RZ-W_OI_61-103.pdf

BY ORDER OF COMMANDER AFRL/RZ-West OPERATING INSTRUCTION 61-103

OF AIR FORCE RESEARCH LABORATORY (AFRL)

23 August 2011 Scientific/Research and Development

AFRL/ RZ-West Test Management

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for downloading through Livelink at https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/PR_OIs

RELEASEABILITY: There are no releaseability restrictions on this publication.

OPR: AFRL/RZSO Certified by: AFRL/RZS

(Mr. Mike Huggins) Supersedes AFRL/RZ West OI 61-103, 1 July 10 Pages: 21

This Operating Instruction (OI) implements Air Force Instruction (AFI) 99-103, Capabilities Based Test and Evaluation and AFRLI 61-103, AFRL Research Test Management. It provides mandatory procedures for test operations at the Air Force Research Laboratory Propulsion Directorate (AFRL/RZ) at Edwards Research Laboratory (RZ-W). It applies to all RZ-W military and civilian personnel as well as on-site contractors. References: AFI 91-202, U.S. Air Force Mishap Prevention Program; AFRL/RZ-W OI 91-202, Environmental, Safety, and Occupational Health (ESOH) Programs. Refer recommended changes and questions about this publication to the Office of Primary Responsibility (OPR) using the AF IMT 847, Recommendation for Change of Publication; route AF IMT 847s from the field through the appropriate functional chain of command. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with AFMAN 33-363, Management of Records, and disposed of in accordance with the Air Force Records Disposition Schedule (RDS) located at https://www.my.af.mil/afrims/afrims/afrims/rims.cfm. The use of the name or mark of any specific manufacturer, commercial product, commodity, or service in this publication does not imply endorsement by the Air Force.

Test activities requiring an RZ-W Form 27, Experimental/Test Operation Safety Permit shall comply with this instruction (Ref AFRL/RZ-W OI 91-202, Chap 13). Basic research processes (laboratory and bench scale testing) requiring an AFRL/RZ-W Form 5, Laboratory Safety Permit, (Ref AFRL/RZ-W OI 91-202, Chap 14) are not required to comply with this instruction.

SUMMARY OF CHANGES

This publication has undergone administrative changes.

https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/PR_OIs� https://www.my.af.mil/afrims/afrims/afrims/rims.cfm�

RZ- W OI 61-103, 23 August 2011

TABLE OF CONTENTS

Section 1 – Purpose and Implementation………………………………………………………...3

Section 2 – Responsibilities…………………………………………………………...…………3

Section 3 – Scope……………………………………………...…………………………………5

Section 4 – Concept Discussions…………………………….......………………………………5

Section 5 – Cost Estimating……………………………………...………………………………5

Section 6 – Authority to Proceed…………………………………….….…….…………………5

Section 7 – Kickoff/Concept Program Overview.…………....………………………………….6

Section 8 – Detailed Requirements Planning…………………………………………………….6

Section 9 – Design………………………………………………………………………………..8

Section 10 – Documentation and Procedures Creation…………………………………………..8

Section 11 –Review Board………………….……………………………………………………10

Section 12 – Facility and/or Special Test Equipment (STE) Buildup………………..…….……11

Section 13 –System Verification and Validation………………………………..………………11

Section 14 –System Readiness Reviews (SRR)………….………………………….…………..11

Section 15 –Facility Verification and Validation………………………………..………………11

Section 16 –Facility Readiness Reviews (FRR)………….………………………….………….12

Section 17 – Test Verification and Validation…………………………………………………..12

Section 18 - Combined System Test (CST).……….…………………….………….…………..12

Section 19 – Test Readiness Review (TRR)…………………………………………………….13

Section 20 – Post Test Activity………………………………………………………………….13

Section 21 – Mishap Notification……………………………………….……………………….14

Section 22 – Test Management Team……………………………….…….…….………………14

Section 23 – Cleanup and Disposal………………………………………………..….…………14

Section 24 – Project Completion or Termination.……………………………………………….14

Section 25 – Forms………………………………………………………………………………15

APPENDICIES

Appendix 1 – Acronym List………………………………………………………………….…16

Appendix 2 – Research and Development Test Operations and Safety Process…….…..…..…18

Appendix 3 – Verification and Validation…………………………………………….….…….19

Appendix 4 – Liquid Rocket Engine Test Verification and Validation………………….……..20

Appendix 5 – Solid Rocket Motor Test Verification and Validation…………….……………..21

RZ-W OI 61-103, 23 August 2011

1.0. PURPOSE AND IMPLEMENTATION:

1.1. In order to demonstrate rocket propulsion technologies, experiments on rocket propulsion systems and components must be conducted. The primary functions of these experiments are to gather data or demonstrate effective and suitable systems, and to identify and resolve deficiencies as early as possible.

