The new request mustcontain additional rationale, justifying continuednoncompliance, and a copy of the original waiver mustbe attached.

Waiver requests should be submitted as soon as theneed is identified. Prior to submittal, all waiverrequests should be coordinated with the appropriategovernmental sponsor and submitted to the LSSO. Thewaiver request shall contain the following:

a. The payload name and the model of the payload orsupport equipment as applicable.

b. The specific component and the subsystem in

which the component functions shall beidentified.

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c. The specific requirement (one per waiver) anddocument and paragraph number against which thewaiver is being sought.

d. The hazard created by noncompliance to this

requirement and a cross-reference to the relatedhazard report. (The related hazard report shouldreference the waiver.)

e. Reason for noncompliance to this requirement. f. Give rationale for acceptance of this waiver,

including any required support data anddrawings, and list possible methods andtechniques used in mitigating the hazards.

g. This waiver request must be signed by the

program manager of the payload organization.

3.3.3.2 Deviations - When a deviation is granted, thenoncompliance condition may be approved for more thanone mission. Deviations will be applicable where theassociated hazard to the Space Shuttle is notaffected by manifesting with other SSP payloads,location of the payload in the Orbiter, or mission-unique environmental conditions. Noncompliancereports to be considered for a deviation will bethose where the design, procedure, configuration,etc., do not comply with the safety requirement inthe exact manner specified, but the intent of therequirement has been satisfied and a comparable orhigher degree of safety is achieved.

3.4 DOCUMENTATION CHANGES

Changes or modifications which affect any approvedphase safety review or launch site documentation mustbe provided to the LSSO for review and reapproval.



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4.0 SAFETY REQUIREMENTS

Payload organizations shall comply with the followingpolicies, practices, and regulations.

4.1 OPERATIONAL CONSIDERATIONS

4.1.1 Failure Tolerance

The interaction of payload, GSE, launch sitefacilities, and operator monitoring/intervention musttolerate a minimum number of credible failures and/oroperator errors as determined by the hazard levelanalyses. This applies when failure to perform afunction or the inadvertent performance of a functionresults in a hazardous event. The requirementscontained in Section 4 are intended to provide theproper failure tolerance for GSE when used alone orin conjunction with a payload and/or facility.Verification of compliance with the technicalrequirements of this document will normallydemonstrate the intent of this paragraph. When thetechnical requirements do not provide for failuretolerance, the adequacy of the controls shall bedetermined during the safety review process.

4.1.2 Personnel Policies

Payload organizations shall provide a description oftheir Training/Certification Program to the LSSO aspart of the payload organization Launch Site SafetyPlan. This program shall specify the personneltraining required and the certification proceduresemployed to establish acceptable skill levels for allpersonnel involved in the ground processing of SSPpayloads and GSE. Ground processing shall beperformed only by persons certified in the disciplinerequired for that process.

4.1.2.1 Training - Safety and health inputs to trainingprograms shall be tailored to the task categoriesinvolved and included in lesson plans andexaminations. Safety training of operating personnelis the responsibility of the payload organization.The payload organization shall meet the applicablefacility and operating site requirements. It should



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be noted that there are certain launch site safetytraining requirements which are necessary in theprocess of obtaining area badging permits. Safetytraining will include such subjects as the following:

a. Hazard types, recognition, causes, and effects. b. Prevention and control measures. c. Safe operating procedures. d. Checklists. e. Safeguards and safety devices. f. Personal protective equipment (PPE). g. Monitoring and warning devices. h. Emergency and contingency procedures.

4.1.2.2 Certification - The payload organization shallprovide a list to the LSSO prior to commencement ofhazardous operations of all personnel authorized toparticipate in hazardous operations certifying eachindividual's training and qualification by system toperform a specific hazardous operation.

4.1.2.3 Physical Examination - Personnel performing selectedhazardous operations are required to have up-to-datephysical examinations which meet the requirements ofthe cognizant medical office. Examples of personnelwho require these examinations include ordnanceworkers, crane operators, propellant handlers,Propellant Handlers Ensemble (PHE) operators, andpersonnel working with certain types of ionizing andnonionizing radiation. The requirements necessary tosatisfy this examination may be obtained from thecognizant medical office and the individualexamination records must be furnished to that office.

4.1.2.4 Safety Enforcement - The payload organization willdescribe the means by which occupational andoperational safety requirements of the launch siteand this Handbook are enforced; it will address howviolations of safety requirements are handled withinthe organization and what measures will be taken topreclude further violations.



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4.1.3 Hazardous Operations

a. A ground processing activity is classified ashazardous based on the following considerations:

(1) Energy is involved and loss of controlcould result in injury to personnel ordamage to equipment.

(2) A significant change from ambient condition

will occur; e.g., increase or decrease ofoxygen content, pressure, or temperature.

(3) Presence of hazardous materials or physical

agents which presents potential exposure topersonnel.

b. TOP's are required for any activity, either by

itself or in combination with another, which canresult in injury to personnel or damage toproperty involving, but not limited to, thefollowing:

(1) Work Area/Environment.

(2) Ordnance.

(3) Propellants.

(4) Cryogenics.

(5) Lifting/Handling.

(6) Radiation.

(7) Toxics/Combustibles/Corrosives.

(8) Pressure.

(9) Electrical.

c. All hazardous or LSSO designated proceduresrequire notification of the LSSR at least 24hours prior to their performance. The LSSR willmonitor all or selected sections of theseprocedures.



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d. Concurrent hazardous operations within the samehazard control area are prohibited.

e. Concurrent operations within a hazard control

area require LSSR or LSSO approval.

4.1.4 Safety Inspection

LSSR and payload organizations shall perform jointsystematic safety inspections of the facility,working environment, related GSE, and any work inprogress which could cause accidental injury topersonnel or damage to hardware. Primary emphasiswill include payload/GSE, critical processingequipment, facility maintenance status and associatedequipment locations, and facility ingress/egressprovisions and routing. Discrepancies identifiedfrom any of the inspections shall be corrected by theappropriate organization prior to conductinghazardous operations or bringing hazardous materialsinto the area. These safety inspections shall beperformed on payload processing facilities at thefollowing minimum times:

a. Prior to payload/GSE installation in thefacility.

b. Immediately after installation of payload/GSE.

c. Immediately before the start of LSSO selected

hazardous operations.

d. After any facility or equipment modificationwhich may affect hazard potential.

4.1.5 Safety Equipment

The payload organization shall ensure that personnelprotection is provided when engineering controlsalone are not adequate to provide sufficient employeeprotection. Payload processing activities which areconsidered normal to general industry shall be incompliance with the requirements of acceptedindustrial safety practices. Payload processingoperations which require PPE are identified in theappropriate sections of this Handbook.



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The payload organization is required to review withthe LSSO and Biomedical Office those operations notspecifically identified which might require PPE. AllPPE shall be approved by the LSSO and BiomedicalOffice.

4.1.6 Tools

* 4.1.6.1 Temporary Restraints - Temporary restraints, such astethers, shall be used for individual tools toprevent misplacement or loss in critical areas whenworking above personnel or sensitive equipment. KHB5310.1, General Operating Procedure 5-3, establishesrequirements and assigns responsibilities for theimplementation and maintenance of an effective toolcontrol program at the KSC.

4.1.6.2 Control of Tools - All tools and related equipmentused in the proximity of flight articles shall becontrolled to minimize the potential for foreignobject damage. The payload organization shallidentify the means to implement this requirement.

* 4.1.7 Photography

The LSSO requires that the use of photographiclighting equipment (e.g., flashbulbs, strobe lights,and photofloods) be restricted within 100 feet of theOrbiter/payload whenever they are loaded with anypropellant, within 100 feet of a propellant storagetank, and within 10 feet of exposed solidpropellants. Photo equipment used above a payloadmust be tethered and the light sources shielded toprevent debris from falling onto the payload. Thepayload organization shall obtain LSSO approval touse photographic equipment in these and otherhazardous atmosphere locations.

4.2 PERSONNEL SAFETY

The payload organization shall ensure a safe andhealthful working environment through good design,effective training, and appropriate PPE.

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4.2.1 Human Factors

Since human factors affect the interface betweenpersonnel and equipment, the payload organizationshall consider human factors in the design of GSE andthe payload. MIL-STD-1472 and NASA-STD-3000 containguidance on human factors engineering and should beused in the design of GSE. Potential hazardsresulting from the human interface shall be addressedby the payload organization during the Phase ReviewProcess. To minimize the effects of these hazards,the following criteria shall be applied in the designand development of the payload, GSE, and groundoperations.

4.2.1.1 Human Error - Consideration shall be given to thepotential for human error in the personnel/equipmentinterface. Controls shall be instituted to prevent ahazardous condition which may result from suchactions as mismating a connector, throwing the wrongswitch, misreading a gauge, etc. Controls shall beinstituted via design rather than procedural controlwhere feasible. All equipment controls shall belabeled.

4.2.1.2 Noise - The payload organization shall implement ahearing conservation program to provide hearingprotection for any noise levels of 85 decibels A-scale (dBA) or greater, regardless of the length ofexposure. Where noise levels occur on intervals of 1second or less, they shall be considered continuous.When personnel are exposed to sound exceeding thoselevels, feasible engineering or operational controlsshall be utilized. If such controls fail to reducesound levels to an acceptable level, PPE shall beprovided and used. Exposure to impulsive or impactnoise shall not exceed 140 decibels (dB).

4.2.1.3 Hazardous Materials - The payload organization shallassure through design/procedural controls thatpayload/ground processing GSE and operations will notexpose personnel to hazardous materials in excess ofthe limits specified by the cognizant BiomedicalOffice.



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4.2.1.4 Physical -

a. Accidental contact with sharp surfaces orprotrusions shall be prevented by the use ofductile materials, energy absorbing devices,shields, rounded corners, and flush-mountedfeatures. Sharp surfaces or protrusions includeedges, crevices, points, burrs, wire ends, screwheads, corners, brackets, rivets, braided cable,cable swages, cable strands, clamps, pins,latches, lap joints, bolt ends, lock nuts, etc.,which if contacted, could injure operatingpersonnel.

b. Hazards shall not be created by the

inaccessibility of flight or ground hardware.Physical access for safety critical operationsor maintenance functions shall be provided.Protrusions which create a hazard such as hoses,wave guides, cables, brackets, etc., whichcannot be eliminated by design, shall be made tobe removable during service or maintenancefunctions.

c. Moving parts such as fans, belt drives, turbine

wheels, and similar components that could causepersonnel injury or equipment damage due toinadvertent contact or entrapment of floatingobjects shall be provided with guards or otherprotective devices.

d. Wherever possible, equipment requiring

adjustment during its operation shall haveexternal adjustment provisions and provideelectrical shock protection when applicable.

e. GSE shall be designed to minimize the

requirement for operations and maintenancepersonnel to wear protective clothing duringnormal operations and maintenance. Valves,gauges, levers, bolts, nuts, and any other itemrequired to be moved, turned, manipulated, ormonitored by personnel in protective equipmentshall be sized to facilitate operation. Suchitems should be located to optimize access tothe item while the operator is in a standingposition. Sufficient clearance should beprovided to preclude brushing against other



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surfaces. Suitable provisions to preventdamaging the protective equipment and to preventpersonnel fatigue and discomfort shall beincluded in the GSE design.

f. All GSE designs should include a center-of-

gravity analysis to ensure that the GSE/flighthardware does not tip, fall, slide, or allow forany type of sudden load shift.

4.2.1.5 Temperature - The payload organization shall protectpersonnel from equipment which can generate high orlow temperatures greater than 45 oC (113 oF) or lessthan 0 oC (32 oF). This equipment shall be shielded,insulated, isolated, and/or oriented away frompersonnel and labeled to warn them of the danger.

4.2.1.6 Radiation - The payload organization shall advise andprotect personnel from equipment which radiatesionizing or non-ionizing radiation.

4.3 PAYLOADS AND GROUND SUPPORT EQUIPMENT (GSE)

4.3.1 Biomedical Subsystems

Hazardous biomedical subsystems consist of medicalexperiment equipment designed to obtain data on man'sadaptation and performance in the space environment.They also consist of scientific equipment designed toobtain experimental data on the effects of spaceenvironments on microorganisms, plant, and animallife. The payload operator shall provide completehandling procedures for all hazardous biomedicalsubsystems.

4.3.2 Electrical

All electrical equipment shall meet the requirementsof this section to preclude hazardous conditions.

4.3.2.1 Electrical Requirements -

a. Electrical connectors shall be designed to makeit physically impossible to inadvertentlyreverse a connection or mate the wrongconnectors if a hazardous condition can becreated. These connectors for energizedcircuits must also be of "scoop-proof" design so



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a partial inadvertent mismate will not providepin-to-pin contact.

b. Electrical equipment shall not cause ignition of

adjacent materials. The requirements forexplosion/hazardproofing at the launch site areidentified in Paragraphs 4.4.2.3 and 4.4.2.4.

c. Malfunction of the payload or GSE circuitry

shall not induce overload into the Orbiter, GSE,or facility electrical systems.

d. Electrical equipment shall be designed to

provide personnel protection from accidentalcontact with alternating current (AC) voltagesin excess of 30 volts root mean square (rms) or50 volts direct current (DC) or any lowervoltage that could cause injury.

e. Construction of the payload and electrical GSE

shall assure all conductive external parts andsurfaces are at ground potential at all times.

f. Cables extending across work areas shall be

protected against damage from personnel activityor equipment use.

g. Switches/controls which can create hazardous

conditions if inadvertently operated shall beguarded, shielded, or otherwise protectedagainst inadvertent switching.

h. Electrical fuse and switch boxes shall be

labeled on the outside or inside cover to showthe voltage present, rated fuse capacity, andequipment that the circuit controls.

i. Non-bypassable interlocks shall be used to

prevent possible shock whenever a voltage inexcess of 500 volts is exposed upon opening anaccess door, cover, or plate.

j. All GSE shall meet the requirements of the

"National Electric Code (NEC), National FireProtection Association 70 (NFPA 70)."

k. Dead-end wires shall be completely insulated.



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l. Three-phase power sequencing must be verified ineach KSC processing facility prior toconnection.

m. Battery charging/conditioning shall be

accomplished in the battery laboratories unlessapproval is granted from the LSSO to accomplishthe charging elsewhere. Battery chargingequipment shall be continuously monitored bypersonnel. Charging/conditioning performed inhazardous locations shall comply with paragraphs4.4.2.4.1 and 4.4.2.4.2. The payloadorganization should consider incorporatingvoltage and current limiters, fuses, diodes, andtemperature and pressure monitors in thecharging/conditioning electrical GSE.

n. The payload should be assessed to determine if

the loss of power during any phase of groundprocessing is a hazard to personnel orequipment. If so, an alternate or backup powersource may be required.

