KSC-DE-512-SM_RevL_Change_5_Latest.pdf

KSC-DE-512-SM

REVISION L, CHANGE 5

National Aeronautics and Space Administration

John F. Kennedy Space Center

KSC FORM 16-12 (REV. 6/95) PREVIOUS EDITIONS ARE OBSOLETE (CG 11/95)

METRIC/INCH-POUND

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FACILITY SYSTEMS, GROUND SUPPORT SYSTEMS,

AND GROUND SUPPORT EQUIPMENT

GENERAL DESIGN REQUIREMENTS

FEBRUARY 29, 2012

CHANGED JULY 20, 2016

ENGINEERING DIRECTORATE

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RECORD OF REVISIONS/CHANGES

REV

LTR

CHANGE

NO. DESCRIPTION DATE

Basic issue. January 1983

A General revision. March 1986

A-1 Added requirements for SCAPE suit operations and EMI compatibility.

February 20, 1987

B General revision. June 1988

B-1 Added requirements for marking of test weights. July 26, 1991

C General revision. March 10, 1993

D Miscellaneous changes. August 5, 1994

D-1 Added requirements for design of facility premises wiring.

December 15, 1994

E Added requirements for instrumentation calibration and quick release pins.

June 1, 1995

F Revised miscellaneous references. August 5, 1996

G Updated miscellaneous references and text. December 18, 1998

H Updated miscellaneous references and text. September 14, H-1 Revised 3.3.3.2.13. May 30, 2002

J Updated miscellaneous references and text.

Incorporated change H-1.

October 15, 2002

K Updated miscellaneous references and text. All pages reformatted.

September 30, L Complete rewrite and align with NASA-STD-5005. February 29, 2012

L-1 Updated reference documents, abbreviations, and terms.

February 28, 2013

L-2 Updated reference documents, abbreviations, and terms.

June 23, 2014

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RECORD OF REVISIONS/CHANGES

REV

LTR

CHANGE

NO. DESCRIPTION DATE

L-3 Permitted the use of cleaning standards that are functionally equivalent to ISO 14952.

July 29, 2014

L-4 1. Updated KSC Directorate from Center Operations to Spaceport Integration and Services in 1.2.g(2).

2. Updated applicable documents in 2.2 and 2.3.

3. Replaced content of 4.2.3.4 with callout of

KNPR 8700.2.

4. Added guidance statement under 4.3.1 to allow use of industry standards for facility-style drawings.

5. Clarified and expanded the exceptions to load testing in 4.6.2.1.

6. Deleted 4.6.2.2 (redundant to 6.4.14) and renumbered subsequent paragraphs.

7. Added allowance for cleaning hydraulic systems to industry standards in 5.2.5.

8. Clarified requirement for structural design of ECS ducting in 5.2.6.

9. Added 5.2.13.3 a. through f. to emphasize requirements for pressure relief devices currently specified in NASA-STD-8719.17.

10. Corrected reference to KNPR 8715.3 section in 5.2.15.

11. Added 5.4.2.1.c and d to clarify welding requirements of superaustenitic stainless-steel tubing.

12. Updated 5.4.4 to allow use of SAE AS fittings.

13. Updated guidance statement in 5.4.21.1.a to clarify use of star washers.

14. Updated 5.6.3 to replace KSC-STD-SF-0004 with MIL-STD-101.

15. Updated 6.3.1.4.2.b to clarify the use of 303 stainless steel.

16. Updated 6.4.14.e to clarify qualification and certification of NDE personnel.

17. Added 6.4.17 for requirement to inspect flex hoses.

18. Updated reference documents in Appendix C.

August 3, 2015

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L-5 1. Deleted NASA-HDBK-1001 from 4.2.4.1 because it has been cancelled, and replaced references to it with NASA-TM-2008- 215633 in all other locations.

2. Inserted paragraph 4.3.3 to add the requirement for Modeling and Simulation, and added NASA-STD-7009 to 2.2, Applicable Documents.

3. Moved KSC-STD-G-0003 in 4.5 from requirement to guidance section.

4. Deleted NPD 8730.2 from guidance section in 4.5 and Appendix C, Reference Documents.

5. Moved KSC-STD-G-0003 from 2.2, Applicable Documents, to Appendix C, Reference Documents.

6. Added 5.2.13.3.d for pressure relief device minimum inlet size required by ASME BPVC and renumbered subsequent paragraphs.

7. Updated 5.4.2.1.c to clarify welding of AL6XN tubing.

8. Clarified 5.4.19.3 for printed circuit boards.

9. Deleted NASA-STD-6002 from 5.6.1.b because it has been cancelled and from 2.2, Applicable Documents.

10. Clarified application of PTCFE in 6.1.b.

11. Clarified use of MAPTIS in 6.2.d.

12. Deleted paragraph 6.3.1.4.2.c because it is redundant to 5.4.2.1.a.

13. Simplified requirements for elastomers in

6.3.1.5.1, and moved information to the guidance statement.

14. Moved MIL-HDBK-149 from 2.2, Applicable Documents, to Appendix C, Reference Documents.

15. Simplified requirements for fungus resistance in 6.3.1.5.7 and moved information to the guidance statement.

16. Clarified soldering requirement in 6.4.3.c.

17. Deleted 6.4.7.a and renumbered subsequent paragraphs.

18. Deleted MSFC-SPEC-445 from 6.4.7 and

2.2, Applicable Documents.

July 20, 2016

Revision L

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FOREWORD

KSC-DE-512-SM establishes overall requirements and best design practices to be used at the John F. Kennedy Space Center (KSC) for the development of ground systems (GS) in support of operations at launch, landing, and retrieval sites. These requirements apply to the design and development of hardware and software for ground support equipment (GSE), ground support systems (GSS), and facility ground support systems (F-GSS) used to support the KSC mission for transportation, receiving, handling, assembly, test, checkout, servicing, and launch of space vehicles and payloads and selected flight hardware items for retrieval.