1.2. Test planners will make facility selection in accordance with AFI 99-103.

2.0. RESPONSIBILITIES:

2.1. The Chief, Space and Missile Propulsion Division is responsible to ensure that the configuration and operation of the experimental facilities is managed so that the test and evaluation mission can be met.

2.2. The Chief, Experimental Demonstration Branch (AFRL/RZSO) is directly responsible for managing and administrating the research and development test operation programs. The AFRL/RZSO Chief is advisor for the AFRL/RZ management and the focal point for all test operation concerns and appointed as the AFRL/RZ-W Test Lead.

2.3. AF Functional Managers, Division and Branch Chiefs, are responsible for implementing the research and development test operations program and standards in their areas of functional responsibility. They will ensure that all assigned personnel are adequately trained and equipped to perform their assigned duties. They will develop and maintain area-specific job training outlines and maintain training documentation.

2.4. AF Employees are responsible for understanding and observing applicable standards that apply to their jobs.

2.5. On-site Contractors must comply with provisions in this operating instruction.

This operating instruction does not relieve contractor employees from compliance with federal, DoD, Air Force, and local regulations and instructions.

2.6. The Air Force Program Manager (PM) is responsible for the program requirements, cost, and schedule as well as responsibilities assigned through AFRLI 61- 103 (para 2.8) and higher regulations. The PM is the primary customer interface. The PM is responsible for coordinating with all support organization necessary for operations.

The program manager and test director shall not be the same person.

2.7. The Test Director (TD) is responsible for the facility operation and performance, test team safety, crew readiness, and associated resources. The test director is responsible for making sure the facility meets the test requirements. The test director is appointed by the responsible branch chiefs, from the pool of highly experienced test conductors. The test director is a qualified test conductor for the program.

2.8. The Test Conductor (TC) is the leader of the test crew and responsible for conducting all test activities, including test data, video, pre-test preparations, etc. The test conductor directs the step-by-step performance of the test. The test conductor is appointed by the responsible branch chiefs, from the pool of qualified test conductors.

The test conductor has full control room authority. Test conductor is an operation day role, meaning a single program may have multiple qualified test conductors in addition to the test director.

2.9. Test Article Director (TAD) is responsible for the test article. This role is usually performed by the customer. The TAD indicates what work must be performed on the test article, the preferred manner and sequence in which it is to be performed, and is responsible for all work performed on the test article itself. TAD is appointed by the customer’s company management, if required.

2.10. AFRL/Det 7 Chief of Safety responsibilities are defined in AFRL/RZ-W OI 91- 202, Environmental, Safety, and Occupational Health (ESOH) Program. The AFRL/Det 7 Chief of Safety assigns an SRB Chairperson.

2.11. Customer is the organization that has a requirement for testing.

2.12. AFRL/RZ-W Munitions Control Officer will complete the AFRL/RZ-W Form 21 and other duties as identified in AFRL/RZ-W OI 21-201, Munitions Customer Support.

2.13. Red Crew Members are technicians who perform explosive and hazardous operations.

2.14. Red Crew Leader (RCL) is the lead of the red crew member. The red crew leader is responsible for all personnel that enter the red area during explosive and hazardous operations.

2.15. Test Crew is defined as the personnel that have active steps to perform as part of the test procedures.

2.16. Test Team is defined as all personnel involved with the test. On test day the test team consists of the test crew and support personnel (customers, QA, Safety, management, engineering, etc.)

2.17. Control Room Monitor. Not all programs will have a control room monitor and the control room monitor’s duties very based on program requirements and facility layout. If required, the Test Director will appoint the control room monitor and define their duties.

3.0. SCOPE. This guidance applies to all AFRL research test activities, including experiments and demonstrations that involve AFRL assets (full or partial ownership) or AFRL personnel (government, military and contractors), or where AFRL either holds mishap accountability or some level of liability. This guidance also applies to all tests executed by organizations under contract to AFRL where AFRL holds either mishap accountability or some level of liability. A flowchart of the Test Operations and Safety Process is provided in Attachment 2.