4.3.2.2 Grounding, Bonding, and Shielding -

a. The design, construction, and installation ofequipment shall be such that all external parts,surfaces, and shields are at ground potential atall times.

b. Grounding and bonding schemes shall ensure

proper interfacing between equipment andfacility.

c. Power cords on GSE shall provide a non-current

carrying ground conductor unless the unit isdouble insulated.

d. Grounding/bonding connections of GSE shall be

designed to minimize the possibility ofinadvertent disconnection.

e. Solder shall not be used for external

connections.

f. Threaded fasteners shall use lock washers.



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g. GSE external bonding straps and jumpers shall becapable of carrying the maximum expected faultcurrent.

h. Additional grounding requirements for ordnance

and propellant operations are included in theapplicable sections.

4.3.2.3 Electrical Maintenance Operations - Maintenanceoperations on energized electrical circuits arenormally prohibited. Maintenance operations shall beperformed in accordance with accepted industrialpractice. In addition, the following shall beincluded:

a. Any accessible capacitor circuitry whichpresents a hazard to personnel shall bedischarged prior to performing maintenance.

b. Protective equipment such as nonconducting fuse

pullers, rubber gloves, nonconductive matting,etc., shall be used when working on energizedcircuits which could cause personal injury.

c. Procedures for tagging and lockout of control

switches and circuit breakers shall be provided.

d. All grounds shall be verified to be intact.

e. Worn, abraded, or defective insulating materialshall be repaired or replaced.

f. Only fuses of proper voltage and current ratings

shall be used in circuits. No other materialwill be used in place of a fuse.

4.3.2.4 Electrical Control of Hazardous Functions - Whereelectrical GSE is used to control a potentiallyhazardous function, it shall be designed to befailure tolerant. Acceptable failure tolerance willbe determined by the LSSO during the safety reviewprocess. Where feasible, failure tolerance shall beimplemented through design control rather thanprocedural control. Design control can beimplemented by eliminating the potential hazard(e.g., the current-limiting features in EEDbridgewire checkers), providing a fail safe design(e.g., current-limiting fuses) or requiring multiple



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component failures and/or operator actions prior to ahazardous event occurring.

4.3.2.5 Energized Electrical Equipment -

a. Energized equipment will be manned or connectedto the manned facility emergency power shut-offsystem. The electrical equipment will bepowered down during non-working hours. Allelectrical equipment located outside a hazardousprocessing area will be inhibited from supplyingpower to electrical equipment located within thehazardous processing area during non-workinghours.

b. Electrical equipment that must remain energized

for hazardous operations (i.e., maintainingspacecraft thruster solenoid valves in an openedor closed state) shall be equipped with anuninterrupted power source such as a batterybackup.

4.3.2.6 Battery charging operations should occur in anapproved charging facility. Battery chargingrequirements for batteries that cannot be removedfrom flight hardware will be assessed on a case-by-case basis.

4.3.3 Pressure/Vacuum Systems

Pressurized systems contain fluids above atmosphericpressure. Vacuum systems contain fluids belowatmospheric pressure. Pressure system elementsinclude tanks, accumulators, lines (e.g., piping,tubes and hoses), fittings, gauges, filters, valves,regulators, and other components.

4.3.3.1 Pressure System Requirements -

4.3.3.1.1 Flight pressure systems shall meet the requirementsof NSTS 1700.7, Chapter 2, Technical Requirements.



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* 4.3.3.1.2 The following requirements shall be met by bothflight and ground pressure systems:

a. To preclude personnel injury, provisions shallbe made for accomplishing remotely controlledpressurization of the flight pressure system.Exception to this requirement is when theconditions of Paragraph 4.3.3.2.1 do not applyor when the payload operator provides acertification statement of system pressuretesting to the LSSO in accordance with Paragraph4.3.3.2.2. Normally, remote pressurization ofGSE is not required.

b. Regulator failure shall not create a hazard to

personnel or equipment during ground processing.

c. All items, including gauges, which come incontact with the service fluid shall be ofcompatible material.

d. All pressure system connectors shall be selected

to make it physically impossible to mix fluidmedia if a hazardous condition can be created bymixing two fluids. Example: Fuels andoxidizers or GN 2 and GHe in an LH 2 system.

4.3.3.1.3 GSE containing pressure systems shall meet thefollowing requirements:

a. Pressure vessels used in GSE systems shall meetthe design, test, labeling, marking (it isdesired but not necessary to have the pressurevessel code stamped), and operating requirementsas specified in "American Society of MechanicalEngineers (ASME) Boiler and Pressure VesselCodes," Section VIII, Unfired Pressure Vessels,Division I or Division II, as applicable. Ifthe pressure test is based on a level less thanthe pressure vessel maximum allowable workingpressure (MAWP), the vessel shall be derated tomaximum operating pressure (MOP). Pressurevessels shall be registered with the NationalBoard of Boiler and Pressure Vessel Inspectors,or the user must maintain the design drawingsand design and stress calculations for the lifeof the vessel.

* Denotes Change



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b. GSE pressure systems hardware other thanpressure vessels shall be marked as follows:

(1) Pressure system lines (where the functionof the line is not immediately apparent)shall be labeled with the MOP, fluidcontent, and direction of flow. Labelingshould be in accordance with KSC-STD-SF-0004, "Color-coding of Fluid SystemsPiping."

(2) If used, color-coding should comply with

KSC-STD-SF-0004. (3) Other system components shall be labeled

with their manufacturer's name and partnumber, serial number (if applicable),pressure rating, and direction of flow.

c. Pressure systems components (excluding pressure

vessels) shall have a design burst pressure(D.B.) of at least 4 times the MOP of the system(low carbon stainless steels shall have a D.B.of 4.5 times MOP) and should conform to eitherMIL-STD-1522, "A Standard General Requirementfor Safe Design and Operation of PressurizedMissile and Space Systems," or JSC SW-E-0002,"Space Shuttle Program GSE General DesignRequirements." Components shall be pressuretested at 1.5 times MOP unless otherwiseapproved by the LSSO.

d. Regulators shall be selected so that their

working pressure falls within the center 50% oftheir total pressure range if susceptible toinaccuracies or creep.

e. Flight and GSE components downstream of a GSE

regulator shall be designed to safely operateunder full upstream pressure. Open-ended purgesystems may be protected by flow restrictionorifice devices.

f. If the requirements of Paragraph e (above)

cannot be met, relief devices shall be providedin accordance with ASME/ANSI codes, and aminimum shall be provided as follows:



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(1) Downstream of last GSE regulator prior toflight hardware interface.

(2) GSE pressure vessels. (3) Downstream of regulators where upstream

pressure exceeds downstream designoperating pressure.

(4) Container purge systems using metal tubing

or flexhose. (5) Container purge systems using plastic

tubing when the failure of the tubeprovides sufficient margin of safety to thedownstream equipment.

(6) All relief devices shall be relief valves

when pressure exceeds 149 psig.

g. Set pressure: Pressure relief valves shall beset to relieve at a pressure not to exceed theMAWP of the vessel or the design pressure of thesystem involved (including flight systems), andthe set limits shall be specified in theOperation and Maintenance Requirements andSpecifications Document (OMRSD) or otheroperating and maintenance documents. Thesetting of relief valves must always besufficiently higher than the operating pressureto ensure that the valves will reclose above theoperating pressure. See ASME Code, SectionVIII, Division 1, paragraph UG-134, andAppendix M, paragraph M-11, and ANSI/ASME B31.3,paragraph 322.6.3.

h. Required relieving capacity: For pressure

vessels, the required relieving capacity shallbe determined in accordance with the ASME Code,Section VIII, Division 1, paragraph UG-133, orDivision 2, paragraph AR-150.

For piping/tubing systems, the requiredrelieving capacity shall be equal to or greaterthan the maximum flow capability of the upstreamregulator or pressure source and shall preventthe pressure from rising above the limitsspecified in ANSI B31.3. See ASME Code, Section



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VIII, Division 1, paragraph UG-133, and Division2, paragraph AR-150, and ANSI/ASME B31.3,paragraphs 301.2 and 322.6.3.

i. Relief devices shall be located so other

components such as shut-off valves cannot renderthem inoperative. Relief devices and theirassociated discharge plumbing shall beadequately supported such that their dischargeimpulse will not cause structural failure.

j. Pressure relief for toxic liquids and/or vapors

shall be designed and located so that gases andliquids or vapors will not enter any inhabitedareas. Pressure relief for inert gases shallnot be discharged into a confined, occupied areawhere oxygen content could be lowered belowacceptable limits. Pressure reliefs for highpressure gases and liquids shall be located suchthat the discharge will not endanger personnel.

k. Pressure systems shall be equipped with gauges

as follows:

(1) Downstream of each regulator.

(2) On any storage system.

(3) On any section of the system wherepressure trapped by isolation valvescreates a hazard.

l. All pressure gauges shall comply with thefollowing requirements:

(1) Gauges shall be selected so that theoperating pressure is not more than 75% ofthe highest graduation.

(2) Pressure gauges shall be of one piece,

solid front construction and shall have anoptically clear shatterproof window.Gauges should be designed for bolted flushfront panel mounting.

(3) Gauges shall have blowout backs to allow

unrestricted venting in the event the gaugesensing element ruptures.



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(4) All items which come in contact with theservice fluid shall be constructed ofcompatible material. Use of material otherthan 316SS requires LSSO approval.Bourdon-tube bleed screws may be of any300SS.

(5) A due date calibration sticker shall be

affixed to gauges used for safety-criticalmonitoring.

(6) Gauges shall be equipped with a bourdon-

tube bleeder or equivalent device tofacilitate cleaning.

m. All GSE using flexhoses with pressures above 150

psig shall be designed to provide attachmentsfor flexhose restraining devices.

n. Isolation valves shall be designed to permit

flow or isolation in both directions at thevalve's MAWP.

o. Pressure systems shall be designed so pressure

cannot be trapped in any part of the systemwithout bleed capability.

p. Manually operated valves and regulators shall be

selected so over-torquing the valve stem orregulator adjustment cannot damage soft seats tothe extent seat failure occurs. Designs usinguncontained seats are unacceptable.

q. Pressure system elements which are not intendedto be reversible shall be designed or markedsuch that they will not be connected in areverse mode.

r. Lines, relief devices, and other pressure system

elements shall be routed and/or located toprovide for the protection of other systems andpersonnel.

s. Control stations shall have adequate

instrumentation to allow personnel to monitorpressure levels and confirm initiated actionshave occurred.



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t. Control stations shall be designed so theoperator does not have to leave the station tomonitor hazard levels.

u. Systems shall have shut-off valves located as

close to the supply vessel as practicable. v. Check valves shall be provided where backflow of

fluids would create a hazard.

4.3.3.1.4 Vacuum Systems - Relocated to Paragraph 4.3.3.3.

4.3.3.1.5 Flexible Hoses - Flexible hoses consist of aninnerliner tube of teflon or other material(compatible with the service fluid) reinforced bylayers of wire and/or fabric braid or wrap. Use offlexhoses should be minimized. Requirements forflexible hoses are as follows:

a. Connection, disconnection, installation,inspection, maintenance, and testing shall beaccomplished in accordance with themanufacturer's specifications andrecommendations unless otherwise specified inthis document.

b. Flexible hoses shall be installed so they do not

carry any external mechanical load and are notsubjected to tension, torsion, or overheating.

c. All flexible hoses shall have a design burst

pressure equal to or greater than 4 times theMAWP.

d. All flexible hoses pressurized to 150.0 psig

(10.34 bars) or greater shall be contained orrestrained. Hose restraint shall beaccomplished using a chain or cable securelyanchored to a substantial object and to the hoseassembly at the following points: 1) Hose endconnector; 2) each union or hose splice; and 3)intervals not to exceed 6 feet (1.83 meters).Hose restraint devices and attachment methodsshall be approved by the LSSO.

e. The payload organization shall establish

criteria and obtain LSSO approval for periods ofinspection and retest. Time in service, type of



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service, and pressure are factors fordetermining need of pressure test. LSSOapproval shall be obtained prior to performingpressure testing at the launch site.

f. All flexible hoses shall be inspected prior to

use. Flexible hoses which show signs ofphysical damage shall be replaced.

g. Flexible hose assemblies shall be pressure

tested to 1.5 times their MAWP. h. GSE flexible hoses shall be identified and

marked. Each flexible hose assembly shall havea metal tag(s) attached which bears thefollowing information:

(1) Date of prooftest (month and year).

(2) Dedicated fluid service; e.g., fuels,oxidizers, hydraulics.

(3) MAWP.

(4) Identifier (manufacturer/part number).

j. After each pressure test recertification, the

old tag(s) will be removed and new onesattached.

* 4.3.3.1.6 GSE Hydraulic Systems - GSE hydraulic systems shallcomply with MIL-STD-1522 and the followingrequirements:

a. Hoses shall be in accordance with MIL-H-25579,"Hose Assembly, Tetrafluoroethylene, HighTemperature, Medium Pressure," Class 1, or"Society of Automotive Engineers (SAE)Standards," and shall be suitably protectedagainst chafing where necessary to preventdamage to the hose or adjoining structure,tubing, wiring, and other equipment. (Systemsover 3,000 psi will be handled on a case-by-casebasis.)

b. Only system compatible lubricants shall be used

on threaded fluid line connections.• Denotes Change



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c. Pressurized reservoirs shall have the pressurecontrolled by a pressure regulator, and shallhave an air-space relief valve to protect fromexcessive pressure.

d. Reservoirs shall be provided with a fluid levelindicator.

e. The suction head of all pumps shall be

maintained between the limits recommended by thepump manufacturer.

f. Pump pulsations shall not adversely affect

system tubing, components, and supports andshall not cause damage or improper operation ofthe equipment on flight systems.

g. The system shall not cause damage to critical

systems due to reduced flow, such as that causedby single pump operation of a multipump system,or increased flow, such as that caused byaccumulator operations.

4.3.3.2 Pressure System Operations - Pressure systemoperations shall comply with the following:

4.3.3.2.1 The following flight and ground support systempressurization operations shall be accomplishedremotely (e.g., locate control station behind a blastshield) unless otherwise approved by the LSSO:

a. The first time a flight system is pressurizedabove 25% of the design burst at the launchsite. This pressure is designated the "initialpressurization level."

b. Any flight system pressurization above theinitial pressurization level; this latterpressurization becomes the new initialpressurization level.

c. Any pressurization above MOP/MAWP. d. Any pressurization of a system that has suspect

integrity.