During the 1950s and early 1960s, the Missile Firing Laboratory (later renamed to the Launch Operations Directorate) was the launch operations arm of Redstone Arsenal and the Army Ballistic Missile Agency. The Missile Firing Laboratory used Army specifications and standards for its design and development of ground systems. KSC’s effort to develop standards began with GP-863, General Criteria for Design of New Equipment and Facilities, which was released in July 1970 and updated three years later. GP-863 focused on operability, reliability, maintainability, useful life, environmental, transportability, human performance, safety, logistics, documentation, and quality assurance. KSC-DE-512-SM, Facility Systems, Ground Support Systems, and Ground Support Equipment, General Design Requirements, replaced GP-863 in 1983. The early revisions of KSC-DE-512-SM contained requirements, along with guidance for accomplishing detailed designs. Later revisions became more formal and the “shall” statement became the phrase to identify each requirement.

This standards manual supplements NASA-STD-5005 by including KSC-site-specific and local-environment requirements. KSC-DE-512-SM is a single, complete document for design and development of KSC ground systems for use at launch, landing, and retrieval sites.

These requirements and practices are optional for equipment used at manufacturing, development, and test sites.

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CONTENTS

1. SCOPE

1.1 Purpose

1.2 Applicability

1.3 Tailoring and Waivers

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government Documents

2.3 Non-Government Documents

2.4 Order of Precedence

3. ACRONYMS, ABBREVIATIONS, AND DEFINITIONS

3.1 Acronyms and Abbreviations

3.2 Definitions

4. GENERAL REQUIREMENTS

4.1 General

4.2 Characteristics

4.2.1 Performance Characteristics

4.2.1.1 GS Designed to Meet Flight Hardware Requirements

4.2.1.2 Ground System Degradation and Contamination

4.2.1.3 GS Design for Access

4.2.1.4 Interfaces

4.2.2 Physical Characteristics

4.2.2.1 Design Life Duration

4.2.2.2 Limited-Life Items

4.2.2.3 Colors

4.2.3 Reliability

4.2.3.1 Redundancy

4.2.3.2 Failure Tolerance

4.2.3.3 Failure Propagation

4.2.3.4 System Safety and Reliability Analysis

4.2.4 Environmental Conditions

4.2.4.1 Natural Environment

4.2.4.2 Launch-Induced Environment

4.2.4.2.1 Launch-Induced Damage

4.2.4.3 Controlled Interior Environment

4.2.4.4 Controlled Clean Environment

4.2.4.5 Uncontrolled Interior Environment

4.2.4.6 Fire/Explosion Hazardproofing

4.2.4.7 Environmental Test Methods

4.2.4.8 Seismic Environment

4.3 Documentation

4.3.1 Drawings and Specifications

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4.3.2 Technical Documentation

4.3.3 Modeling and Simulation

4.4 Logistics

4.4.1 Limited-Life Item Tracking

4.5 Qualification

4.6 Quality Assurance

4.6.1 General

4.6.1.1 Definition of Quality Requirements

4.6.1.2 Personnel Training

4.6.2 Testing

4.6.2.1 Load Test

4.6.2.2 Metrology and Calibration

4.6.3 Quality Conformance Verification

4.7 Packaging, Handling, and Transportation

4.7.1 Shipping and Storage Containers

4.7.2 Parts Protection

5. DESIGN AND CONSTRUCTION REQUIREMENTS

5.1 Structural Design

5.1.1 GS Structures and Equipment

5.1.1.1 Steel Structures

5.1.1.2 Aluminum Structures

5.1.2 Factors of Safety

5.1.3 Structural Design Loads

5.2 Mechanical Design

5.2.1 Pneumatics

5.2.1.1 Breathing-Air Systems

5.2.1.2 Vacuum and Compressed-Air Systems

5.2.2 Cryogenics

5.2.3 Hypergols

5.2.4 Hydrocarbons

5.2.5 Hydraulics

5.2.6 Environmental Control Systems (ECSs) and Environmental Control and Life Support Systems (ECLSSs)

5.2.7 Life Support

5.2.8 Lifting Devices

5.2.9 Threaded Fasteners

5.2.10 Tethering Provisions

5.2.11 Jacks

5.2.12 Transportation Equipment

5.2.12.1 Towed GS

5.2.12.2 Transportation Equipment Interface Loads

5.2.13 Pressure Systems

5.2.13.1 Code-Stamped Vessel Registration

5.2.13.2 Pressure Vessels Used in Transporting Commodities

5.2.13.3 Pressure Relief Devices

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5.2.14 Piping Systems

5.2.15 Pressure Vessel/System Certification

5.2.16 Ground-to-Flight-Vehicle Umbilical Systems

5.3 Electrical/Electronic Design

5.3.1 Electrical Control and Monitor Equipment

5.3.2 Electrical Design of Pneumatic and Hydraulic Components

5.3.3 Pyrotechnic Systems

5.3.4 Electrical Power Systems

5.3.5 Bonding and Grounding

5.3.6 Hazardproofing

5.3.7 Software

5.3.8 Firmware

5.4 Parts

5.4.1 Electrical, Electronic, and Electromechanical (EEE) Parts

5.4.1.1 Electrostatic-Discharge (ESD)-Sensitive Components and Assemblies

5.4.2 Stainless-Steel Tubing

5.4.2.1 Superaustenitic Stainless-Steel Tubing

5.4.3 Pipe

5.4.3.1 Aluminum Pipe

5.4.3.2 Expansion Joints

5.4.4 Metallic Fittings

5.4.5 Fluid System Protective Covers

5.4.6 Fluid System Components

5.4.6.1 Fluid System Component Acceptance Criteria

5.4.7 Electrical-Power Receptacles and Plugs

5.4.8 Electrical-Power Cable

5.4.9 Electrical Cable and Harnesses

5.4.10 Fiber Optics

5.4.11 Electrical Hookup Wire

5.4.12 Connectors

5.4.13 Coaxial Radio Frequency (RF) Connectors

5.4.14 Protective Covers or Caps for Electrical Connectors

5.4.15 Optical Covers or Caps

5.4.16 Sensors and Transducers

5.4.16.1 Sensor and Transducer Acceptance Criteria

5.4.17 Purged Electrical Enclosures

5.4.18 Racks, Panels, and Modular Enclosures

5.4.19 Printed Circuit Boards

5.4.19.1 Printed Circuit Board Design

5.4.19.2 Printed Circuit Board Fabrication and Acceptance

5.4.19.3 Printed Circuit Assembly Fabrication and Acceptance

5.4.20 Electric Motors and Generators

5.4.20.1 Motor Starters and Controllers

5.4.21 GS Fasteners

5.4.21.1 Reuse of Self-Locking Fasteners

5.4.21.2 Liquid-Locking Compounds

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5.5 Electromagnetic Interference (EMI)