4.0. CONCEPT DISCUSSION. Typically concept discussion is customer driven. The customer approaches AFRL/RZS with a proposal for testing at AFRL. The customer and AFRL/RZS will formulate a conceptual approach. Concepts shall include enough detail to allow AFRL/RZS to provide a “reasonable” conceptual cost estimate including: test article description, operating parameters, conceptual design, number of tests, conceptual test plan, risk reduction, data and instrumentation requirements.

5.0. COST ESTIMATING. Customer submits a formal or informal RFQ or RFP if a detailed approach is requested, triggering AFRL/RZS to evaluate the requested scope, which typically includes an initial assessment of program risk & impact to ongoing effort.

6.0. AUTHORITY TO PROCEED. The program manager is responsible for making sure the appropriate documents are in place to start a program. These documents shall include an AFRL Form 4 and could include a Memorandum of Agreement (MOA), Memorandum of Understanding (MOU), Commercial Test Agreement (CTA), Cooperative Research and Development Agreement (CRDA), Test Requirements Document (TRD), In-House Program Summary/Lab Management Review (LMR) or Statement of Work (SOW). An active JON is the end result of this step.

6.1. AFRL Form 4, Initial Safety Risk Assessment. The PM will fill out the AFRL Form 4 and submit it to the System Safety Manager. A copy of the completed AFRL Form 4 must be filed in the program folder by the program manager.

6.2. Memorandum of Agreement (MOA) or Memorandum of Understanding (MOU). This is a document signed by authorized representatives of organizations that are working together, such as another government agency and AFRL/RZS. The agreement establishes the organizational relationship and responsibilities, and mishap accountability. Prepare a MOA or MOU for test activities with test organizations that are not associated with AFRL/RZ. An MOA is the preferred for use at AFRL Edwards.

Memorandum of Understanding/Memorandum of Agreement RZ OI 61-8 provides more details.

6.3. Commercial Test Agreement (CTA). Commercial Test Agreements (CTA) is entered into pursuant to the provisions of 10 USC 2539b which allows government laboratories to do work for commercial customers. The agreement establishes the organizational relationship and responsibilities, and mishap accountability.

Implementing guidance is contained in the DoD Financial Management Regulation, Chap

14. There are several restrictions, the government cannot compete with the private sector, fees must be paid in advance of work, and there are also specific warranty and liability provisions.

6.4. Cooperative Research and Development Agreement (CRDA). The CRDA is an agreement between one or more federal laboratories and/or nonfederal organizations including private companies, universities, other state and local governments, other public and nonprofit organizations, etc. The CRDA allows the nonfederal organizations to contribute resources including personnel, facilities, intellectual property, and funding while the federal organization can contribute all of the above except funding. The agreement establishes the organizational relationship and responsibilities, and mishap accountability between AFRL/RZ and nonfederal organization.

6.5. Test Requirements Document (TRD). This is a document signed by authorized representatives of organizations that are working together when the funding is coming from another government agency, but the technical requirements are coming from an outside organization. For example another government agency is funding a commercial customer and AFRL/RZSO to perform a test. The agreement establishes the organizational relationship and responsibilities, and mishap accountability between AFRL/RZ and the contractor organization.

6.6. In-House Program Summary/Lab Management Review (LMR). This is the document used to approve in-house research. This document describes the corporate resources required to include manpower, facility utilization, and the peak power requirements. RZ OI 61-2, In-house Research Program Management and In-house Project of the Quarter, describes the in-house program management process and RZ OI 61-202, Lab Management Review (LMR), describes the LMR process in more detail.

6.7. Statement of Work (SOW). This is a document created by organizations that are working together, such as another government agency and AFRL/RZS. The agreement establishes the scope of work to be performed by AFRL, and shall include mishap accountability.

7.0. KICK-OFF/CONCEPT PROGRAM OVERVIEW. Upon receipt of authority to proceed, the program manager will give a kick-off/concept program overview briefing. The following will be invited customer, responsible test organization, safety, bioenvironmental, environmental, fire department, quality assurance, civil engineering, and support contractor(s).