4.3.3.2.2 Remote pressurization may not be required if thepayload organization provides documentation whichcertifies the following:



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a. The assembled system has been pressure tested ata pressure which is at least 1.5 times thesystem MOP unless otherwise approved by theLSSO. Flight systems may be pressure tested atthe component level if welds will be x-rayedafter assembly.

b. The assembled system has been functionally leak

tested at a pressure equal to or greater thanMOP. The system logbook shall track systemhandling/movement in addition topressurizations, maintenance, etc.

c. System configuration has not been modified or

repaired subsequent to the above testing.Unwelded relief or sensing devices may bereplaced after system pressure testing but notafter system leak testing, in accordance withParagraph 4.3.3.2.9.

d. A procedure has been written which requires

inspection of the system upon arrival at thelaunch site for damage sustained duringtransportation and handling. The procedureshall also require a check of the pressuresystem logbook to verify that activity after thepressure test and leak test did not affect theintegrity of the system. Provide procedure nameand number, step numbers and tests which requirethe inspection, and any additional inspectioncriteria.

4.3.3.2.3 Personnel will be allowed in the immediate proximityof pressure systems only when pressure does notexceed the system MOP.

4.3.3.2.4 System integrity shall not be broken on pressurizedsystems without first depressurizing to 10 psig orless. Depressurization shall be accomplished onlyusing components designed for the purpose. Backingoff of line fittings, when pressures exceed 10 psig,to depressurize is permitted if the trapped volumedoes not exceed 1.5 cubic inches. Tightening of linefittings under pressure is also prohibited.

4.3.3.2.5 Systems shall not be pressurized or depressurized atrates which present unsafe situations, such as heat



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rise to autoignition. These rates shall beidentified in the applicable operating procedure.

4.3.3.2.6 Pressure system bolts and fittings shall not betorqued while the component is under pressure.

4.3.3.2.7 Relief valves shall be inspected, reset, tested, andlabeled annually.

4.3.3.2.8 Pressure gauges shall be inspected and calibratedannually and a due date label applied where used insafety critical systems.

4.3.3.2.9 All nonhydraulic pressure systems are to be leaktested with an inert medium at MOP at the launch siteprior to using propellants or hazardous gases. Anytime a component is modified, repaired, or replaced,it shall be pressure tested to 1.5 times MOP at thecomponent level. If the component is welded into thesystem, the welds shall also be pressure tested at1.5 times MOP. The reassembled system shall again beleak tested at MOP using an inert medium.

4.3.3.3 Vacuum Systems and Requirements - Negative pressureprotection shall be provided for systems not designedto withstand pressure below 1 atmosphere. This canbe accomplished by the use of check valves or ambientautomatic pressure valves. Vacuum systems should bedesigned to T.O. 00-25-223, "Integrated PressureSystems and Components (Portable and Installed)."

4.3.4 Radiation

Sources of ionizing and nonionizing radiation must beadequately controlled during all phases of ground,launch, and postlaunch operations to assure theprotection of personnel, facilities, and equipment,and the compliance with applicable federal, state,and NASA/DOD regulations and requirements. Suchsources include radioactive materials, radiation-producing equipment (e.g., x-ray devices, particleaccelerators, radio frequency/microwave emitters,etc.), lasers, and optical emitters (e.g.,ultraviolet, infrared, and high intensity visiblelight sources). Specific requirements are providedin detail in the referenced applicable controldocuments and must be coordinated through the LSSO.All payload organizations are responsible for



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compliance with the applicable launch siterequirements.

* 4.3.4.1 Radiological Health -

a. Applicable radiological health program documentsgoverning uses of ionizing and nonionizingradiation sources at ER include:

(1) KHB 1860.1, "KSC Ionizing RadiationProtection Program"

(2) KHB 1860.1, Appendix D, "Radiological

Controls for Major Radiological Sources(MRS) and Nuclear Assemblies"

(3) KHB 1860.2, "KSC Non-Ionizing Radiation

Protection Program" (4) AFI 91-110, "Nuclear Safety Review and

Launch Approval for Space or Missile Use ofRadioactive Material and Nuclear Systems"

(5) AFI 40-201, “Managing Radioactive Materials

in the USAF”

(6) 45 SWI 40-201, "Radiation ProtectionProgram"

(7) AFOSH STD 161-9, "Exposure to

Radiofrequency Radiation"

(8) AFOSH STD 161-10, "Health Hazards Controlfor Laser Radiation"

The above-mentioned documents contain procedural/administrative requirements for radiation sourceapprovals and usage.

b. All uses of radiation sources require review andevaluation for approval by the appropriatelaunch site Radiation Protection Officer (RPO).Radioactive materials procurement, use, storage,and transportation at launch/landing sites aresubject to specific requirements. Suchactivities must be coordinated with thelaunch/landing site RPO at least 60 days inadvance of arrival to the launch site to assure



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compliance with applicable regulations.Identification of the launch/landing site RPOwill be provided through the LSSO.

c. General radiological health requirements

include, but are not limited to, the followingitems:

(1) Radiation sources and associated equipmentwill be designed, constructed, installed,and utilized so as to assure personnelexposures and the potential for releasesare kept as low as practicable and belowapplicable regulatory limits.

(2) Flight radioactive sources should be

installed as late in the countdown aspractical.

(3) Radiation sources shall be handled/operated

utilizing only approved personnel,procedures, and equipment.

(4) Inactive, unattended, or stored radiation

sources shall be secured againstunauthorized access or operation at alltimes.

(5) Appropriate personnel access controls shall

be established in all areas where radiationsources are used, operated, or installed.

(6) PPE and/or dosimetry shall be approved or

utilized as assigned.

d. Radiation exposures shall be as low asreasonably achievable but shall not exceed thelimits established in the above referenceddocuments.

e. Major Radiological Sources (MRS's) such as

radioisotope thermoelectric generators (RTG's),radioisotope heater units (RHU's), nuclearreactors/assemblies, accelerators, etc., mustcomply with additional controls and requirementsas provided in the applicable program documents.Generally, radiation sources equal to/greaterthan 1 curie, or capable of generating radiation



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levels equal to/greater than 1 rem/hour, areconsidered to be MRS's. Specific requirementsfor MRS activities include, but are not limitedto, the following:

(1) The payload organization shall provide adetailed description of the launch/landingsite processing flow not later than 6months prior to initial arrival of an MRSat the launch site. The description shallinclude identification of activitiesdirectly associated with MRS's, otheractivities occurring in the presence ofMRS's, and any GSE associated with suchactivities. The detailed processing flowshall be developed incorporating thefollowing requirements:

(a) The number and duration of MRSprocessing activities and associatedpersonnel proximity to an MRS shall beminimized. Payload and launch vehicleactivities involving personnelproximity to an MRS shall also beminimized.

(b) The number of facilities utilized in

MRS processing activities shall beminimized. Such facilities shall beutilized on a sole-use ornoninterference basis.

(c) Each processing activity shall be

assessed on the basis of personnelexposure incurred versus missionbenefit achieved by the activity.

(d) MRS installation for flight shall be

made as late as operationallyfeasible.

(e) The payload organization shall providefor and utilize nonradioactive/passivehigh fidelity MRS models wheneverfeasible.

(f) The payload organization shall providea detailed baseline dose projection



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for payload organization personnelinvolved in launch/landing site MRSactivities. This baseline must beprovided no later than 6 months priorto initial arrival of an MRS at thelaunch site.

(g) A description of proposed changes to

the MRS processing flow (including GSEand operations) with supportingrationale must be submitted by thepayload organization prior toimplementation. The rationale shallinclude the reason for the change andan assessment of its impact on thesafety analysis, the baseline doseprojection, other processingactivities, procedures, hardware, etc.

(h) Payload organization activities

involving radiological contingencyplanning and nuclear safety analysesshall be coordinated with the launchsite RPO.

(i) The payload organization must obtain

final approval of their MRS radiationuse authorization request from thelaunch site RPO not later than 6months prior to launch or 90 daysprior to MRS arrival at the launchsite, whichever is earliest. Finalapproval is contingent upon closure ofall open items by the payloadorganization to the satisfaction ofthe launch site RPO.

f. General requirements for GSE utilizingradioactive gases are as follows:

(1) The payload organization shall document thedesign and maintain records of maintenance,checkout, and use of GSE systems utilizingradioactive gases at the launch sites.Such records shall be available to the LSSOand the launch site RPO.



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(2) Planned releases and the potential foraccidental releases of radioactive gasesshall be minimized. The launch site RPOmay require recapture of radioactive gasesprior to venting of residual quantities.

(3) Vent outlets shall be placed at heights or

locations inaccessible to personnel. Thevents shall be located to prevent reentryof exhaust into habitable areas and shallbe conspicuously identified.

(4) Venting of radioactive gases will require

favorable meteorological conditions andlaunch site RPO concurrence.

(5) Operations involving flow of radioactive

gases will not occur during normal workinghours unless specifically authorized by thelaunch site RPO.

4.3.4.2 Radiation Safety - Additional radiation hazardcontrols required by the LSSO are provided below:

a. Radiation sources associated with payloads mustbe compatible with and have no adverse safetyeffects on ordnance items, propellants, highpressure systems, critical structure components,or systems of any other payload, the SpaceShuttle, or its crew.

b. RTG's and other major radiological sources shall

be provided with redundant ground coolingsystems, if cooling is required to maintainsafety, to assure adequate heat dissipationduring prelaunch and postflight operations.Disposal of this coolant shall be coordinatedwith the appropriate Biomedical Office.

c. Radiation source shields, interlocks, fail-safe

systems, and limit switches shall be checked forproper operation.

d. All radiating systems shall be designed,

constructed, and operated to prevent exposure ofpersonnel, facilities, and equipment to extremetemperatures, high voltages, toxic fumes andgases, and unnecessary radiant energy.



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4.3.4.3 Optical Systems - The potential hazards which must beconsidered in the design, handling, and operation ofoptical equipment and associated energy sources maybe grouped into five categories as follows:

a. Hazardous optical radiation to includeultraviolet, infrared, and visible radiation.

b. Temperature extremes. c. Shatterable materials. d. Contamination from gases and cryogenics. e. High voltage and x-rays.

4.3.4.3.1 General Optical Requirements - The followingrequirements shall apply to both flight and groundoptical systems:

a. Optical instruments shall be designed such thatharmful light intensities and wavelengths cannotbe viewed by operating personnel.

b. Quartz windows, apertures, or beam stops and

enclosures shall be used for hazardouswavelengths and intensities unless othersuitable protective measures are taken toprotect personnel from ultraviolet and/orinfrared burns or x-ray radiation.

c. Light intensities and spectral wavelengths at

the eye piece of direct-viewing optical systemsshall be limited to levels below the maximumpermissible exposure (MPE).

4.3.4.3.2 Laser System Requirements - In addition to thereferenced documents, the following requirementsshall apply to both flight and ground hazardous lasersystems:

a. Limit stops, interlocks, and shields shall beprovided to ensure that a laser beam cannot bemisdirected.

b. Laser power shall be locked out during all

operations except laser testing.



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c. Positive locking features shall be provided topreclude focus and/or directional changes due tovibrations or inadvertent contact by operatingpersonnel.

d. Laser systems shall be designed so that all

external components are at ground potential atall times.

e. Materials used must be able to withstand the

stresses caused by repetitive laser pulsing forthe duration of checkout and missionperformance.

f. Laser systems shall incorporate a shutter

system, beam stop, or attenuator capable ofpreventing output emissions in excess of theappropriate MPE level when the laser or lasersystem is on standby.

g. Provisions shall be made to measure power output

and perform boresighting with the beam totallyenclosed and without unnecessary exposure tooperating personnel.

h. Laser target materials shall be nonreflective

and fire resistant and shall not emit toxiccontaminants.

i. Laser installations shall incorporate adequate

means to prevent the accumulation of hazardouscooling fluids and their by-products.

j. Whenever toxic chemicals and/or cryogenic

materials are utilized with laser systems, shut-off valves shall be provided to control leakagein the event of a line rupture.

4.3.4.3.3 Laser Operations - Laser operations shall include butnot be limited to the following requirements:

a. Alignment of target, optics, filters, etc.,shall be accomplished utilizing low-poweredvisible lasers.

b. Active beam or target viewing shall be done only

by closed circuit television or an opticalcomparator with an appropriate filter.



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c. Laser beams shall not be directed towardflammable or explosive materials.

d. Activated lasers shall not be left unattended. e. Personnel whose occupation or assignment may

involve exposure to laser radiation shall uselaser safety goggles approved by the BiomedicalOffice. These goggles shall protect for thespecific wavelength of the laser and be ofoptical density adequate for the energy levelsinvolved.

4.3.5 Ordnance

4.3.5.1 Electroexplosive Device (EED) Categories - EED's arecategorized at ER based on the effects of inadvertentinitiation. EED classifications are as follows:

Category A: Category A electroexplosive devices arethose which, by the expenditure of their own energy,or because they initiate a chain of events, may causeinjury or death to people or damage to property.

Category B: Category B electroexplosive devices arethose which will not, in themselves, or by initiatinga chain of events, cause injury to people or damageto property.

A device shall be assigned Category A prior toinstallation whenever test data to the contrary isnot available. A device assigned Category A prior toinstallation may be downgraded to Category B afterinstallation if the effects of the device and thesubsequent chain of events are controlled to thesatisfaction of the LSSO. Conversely, a deviceassigned Category B prior to installation may requireupgrading to Category A after installation. Thepayload organization shall categorize all EED's forboth the pre- and post-installation situations and beable to provide the LSSO with supporting data foreach categorization.

* 4.3.5.2 General Ordnance Requirements - All ordnance systemsshall comply with the requirements of NSTS 1700.7 andthe following:

* Denotes Change



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a. All ordnance and solid propellant motors shallbe handled and stored in accordance with therequirements of their hazard classification andstorage compatibility grouping. Items whichhave not previously been classified shall betested in accordance with T.O. 11A-1-47/DLAR8220.1, "Explosives Hazards ClassificationProcedures," and classified accordingly. NSS1740.12, “Safety Standard for Explosives,Propellants and Pyrotechnics,” and AFMAN 91-201, "Explosive Safety Standards," will be used forguidance for storage, handling, andtransportation of ordnance and propellants. SeeAppendix D for ordnance storage and handlingdata requirements.

b. All Category A ordnance circuits must be capable

of being physically disconnected between theordnance device and the power source as close tothe ordnance item as possible.

c. Category A ordnance and associated circuitry

shall be accessible in the Orbiter to facilitateelectrical checkout and connection as late aspossible prior to launch.

d. All ordnance device installations at the launch

site shall be in an ordnance sited or licensedfacility.

e. For Category A EED's, electrical connections

shall be made in the Orbiter unless otherwiseapproved by the LSSO.

f. Prior to electrical connection of Category A

EED's, a DC power-on and power-off no-voltagecheck shall be made. The power-off no-voltagecheck shall be performed immediately before theconnection.

g. Receipt of installed or early installation and

connection of Category B EED's may beaccomplished with the LSSO approval, providedthe connection of these devices does notrestrict interface verification tasks.