5.6 Identification Markings and Labels

5.6.1 Systems and Equipment

5.6.2 Load Test

5.6.3 Piping Systems

5.6.4 Compressed-Gas Cylinders

5.6.5 Load Capacity

5.6.6 Electrical-Cable and Harness Assemblies

5.6.7 Serial Numbers

5.7 Interchangeability

5.8 Safety

5.8.1 Hazard Analysis

5.8.2 Safety Requirements on KSC Property

5.8.3 Safety Requirements on Air Force Property

5.8.4 Safety Requirements on Other NASA Property

5.8.5 Caution and Warning Indications

5.9 Human Factors

5.10 Security of Information Technology (IT)

6. MATERIALS AND PROCESSES REQUIREMENTS

6.1 Material Properties Design Data

6.2 M&P Controls

6.3 Detailed Requirements

6.3.1 Flammability and Compatibility Requirements

6.3.1.1 Flammability Control

6.3.1.2 Electrical-Wire Insulation Materials

6.3.1.3 Fluid Compatibility

6.3.1.3.1 Fluids Other than Oxygen

6.3.1.3.2 Oxygen Systems

6.3.1.4 Metals

6.3.1.4.1 Carbon and Low-Alloy Steel

6.3.1.4.2 Corrosion-Resistant Steel

6.3.1.4.3 Aluminum

6.3.1.4.4 Nickel-Based Alloys

6.3.1.4.5 Titanium

6.3.1.4.6 Copper Alloys

6.3.1.4.7 Beryllium and Beryllium Alloys

6.3.1.4.8 Tin

6.3.1.5 Nonmetals

6.3.1.5.1 Elastomers

6.3.1.5.2 Composite Materials

6.3.1.5.3 Refractory Concrete

6.3.1.5.4 Lubricants

6.3.1.5.5 Limited-Life Materials

6.3.1.5.6 Plastic Film, Foam, and Adhesive Tape (PFA)

6.3.1.5.7 Fungus Resistance

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6.4 Processes

6.4.1 Welding

6.4.1.1 Welding Procedure Qualification

6.4.1.2 Welder/Welding Operator Performance Qualification

6.4.1.3 Weld Classification and Inspection

6.4.2 Brazing

6.4.3 Soldering

6.4.4 Heat Treating and Plating

6.4.5 Forging

6.4.6 Casting

6.4.7 Adhesive Bonding

6.4.8 Fluid System Cleanliness

6.4.9 Crimping

6.4.10 Potting and Molding

6.4.11 Electrical-Cable Design and Fabrication

6.4.12 Conformal Coating

6.4.13 Corrosion Control

6.4.13.1 Stress Corrosion Cracking (SCC)

6.4.14 Nondestructive Evaluation

6.4.15 Hydrogen Embrittlement

6.4.16 Contamination Control

6.4.17 Flex Hose Inspection

APPENDIX A. GROUND SYSTEM IDENTIFICATION SYSTEM COLORS

APPENDIX B. DELIVERABLES

APPENDIX C. REFERENCE DOCUMENTS

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FACILITY SYSTEMS, GROUND SUPPORT SYSTEMS, AND GROUND SUPPORT

EQUIPMENT GENERAL DESIGN REQUIREMENTS

1. SCOPE

1.1 Purpose

KSC-DE-512-SM establishes requirements and guidance for design and fabrication of ground systems (GS) that includes: ground support equipment (GSE), ground support systems (GSS), and facility ground support systems (F-GSS) to provide uniform methods and processes for design and development of robust, safe, reliable, maintainable, supportable, and cost-effective GS in support of space flight and institutional programs and projects. This standard is intended to supplement the minimum requirements of NASA-STD-5005 by applying more stringent, restrictive, or demanding requirements applicable to the specific KSC environment. This standard also provides requirements for GSS and F-GSS because these systems are not covered in NASA-STD-5005.

1.2 Applicability

The applicability of KSC-DE-512-SM relative to other NASA and industry design standards is shown graphically in Figure 1.

a. This standards manual applies to all new GS for programs and projects assigned to

KSC.

b. KSC-DE-512-SM establishes minimum design requirements for ground systems, as defined herein, for NASA programs and projects assigned to KSC. This standards manual is intended to establish uniform engineering best practices and methods in the design, documentation, procurement, fabrication, assembly, test, and installation of ground systems to support KSC operations.

c. This standards manual is required for use by KSC design entities and their support contractors and may be cited in contracts, projects, and other documents as necessary to provide a technical requirement.

d. Rationale and guidance are provided in italic text after the requirement where more definition is needed.

e. The requirements of this standard are optional for hardware used only at manufacturing, development, or test sites but are required for hardware used at launch, landing, and retrieval sites.

f. A program may invoke additional requirements that differ from the requirements stated herein. These requirements will be evaluated and approved for use by the KSC Engineering and Technology Directorate Technical Authority. See KSC-PLN-5400 and paragraph 1.3.

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g. KSC Directorates are responsible to invoke this standards manual for design and development of ground systems. KSC Directorates have responsibilities described as follows:

(1) Engineering and Safety and Mission Assurance (S&MA) have the responsibility to determine categories or types of GS (e.g., critical vs. noncritical) and any additional requirements resulting from these categories or types.