8.0. DETAILED REQUIREMENTS PLANNING. The documents that will be used throughout the program will be listed in the Implementation Plan. Common requirements documents used at AFRL are:

8.1. Implementation Plans. The implementation plan is used to tailor the test strategies and plans to the specific test program. The implementation plan defines the documentation (FRD, ICD, etc), reviews, processes (including in-process QA, if required), and associated levels of detail required commensurate with the complexity, cost and risk of the program. The program manager is responsible for putting together an implementation plan with the assistance of the test director. The program manager presents the implementation plan to the AFRL/RZ-W Test Lead. Major revisions to the implementation plan will be presented to the AFRL/RZ-W Test Lead.

8.2. Facilities Requirements Document (FRD). This document defines the requirements to direct the design and build-up of a facility. The program manager with the assistance of the test director put together a FRD. The program manager, customer, and test director approve the FRD.

8.3. Interface Control Document (ICD). This document defines the mechanical, operational, electrical, hydraulic, pneumatic, and instrumentation and control interface characteristics to be controlled on the test program. Information within the ICD pertains to interfaces between the test article and test facility. The program manager and customer with the assistance of the test director put together the ICD. The program manager, customer, and test director approve the ICD.

8.4. AFRL Test Safety Plan. The Safety Plan is used to assist the program manager in identifying safety documentation required to perform an experimental test. The System Safety Engineering representative with the assistance of the test director or program manager puts together a test safety plan (See AFRL/RZ-W OI 91-202, Environmental, Safety, and Occupational Health (ESOH) Programs).

8.5. Test Plan. This document details the test requirements. The customer is responsible for providing this document. The program manager, test director, and test conductor are responsible for verifying the requirements in the test plan are met. The program manager, customer, and test director approve the Test Plan.

8.6. Verification and Validation Plan (V&V Plan). The V&V Plan lists all the inspections, testing, analysis, and demonstrations that need to be performed to meet facility and test requirements. The implementation of the V&V plan is performed in two or three parts: the system verification and validation prior to SRR, if required, the facility verification and validation prior to FRR, and the test verification and validation prior to TRR. The V&V plan will be tailored to meet the test program requirements.

Requirements come from FRDs, ICDs, test plans, TMDE, codes, regulations, best practices, etc. Reference attachment 3. Once the design is approved the V&V Plan is revised to reflect the final design and then presented to the TRB. The test director is responsible for putting together a V&V plan with the assistance of the program manager and test conductor. The total focus of the Verification and Validation plan is to reduce technical risk and the TRB will evaluate the veracity of this plan.

9.0. DESIGN:

9.1. Conceptual design is completed at the time that the first schematic of the system is agreed to by the test team in section 4.0 and 5.0. An estimate of cost is also produced at this time and becomes the basis for gaining funding approval. It will be difficult to increase the funds over the conceptual cost estimate. Percent completion of design is approximately 5%.

9.2. Preliminary design concluded by a preliminary design review. A detailed project schedule, an initial drawing list, an initial component list and an initial instrumentation list are required. Upon approval of a preliminary design, and based on funding availability, the program can proceed with long lead procurements, negotiations with potential sub-contractors, proceed to final or critical design review, etc.

9.3. Depending upon the complexity and scope of the project there may be periodic additional design reviews.

9.4. Documents that are affected during the design process must be updated to include changes that are generated during the design process.

9.5. The TRB/SRB will review the final or critical design and provide recommendations to the program manager and test director for final disposition. The program manager, test director, and if required the customer will approve a final or critical design review. It is important for the program manager and test director to be satisfied that the drawing list, the component list, the instrumentation list, and that the configuration management/quality assurance files will be adequate for the audits that will come after the system buildup is complete.

9.6. Released drawings, specifications, etc will be placed in Configuration Management & Control.

10.0. DOCUMENTATION AND PROCEDURES CREATION. NCARs and procedures will be managed in accordance with the RZSO Configuration Management Program or equivalent.

10.1. AF Form 813, Request for Environmental Impact Analysis. The program manager with the assistance of the test director is responsible for putting together the AF Form 813. Must be completed and approved prior to construction and test operations.

Processing requires 15-30 days. A copy of the AF Form 813 must be filed in the program folder by the program manager.

10.2. AFRL/RZ-W Form 27, Experimental/Test Operations, Safety Permit and Hazard Analysis. The program manager and test director are responsible for putting together the AFRL/RZ-W Form 27. The AFRL/RZ-W Form 27 must be completed and approved prior to any test operations. The AFRL/RZ-W Form 27 must be filed in the program folder by the program manager and a copy available in the test facility for review by all personnel.