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4.3.5.3 Safe and Arm (S&A) Devices -

a. Transition from the SAFE to the ARM positionshall require 90 degrees of rotation of themechanical barrier.

b. The S&A device shall not be capable of

propagating the ordnance train with the barrierrotated less than 50 degrees from the SAFEposition.

c. The visual and remote SAFE position shall not be

indicated unless the device is less than 10degrees from the normal SAFE position.

d. Firing circuits of S&A devices shall be

electrically connected after payloadinstallation in the Orbiter. S&A deviceswithout a direct interface with the Orbiter maybe electrically connected after final ordnanceelectrical system checks and power is removedfrom the system. The S&A safing pin shallremain installed until final closeout of thepayload bay.

e. S&A Rotation Tests: Rotation of S&A devices

during ground test and processing shall be donewith the explosive transfer assembly (ETA)disconnected from the S&A or at the point of ETAterminus. All rotation tests of S&A's shall becompleted before firing circuits areelectrically connected. If the firing circuitsmust be connected during a rotation test, asafety assessment shall be provided to show thatinadvertent ignition of the detonators will notcause a hazardous condition. All rotationsrequire LSSO approval.

4.3.5.4 Ordnance Operations -

a. Ordnance shall be processed only in those areasapproved by the LSSO. Solid/liquid propellantsdesignated for one payload shall not share anoperating location with items designated foranother payload except for payload integrationactivities.



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b. Test equipment used to check component andcircuit operation must be of a type that limitsenergy input and must be approved by the LSSO.See Paragraph 4.3.5.6 for additionalrequirements.

c. Electrical continuity and resistance checks of

ordnance circuitry shall be performed using onlyin-calibration test equipment approved by theLSSO.

d. All ordnance deliveries to the launch site shall

be coordinated with the LSSO. e. All ordnance deliveries from storage to the

payload organization shall be coordinated withthe LSSR.

f. Electromagnetic interference (EMI) testing shall

not be conducted with live EED's installedwithout approval of the LSSO.

g. Materials susceptible to the generation,

collection, and holding of static electricalcharges shall be selected from the LSSO-approvedlist.

h. Disposal of surplus or defective ordnance items

shall be coordinated by the LSSO. Dispositionshall be determined jointly by the LSSO and thepayload organization.

i. Based upon the radio frequency (RF) and EED

susceptibility, installation, removal, andelectrical connection/disconnection may requireRF silence. Local RF silence and no-switchingperiods are required. The periods of RF silenceshall be requested by the payload organizationand shall be identified by an LSSO-approved TOP.

j. Grounding/bonding is required to ensure that

electro-static charges cannot build up to levelswhich can cause ignition of ordnance items.

k. EED faraday caps are required during storage,

handling, and after mechanical installation.They shall not be removed until electricalconnections are to be made.



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l. All personnel within the hazard control areaduring ordnance operations shall wear nonstatic-producing, flame-retardant coveralls. Personsperforming the work shall wear approvedgrounding devices.

4.3.5.5 Ordnance Marking -

a. Live ordnance and associated flight items (e.g.,arm plugs) shall be the natural body color ofthe device.

b. Nonflight items shall be color-coded, and this

color-coding shall be submitted to the LSSO aspart of the ground safety data package.

4.3.5.6 Ordnance Test Equipment - Requests for approval foruse of ordnance electrical test equipment used fortesting explosive ordnance items or circuitsconnected to these items prior to or afterinstallation shall be submitted to the LSSO. Thepayload organization shall provide the model number,engineering drawings and specifications, and thesystem safety analysis of the test equipment.Approval by the LSSO shall be by manufacturer modelnumber and requires a valid calibration seal for useat the launch site.

a. EED Bridgewire Resistance Measurement Meters _

(1) The meter shall be designed such thatmaximum available applied current does notexceed 10% of the no-fire current of theEED or 50 mA, whichever is less. It shallalso be designed so that in a worst case(multiple) failure condition, the availableapplied current cannot exceed the no-firecurrent of the EED.

(2) The optimum resistor location is adjacent

to the output leads and inaccessible.Other locations are also acceptable, if itcan be shown that bypassing the resistor isnot credible. (Current-limiting resistorsin the test leads, to meet the aboverequirements, are unacceptable.)



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(3) Meter leads shall be shielded and connectorshell-to-shell contact shall precede pin-to-pin contact.

(4) Calibration shall be at least annually.

Calibration procedures shall verify thesafe configuration; e.g., the propervoltage battery with the encapsulatedcurrent-limiting resistor installed.

b. No-Voltage Meters. No-voltage meters shall bedesigned to detect one-tenth of the no-firelevel of the EED or 50 mV, whichever is less, ata pulse width of 1 millisecond. The use ofcomputerized no-voltage meters is acceptable ifproper current-limiting can be demonstrated.

4.3.6 Mechanical, Electromechanical Devices

Mechanical or electromechanical devices used for suchpurposes as structure deployment or actuating releasemechanisms must be evaluated to establish whether inthe event of inadvertent activation damage toequipment or injury to personnel could occur. If itis determined inadvertent activation is eithercritical or catastrophic, then the device must befailure tolerant in accordance with Paragraph 4.1.1.These devices shall be identified in the operationalhazards analysis with the requirement for caution andwarning notations incorporated in the TOP's (See3.3.2).

4.3.7 Propellants

The design considerations contained in Air ForceSystems Command Design Handbook, AFSC DH 1-6, "SystemSafety," Chapter 3, Section 3e, and Chapter 4,Section 4b, are a useful guide and should be used inconjunction with the requirements of NSTS 1700.7 fordesigning payload liquid/gas propellant systems. Ifthe following minimum requirements cannot be met,consideration will be given on an individual basis toother design techniques.

4.3.7.1 Propellant System Requirements -

a. Materials selected for use in propellant systemsshall be compatible with propellants used. This



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should include compatibility under operatingpressure, shock, vibration, and temperatureloadings and include analysis of items such asstress corrosion. Refer to either Air ForceManual, AFM 161-30, "Chemical Rocket/PropellantHazards," Volume II, or John Hopkins University,"Chemical Propulsion Information Agency (CPIA)Publication Number 394, ChemicalRocket/Propellant Hazards," Volume III, forspecific propellant properties.

b. Propellants shall be separated so malfunction of

either the oxidizer or fuel subsystems cannotcause mixing.

c. Incompatible system connections shall be keyed

or sized so it is physically impossible tointerconnect them.

d. For systems requiring nonmetallic materials,

materials selected shall not result in hazardousreactions.

e. For systems requiring insulation or acoustic

damping, nonabsorbent, nonflammable materialsshall be used in compartments or spaces wherefluids and/or vapors could invade the area.

4.3.7.2 Propellant Systems GSE Requirements -

a. A positive means of shutting off propellant flowfrom tanks shall be provided and shall bereadily accessible.

b. The actuator for remotely controlled valves

shall be capable of opening and closing thevalve under design flow and pressure. Throttlecapability shall be considered in the selectionof remotely controlled valves. Ball and gatevalves should not be used.

c. Remotely controlled valves shall provide for

remote monitoring of open and closed positions.

d. Normally open or closed valves shall have aspring on the actuator capable of operating thevalve to the fail-safe position without an



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external actuating force under system operatingconditions.

e. Manually operated valves shall be capable of

being opened or closed under full systempressure.

f. Balanced manual valves that utilize external

balancing ports or vents open to the atmosphereshall not be used.

g. The payload organization shall describe their

plans for controlling a propellant leakthroughout the ground processing timeline up to,and including, installation into the Orbiterpayload bay.

h. Provisions shall be made so propellants cannot

be trapped in any part of the system withoutprovisions for draining.

i. Hypergol equipment (e.g., valves, quick

disconnects) must be designed to be compatiblewith and operated by personnel wearing PHEgloves.

j. Hazardous fluid vent system requirements are as

follows:

(1) Pressure relief vents for hazardous fluidsshall be designed and located so vaporswill not enter any inhabited areas.

(2) Venting of toxic fluids shall be through a

scrubber or neutralizing agent or bysimilar methods which would preventunauthorized release.

(3) Each line venting into a multiple use vent

system shall be protected against backpressurization by means of a check valve ifthe upstream system cannot withstand theback pressure or where contamination of theupstream system cannot be tolerated.

(4) Incompatible fluids shall not be discharged

into the same vent or drain system.



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(5) Fuel or toxic fluid vent systems shall beequipped with a means of purging the systemwith an inert gas to prevent explosivemixtures and/or to maintain systemcleanliness.

(6) Vents shall be placed in a location

normally inaccessible to personnel and at aheight or location where venting will notnormally be deposited into habitablespaces. Each vent shall be conspicuouslyidentified using appropriate warning signs,labels, and markings approved by the LSSO.

(7) Vent systems shall be sized to provide

minimum back pressures consistent withrequired venting flow rates. In no caseshall back pressures interfere with properoperation of relief devices.

k. Serviceable hypergolic components, such as quickdisconnects, filters, hoses, valves, etc., shallbe permanently marked by electroetch, metalimpression stamp, or other permanent method toindicate the specific hypergolic fluid to whichthe component will be exposed.

l. Items used in any fuel or oxidizer system shall

not be interchanged after exposure to therespective media.

m. Lubricants for hypergolic systems shall be

restricted to Krytox 240AC or equivalent. Useof a lubricant other than Krytox 240AC shall beapproved by the LSSO.

n. Hypergolic propellant pumps shall be

specifically designed for the particularhypergolic fluid.

o. All components, including flow meters, used in

hypergolic propellant systems shall be designedand qualified for hypergolic applications.

p. Flanged connections shall utilize the following

types of flanges: slip-on, weldneck, lappedjoint, or blind. Bonding straps shall be usedacross flanged connections.



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q. Materials used in contact with fuels, oxidizers,

or combustible gases shall be selected, tested,and certified in accordance with therequirements of NASA-STD-6001, “Flammability,Odor, Offgassing, and CompatibilityRequirements and Test Procedures for Materialsin Environments that Support Combustion."

r. All controls and adjustments shall be identified

by component number, system function, anddirection of operation. The direction of fluidflow shall be clearly indicated with permanentmarkings on the exterior of each component.

s. All calibration adjustments, locked or unlocked,shall be designed so the setting, position, oradjustment cannot be altered when the equipmentis subjected to the service condition.

t. Sight glasses used for liquid level indicators

shall be protected from physical damage. u. The payload organization shall maintain records

of the design, maintenance, checkout, and usageof GSE systems used at the launch sites. Theserecords shall be available to the LSSO.

v. Check valves (one-way flow) shall be provided

whenever a hazardous/contaminated substance canbackflow into another system.

w. Liquid shall not be able to be trapped betweenvalves if changes in ambient temperature canresult in pressure rises above 110% of MOP. Ifthe potential for this condition exists,automatic relieving is required.

* 4.3.7.3 Propellant Systems Operations -

a. New, modified, and/or repaired propellantstorage or transfer systems must be validated byfunctional test prior to being certified foroperational use. The following shall also berequired as part of the certification procedure:

(1) A leak test at MOP with an inert gas shallbe performed.



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(2) Pressure control units shall be verified by

use of certified, calibrated gauges. (3) Emergency shutdown systems and procedures

shall be demonstrated using a refereefluid.

(4) Proper operation of quick disconnects shall

be demonstrated.

b. Simultaneous operations with hypergolicpropellants are prohibited.

c. The payload and the propellant loading system

must be commonly grounded and bonded duringpropellant transfer operations.

d. Prior to opening a toxic propellant system, it

must be drained and flushed or purged toconcentration levels approved by the LSSO.

e. Prior to replacement or storage of components or

system repair, hypergolic or toxic systemcomponents shall be flushed and purged of allresidual elements and appropriately capped orbagged and labeled prior to movement.

f. Disposal of propellants shall be coordinated

with the LSSO. g. Venting of toxic vapors to atmosphere shall only

be done with LSSO approval. h. Procedures shall contain emergency instructions

developed by the payload organization to handleleaks and spills. These procedures shall beconsistent with either AFM 161-30, Volume II, orCPIA #394, Volume III.

i. Propellant transfers shall be performed only in

areas and at times approved by the LSSO.Personnel shall be limited to those needed indirect support of these operations.

j. PPE which provides full respiratory protection

and body coverage shall be worn during anydynamic payload and/or GSE toxic propellant



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transfer operations, or whenever the toxicpropellants are not in a sealed system. At allother times that toxic propellants are present,emergency escape breathing devices shall beavailable for all personnel. Full respiratoryprotection and body coverage is mandatory forthe following:

(1) Any connection/disconnection of apropellant transfer system if it containstoxic propellants.

(2) Any connection/disconnection of a

propellant transfer system that hadcontained toxic propellants andconcentration levels have not been verifiedto be below safe concentration levels.

(3) All toxic propellant sampling operations. (4) Any servicing/deservicing/internal

circulation (dynamic flow) of toxicpropellants until system integrity has beenverified; i.e., no leakage is present.

(5) Any application of pressure to the toxic

propellant transfer system until astabilization period of 15 minutes minimumhas been achieved and system integrity hasbeen verified.

k. Downgrading from air supplied respiratory andfull body coverage in item j above requires theLSSR's concurrence.

l. All PPE shall be compatible with the toxic

propellants involved, and their use shall beapproved by the LSSO and the appropriateBioenvironmental Engineering/Biomedical Office.

m. Toxic vapor monitoring is required during break-

in to any propellant system which has beencontaminated by propellants and during thehandling of contaminated parts. Toxic vapormonitoring is also required at the conclusion ofany hazardous operation listed in Item j of thisSection prior to opening of the control area tounprotected personnel.



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4.3.8 Cryogenics

All cryogenic systems shall comply with therequirements of Paragraph 4.3.7, Propellants, and thefollowing requirements.