(2) Spaceport Integration and Services, Protective Services, Authority Having Jurisdiction, has the responsibility and authority to define hazardous areas and approve designs that provide equipment to these areas.

h. This standards manual applies to the following ground systems (see paragraph 3.2):

(1) ground support equipment,

(2) ground support systems,

(3) facility ground support systems,

(4) special test equipment, and

(5) modifications to commercial off-the-shelf (i.e., modified off-the-shelf [MOTS]).

i. NASA-STD-5005 may be applied by the governing program for GSE provided by entities other than KSC.

j. This standards manual does not apply to the following:

(1) tools (standard shop),

(2) facilities and utilities (in-house and architect & engineering [A&E] firms), or

(3) commercial off-the-shelf (COTS) equipment.

KSC-DE-512-SM does not cover the design and fabrication of tools, facilities and utilities, and COTS equipment. However, other KSC standards and industry standards may apply to these designs.

k. The Technical Authority determines the classification of equipment listed in paragraphs 1.2.h, 1.2.i, and 1.2.j.

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Vendor

Industry Standards

Tools

GSE Designs Not Managed by KSC

KSC

Institutional

Designs

Ground System Designs

Managed by KSC

NASA-STD-

KSC-DE-

512-SM

NASA, KSC,

and Industry

Standards

Ground Support

Equipment

Ground Support Systems

Facility Ground Support Systems

Facilities and Infrastructure

Systems

Examples

• Commercial Off-the-Shelf

• Torque Wrench

• Voltmeter

• Hand Tools

Examples

• Special Test Equipment used as GSE

• Umbilicals

• Ground Special Power

• Launch Control System

• Fluid and Electrical systems with interfaces to flight hardware

Examples

• Special Test Equipment used as GSS

• Cryogenics storage and distribution

• Pneumatics storage and distribution

• Electrical power and distribution

Examples

• Environmental Control System

• Hypergol scrubber

• Access Platforms

• Pneumatics between facilities

Examples

• Buildings

• HVAC

• 60 Hz Power

• Elevators

• Telephones

• Communications

• Shop air

Figure 1. KSC-DE-512-SM Applicability

1.3 Tailoring and Waivers

Individual provisions of this standards manual should be and are intended to be tailored (i.e., modified or deleted) to meet specific program and project needs. All tailoring shall be evaluated for use by the KSC Engineering Directorate Technical Authority (see KSC-PLN-5400). Waivers to institutional requirements shall follow the process in

KDP-KSC-P-1865.

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2. APPLICABLE DOCUMENTS

2.1 General

The latest issuances of documents listed in this section contain provisions that constitute requirements of this standard as cited in the text.

The applicable documents are accessible via the NASA Standards and Technical Assistance Resource Tool at http://standards.nasa.gov or may be obtained directly from the standards developing organizations or other document distributors.

2.2 Government Documents

Department of Defense

AFSPCMAN 91-710 Range Safety User Requirements Manual, Volume 3, Launch Vehicles, Payloads, and Ground Support Systems Requirements

MIL-DTL-16878 Wire, Electrical, Insulated, General Specification for

MIL-DTL-22992 Connectors, Plugs and Receptacles, Electrical, Waterproof, Quick Disconnect, Heavy Duty Type, General Specification for

MIL-DTL-24308 Connectors, Electric, Rectangular, Nonenvironmental, Miniature, Polarized Shell, Rack and Panel, General Specification for

MIL-DTL-38999 Connectors, Electrical, Circular, Miniature, High Density, Quick Disconnect (Bayonet, Threaded and Breech Coupling), Environment Resistant, Removable Crimp and Hermetic Solder Contacts, General Specification for

MIL-HDBK-17-1 Composite Materials Handbook, Volume 1, Polymer Matrix Composites Guidelines for Characterization of Structural Materials

MIL-HDBK-17-2 Composite Materials Handbook, Volume 2, Polymer Matrix Composites Materials Properties

MIL-HDBK-17-3 Composite Materials Handbook, Volume 3, Polymer Matrix Composites Materials Usage, Design, and Analysis http://standards.nasa.gov/

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MIL-HDBK-17-4 Composite Materials Handbook, Volume 4, Metal Matrix Composites

MIL-HDBK-17-5 Composite Materials Handbook, Volume 5, Ceramic Matrix Composites

MIL-HDBK-263 Electrostatic Discharge Control Handbook for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices) (Metric)

MIL-HDBK-700 Plastics

MIL-HDBK-6870 Inspection Program Requirements, Nondestructive for Aircraft and Missile Materials and Parts

MIL-PRF-39012 Connectors, Coaxial, Radio Frequency, General Specification for

MIL-STD-101 Color Code for Pipelines and for Compressed Gas Cylinders

MIL-STD-202 Test Method Standard, Electronic and Electrical Component Parts

MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems

MIL-STD-810 Environmental Engineering Considerations and Laboratory Tests

MIL-STD-889 Dissimilar Metals

MIL-STD-1686 Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

Federal (FED)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1926 Safety and Health Regulations for Construction

49 CFR 171 through 180 Hazardous Materials Regulations (Department of Transportation)

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HF-STD-001 Human Factors Design Standard (Federal Aviation Administration)

DOT/FAA/AR-MMPDS Metallic Materials Properties Development and Standardization (MMPDS)

NASA

NASA-STD-4003 Electrical Bonding for NASA Launch Vehicles, Spacecraft, Payloads, and Flight Equipment

NASA-STD-5005 Standard for the Design and Fabrication of Ground Support Equipment

NASA-STD-5008 Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment

NASA-STD-5009 Nondestructive Evaluation Requirements for Fracture-Critical Metallic Components

NASA-STD-6001 Flammability, Offgassing, and Compatibility Requirements and Test Procedures

NASA-STD-6002 Applying Data Matrix Identification Symbols on Aerospace Parts

NASA-STD-7009 Standard for Models and Simulations

NASA-STD-8719.9 Standard for Lifting Devices and Equipment

NASA-STD-8719.12 Safety Standard for Explosives, Propellants, and Pyrotechnics

NASA-STD-8719.17 NASA Requirements for Ground-Based Pressure Vessels and Pressurized Systems (PV/S)