10.3. AFRL/RZ-W Form 21, Request for Storage or Transfer of

Explosive/Propellants. The AFRL/RZ-W Form 21 must be completed and approved before shipment is authorized by the program manager to be shipped to AFRL.

10.4. Non-Conformance and Corrective Action Report (NCAR). NCAR documents are designed to record information on products or components that are received or fabricated and do not meet the original design requirements or code compliance during receiving inspection, fabrication, construction, testing or operations. See RZSO Configuration Management Program for details.

10.5. Test Operating Procedures (TOPs), Standard Operating Procedures (SOPs), and Checklists (CLs). Upon completion of the Design Phase and preliminary technical risk assessment, preliminary hazard analysis and other documents will be used to develop operating procedures. They are defined as a written document in the form of a logical sequence of tasks and events to be followed in order to accomplish an operation.

Operating procedures serve to carry out experimental and/or hazardous operations in a checklist-like format to assure proper operation thus reducing risks to the personnel, facility, equipment, environment, and test article. Operating procedures are intended to be either project/test or facility-related. TOPs are to be used for project specific procedures or countdowns for rocket firings and other tests. SOPs and CLs are to be used for multi-project repetitive facility-related operations, such as steam plant operation, stand alone operations, facility checklists, or thrust stand calibration. Generally, SOPs and CLs are subset operations that would often be called out in a TOP as one of the operations necessary to carry out a test. See the Test Operations Handbook, Section TOHB-AFRL-0002, Procedure Writing, for procedure writing guidelines and sample format.

10.5.1. The TD is responsible for developing the TOPs, SOPs and CLs. If the test director does not personally write the TOP/SOP/CL, the test director is still responsible for reviewing the TOP to assure it will perform the required testing in a safe manner. The test director is also responsible for ensuring that all the procedures, TOPs, SOPs, and CLs, have been approved prior to performing the operation.

10.5.2. The program manager, weapons safety manager, responsible Branch Chiefs, and the AFRL/Det-7 Chief of Safety approve TOPs, SOPs and CLs that deal with red operations, including all explosive/propellant operations. See the Test Operations Handbook, Section TOHB-AFRL-0002, Paragraph VI, Signature and Revision Pages for complete list of required signatures.

10.5.3. TOPs, SOPs and CLs are controlled by the Configuration Management System; see RZSO Configuration Management Program or equivalent. “Red Lines” are changes that are made to the procedure. “Red Lines” are permitted to maintain the system integrity or to correct errors. “Red Lines” should be annotated in red ink on the TOP, SOP, or CL. The test director will determine when the quantity of “Red Line” changes warrants a revision to the TOP or SOP.

Minor deviations from the procedure are authorized by the test director and coordinated with the program manager, test conductor, and red crew leader.

Major deviations from the procedure, as determined by the test director, must be approved by the program manager, test conductor, customer, a technically qualified red crew member, and the chairmen of the TRB and SRB.

11.0. REVIEW BOARDS.

11.1 Technical Review Board (TRB). The TRB is responsible for reviewing the technical soundness of the facility system designs, verification and validation plan, test plans, procedures, and test readiness data to evaluate if the program will meet the test requirements and program risk. Based on these evaluations, the TRB makes recommendations and identifies deficiencies to the test team’s approach to help reduce the technical risk to the program. From these reviews, the TRB will assess the risk mitigation plan, make recommendations, and identify the consequences of those recommendations. AFRL Form 19B, Technical Review Board, will be used to document the technical review process. The findings are presented to the SRB and at the Test Readiness Review.

11.1.1 The AFRL/RZ-W Test Lead determines if a TRB is required for all test facilities under AFRL/RZS management. The AFRL/RZ-W Test Lead selects qualified TRB chairperson and members, and verifies their availability with their supervisor. The selected members are officially appointed to the TRB by letter.

11.1.2 The program manager and test director will provide all relevant program documents to the TRB chairperson for distribution to the TRB members. The TRB chairperson schedules the TRB meeting time and location, sets the agenda, prepares meeting minutes and tracks action items. The program manager and/or the test director will provide the TRB with a program overview to include test requirements, techniques, approaches, and objectives.

The program manager will also define the schedule and detailed task plan.

11.1.3 The TRB chairperson will present the board’s assessment at the TRR and a copy of these presentations will be filed by the program manager.