* 4.3.8.1 Cryogenic Systems Requirements -

a. Source flow shall have throttling capability.

b. Pressure containing components within hydrogensystems shall be selected for minimum hydrogenblistering or hydrogen embrittlementsusceptibility.

c. GSE cryogenic valves with extended stems shall

be installed with the actuator approximatelyvertical above the valve.

a. Joints in piping systems shall be of eitherbutt-welded, flanged, bayonet, or hub type.

b. Cryogenic systems shall provide for thermal

expansion and contraction without imposingexcessive loads on the system. Bellows,reactive thrust bellows, or other suitable loadrelieving flexible joints may be used.

f. GSE vacuum-jacketed systems shall be capable ofhaving the vacuum verified.

g. Cryogenic systems shall be designed so anywhere

a cryogen can be trapped between any valves inthe system, automatic relief is incorporated topreclude excess pressure caused by conversionfrom liquid to gaseous state causing a rupture.

h. Cryogenic systems shall be insulated with an

oxygen compatible material or be vacuum-jacketedto preclude liquefaction of air.

4.3.8.2 Cryogenic Systems Operations -

a. Cryogenic systems must be pressure tested withan inert medium at cryogenic temperaturefollowed by a prooftest at ambient temperatures(no less than 60 oF). Pressure testing shall be



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1.5 times MOP except where lesser factors (noless than 1.1 times MOP) are warranted to avoidadverse effects (e.g., plastic deformation orstrain hardening) on the system.

b. Cryogenic systems, including vacuum-jacketed

pipe, shall be cold-shock tested with anappropriate cryogenic inert medium (at MOP orgreater) prior to introducing any hazardouscommodity into the system. For liquid hydrogensystems, a mass spectrometer leak test withliquid helium is required. Cold-shock leaktesting can be accomplished at proof pressure tosatisfy the cryogenic proof requirements inParagraph A.

c. Simultaneous loading of fuels and oxidizers must

be approved by the LSSO. d. All personnel involved in cryogenic propellant

transfer operations, repairs, or adjustments tothe system must wear LSSO and Biomedical Officeapproved PPE.

e. Flammable cryogenic systems shall be capable of

being connected to an external vent system.

4.3.9 GSE Materials

a. A list of materials shall be maintained for eachpiece of GSE which interfaces with hazardousfluids. Hazardous fluids include, but are notlimited to, gaseous oxygen, liquid oxygen,gaseous hydrogen, liquid hydrogen, hydrazine,nitrogen tetroxide, monomethyl-hydrazine, Freon-21, ammonia, and potassium hydroxide. This listwill be of sufficient detail to permit anevaluation of the compatibility of the GSEdesign with the environment in which it is to beused.

b. Mercury in liquid or vapor form shall not be

used in GSE if a substitute of equivalentperformance exists or an appropriate alternatedesign or method can be used. Mercury shall notbe used in any applications where contaminationof flight hardware or exposure to personnelcould result.



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c. Cleaning solvents and adhesive materials shall

be contained in NFPA-approved safety containers.The use of and quantity allowed in the payloadprocessing work area shall be approved by theLSSO. All users of these materials must complywith local fire, safety, and health regulations.Except where approved by the LSSO, the use ofglass containers is prohibited in all payloadprocessing work areas.

d. Use of flammable materials and static-producing

materials shall be kept to a minimum in allpayload processing areas. If any plastic filmis to be used, the material shall be selectedfrom the LSSO approved plastics list. Thematerial, quantity, and location of use shall beincluded in the payload organization safety datapackage and approved by the LSSO. If a plasticfilm is not on the approved list, a sample(minimum 1 square yard) shall be submitted tothe LSSO for test/evaluation and approval.

e. GSE containing components made of shatterable

materials which is to be used inside theOrbiter, or in areas where it could fall intothe Orbiter, shall be designed to providepositive containment to prevent fragments fromentering the Orbiter.

f. GSE designed for use directly in the Orbiter

crew cabin or payload bay must meet the samematerials flammability requirements as thepayload/experiment itself. For theserequirements, see NSTS 1700.7, Paragraph 209,Subparagraphs 2 and 3.

g. GSE used in flight vehicle habitable areas or in

the payload bay shall not be painted or coatedwith materials subject to chipping, flaking, orscaling.

h. Materials should be selected which are not

nutrients for biological agents such as mold,mildew, fungus, etc. Experiments in habitableareas should not provide a source ofcontamination. Materials which are nutrientsshould be hermetically sealed or treated to



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render the exposed surfaces resistant tobiological attack.

* 4.3.10 Industrial Hygiene

Hazardous materials and physical agents must becontrolled during all phases of launch/landing siteoperations to protect personnel by preventingexposures in excess of applicable limits and tocomply with applicable federal and state regulationsand requirements.

a. Descriptive information concerning proposed usesof hazardous materials and physical agents willbe provided by the payload organization to theLSSO for review and evaluation by the BiomedicalOffice.

b. General Industrial Hygiene requirements include,

but are not limited to, the following:

(1) Equipment which contains, possesses, oremits hazardous materials and/or physicalagents will be designed, constructed,installed, and operated in a manner toensure the potential for exposure is keptas low as feasible.

(2) The payload organization shall provide a

list of all hazardous materials andphysical agents containing names,quantities, locations, and proposed uses(reference Paragraph 3.2.i). The payloadorganization shall also submit to the LSSOone copy of the MSDS for each of thesematerials upon or before arrival at the ER.MSDS's must also be submitted if, at anytime, additional materials (not previouslyidentified) are introduced onto the ER.

(3) Hazardous materials and physical agents

shall be used only by properly trainedpersonnel and in accordance with proceduresreviewed by the Biomedical Office andapproved by the LSSO.

(4) Engineering or administrative controls

shall be the primary means for preventing



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personnel exposures. When such controlsare not feasible or adequate to controlexposure, PPE will be required. PPE shallbe approved by the Biomedical Office.

(5) Planned releases of hazardous materials

shall not be permitted without review andapproval by the LSSO and the BiomedicalOffice. Supportive data shall be providedby the payload organization to identifymaximum expected quantities andconcentrations of planned releases.

(6) All activities involving hazardous

materials or physical agents are subject tomonitoring by the Biomedical Office.

c. Specific Industrial Hygiene requirements arecontained in the following documents:

(1) KHB 1840.1, "Industrial Hygiene Handbook"

(2) KMI 1800.1, "Environmental Health Program"

(3) KMI 1800.2, "KSC Hazard CommunicationProgram"

(4) 29 CFR 1910, "Occupational Safety and

Health Administration; General IndustrialStandards"

(5) AFOSH STD 48-8, "Controlling Exposures to

Hazardous Materials"

(6) "American Conference of GovernmentalIndustrial Hygienists (ACGIH) ThresholdLimit Values for Chemical Substances andPhysical Agents in the Work Environmentwith Intended Changes"

4.3.11 Oxygen

The use of gaseous or cryogenic oxygen involvesunique design requirements with respect to materialscompatibility. Prior to commencement of design, thepayload organization shall contact the LSSO toidentify specific safety/compatibility requirementsto be incorporated in design. Specific KSC documents



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providing results of compatibility testing are79K09560 for liquid oxygen testing and 79K09561 forgaseous oxygen testing.

4.4 ENVIRONMENTAL

4.4.1 Meteorological Requirements

4.4.1.1 Propellants - Meteorological conditions establishedherein shall be observed by all agencies inscheduling and conducting transfer, handling, and useof toxic propellants.

a. Propellant operations shall not commence whenthe potential for passage of an electrical stormis within 5 miles. Propellant operations duringstorm passage shall be interrupted orexpeditiously concluded at the discretion of theLSSR or supervisor in charge of the operation.

b. The supervisor responsible for the

transfer/handling operations is responsible forobtaining the prevailing meteorologicalconditions, determining that the conditions meetthose specified herein, and obtaining LSSRapproval to proceed.

c. In order to protect personnel not involved in

toxic propellant operations and the publicdomain, downwind concentrations of toxicpropellant materials shall be controlled bylimiting operations to certain meteorologicalconditions. Concentrations of toxic propellantsshall be kept at or below Biomedical Officeapproved safe levels at the launch siteboundaries in the public domain and in thelaunch site industrial areas.

d. Personnel shall be evacuated or provided with

emergency escape breathing devices andcommunications equipment in areas potentially atrisk from toxic propellant operations asdetermined by the LSSO.

e. Evacuation of personnel shall be used in those

situations where the potential forinjury/illness is present.



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f. Local propellant operations shall requireprotection in the immediate downwind sector.

4.4.1.2 Ordnance - Ordnance items shall not be transported,handled, installed/removed, or electricallyconnected/disconnected when the passage of anelectrical storm is within 5 nautical miles.Ordnance operations shall be interrupted or safedduring storm passage.

4.4.2 Hazardous Atmosphere

4.4.2.1 General - Hazardous atmospheres are defined asfollows:

a. Flammable/Explosive Atmospheres - Hazardousatmospheres are defined as follows: Apercentage of the lower explosive limit (LEL)shall be established to define a hazardousatmosphere for flammable/explosive gases orvapors by the LSSO on a case-by-case basis.Factors such as commodity involved, quantity,confinement area, the presence of oxygen-enriched atmospheres (greater than 25%),credible time for a hazardous condition todevelop, and response time to complete emergencyactions must be considered in establishing thepercentage of the LEL. This percentage isusually 25% of the commodity LEL.

b. Oxygen Deficient Atmospheres - A hazardous

oxygen-deficient atmosphere may develop inenclosed spaces where operations or processesconsume oxygen or release asphyxiating gases orvapors into the atmosphere. Entry into anyatmosphere containing less than 19.5% oxygen isconsidered hazardous.

c. Toxic/Corrosive Atmospheres - Hazardous

toxic/corrosive atmospheres may be present whereprocesses or operations generate airbornematerials. Hazardous airborne materials includedusts, fibers, mists, fogs, smokes, fumes,gases, and vapors.

* 4.4.2.2 Confined Space Entry - Confined space entries will beperformed in accordance with the procedure describedin KHB 1840.1, Appendix A.



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4.4.2.3 Hazardous Atmosphere Areas for Electrical Equipment -

4.4.2.3.1 The hazardous atmospheric area for flammable liquids,such as propellants, are defined as follows:

a. Service carts, drums, storage vessels, orpayload tanks - 50 feet radially from thecontainer or as specified by the LSSO.

b. Vents - 50 feet radially from the vent opening. c. Transfer lines - 25 feet radially from the line. d. All installation configurations shall be

evaluated for approval by the LSSO.

4.4.2.3.2 The hazardous atmospheric area for solid propellantsis within 10 feet of any exposed propellant. Solidpropellants are considered exposed when -

a. The motor nozzle is not attached and the nozzleend does not have a cover that precludespropellant offgassing or,

b. The nozzle is attached but does not have a

nozzle plug installed sufficient to precludepropellant offgassing or,

c. Unassembled motor segments that do not have

front and rear covers that prevent offgassing.

4.4.2.4 Requirements for Electrical Equipment in HazardousAtmospheres -

4.4.2.4.1 When within areas prescribed in Paragraph 4.4.2.3above, electrical equipment that is operated duringsystem pressurization or flow of flammablepropellants shall be either explosionproofed inaccordance with the NEC (NFPA 70) or hazardproofed.Hazardproofing may be obtained by potting,hermetically sealing, or by positive pressurizationwith an inert gas or clean air as described in NFPA496. The electrical equipment must be monitored atall times when powered.

4.4.2.4.2 Electrical equipment to be operated in enclosed roomsor areas where propellants are present but in a



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static state (i.e., no flow or change ofpressurization) shall be controlled by a switch at asingle monitoring station capable of deactivating all"nonexplosion/nonhazardproof" equipment within thearea. This station must be manned at all times whenthe equipment is in use. The master switch shall beexplosion/hazardproof if it is located within thehazard area. Equipment which cannot be connected tothe master switch shall be identified to the LSSOduring the phase safety review process.

4.4.2.4.3 Hazard groups for hazardous atmospheres are listed inthe NEC (NFPA 70). For the purpose of this Handbook,kerosene (RP & JP fuels), oxygen, and solidpropellants are to be considered Class I, Group D.Hydrazine is Class I, Group C.

4.4.3 Humidity

Any operations involving solid or liquid propellantsor Category A EED's shall not be conducted athumidity levels below 30%. Exceptions shall only beapproved by the LSSO on a case-by-case basis.

4.4.4 Toxic Materials

The LSSO and Biomedical Office will establishcriteria for operational controls involving all toxicmaterials.

4.5 HANDLING AND TRANSPORTS

Many standards and guides list design requirementswritten to achieve a safe operation, such as Code ofFederal Regulations, 29 CFR, "Occupational Safety andHealth Administration, Department of Labor," Part1910, and the "NASA Safety Standard for LiftingDevices and Equipment," NSS/GO-1740.9. The specialnature of launch site safety mandates rigorousconsiderations in both design and process parameters.

The following definitions are to be used in thissection:

a. Lifting devices - slings, linkage, mechanisms,etc., that extend between a lifting hook on ahoist and the object being lifted. Only thoseitems below the lifting hook are intended to be



45 SW HB S-100August 19, 1999

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designed to the criteria contained in thisHandbook. The requirements for the design ofhoists, winches, and cranes are not included.Other systems, if required, shall comply withthe NSS/GO-1740.9.

b. Ground handling/transportation devices - trucks,

dollies, transporters on which an object isplaced for subsequent transportation orrotation.

c. Work stand - work platforms, ladders, etc., that

are fixed structures, are designed specificallyto support personnel, and do not experience thedynamic loading associated with lifting andtransportation.

d. Support stand - GSE structure designed to

support flight or ground equipment. e. Rated load - the maximum static weight that the

basic equipment can safely support or lift. f. Working (actual) load - the expected or measured

weight of a piece of equipment that is to besupported, lifted, or transported.

4.5.1 Hoisting and Handling

4.5.1.1 General - All payload organization lifting equipmentand its usage must meet the requirements of 29 CFR,Part 1910; the American National Standards Institute,ANSI B30 Series, "American National Standard Safety,Standards for Cranes, Derricks, Hoists, Hooks, Jacksand Slings"; or the NSS/GO-1740.9, "NASA SafetyStandard for Lifting Devices and Equipment," and therequirements herein.

a. All lifting and hoisting equipment must showevidence of the equipment having been tested incompliance with the above reference documentsand the requirements of the paragraphs in thissection. This must be accomplished within 1year prior to use.

b. Records of all testing and inspections shall be

maintained and shall be made available to theLSSO upon request.