NASA-STD-8739.1 Workmanship Standard for Polymeric Application on Electronic Assemblies

NASA-STD-8739.2 Workmanship Standard for Surface Mount Technology

NASA-STD-8739.3 Soldered Electrical Connections

NASA-STD-8739.4 Crimping, Interconnecting Cables, Harnesses, and Wiring

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NASA-STD-8739.5 Fiber Optic Terminations, Cable Assemblies, and Installation

NASA-TM-2008-215633 Terrestrial Environment (Climatic) Criteria Guidelines for Use in Aerospace Vehicle Development

NPR 2810.1 Security of Information Technology

NPR 6000.1 Requirements for Packaging, Handling, and Transportation for Aeronautical and Space Systems, Equipment, and Associated Components

NPR 7150.2 NASA Software Engineering Requirements

NPR 8705.2 Human-Rating Requirements for Space Systems

NPR 8715.3 NASA General Safety Program Requirements

George C. Marshall Space Flight Center (MSFC), NASA

MSFC-STD-3029 Guidelines for the Selection of Metallic Materials for Stress Corrosion Cracking Resistance in Sodium Chloride Environments

John F. Kennedy Space Center (KSC), NASA

120E3100003 Electrical Cable Fabrication Requirements

79K07491 Installation of Purge Hardware

79K80000 Series Fluid Component Specification Drawings

KDP-KSC-P-1865 Institutional Requirement Deviation/Waiver Process

KSC-PLN-5400 Technical Authority and Technical Excellence Implementation Plan

KNPR 8700.2 KSC System Safety and Reliability Analysis Methodology Procedural Requirements

KNPR 8715.3 KSC Safety Practices Procedural Requirements

KNPR 8730.1 KSC Metrology and Calibration Procedural Requirements

KNPR 8730.2 Quality Assurance Procedural Requirement

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KSC-DD-818-TR Summary of Measurements of KSC Launch- Induced Environmental Effects (STS-1 through

STS-11)

KSC-DF-107 Technical Documentation Style Guide

KSC-E-165 Electrical Ground Support Equipment Fabrication, Specification For

KSC-E-166 Electrical Ground Support Equipment, Installation and Assembly, Specification for

KSC-GP-425 Fluid Fitting Engineering Standards

KSC-GP-435 Engineering Drawing Practices, Vol. 1: Aerospace and Ground Support Equipment

KSC-GP-864 Electrical Ground Support Equipment Cable Handbook

KSC-GP-986 Design Criteria for Reusable Space Vehicle Umbilical Systems

KSC-NE-9187 Sensors, Transducers and Signal Conditioning Systems Selection Guidelines

KSC-PLN-5406 Design and Development Electrical, Electronic, and Electromechanical (EEE) Parts Plan

KSC-SPEC-E-0002 Modular Electrical Enclosures, Racks, Consoles, and Accessories, Specification for

KSC-SPEC-P-0012 Refractory Concrete, Specification for

KSC-SPEC-P-0027 Tubing, Steel, Superaustenitic, Corrosion Resistant, UNS N08367 and UNS S31245, Seamed, Bright Annealed, Passivated, Specification for

KSC-SPEC-Z-0007 Tubing, Steel, Corrosion Resistant, Types 304 and 316, Seamless, Annealed, Specification for

KSC-SPEC-Z-0008 Fabrication and Installation of Flared Tube Assemblies and Installation of Fittings and Fitting Assemblies, Specification for

KSC-SPEC-Z-0009 Lubrication, Thread, Corrosion-Resistant Steel and Aluminum Alloy Tube Fittings, Specification for

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KSC-STD-132 Potting and Molding Electrical Cable Assembly Terminations, Standard for

KSC-STD-141 Load Test Identification and Data Marking, Standard for

KSC-STD-164 Environmental Test Methods for Ground Support Equipment, Standard for

KSC-STD-E-0001 Design of Electrical Control and Monitoring Systems, Equipment (GSE), and Panels, Standard for

KSC-STD-E-0002 Hazardproofing of Electrically Energized Equipment, Standard for

KSC-STD-E-0004 Pneumatic and Hydraulic Mechanical Components, Electrical Design, Standard for

KSC-STD-E-0011 Electrical Power Receptacles and Plugs, Standard for

KSC-STD-E-0012 Facility Grounding and Lightning Protection, Standard for

KSC-STD-E-0015 Standard for Marking of Ground Support Equipment

KSC-STD-E-0022 Bonding, Grounding, Shielding, Electromagnetic Interference, Lightning and Transient Protection, Design Requirements for Ground Systems

KSC-STD-P-0006 Quick Release Pins and Pin Tethers, Standard for

KSC-STD-Z-0005 Pneumatic Ground-Support Equipment, Design of, Standard for

KSC-STD-Z-0006 Hypergolic Propellants Ground Support Equipment, Design of, Standard for

KSC-STD-Z-0008 Ground Life Support Systems and Equipment, Design of, Standard for

KSC-STD-Z-0009 Cryogenic Ground Support Equipment, Design of, Standard for

MMA-1985-79 Standard Test Method for Evaluating Triboelectric Charge Generation and Decay

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2.3 Non-Government Documents

Aerospace Industries Association (AIA)/National Aerospace Standards (NAS)

AIA/NAS 410 NAS Certification and Qualification of Nondestructive Test Personnel

Aluminum Association (AA)

ADM Aluminum Design Manual

American Institute of Steel Construction (AISC)

AISC 325 Steel Construction Manual

American National Standards Institute (ANSI)

ANSI C18.2M Part 1 American National Standard for Portable Rechargeable Cells and Batteries – General and Specifications

ANSI C18.3M Part 1 American National Standard for Portable Lithium Primary Cells and Batteries – General and Specifications

American Society for Testing and Materials (ASTM)