11.2. Safety Review Board (SRB). The AFRL/Det 7 Chief of Safety assigns an SRB Chairperson. (See AFRL/RZ-W OI 91-202, Environmental, Safety, and Occupational Health (ESOH) Programs) The SRB Chairperson will select SRB members and coordinate with the appropriate branch chief to support the Safety Review Board process. The selected members are officially appointed to the SRB by letter. The findings are presented to the program manager, test director and at the Test Readiness Review.

11.3. Combined TRB/SRB. The AFRL/RZ-W Test Lead and the AFRL/Det 7 Chief of Safety can decide to combine the TRB and the SRB. A combine TRB/SRB appointment letter will be signed by the AFRL/RZ-W Test Lead and the AFRL/Det 7 Chief of Safety. Combined TRB/SRBs will still have a TRB chairperson and a SRB chairperson. Combine TRB/SRBs will meet all the criteria of the previous paragraphs with the exception of the TRB findings being presented to the SRB.

12.0. FACILITY AND/OR SPECIAL TEST EQUIPMENT (STE) BUILD-UP. Before construction/modification of the facility, the test director in coordination with safety, environmental, and bioenvironmental will verify that all required documentation is in place; for example approved drawings and permits. Buildup activities shall be documented in accordance with the RZSO Configuration Management Program or equivalent.

13.0. SYSTEM VERIFICATION AND VALIDATION (V&V). Verification and validation will be done per the V&V Plan (Section 8.6). System V&V is the completion of the steps required to verify the system is ready for System Readiness Review, if required. Reference

ATTACHMENT 3.

14.0. SYSTEM READINESS REVIEWS (SRR). A System Readiness Review is presented to the responsible branch chiefs after a system has been installed and all systems verification and validation has been completed, but before the propellant systems have been charge. Not all systems require an SRR. The program manager and test director are responsible for coordinating with the responsible branch chiefs to determine which systems required SRRs. The result of the SRR is approval to charge propellant systems for cold flows. The AFRL/RZS Division Chief and AFRL/Det 7 Chief of Safety will be invited to the SRR.

14.1. The program manager and test director are responsible for organizing and scheduling the SRRs.

14.2. The test team presents information about the systems, so that the responsible branch chiefs can approve the acceptance of the system modification/build-up and checkouts. The items to be considered should be based on the system and complexity, such as but not limited to; quality assurance and other inspections, system material compatibility, system cleanliness, environmental and safety compliance, structural integrity, system components compliance, mechanical systems assessment, instrumentation and control systems assessment, procedure readiness, physical configuration audit, functional checkout, and activation plan.

14.3. The responsible branch chiefs provide verbal approval to proceed with the charging of propellant systems for cold flows.

15.0. FACILITY VERIFICATION AND VALIDATION (V&V). Verification and validation will be done per the V&V Plan (Section 8.6). Facility V&V is the completion of the steps required to verify the system is ready for Facility Readiness Review. A QA walkthrough of the area will be performed as part of the facility V&V. Reference ATTACHMENT 3.

16.0. FACILITY READINESS REVIEWS (FRR). A Facility Readiness Review is presented to the test approval authority, as defined in section 16.5, after a system or facility has been installed and all facility verification and validation has been completed, but before the test article is installed or live propellants are loaded into the system. The result of the FRR is approval to install the test article and/or live load propellants.

16.1. The program manager and test director are responsible for organizing and scheduling the FRRs.

16.2. The test team presents information about the systems, so that the TAA can approve the acceptance of the facility modification/build-up and checkouts. The items to be considered should be based on the facility and complexity, such as but not limited to;

quality assurance and other inspections, system material compatibility, system cleanliness, environmental and safety compliance, structural integrity, system components compliance, mechanical systems assessment, instrumentation and control systems assessment, procedure readiness, physical configuration audit, functional checkout, and activation plan. The TAA will be provided with a copy of the slide presentation prior to FRR.

16.3. A single FRR can be performed to activate the entire facility at once, or more FRRs can be performed to activate portions of the facility as required to meet the program schedule. If one or more systems have been approved prior to the delta FRR, then for those systems only the changes since the previous FRR are required to be briefed at the delta FRR.

16.4. The AFRL/RZ-W test approval authority acknowledges acceptance of risk and provides approval to proceed with the installation of the test article and/or live loading of propellants by endorsing the FRR version of the AFRL/RZ-W Form 27.