4-52 of 59

c. Rated loads will be posted on all lifting and

hoisting equipment and fixtures. d. Magnetic particle, dye penetrant, radiography,

or other suitable crack-detecting tests shall beperformed on all load-bearing hooks, shackles,and eyebolts after the initial prooftest of theassembled sling but prior to use and annuallythereafter. The nondestructive inspection (NDI)method selected will require approval by theLSSO during the phase safety review process. Adefect-detecting method such as radiography orultrasonics which evaluates the material through100% of its depth shall be performed on allwelds constituting a single point of failure(i.e., critical weld) after the initialprooftest of the assembled sling. Criticalwelds shall be eliminated where feasible. Ifthe payload organization certifies that theirlifting hardware is for a specific function, isproperly controlled in terms of usage/misusageand the environment, and has undergone athorough NDI prior to application of aprotective coating, the LSSO may not require anannual NDI.

e. Thimbles, shackles, links, eyebolts, swaged

fittings, wire ropes, and similar devices mustbe subjected to and comply with the testing,preoperational and periodic inspection, andmaintenance requirements set forth in theapplicable ANSI B30 Series or the NSS/GO-1740.9.Eyebolts which are permanently fixed to the loadare to be considered exempt from proofloadingand NDI requirements. However, the eyeboltsmust comply with the design requirements ofTable 4-1.

f. Eyebolts that can be removed and replaced must

have a positive means of determination of fullthread engagement (e.g., shoulder, colormarking, etc.).

g. Attach points to payloads for the purpose of

ground handling shall be classified as eitherutilizing the flight structural interfaces tothe Orbiter or having special attach fittings



45 SW HB S-100August 19, 1999

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for the purpose of ground handling. Whenutilizing the flight attach fittings for groundhandling, structural analysis shall not berequired if this determination has been made forflight dynamics. When special fittings forground handling are used, an analysis shall beconducted to ensure the load paths have adequatesafety factors for ground handling. The attachpoints (S/C) and fittings (GSE) shall beadequately described in the safety data package,including single failure points, verificationmethods (e.g., prooftesting, NDI), and themethods used to assure proper connection duringground handling.

h. Proofloading and associated NDI will be

reaccomplished for modified or repaired liftingequipment.

i. In accordance with 29 CFR, Part 1910, a load

will not be lifted, suspended, or transportedover personnel. This requirement should beconsidered during design of GSE for hardwareintegration and assembly.

4.5.1.2 Requirements for Slings -

a. Slings shall be designed and tested as anassembled unit (unless otherwise approved by theLSSO) which includes spreader beams and droplegs (ropes, chains, shackles, eyebolts, pins,turnbuckles, etc.) in accordance with Table 4-l.Proof or periodic load test shall beaccomplished within 1 year prior to use.



4-54 of 59

Table 4-1 Sling Requirements

SLINGCOMPONENT

SAFETY*FACTOR

(ULTIMATE:RATED)

PROOFTEST

(PROOF:RATED)

PERIODICLOAD TEST

(TEST:RATED)

NASA/KSC DOD**

Wire Rope 5 2 1.25 2

Alloy Steel Chain 5 2 1.25 2

Metal Mesh 5 1.5 1.25 2

Natural orSynthetic Web

5 1 1 1

Natural orSynthetic Rope

Manila 5*** 1 1 1

Polypropylene 6*** 1 1 1

Polyester 9*** 1 1 1

Nylon 9*** 1 1 1

Structural Members(e.g., spreaderbeams)

5**** 2 1.25 2

Shackles,Turnbuckles,Eyebolts, etc.

5 2 1.25 2

* As relates to this table, safety factor is defined as theratio of a load that predicts a failure to a rated load.

** DoD ownership, sponsorship, or at a DoD location.

*** Use of rope slings will be limited to 50% of the ratedcapacity (manufacturer's rating).

**** A 3:1 safety factor against the worst case failure modethat will result in local yielding is acceptable.



45 SW HB S-100August 19, 1999

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b. All sling assemblies shall be visually inspectedeach day prior to use. A periodic inspectionshall be performed by the using organization ona regular basis with frequency of inspectionbased on frequency of sling use, severity ofservice conditions, nature of lifts beingperformed, and experience gained on the servicelife of slings used in similar circumstances.Periodic inspections shall be performed by anauthorized person. Any deterioration whichcould result in appreciable loss of originalstrength shall be carefully noted, anddetermination made whether further use of thesling would constitute a safety hazard.Periodic inspections shall be conductedannually, as a minimum.

c. Wire rope slings shall be immediately removed

from service if any of the following conditionsare present:

(1) Ten randomly distributed broken wires inone rope lay or five broken wires in onestrand in one rope lay.

(2) Wear or scraping of one-third the original

diameter of outside individual wires. (3) Kinking, crushing, bird caging, or any

other damage resulting in distortion of thewire rope structure.

(4) Evidence of significant heat damage. (5) End attachments that are cracked, deformed,

or worn. (6) Hooks that have been opened more than 15%

of the normal throat opening measured atthe narrowest point or twisted more than 10degrees from the plane of the unbent hook.

(7) Significant corrosion of the rope or end

attachment.



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d. Structural sling inspection shall be performedat least annually. Discrepancies found duringthe following inspections shall be cause forreplacement or repair:

(1) Verify, overall, that there is no evidenceof visual damage, gouges in metal, flakingpaint, loose bolts, rivets, or connections,or deformation such as galling or gouges inpins, eyes, and end connections.

(2) Ensure there are no bent, deformed,cracked, or excessively corroded support ormain members.

(3) Inspect load-bearing bolts and verify thatthere is no visual evidence of bending,cracking, gross wear, or improperconfiguration.

(4) Inspect attached and lifting lugs forvisual deformation and evidence of localyielding.

(5) Ensure there are no elongated attach orlifting holes.

(6) Inspect around fasteners for local yieldingand deformation.

(7) Remove and inspect load-bearing slip pinsfor visual deformation, evidence ofbending, abnormal defects such as galling,scoring, brinelling, and diameters notwithin drawing tolerances. NDI shall beused when required by design requirementsor when cracks are suspected.

(8) Inspect pin bores visually for cracks,deformation, local yielding, scoring,galling, and brinelling. NDI shall beperformed as required.

(9) Inspect welds for cracks and evidence ofdeformation, deterioration, damage, orother defects by - (a) Visual inspection of all welds.



45 SW HB S-100August 19, 1999

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(b) Magnetic particle, x-ray, or other

suitable crack-detecting methods asappropriate for critical welds asidentified on the drawings.

(10) Inspect all parts, particularly bare metal,for corrosion. Corrosion-protect allsurfaces that are to be painted,lubricated, or coated with strippablevinyl, as necessary. Do not paint overuninspected areas; do not paint overcracks, deformations, deterioration, orother damage until engineering assessmenthas been made.

e. For identification and onsite assurancepurposes, equipment shall have a periodicrecertification tag containing equipmentidentification, next required test date, andquality control stamp. Hoists/winches andslings shall have proofload tags containingrated load, proofload, and proofload date.

f. Slings which have components that are normally

disassembled shall be either marked, coded, ortethered to assure proper assembly of verifiedhardware. Components not marked, coded, ortethered will invalidate theproofload/certification of the whole assembly.Removable lifting lugs used on flight hardwareor GSE must be identified to ensure the lugs canbe reinstalled in the proper location ifnecessary.

g. Synthetic or natural rope slings shall be

derated by 50% after the proofload; this thenbecomes the rated load; i.e., manufacturer'srating x 1.0 (prooftest factor) x 0.50 (deratingfactor) = posted rated load.

4.5.1.3 Hydrasets - Hydrasets shall be initially load testedto 200% and annually thereafter to 125% of theirrated load. Hydrasets shall be tested to 125%whenever seals are replaced. Manufacturer's



4-58 of 59

certification of test is acceptable for either new orreworked hydrasets. The piston rod must be fullyextended for load test. An operational test of thepump shall be done every 6 months.

4.5.1.4 Chainfall - Chainfalls shall be initially andannually load-tested to 125% of rated load.

4.5.1.5 Load cells - Load cells shall be annually load-testedand calibrated to 100% of their rated load.

4.5.1.6 Stands -

a. Ground handling devices and support stands shallhave a safety factor of 3:1 against yield.

b. Personnel work stands shall have a safety factor

of 4:1 against ultimate. c. A one-time prooftest and NDI of support stands

shall be required based upon hazard potential.The prooftest level shall be at least 1.25 timesthe rated load. An LSSO-approved NDI shall beperformed after the prooftest. A prooftest andNDI shall be required after misuse ormodification.

* 4.5.2 Transporters

a. Prior to use, checks will be made to ensure -

(1) Proper tire inflation.

(2) An operable braking system.

(3) Tow bar and safety chains are properlyfastened.

(4) Payload securing devices are properly

tightened.

(5) Availability of wheel chocks.

(6) Availability of fire extinguisher(s).

* Denotes Change



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b. Maximum speed shall be prominently and permanentlydisplayed on both the front and rear of thetransporter.

c. Transporters shall be parked only in approved areas.

d. Movement of transporters carrying liquid fuel, solidmotors, or installed ordnance shall comply with AFMAN91-201 and not commence when electrical storms arewithin 5 nautical miles.

e. Transporters shall have a safety factor of 3:l

against yield; however, commercially availableequipment (e.g., flatbed trailers) are acceptable.



45 SW HB S-100August 19, 1999

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* 5.0 MISHAP INVESTIGATION AND REPORTING

5.1 NASA MISHAP INVESTIGATION CONTROL

Reporting and investigation for mishaps involvingNASA payloads and associated GSE will be conductedunder the provisions of NHB 1700.1, "NASA SafetyPolicy and Requirements Document” and NASA PolicyDirective, NPD 8621.1, "NASA Mishap Reporting andInvestigating Policy." Investigation of mishapsinvolving NASA-sponsored (non-USAF) payloads andassociated GSE occurring after arrival at NASAfacilities will also be conducted under the sameprovisions.

5.2 USAF MISHAP INVESTIGATION CONTROL

Reporting and investigation of mishaps involving DoDor foreign military payloads or personnel will becontrolled by AFI 91-204, “Safety Investigations andReports.”

5.3 MISHAP REPORTING

5.3.1 Mishap Contacts

The payload organization shall immediately report tothe LSSO mishaps which result in death orinjury/exposure of personnel or damage to resources,equipment, or facilities. Close calls shall besimilarly reported. The LSSO mishap point of contactis as follows:

a. For NASA-sponsored payloads at the ELS: KSCPayloads, Space Station, and Industrial SafetyDivision (EI-F).

b. For DoD-sponsored payloads at the ER: 45 SW

Systems Safety Office, Large Launch SystemsElement (45 SW/SESL).

c. At contingency landing sites: The designated

onsite LSSR.

* Denotes Change



5-2 of 3

Note: In the event that the mishap involves therelease of and/or exposure to hazardous chemicalagents, the Biomedical Office representative will benotified in addition to the LSSO.

d. Facility operators involved with or observing amishap shall notify their safety point ofcontact.

Note: The LSSO mishap point of contact, above, isresponsible for further notification to other LSSOmishap points of contact as necessary.

5.3.2 Payload Organization Involvement

The payload organization is responsible forinvestigating all mishaps and anomalies with whichthey may be involved, to the extent of theirinvolvement.

5.3.3 Payload Organization Responsibilities

For mishaps involving payload organizations, thefollowing defines investigation and written reportingresponsibilities:

a. If government personnel/property, includingcontractors, are injured/damaged from orcontribute to the mishap, then the payloadorganization shall report as follows:

(1) A preliminary written report of the mishapto the LSSO mishap point of contact withinone working day after the mishap occurs.

(2) Further reporting and investigation will be

conducted in accordance with KHB 1710.2,“Kennedy Space Center Safety PracticesHandbook,” Annex B or AFI 91-204, asappropriate. The payload organization maybe requested to conduct its owninvestigation concurrently with thegovernment investigation.

(3) The payload organization will provide a

copy of the final report to the LSSO mishappoint of contact.



45 SW HB S-100August 19, 1999

5-3 of 3

b. If only payload organization personnel/property,including payload organization contractors, areinjured/damaged from or contribute to themishap, and the mishap is not considered a nearmiss to government property/personnel, then thepayload organization shall report as follows:

(1) When the LSSO mishap point of contact isnotified, the need for a preliminarywritten report will be determined.

(2) Investigation shall be done by the payload

organization using its own internalprocedures.

(3) A copy of the final report of the mishap

investigation shall be sent to the LSSOmishap point of contact for Lessons Learnedpurposes.

5.3.4 Investigation Boards

A government-directed investigation board, whenconvened, is responsible for the officialinvestigation report. All other investigation andreporting activities will be under its control.Concerned organizations and element contractors shallcooperate fully in a mishap investigation, providingrecords, data, administration and technical support,and services requested by the investigatingboard/official.

5.3.5 Mishap Scene

The scene of the mishap shall not be disturbed untilthe investigating authority has given concurrence todo so.



45 SW HB S-100August 19, 1999

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* APPENDIX A

ACRONYMS, ABBREVIATIONS, AND GLOSSARY OF TERMS

AC - Alternating Current.

ACGIH - American Conference of Governmental IndustrialHygienists.

AFI - Air Force Instruction.

AFMAN - Air Force Manual.

AFOSH - Air Force Occupational Safety and Health.

AFR - Air Force Regulation.

AFSC - Air Force Systems Command.

AFSCF - Air Force Satellite Control Facility.

ANSI - American National Standards Institute.

ASME - American Society of Mechanical Engineers.

AWG - American Wire Gauge.

BUDDY SYSTEM - The buddy system requires that two people bedesignated to be concerned with each other's safety in ahazardous situation. The system does not demand shoulder-to-shoulder contact, but rather visual contact and a proximitythat allows each buddy to help the other in an emergency.

C - Centigrade.

CCAS - Cape Canaveral Air Station.

CFR - Code of Federal Regulations.

CLOSE CALL - An unplanned occurrence in which there is noinjury/damage but under similar circumstances could haveresulted in a reportable mishap.

cm2 - Centimeter Squared.

CPIA - Chemical Propulsion Information Agency.

* Denotes Change



A-2 of 8

CREDIBLE - A condition that can occur and is reasonably likelyto occur. For the purpose of this document, failures ofstructure, pressure vessels, and pressurized lines and fittingsare not considered credible failure modes if those elementscomply with the applicable requirements.

CRITICAL WELD - A weld where a single failure of any portioncould result in injury to personnel or damage to property orflight hardware.

DAMAGE - Breakage, mangling, mutilation, ruin of items,transmitted across system or component interfaces inadvertentlyby internal or external action, including component failure andhuman error which could cause obstruction of critical functionsand requiring repair or replacements.