ASTM A123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A312 Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A325 Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A380 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A490 Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

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ASTM A653 Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM A780 Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM A967 Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts

ASTM B241 Standard Specification for Aluminum and Aluminum-Alloy Seamless Pipe and Seamless Extruded Tube

ASTM D7194 Standard Specification for Aerospace Parts Machined from Polychlorotrifluoroethylene

(PCTFE)

ASTM E1417 Standard Practice for Liquid Penetrant Testing

ASTM E1444 Standard Practice for Magnetic Particle Testing

ASTM E1548 Standard Practice for Preparation of Aerospace Contamination Control Plans

ASTM E1742 Standard Practice for Radiographic Examination

ASTM E2217 Standard Practice for Design and Construction of Aerospace Cleanrooms and Contamination Controlled Areas

ASTM E2375 Standard Practice for Ultrasonic Testing of Wrought Products

ASTM MNL 36 Safe Use of Oxygen and Oxygen Systems:

Handbook for Design, Operation, and Maintenance

American Society of Civil Engineers (ASCE)

ASCE-7 Minimum Design Loads for Buildings and Other Structures

American Society of Heating, Refrigeration, and Air-Conditioning Engineers (ASHRAE)

ASHRAE Handbook—Fundamentals

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American Society of Mechanical Engineers (ASME)

ASME BPVC-VIII ASME Boiler & Pressure Vessel Code, Section VIII, Division 1: Rules for Construction of Pressure Vessels, Division 2: Alternative Rules, Division 3:

Alternative Rules

ASME BPVC-X ASME Boiler & Pressure Vessel Code, Section X, Fiber-Reinforced Plastic Pressure Vessels

ASME Y14.100 Engineering Drawing Practices

ASME B30.1 Jacks, Industrial Rollers, Air Casters, and Hydraulic Gantries

ASME B31.3 Process Piping

ASME B31.8 Gas Transmission and Distribution Piping Systems

ASME B31.9 Building Services Piping

American Welding Society (AWS)

AWS C3.2M/C3.2 Standard Method for Evaluating the Strength of Brazed Joints

AWS C3.4M/C3.4 Specification for Torch Brazing

AWS C3.5M/C3.5 Specification for Induction Brazing

AWS C3.6M/C3.6 Specification for Furnace Brazing

AWS C3.7M/C3.7 Specification for Aluminum Brazing

AWS D17.1/D17.1M Specification for Fusion Welding of Aerospace Applications

Compressed Gas Association (CGA)

CGA C-7 Guide to the Preparation of Precautionary Labeling and Marking of Compressed Gas Containers

ESD Association

ESD S20.20 For the Development of an Electrostatic Discharge Control Program for – Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

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International Electrotechnical Commission

IEC 60807 Rectangular Connectors for Frequencies Below 3 MHz

International Organization for Standardization

ISO 14952 Space systems — Surface cleanliness of fluid systems — Parts 1 through 6

IPC – Association Connecting Electronics Industries

IPC-2221 Generic Standard on Printed Board Design

IPC-2222 Sectional Design Standard for Rigid Organic Printed Boards

IPC-2223 Sectional Design Standard for Flexible Printed Boards

IPC-2252 Design Guide for RF/Microwave Circuit Boards

IPC-6011 Generic Performance Specification for Printed Boards

IPC-6012 Qualification and Performance Specification for Rigid Printed Boards

IPC-6013 Qualification and Performance Specification for Flexible Printed Boards

IPC-6018 Microwave End Product Board Inspection and Test

IPC J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies, Performance Class 3

IPC J-STD-001(S) Space Applications Electronic Hardware Addendum to IPC J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies

National Fire Protection Association (NFPA)

NFPA 59A Standard for the Production, Storage, and Handling of Liquefied Natural Gas (LNG)

NFPA 70 National Electrical Code

NFPA 70E Standard for Electrical Safety in the Workplace

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NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical Equipment

Sheet Metal and Air Conditioning Contractors’ National Association (SMACNA)

SMACNA 1958 HVAC Systems Duct Design

Society of Automotive Engineers (SAE)

SAE AMS-DTL-23053/5 Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Flexible, Crosslinked

SAE AMS 2175 Castings, Classification and Inspection of

SAE AMS 2403 Plating, Nickel, General Purpose

SAE AMS 2404 Plating, Electroless Nickel

SAE AMS 2423 Plating, Nickel Hard Deposit

SAE AMS 2460 Chromium Plating

SAE AMS 2488 Anodic Treatment – Titanium and Titanium Alloys Solution pH 13 or Higher

SAE AMS 2647 Fluorescent Penetrant Inspection Aircraft and Engine Component Maintenance

SAE AMS 2759 Heat Treatment of Steel Parts, General Requirements

SAE AMS 2759/9 Hydrogen Embrittlement Relief (Baking) of Steel Parts

SAE AMS 2770 Heat Treatment of Wrought Aluminum Alloy Parts

SAE AMS 2771 Heat Treatment of Aluminum Alloy Castings

SAE AMS 2772 Heat Treatment of Aluminum Alloy Raw Materials

SAE AMS 2774 Heat Treatment Wrought Nickel Alloy and Cobalt Alloy Parts

SAE AMS-H-6875 Heat Treatment of Steel Raw Materials

SAE AMS-H-81200 Heat Treatment of Titanium and Titanium Alloys

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SAE AMS-QQ-P-416 Plating, Cadmium (Electrodeposited)

SAE AMS-STD-2154 Inspection, Ultrasonic, Wrought Metals, Process for

SAE ARP 1247 Aerospace Ground Support Equipment – General Requirements

SAE ARP 1658 Hose Assemblies, Installed, Visual Inspection Guide for

SAE ARP 4402 Eddy Current Inspection of Open Fastener Holes in Aluminum Aircraft Structure

SAE AS 4787 Eddy Current Inspection of Circular Holes in Nonferrous Metallic Aircraft Engine Hardware

SAE AS 5942 Marking of Electrical Insulating Materials

SAE AS 8090 Mobility, Towed Aerospace Ground Equipment, General Requirements for

SAE AS 22759 Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy

SAE AS 50151 Connectors, Electrical, Circular Threaded, AN Type, General Specification for

SAE AS 50861 Wire, Electric, Polyvinyl Chloride Insulated, Copper or Copper Alloy

2.4 Order of Precedence

This standard establishes requirements and guidance for design and fabrication of KSC ground systems (GSE, GSS, and F-GSS), but does not supersede or waive established Agency requirements found in other documentation. Conflicts between this standard and applicable documents cited herein shall be resolved by the responsible Technical Authorities.