16.5 For low risk tests, the responsible Branch Chiefs approves the AFRL/RZ-W Form

27. For medium risk tests, the AFRL/RZS Division Chief approves the permit. For high-risk tests, the AFRL/CC approves the permit.

17.0. TEST VERIFICATION AND VALIDATION (TEST V&V). Test verification and validation will be done per the V&V Plan (Section 8.6) tailored to the test program requirements.

Test V&V is the completion of the steps required to verify the systems and/or test article are ready for test. A QA walkthrough of the area will be performed as part of the test V&V. For liquid rocket engines use ATTACHMENT 4 and for solid rocket motors use ATTACHMENT 5 to determine the steps required to complete for the Test V&V. CST is part of the Test V&V, see section 18.

18.0. COMBINED SYSTEM TEST (CST). The two purposes of CSTs are a Validation of System Readiness (VSR) and Test Countdown Rehearsal (TCR). For liquid rocket engines use ATTACHMENT 4 and for solid rocket motors use ATTACHMENT 5 to determine the steps required to accomplish both VSR and TCR required to accomplish two successful CSTs.

18.1. The test director will hold a debriefing meeting with the team leads including but not limited to the Customer, Safety Representative, quality assurance representative, program manager, test conductor, Red Crew Leader, and Instrumentation Lead and incorporate any changes or further actions required.

19.0. TEST READINESS REVIEW (TRR). A Test Readiness Review (TRR) is presented to the Form 27 approval authority, as defined in section 19.8, by the Test Team after all verification and validation steps are complete. The purpose of the TRR is to satisfy the AFRL/RZ-W management and the Customer of the following: test article pedigree, condition, and readiness are documented and reviewed, the systems are ready for testing, pretest analyses are complete, test personnel are qualified, non-conformances have not increased the risks associated with conducting the tests, all reasonable efforts have been made to minimize program and safety risks, test data will meet the test plan requirements, and all review boards recommendations have been dispositioned.

19.1. A TRR is required, except for low risk tests wherein the requirement is at the discretion of the test approval authority.

19.2. The program manager is responsible for organizing and scheduling the TRRs.

The program manager obtains the participation and attendance of contractors, test engineers, senior management, safety and health, quality assurance, customer, TRB and SRB chairpersons, and other agencies as necessary. Copies of all slides will be provided to the Test Director prior to the review. This includes PM, TRB, SRB, and QA presentations. The TAA will be provided with a copy of the slide presentation prior to

TRR.

19.3. The TRB chairperson presents the technical risk assessment.

19.4. The SRB chairperson presents the safety risk assessment.

19.5. QA present that their in-process checklist is complete.

19.6. The TD is responsible for conducting the TRR and briefing the results of the V&V including the results of the CSTs.

19.7. The AFRL/RZ-W test approval authority acknowledges acceptance of risk and signifies approval to proceed with the test by endorsing the AFRL/RZ-W Form 27.

19.8. For low risk tests, the responsible Branch Chiefs approves the AFRL/RZ-W Form

27. For medium risk tests, the AFRL/RZS Division Chief approves the permit. For high-risk tests, the AFRL/CC approves the permit.

20.0. POST TEST ACTIVITY. The following will be included as post test activities:

20.1. Data Reduction. Data must be recovered and presented in a format acceptable to the customer or as agreed to in the test plan.

20.2. Post Ops Reports. A post ops report must be completed after a test. The format will be test specific as defined by the test team.

20.3. Lessons Learned and Best Practices. Lessons learned will be documented using AFRL Form 20, Lessons Learned. A copy of the completed AFRL Form 20s shall be provided to the Safety Office.

20.4. Post Test Inspections: Visual, dimensional, ultrasound, x-ray, and etc.

inspection of test article and/or facility

21.0. MISHAP NOTIFICATION. After the initial response is complete and the situation has stabilized, test team members will initiate mishap notification procedures according to the AFRL/RZ-W 91-202 and AFRLI 61-103, AFRL Research Test Management.

22.0. TEST MANAGEMENT TEAM. The program manager, test director, and customer will evaluate the post test activities and determine if testing is complete or the steps required for recycle.

23.0. CLEAN-UP AND DISPOSAL. At the end of the program, all hazardous materials and waste will be removed from AFRL and disposed. The test stand will be left in a safe configuration.