D.B. (DESIGN BURST PRESSURE) - A specified test pressure thatpressurized components must withstand without rupture todemonstrate design adequacy in a qualification test.

dB - Decibel.

dBA - Decibel, A-scale.

DC - Direct Current.

DEVIATION - Granted use or acceptance of an article for morethan one mission which does not meet the specifiedrequirements.

DH - Design Handbook.

DoD - Department of Defense.

DOP - Detailed Operations Procedure.

EED - Electroexplosive Device.

ER - Eastern Range, including Kennedy Space Center and/or CapeCanaveral Air Station.

EMI - Electromagnetic Interference.

EPD - Emergency Procedures Document.

ETA - Explosive Transfer Assembly.



45 SW HB S-100August 19, 1999

A-3 of 8

EXPLOSIONPROOF APPARATUS - Apparatus enclosed in a case that iscapable of withstanding an explosion of a specified gas orvapor which may occur within it and of preventing the ignitionof a specified gas or vapor surrounding the enclosure bysparks, flashes, or explosion of the gas or vapor within, andwhich operates at such an external temperature that asurrounding flammable atmosphere will not be ignited thereby.

EWR - Eastern and Western Range.

F - Fahrenheit.

FAILURE - The inability of a system, subsystem, component, orpart to perform its required function within specified limits,under specified conditions for a specified duration.

FLUID - Liquids or gases.

GSE (GROUND SUPPORT EQUIPMENT) - The ground equipment andsystems needed to support the payload such as propellantloading units, data recording, instrumentation, etc.

HAZARD - A risk of personnel exposure, injury, or death; or ofhardware damage or loss.

HAZARDPROOF - Prevention of an explosive atmosphere penetratingelectrical fixtures where sparking or arcing could occur.

HAZARDOUS FLUID - Any fluid that is toxic, cryogenic,flammable, or corrosive.

HAZARDOUS MATERIAL - Any solid, liquid, or gaseous materialwhich meets the hazard reporting requirements of 29 CFR1910.1200. This includes commodities which, under foreseeableconditions, are toxic, carcinogenic, cryogenic, explosive,flammable, pyrophoric, water-reactive, corrosive, an oxidizer,a compressed gas, a combustible liquid, or are chemicallyunstable.

HB - Handbook.

I.D. - Identification.

IMC - Interim Message Change.

IUS - Inertial Upper Stage.



A-4 of 8

JP - Jet Propellant.

JSC - Johnson Space Center, NASA, Houston, Texas 77058.

KHB - Kennedy Handbook.

KMI - Kennedy Management Instruction.

KSC - Kennedy Space Center, NASA, Florida 32899.

KSC-STD - KSC Standard.

LEL - Lower Explosive Level.

LSSO - Launch Site Safety Office.

LSSR - Launch Site Safety Representative.

mA - Milliampere.

MAWP (MAXIMUM ALLOWABLE WORKING PRESSURE) - The maximumpressure at which a component can continuously operate based onallowable stress values and functional capabilities. MAWP issynonymous with MDOP (Maximum Design Operating Pressure) or"Rated Pressure."

MDOP - Maximum Design Operating Pressure.

MIL - Military.

MIL-STD - Military Standard.

MISHAP - An unplanned event which results in personnelfatality, injury, or exposure; damage to or loss of the SpaceShuttle, environment, public property, or private property; orcould result in an unsafe situation or operational mode.

MOP (MAXIMUM OPERATING PRESSURE) - The maximum pressure atwhich the system or component actually operates in a particularapplication. MOP is synonymous with MEOP (Maximum ExpectedOperating Pressure) or maximum working pressure.

MPE - Maximum Permissible Exposure.

MRS - Major Radiological Sources.



45 SW HB S-100August 19, 1999

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MSDS - Material Safety Data Sheets.

mV - Millivolt.

mW - Milliwatt.

N/A - Not Applicable.

NASA - National Aeronautics and Space Administration.

NDI - Nondestructive Inspection.

NEC - National Electrical Code.

NFPA - National Fire Protection Association.

NHB - NASA Handbook.

NMI - NASA Management Instruction.

NPD - NASA Policy Directive.

NONCOMPLIANCE REPORT - The request form submitted by thepayload organization to obtain a waiver or deviation for thosetechnical safety requirements of this document that have notbeen met.

NSS - NASA Safety Standard.

OMD - Operations and Maintenance Documentation.

OMRSD - Operation and Maintenance Requirements andSpecifications Document

OMI - Operations and Maintenance Instructions.

OSHA - Occupational Safety and Health Administration.

PAYLOAD - Any equipment or material carried by the SpaceShuttle that is not considered part of the basic Space Shuttleitself. It, therefore, includes items such as free-flyingautomated spacecraft, individual experiments or instruments,payload support equipment, etc. As used in this document, theterm payload also includes payload-provided GSE and systems andflight and ground systems software.



A-6 of 8

PAYLOAD BAY - The 15-foot diameter by 60-foot long enclosedvolume within the Orbiter, designed to carry carriers,payloads, payload-support equipment, and associated mountinghardware.

PAYLOAD ELEMENTS - Experiments, instruments, or otherindividual payload items which are subsets of an integrated,multipayload cargo complement on missions such as Spacelab,etc.

PO (PAYLOAD ORGANIZATION) - The funding or sponsoringorganization for the experiment, payload, or mission. Thisdoes not mean the principal investigator, payload contractor,designer, or developer except to the extent delegated by thesponsoring organization. For NASA-sponsored payloads, a NASAHeadquarters payload program office is the sponsoringorganization and usually delegates to a NASA Field Center theauthority for formal interface with the SSP operator in theimplementation of this document. Other payload organizationsinclude, but are not limited to, the following: DoD, otherU.S. Government agencies, non-U.S. Government publicorganizations, private persons or private organizations,international organizations, European Space Agency, foreigngovernments, etc.

PPE - Personal Protective Equipment

PHE - Propellant Handlers Ensemble.

PHYSICAL AGENT - Any environmental factor, such as noise,temperature extremes, vibrations, etc., which may cause harm orinjury to personnel.

PRESSURE TEST - A test pressure which demonstrates that no partof a pressure system component shall fail, take any permanentset, or be damaged in any manner, when subjected to theapplicable proof pressure.

psi - Pounds Per Square Inch.

psig - Pounds Per Square Inch Gauge.

RATED LOAD - The static weight that the basic equipment cansafely support or lift.

REFEREE FLUID - A compatible fluid, other than that used duringnormal operation of a system, which is substituted for test



45 SW HB S-100August 19, 1999

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purposes because it is safer due to characteristics such asbeing less toxic, less explosive, easier to detect, etc.

REM - Roentgen Equivalent, Man.

REQUIREMENT - A specified mandatory condition which must becomplied with unless a noncompliance report is approved by theCenter Commander/Director.

RF - Radio Frequency.

RH - Relative Humidity.

RHU - Radioisotope Heater Unit.

rms - Root Mean Square.

RP - Rocket Propellant.

RPO - Radiation Protection Officer.

RTG - Radioisotope Thermoelectric Generator.

S&A - Safe and Arm.

SAE - Society of Automotive Engineers.

SAFETY CRITICAL - Any condition, event, operation, process,equipment, or system with a potential for exposing personnel toa hazardous material, injury or death, or for causing damageto, or loss of, equipment or property.

SAFETY FACTOR - The ratio of a load that predicts a failure toa rated load.

S/C - Spacecraft.

SD - Space Division.

SDR - Space Division Regulation.

SHALL - Mandatory action.

SHOULD - Recommended action.

SW - Space Wing (45th Space Wing, Patrick Air Force Base,Florida 32925).



A-8 of 8

SWI - Space Wing Instruction.

SWR - Space Wing Regulation

SSP - Space Shuttle Program.

STD - Standard.

STS (SPACE TRANSPORTATION SYSTEM) - The Space Shuttle,Spacelab, Inertial Upper Stage (IUS), and the ground sitesneeded to support these elements.

SYSTEM CERTIFICATION PRESSURE - The maximum pressure that hasbeen applied to a system; however, no system element can haveits MAWP exceeded when the certification pressure has beenapplied.

TBD - To Be Determined.

T.O. - Technical Order or Technical Manual.

TOP's - Technical Operating Procedures (See Appendix C).

TP - Test Procedure.

UDS - Universal Documentation System.

USAF - United States Air Force.

WAIVER - Granted use or acceptance of an article for a singlemission which does not meet the specified requirements.

WILL - Advising of future action.



45 SW HB S-100August 19, 1999

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* APPENDIX B

COMPLIANCE AND REFERENCE DOCUMENTS

The following documents form a part of this document to theextent specified herein. In the event of a conflict betweenthe reference documents and the contents of this document, thecontents of this document shall be considered supersedingrequirements.

Document Number and TitleReferenced inParagraph

ForCCAS

ForKSC

1. ACGIH TLVs, AmericanConference ofGovernmental IndustrialHygienists (ACGIH)Threshold Limit Values(TLVs) and BiologicalExposure Indices,latest issue

4.3.10.C.7 R X

2. AFM, 161-30, ChemicalRocket/PropellantHazards, Vol. 2, LiquidPropellants, 10 Apr 73;Change 1, Aug 86

4.3.7.1.A4.3.7.3.H

RR

RR

3. AFOSH STD 48-8,Controlling ExposuresChemical Substances,20 Jun 78

4.3.10.C.54.3.10.C.6

XX X

4. AFOSH STD 161-9,Exposure to RadioFrequency Radiation,12 Oct 84

4.3.3.1.A4.3.4.1.D

XX

5. AFOSH STD 161-10,Health Hazards Controlfor Laser Radiation, 30May 80

4.3.4.1.A4.3.4.3.2

X

6. AFI 91-110, NuclearSafety Review andLaunch Approval forSpace or Missile Use ofRadioactive Materialand Nuclear Systems, 18Mar 94

4.3.4.1.A X

*Denotes Change



B-2 of 2


ForCCAS

ForKSC

7. AFI 91-204, SafetyInvestigations andReports, 20 Feb 98

5.2 X

8. AFMAN 91-201,Explosive SafetyStandards, 1 Jan 98

4.3.5.2.A4.5.2.D

RX

RX

9. AFI 40-201, ManagingRadioactive Materialsin the USAF, 25 Jul 94

4.3.4.1.A X

10. AFSC DH 1-6, Air ForceSystems Command DesignHandbook, 20 Dec 78,5th Edition, Division1, Dec 82

4.3.7 R R

11. ANSI B30 Series,American NationalStandard Safety,Standards for Cranes,Derricks, Hoists,Hooks, Jacks, andSlings, latest issue

4.5.1.14.5.1.1.E

XX

XX

12. ASME Boiler andPressure Vessel Codes,latest issue

4.3.3.1.3.A X X

13. 29 CFR, OccupationalSafety and HealthAdministration, General4.3.10.C.5 IndustryStandards, Departmentof Labor, Part 1910,latest issue

4.54.5.1.14.3.10.C.5

RXX

RXX

14. CPIA #394, ChemicalRockets/PropellantHazards, Vol. III,Liquid PropellantHandling, Storage andTransportation, Sept 84

4.3.7.1.A4.3.7.3.H

XX

XX

15. EWR 127-1, RangeSafety Requirements,31 Oct 97

1.1 R R

16. 45 SWI 40-201,Radiation ProtectionProgram, 10 SEP 97

4.3.4.1.A X



45 SW HB S-100August 19, 1999

B-3 of 3


ForCCAS

ForKSC

17. JSC SW-E-0002E, SpaceShuttle Program GSEGeneral DesignRequirements, 20 FEB92, Change 65, 8 Apr 97

4.3.3.1.3.C R

18. NSTS 13830,ImplementationProcedure for STSPayloads System SafetyRequirements Rev. B,15 November 1989

2.0, 3.1, 3.2 R X

19. KHB 1710.2C, “KennedySpace Center SafetyPractices Handbook,”27 Feb 97

5.3.3.A.2 X

20. KHB 1840.1B,“Industrial HygieneHandbook,” 31 Jan 95

4.3.10.C.14.4.2.2

XR

XX

21. KHB 1860.1C, KSCIonizing RadiationProtection Programincluding Appendix D,Radiological Controlsfor Major RadiologicalSources (MRS) andNuclear Assemblies, 20Aug 96, Appendix D, 13Jun 97

4.3.4.1.a X

22. KHB 1860.2A, KSC Non-Ionizing RadiationProtection Program, 20Jun 93

4.3.4.1.A X

23. KMI 1800.1B, KSCEnvironmental HealthProgram, 20 Jan 95

4.3.10.C.3 X X

24. KMI 1800.2B, “KSCHazard CommunicationProgram,” 11 May 94

4.3.10.C.4 X X

25. KMI 1860.1D,“Radiation ProtectionProgram,” 16 Jan 97

4.3.4.1.A X

26. KSC-STD-SF-0004B,Color Coding FluidSystems Piping,

4.3.3.1.1.B.14.3.3.1.3.B.2

RR

RR



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ForCCAS

ForKSC

1 Sept 8227. MIL-H-25579E, Hose

Assembly,Tetrafluoroethylene,High Temperature,Medium Pressure,24 Jan 85, Rev. E

4.3.3.1.6.A X X

28. MIL-STD-1472E,“Behavioral and SocialSciences; HumanitiesHuman FactorEngineering,” 31 Oct 96

4.2.1 R R

29. MIL-STD-1522A,“Standard GeneralRequirements for SafeDesign and Operation ofPressurized Missile andSpace Systems, Jun 84;Notice 2, 4 Sep 92

4.3.3.1.3.C4.3.3.1.6

R R

30. NFPA 496, ElectricalEquipment, Purged andPressurized Enclosuresfor, latest issue

4.4.2.4.1 R R

31. NEC, NationalElectrical Code (NFPA70), latest issue

4.3.2.1.J4.4.2.4.14.4.2.4.3

XXX

XXX

32. NHB1700.1 (VI-B),“NASA Safety Policy andRequirement Document,”1 June 93

5.1 X

33. NSTS 1700.7, SafetyPolicy and Requirementsfor Payloads Using theSpace TransportationSystem, Rev. B,22 May 96

1.2, 3.3,4.3.3.1.1,4.3.5.2, 4.3.7,4.3.9.F

XXXX

XXXX

34. NHB 8060.1C,“Flammability, Odor,and OffgassingRequirements and TestProcedures forMaterials inEnvironments thatSupport Combustion,”

4.3.7.2.Q X X



45 SW HB S-100August 19, 1999

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ForCCAS

ForKSC

2 April 9135. NPD 8621.1G, “NASA

Mishap Reporting andInvestigating Policy,”10 Dec 97

5.1 X

36. Society of AutomotiveEngineers (SAE)Standards

4.3.3.1.6.A X X

37. T.O. 00-25-223,Integrated PressureSystems and Components(Portable andInstalled), Basic, 1June 91, Change 2, 6Feb 96

4.3.3.3 R R

38. T.O. 00-25-229, Valveand Regulator Criteriafor Integrated PressureSystems (Portable andInstalled), Change 4,15 July 94

4.3.3.1.3.B.3 R R

39. DLAR 8220.1, ExplosiveHazards ClassificationProcedures, 1 Mar 81

4.3.5.2.A X X

40. NASA-STD-3000 Man-Systems IntegrationStandards, March 95

4.2.1 R

41. KHB 5310.1C,“Reliability,Maintainability andQuality AssuranceHandbook, GOP 5-3,14 Aug 95

4.1.6 R

42. 79K09560 MSL LOX 4.3.11 R43. 79K09561 MSL GOX 4.3.11 R44. NSS/GO-1740.9, NASA

Safety Standard forLifting Devices andEquipment, 19 Nov 91

4.5 R

45. NSS 1740.12, “SafetyStandard forExplosives, Propellantsand Pyrotechnics,” 2Aug 93

4.3.5.2.A R



B-6 of 6


ForCCAS

ForKSC

46. NSTS 1700.7B Addendum,“Safety Policy andRequirements forPayloads using theInternational SpaceStation (ISSAddendum),” 8 Dec 95

1.2 X X

X = Compliance R = Reference Only

NOTE: For NASA-sponsored payloads at CCAS, the NASA requireddocuments are also applicable. For USAF-sponsored payloads atKSC, the USAF required documents are also applicable.