3. ACRONYMS, ABBREVIATIONS, AND DEFINITIONS

3.1 Acronyms and Abbreviations

°C degrees Celsius °F degrees Fahrenheit A-50 aerozine 50 AA Aluminum Association AC alternating current ADM Aluminum Design Manual AFSPCMAN Air Force Space Command Manual

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AIA Aerospace Industries Association AIAA American Institute of Aeronautics and Astronautics AISC American Institute of Steel Construction AMS Aerospace Material Specification ANSI American National Standards Institute ARP Aerospace Recommended Practice AS Aerospace Standard ASCE American Society of Civil Engineers ASHRAE American Society of Heating, Refrigeration, and Air-Conditioning

Engineers ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials AWS American Welding Society BPVC Boiler and Pressure Vessel Code CFR Code of Federal Regulations CGA Compressed Gas Association CIL Critical Items List COPV Composite Overwrapped Pressure Vessel COTS commercial off-the-shelf DE design DOT Department of Transportation DTL detail ECS Environmental Control System ECLSS Environmental Control and Life Support System ECA Electronic Components, Assemblies & Materials Association ECS Environmental Control System EEE electrical, electronic, and electromechanical e.g. for example EIA Electronic Industries Association EMI electromagnetic interference EPS Electrical Power System ESD electrostatic discharge ETFE ethylene tetrafluoroethylene FAA Federal Aviation Administration FED Federal F-GSS facility ground support system FMEA Failure Mode and Effects Analysis FOD foreign-object debris GO2 gaseous oxygen GP general publication (KSC) GS ground system GSE ground support equipment GSS ground support system HDBK handbook HVAC heating, ventilation, and air conditioning Hz hertz

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ICD interface control document i.e. that is IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers in inch IPC Association Connecting Electronics Industries ISO International Organization for Standardization IT information technology JSC Lyndon B. Johnson Space Center kPa kilopascal KSC John F. Kennedy Space Center ksi one thousand pounds per square inch KTI Kennedy Technical Instruction LNG liquefied natural gas M&P materials and processes MAPTIS Materials and Processes Technical Information System MHz megahertz MIL military mm millimeter MMA Malfunction/Materials Analysis MMH monomethylhydrazine MMPDS Metallic Materials Properties Development and Standardization MNL manual MPa megapascal MSFC George C. Marshall Space Flight Center N4H4 hydrazine N2O4 nitrogen tetroxide NAS National Aerospace Standards NASA National Aeronautics and Space Administration NDE nondestructive evaluation NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association NPD NASA Policy Directive NPR NASA Procedural Requirements NSS NASA Safety Standard OSHA Occupational Safety and Health Administration PCTFE polychlorotrifluoroethylene PFA plastic film, foam, and adhesive tape pH potential of hydrogen PHE propellant handler’s ensemble PPE personal protective equipment PQR procedure qualification record PRF performance specification psi pound per square inch psia pound per square inch absolute PTFE polytetrafluoroethylene

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PV/S pressure vessels and pressurized systems QD quick disconnect RF radio frequency RH relative humidity RP reference publication S&MA Safety and Mission Assurance SAA Systems Assurance Analysis SAE Society of Automotive Engineers SCC stress corrosion cracking SMACNA Sheet Metal and Air Conditioning Contractors’ National

Association SPEC specification SSP Space Shuttle Program STD standard TM technical memorandum TP technical procedure UDMH unsymmetrical dimethylhydrazine UNS Unified Numbering System UTS ultimate tensile strength

vs. versus WPQ welder/welding operator performance qualification WPS welding procedure specification

3.2 Definitions

analysis: use of calculations, numerical simulations, tools, techniques, and physics/engineering-based modeling to determine that the requirement is satisfied.

Rationale: Engineering analysis proceeds by separating the engineering design into the components and disciplines, analyzing, or estimating each component of the operation or failure mechanism separately, and recombining the components in accordance with physics and engineering principles. The methods selected must be supported by appropriate technical rationale and be documented in detail.

catastrophic: a level beyond critical, resulting in loss of life, loss of flight vehicle, or loss of a major ground asset.

commercial off-the-shelf (COTS): equipment, including hardware and associated software/procedures, that is commercially available from the industrial inventory at the time of purchase.

Rationale: Commercial items or components should be used when they satisfy the ground systems function and will not degrade the safety or reliability of the ground or flight system. Requirements should be specified in terms of functionality or performance rather than design. To qualify as COTS, equipment must not be modified (see modified off-the-shelf [MOTS]).

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conventional structures: structures composed predominately of standard structural shapes and connections typical of commercial or residential construction, such as office buildings, warehouses, machine shops, and other facilities whose structures are characterized by well-established design precedents and loading conditions.

corrosive environment: a marine (sea coast) or launch-induced environment that causes degradation of materials due to oxidation or chemical reaction.

Rationale: In the corrosive marine (sea coast) environment at KSC, the most common sources of corrosion are moisture and sodium chloride. The launch-induced environment also introduces hydrochloric acid, which exacerbates the corrosive effects of the marine environment.

critical ground system: a system whose loss of function or improper performance could result in serious injury, damage to flight hardware, loss of mission, or major damage to a significant ground asset.

critical: loss of function or improper performance could result in serious injury, damage to flight hardware, loss of mission, or major damage to a significant ground asset.

criticality: a program-defined measure of the consequences of a failure mode.