24.0. PROJECT COMPLETION OR TERMINATION. The PM will notify the systems safety office when the program is completed or terminated. The PM shall ensure that the test is properly documented and documentation is formatted in accordance with the test plan.

25.0. FORMS

25.1. Prescribed Forms

AFRL/RZ-W Form 21, Request for Storage or Transfer of Explosive/Propellants

25.2. Adopted Forms

AF Form 813, Request for Environmental Impact Analysis AFRL Form 4, Initial Safety Risk Assessment AFRL Form 19B, Technical Review Board AFRL Form 20, Lessons Learned AFRL/RZ-W Form 27, Experimental/Test Operations, Safety Permit and Hazard

Analysis

MICHAEL H. PLATT, Col, USAF Associate Director, Propulsion Directorate Commander, Edwards Research Site

ATTACHMENT 1

Acronym List

AF – Air Force Research Laboratory AFI – Air Force Instruction AFRL – Air Force Research Laboratory AoA - Analysis of Alternatives CDR - Critical Design Review CL – Checklists CRDA - Cooperative Research and Development Agreement CST - Combined System Test CTA - Commercial Test Agreement DoD - Department of Defense DT&E - Developmental Test and Evaluation ERS – Edwards Research Site ESOH - Environmental, Safety, and Occupational Health FRD - Facilities Requirements Document FRR – Facility Readiness Review ICD - Interface Control Document ISSR - Integrated System Readiness Review JON – Job Order Number LMR - Lab Management Review MRTFB - Major Range and Test Facility Base MOA - Memorandum of Agreement MOU - Memorandum of Understanding NCAR - Non-Conformance and Corrective Action Report OI – Operating Instruction PDR - Preliminary Design Review PD - Project Directive PM - Program Manager QA – Quality Assurance RFP – Request for Proposal RFQ – Request for Quote RTO - Responsible Test Organization SMs - Single Managers SOCC – Site Operations Control Center SOP - Standard Operating Procedures SOW – Statement of Work SRR – System Readiness Review SRB - Safety Review Board STE – Special Test Equipment TAD – Test Article Director TC - Test Conductor TCR - Test Countdown Rehearsal TD - Test Director

TMDE – Test Measurement Diagnostic Equipment TOP – Test Operating Procedures TRB – Technical Review Board TRD - Test Requirements Document TRR - Test Readiness Review VSR - Validation of System Readiness V&V -Verification and Validation

ATTACHMENT 2

RESEARCH AND DEVELOPMENT TEST OPERATION AND SAFETY PROCESS

Rev: 19 May 11

Cost Estimating

(RFQ/RFP,

Cost Estimating, Initial Risk Assessment)

Authority to Proceed (Form 4, MOA, MOU, CTA, In-house program summary, TRD, SOW, CRDA, LMR, JON Creation)

Concept Discussion

Detailed Requirements

Planning (Implementation Plan V&V Plan, Test Plan, FRD, ICD, Safety Plan)

Design (Drawings, Analysis, PDR, CDR, Etc.)

Documentation and Procedures

Creation

(TOP, SOP, CL,

AF Form 813, AFRL/PR Form 27, Form 21,Etc.)

TRB Start

Facility and/or STE Build-up

Facility Verification and Validation

Facility Readiness Review Results of FRR is approval to install test article or load live propellants into the system

Test Readiness Review (TRR)

(Results in approval of test permit)

Clean-up and Disposal

Post Test Activity (Data Reduction, Post Ops Reports, Lessons Learned, Best Practices, Post Test Inspection)

Project Completion or Termination Recycle?

Test Verification and Validation

C S T

Test Program Yes

No

Kick-off/ Concept Program Overview

Test

Approved Construction Documents (Drawings, Permits, Etc.)

(related to build-up)

Baseline Procedure Approval (used for V&V and dry runs) SRB Start

Test Management Team PM, TD, and Customer evaluation of post test activities.

Determine steps required for recycle and what point to recycle to in the flow chart.Yes

No

System Readiness Review Results of SRR is approval to charge propellant system for cold flows.

System Verification and Validation

RZ-W OI 61-103, 23 August 2011 19

ATTACHMENT 3

VERIFICATION AND VALIDATION

ATTACHMENT 4

LIQUID ROCKET ENGINES TEST VERIFICATION AND VALIDATION

RZ-W OI 61-103, 23 August 2011 21

ATTACHMENT 5

SOLID ROCKET MOTOR TEST VERIFICATION AND VALIDATION