45 SW HB S-100August 19, 1999

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APPENDIX C

GUIDELINES FOR THE PREPARATION OFTECHNICAL OPERATING PROCEDURES (TOP's)

1. The Safety Community applies the generic term,Technical Operating Procedures (TOP's), to all testor operations procedures. The term "TOP's" onlyimplies that the procedure must meet minimum contentand processing standards. In practice, procedureswill carry the nomenclature of the system under whichthey are developed such as Operations and MaintenanceInstructions (OMI's) of the Operations andMaintenance Documentation (OMD) system, testprocedures (TP's) of the Universal DocumentationSystem (UDS)/Air Force Satellite Control Facility(AFSCF) Support Documentation Guide or DetailedOperations Procedures (DOP) for Inertial Upper Stage(IUS) procedures. The host organization prescribesthe system to be used.

2. TOP's are categorized as follows:

TOP's are classified as hazardous or nonhazardous inaccordance with the criteria provided in Paragraph4.1.3a of the basic document.

a. Category I TOP: Provides detailed proceduresauthorizing work for the operation, maintenance,verification of ground supportsystems/equipment, and instructions forcheckout, servicing, handling, andtransportation of the payload systems/subsystemsand experiments during prelaunch, launch, andpostlaunch operations. Repetitive hazardous andnonhazardous operations use Category I TOP's.

b. Category II TOP: Provides engineeringinstruction, authorizes work, establishes workcontrol methods, and is normally prepared for aone-time-only nonhazardous operation in order toaccommodate special tests or authorize temporaryinstallations, removals, or replacements.

A Category II TOP may also be used for one-time-onlyhazardous operations and for repetitive nonhazardous



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operations when work is of limited scope and does noteconomically justify preparation of a Category I TOP.

3. The review and approval process for TOP's is inaccordance with the TOP category.

a. Category I hazardous TOP's are submitted to theLSSO for safety approval.

b. Category II hazardous TOP's for all operationsat CCAS are submitted to the 45 SW Safety Officefor approval.

c. Category II hazardous TOP's for operations atother than item b. above are submitted to theLSSR for approval.

NOTE: Nonhazardous TOP's are submitted to the LSSOfor review only.

4. All TOP's shall be prepared in clear, preciselanguage that can be readily understood by personnelinvolved in the operations. All hazardous TOP's willbe reviewed for content as follows:

a. A brief description of the task operation orcheckout.

b. Identification of the operating location forhazardous operations (e.g., facility, building,test area, etc.) and/or departing/arriving areas[e.g., Pad 39A, etc.].

c. Specific hazards to which personnel will beexposed during the operation (e.g., explosives,propellants, radiation, etc.). Configuration ofthe payload prior to, during, and at completionof operation shall be provided.

d. Identification of inhibits and a means forverifying that the inhibits are in place.

e. Identification of any condition(s) which causethe TOP to be classified hazardous. Safetyprecautions (CAUTION/WARNING notes) will bespecified for any activities, hazardous ornonhazardous, where specific guidelines must beobserved or actions taken to prevent or limit



45 SW HB S-100August 19, 1999

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hazards. The notes will immediately precede thestep/sequence which directed the action. Publicaddress announcements, where available, will bemade to alert personnel of the dangers andinformation associated with the hazardousoperation. All procedures involving manuallycontrolled pressurization of systems where MAWPcan be reached shall contain a CAUTION/WARNINGstating the MAWP immediately before the stepwhich calls for pressurization. Definitionsare :

Warning: Operational step(s), etc., which ifnot adhered to or observed could result inpersonal injury or exposure.

Caution: Operational step(s), etc., which ifnot adhered to or observed could result indamage to equipment.

f. Identification of organizational elements andfacilities required to support the operation(e.g., Safety, Security, Medical, etc.).

g. Identification of tools, equipment, and clothingrequired for the safe performance of a hazardousoperation or as required by emergency proceduresassociated with the operation. Protectiveequipment shall be specified by manufacturer andmodel number. This information will becontained/specified within the "warning note"immediately preceding the first step/sequence orgroup of steps within a sequence which ishazardous.

h. Safety related quality assurance verificationshave been identified. These include verifyingcalibration of monitoring equipment and gauges,load testing of lifting devices, specificationof torque values, calibration of torquewrenches, etc.

i. A list of referenced documents containing allthe instructions that are specifically calledout within the TOP or required to support theoperation. The list will contain the documentidentifying number, revisions, and title with



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the originator listed in parenthesis after thetitle. Where the latest issue of the documentor drawing is to be used rather than a specificrevision, latest issue (LI) will be entered inthe revision column.

j. Unique safety rules and regulations that cannotbe addressed to a specific step in theoperational sequence of the TOP, but which arerequired for the safe conduct of a hazardousoperation. Note: The final authority for theSafety Requirements Section will be theresponsibility of the appropriate safety office.

k. A list identifying those essential personnelrequired in the specified control area duringhazardous steps/sequences. The list will beincluded immediately preceding the firststep/sequence or group of steps within asequence which are hazardous. The list willidentify the individuals by call sign/functionaltitle, number of personnel, approximatelocation, function, and the organization orcontractor employing the individual. Changes tothis list shall be considered on a case-by-casebasis with approval by the LSSR. If the list isidentical throughout the TOP, it may be detailedonce and referenced thereafter.

l. A procedural step (placed immediately precedingthe first step/sequence of the hazardous steps)to identify/specify each control area forhazardous operations and directing allnonessential personnel to clear the specifiedcontrol area, allowing sufficient time for themto do so before the start of a hazardousstep/sequence. Control areas are normallyspecified in the appropriate LSSO documentationor must be approved by the LSSO. Specialconsideration will be given to a potentialrelease of explosive/toxic vapors. Thecontrolled area will be determined on quantity(worst case calculation).

m. When LSSR participation is required, thefollowing steps are included:



45 SW HB S-100August 19, 1999

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(1) 24-hour notification prior to start ofprocedure.

(2) LSSR concurrence prior to start of

step/sequences or subtask TOP's containinghazardous operations.

(3) Prior to opening the control area for

controlled work at the conclusion ofhazardous activities.

n. A procedural step to verify the payload

organization completion of the facility safetyinspection. A procedural step requiring theperformance of a pretest and pretask briefings.The pretest briefing will immediately precedethe beginning of the operational steps of theTechnical Operating Procedure (TOP). Thepretask briefings will precede eachstep/sequence or group of steps within asequence which are hazardous. If a shift changeoccurs prior to the completion of the hazardoustask, then the briefing must be repeated for therelieving employees. Items to be addressed arespecific hazards personnel and equipment will beexposed to, safety protective equipment,emergency alarms, evacuation routes, emergencyinstructions and Emergency Procedures Documents(EPD's), the specific revisions of TOP's to beused, and identification of critical items.

o. Prior to and following each hazardousstep/sequence, section, paragraph, or stepwithin the TOP text introducing a hazardousoperation(s), notes will be inserted similar tothe following:

(1) Prior to:

WARNING

THE FOLLOWING STEPS/SEQUENCES AREHAZARDOUS - INSTALLATION OF CATEGORY AORDNANCE (SPECIFY ALL HAZARDS)

(2) Following:



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NOTE

END OF HAZARDOUS STEPS/SEQUENCES

p. All hazardous operations require the use of the"Buddy System."

q. Identification of those job categories requiringcertification/license for the performance of theTOP task, and procedural step prior to theperformance of hazardous operations ensuringthat personnel are properly certified, equipped,and briefed.

r. A procedural step verifying that a preroutesurvey has been accomplished before transportingGSE and flight hardware where length, height, orwidth may cause interference problems/hazards.

s. A procedural step verifying that a safetywalkdown of the area involving flight hardwareand/or related GSE has been performed prior tothe commencement of any hazardous steps.

t. A procedural step with the task leader verifyingthat personnel participating in a hazardousoperation are equipped, briefed, and ready toproceed.

u. Each integrated/controlling TOP must specifyspecific safety controls which are contained insub-task TOP's/documents.

v. Emergency Instructions. Any TOP, hazardous ornon-hazardous, must have emergency instructionswhen operations directed in the TOP activatesystems/equipment capable of causing personnelinjury or equipment damage if not expeditiouslyshutdown, safed, or secured should a malfunctionoccur (e.g., electrical, pneumatic, hydraulic,propellants or chemicals, lifting/hoisting).During those periods when individual TOP's arein progress, the emergency instruction in theTOP will take precedence for those operationsunder its control; however, the EPD will containemergency instructions for other emergency



45 SW HB S-100August 19, 1999

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situations not under direct control of an activeTOP. Instructions shall:

(1) Contain specific actions necessary to copewith emergency/contingency conditions andidentify the individual directing theactions.

(2) Address hazards unique to the operation and

shall provide steps for rendering safe(e.g., propellant flow shutdown, pressurerelief, safe ordnance, mission/operationabort, etc.) to protect personnel andequipment.

(3) Be located in an appendix and available to

the test team at all times.

5. Covers used on TOP's must be approved by the LSSO andshall meet the following requirements:

a. Covers shall contain a statement that the TOPcontains hazardous operations or does notcontain hazardous operations. The formatting ofthe cover is at the discretion of the payloadorganization; however, the following format issuggested:

(1) In red block letters at least 3/16 incheshigh:

THIS DOCUMENT CONTAINS HAZARDOUS OPERATIONS (2) In black block letters at least 3/16 inches

high:

THIS DOCUMENT DOES NOT CONTAINHAZARDOUS OPERATIONS

b. Emergency TOP's shall be so identified andshould use a distinctive cover, preferably adifferent color.

c. The cover or title page shall contain theapproval signatures as defined by the LSSO,date, and revision number.



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6. TOP's changes/revisions shall be processed asfollows:

a. Formal changes/revisions to existing Category ITOP's shall be reviewed, filed, and approved bythe LSSO in the same manner as the original TOP.

b. Interim changes to existing Category I and IITOP's may be made providing they are made inaccordance with the following:

(1) Whenever there is insufficient time to makea formal change to a previously releasedTOP.

(2) By an approved deviation or other

documentation authorizing interimchange(s).

(3) Change shall be identified (select

applicable term) as follows:

THIS CHANGE (DOES/DOES NOT) INCREASETHE HAZARD LEVEL OF THIS DOCUMENT

c. Interim changes made to TOP's performed at KSCthat add or increase a hazard, are writtenwithin a hazardous sequence, or involve theflight termination system require LSSO approvalfor release and use. Deviations (modifications)prepared when the LSSR is not present can beapproved prior to performance by the LSSR bytelephone, recorded OIS, or safety radio nets.LSSR signature on the deviation sheet is tofollow as soon as possible.

d. A written approved deviation is required forchanges/deviations to any section of a hazardoustechnical operating procedure, including out-of-sequence testing. For emergency or timecritical operations, the test may continue withthe deviation written after the fact providedconcurrences are recorded on the net.

e. Out-of-sequence performance of nonhazardoustests, operations, sequences, or operationalsteps may be accomplished if the out-of-



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sequencing is annotated (along with time, date,and new location in order) in the TOPdesignating concurrence of key test/taskpersonnel. Changes to technical work steps ofCategory I nonhazardous TOP will require awritten, approved deviation.

f. For both hazardous and nonhazardous procedures,the writer may choose to preplan sequences thatcan be performed out of order. By writing theproper notes identifying these preplannedsequences, they may be performed without therequirement to write a deviation.

g. In addition to Paragraph e above, redlinechanges will only be used to correct clericalerrors or make pen-and-ink changes.



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APPENDIX D

ORDNANCE STORAGE AND HANDLINGDATA REQUIREMENTS

Payload Organization:

Item Identification/Name:

Item Manufacturer:

DoD Hazard Classification (Q.D. Class/Division):

DoD/UN Storage Compatibility Group:

DOT Classification:

DOT Markings:

Explosive Weight (Per Item):

Gross Weight (Including Container):

Gross Weight (Less Container):

Storage Container Dimensions (LxWxH):

Hook Height Required:

Quantity Per Container:

Quantity to be Stored:

Environmental Controls (Temp/RH Requirements):

Point of Contact (POC) - Name/Phone:



45 SW HB S-100August 19, 1999

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*APPENDIX E

PAYLOAD RELATED EMERGENCY PROCEDURES DOCUMENTSAND FACILITY SAFETY PLANS

1. Orbiter Processing Facility (OPF), EmergencyProcedures Document (EPD), OMI No. S9904, Rev. J,3 Sep 87

2. NAVSTAR Processing Facility (NPF) Safety Plan,

1 Sep 87 3. Propellant Servicing Facility (PSF) Safety Plan,

Jan 99 4. PGOC Emergency Preparedness Plan, BPY 1009, Rev. K,

May 98 5. USA Ground Safety Operating Procedures, GSOP 5400,

Vol. 1 and Vol. 2, Rev. A, 1 Dec 97

NOTE: The requirements of the above documents will beenforced per latest issue.

* Denotes Change



E-2 of 2

For copies of this document, send request to:

NASAEI-FKennedy Space Center, FL 32899