Rationale: Criticality of a ground system (GS) is determined by a Safety and Mission Assurance study analysis of the function and application of the equipment. The classifications assigned to the GS will guide the design team in determining which specifications and standards to apply, which materials to select, and how to document the

GS.

demonstration: a verification method that determines the properties on an end item by observation of its operation. This method is generally employed where qualitative operational performance is to be verified. A demonstration must be witnessed and documented.

design life: the operational life of equipment (to include storage life, installed life in a nonoperating mode, and operational service life), after which the equipment will be replaced or recertified. It is the responsibility of the program/project to determine recertification requirements, which may include refurbishment, analysis, or test.

facility: land, buildings, structures, and other real property improvements, including facility systems (utility systems and collateral equipment). Facility systems include heating, ventilation, and air conditioning (HVAC); 60-hertz (Hz) power; potable water; elevators; lighting; shop air;

etc. Facility systems may support or have interfaces with ground systems. The term facility does not include ground support equipment, ground support systems, facility ground support systems, tools, or special test equipment.

facility ground support system (F-GSS): fixed infrastructure and equipment (not including utility systems and collateral equipment) that provides functional or physical support to GSS or

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GSE. F-GSS are specialized systems that are designed, built, and tested to more stringent requirements than conventional facilities and their integral facility systems.

Rationale: F-GSS includes fixed environmental control systems (ECS), breathing air systems, long-run piping systems, high-pressure gases, liquid hydrogen (LH2) and liquid oxygen (LO2) storage spheres, etc. The requirements for F-GSS and GSS are the same, and the distinction between the two is not always clear. The important distinction is between F-GSS and conventional facility systems. Conventional facility systems are not covered by this standard.

factor of safety: a constant that has been defined for yield and ultimate design criteria and that is the ratio of the yield or ultimate design loads to the limit load (the maximum allowable design load). If the factor of safety is defined in terms of stress, it is the ratio of the ultimate or yield stress to the maximum design stress. In fatigue design, it is the ratio of the calculated fatigue life to the allowable design life. This standards manual specifies the minimum factor of safety for GS for specific structural applications (e.g., pressure vessels, threaded fasteners, and aluminum structures).

Rationale: This definition is consistent between ground and flight hardware. This definition is inherently load-based. It reduces to the traditional stress-based definition in the simplest case.

flight hardware: hardware intended for launch into space, including boosters, engines, payloads, and manned or unmanned components.

fracture-critical: classification of hardware where a crack could lead to a failure that results in serious injury, damage to flight hardware, loss of mission, or major damage to a significant ground asset.

ground support equipment (GSE): nonflight equipment, systems, or devices specifically designed and developed for a direct physical or functional interface with flight hardware.

Rationale: Equipment used during the manufacturing of flight hardware is not considered to be GSE. Each program defines when manufacturing ends and processing of the flight hardware begins. If manufacturing equipment is to be used after flight hardware processing begins, it must be designed to meet GSE requirements. GSE does not include tools that are designed for general use and not specifically for use on flight hardware.

ground support system (GSS): equipment or infrastructure (portable or fixed) that provides functional or physical support to GSE. It does not directly interface with flight hardware, although it may supply commodities, power, or data that eventually reaches the flight hardware after being conditioned or controlled by GSE.

Rationale: Design standards for GSS may be similar to or, at the discretion of the program/project, identical to the design standards for GSE. Protective features designed into the GSE prevent failures from propagating to flight hardware.

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ground systems (GS): ground support equipment, ground support systems, and facility ground support systems.

inspection: measurement or examination of one or more characteristics of a product or service and comparison with specified requirements to determine conformity.

limited-life item: equipment or component that degrades due to operating time, cycling, or material aging and that has a shorter lifetime than the system’s design life. Limited-life items require periodic replacement or refurbishment, which must be defined in design and maintenance documents.

modified off-the-shelf (MOTS): commercially available equipment, including hardware and associated software and procedures, modified in accordance with this document for a specific application in GS.

Rationale: Modification of COTS voids the design intent of the original equipment and places responsibility for performance, functionality, and reliability on the designer.

nonconventional structures: structures that are experimental, specific to a space program, or if any of the following apply:

1. Structural members and connections are predominately atypical to commercial or residential construction.

2. The structure supports or provides direct access to flight hardware (e.g., test stands, launch complexes, access platforms in operational or research facilities, towers, and similar special-purpose facilities).

3. Structures are characterized by unusual or inadequately defined loading conditions (launch acoustics, vibration, rocket exhaust, etc.), a lack of established design precedent, or frequent modifications to support changes in the operational requirements.

Rationale: The transition between conventional and nonconventional is the interface between the structure specifically designed for processing and vehicle access and the generic building structure whose purpose is the physical support of the overall facility.

The transition region between conventional and nonconventional structures should be designed to meet the criteria for both types of structure.

safe working load: the maximum assigned load the device or equipment can operationally handle and maintain. This value is marked on the device indicating maximum working capacity.

This is also the load referred to as “rated load” or “working load limit.” If the device has never been downrated or uprated, this also is the “manufacturer’s rated load.”

special test equipment (STE): equipment designed for limited or one-time use in a variety of applications. STE is classified as GSE or GSS and designed to the requirements of this standards manual.

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Rationale: Although its use is limited, STE has the potential to cause damage to flight hardware or injury to personnel. STE includes equipment traditionally known as shop aids.

testing: an activity that determines an item’s ability to meet specified requirements by subjecting the item to a set of physical, chemical, environmental, or operating actions and conditions. It includes measurements taken with certified and calibrated tools in accordance with generally accepted scientific or engineering principles.

tools: equipment designed for general use in a variety of applications. Tools are calibrated, when necessary, in accordance with industry standards.

Rationale: Tools are not designed to specifically interface with flight hardware, nor are they designed to perform a function specific to flight hardware. Their design and general use in industry includes a variety of applications that may be required on flight hardware or GSE. Tools are intended for use by trained technicians and facilitate manual operations, such as torquing fasteners, cutting wire, checking electrical continuity, and verifying surface clearances.