Attachment - RDOI_61-103_AFRL Research Test Management.pdf

BY ORDER OF THE COMMANDER RD OPERATING INSTRUCTION 61-103

AIR FORCE RESEARCH LABORATORY

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for downloading on the https://org2.eis.afmc.af.mil/sites/RDRV/IM/Forms%20and%20Publications/Forms/AllItems.asp x

RELEASABILITY: There are no release restrictions on this publication.

OPR: AFRL/RDMT (Ms. Michelle Hedrick) Certified by: AFRL/RDM (Keith Shrock) Supersedes RDOI 61-103, 10 June 2010 Pages: 25

This instruction implements Air Force Policy Directive (AFPD) 61-1, Management of Science and Technology, Air Force Instruction (AFI) 99-103, Capabilities Based Test and Evaluation, Air Force Materiel Command Instruction (AFMCI) 99-103, Test Management, Air Force Research Lab Manual (AFRLMAN) 99-103, AFRL Flight Test and Evaluation, and AFI 91-202 AFMC Sup 1, The US Air Force Mishap Prevention Program. This Air Force Research Laboratory Directed Energy Directorate (AFRL/RD) Operating Instruction implements AFRLI 61-103, AFRL Research Test Management. This instruction establishes procedures and responsibilities for managing test programs in AFRL/RD and defines the associated review and approval process. It applies to both contractor and government conducted AFRL/RD tests in government facilities and performed outdoors and ensures 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/gcss-af61a/afrims/afrims/rims.cfm. Additionally, if the publication generates a report(s), alert readers in a statement and cite all applicable Reports Control Numbers (RCN) in accordance with AFI 33-324 The Air Force Information Collections and Reports Management Program. Refer recommended changes and questions about this publication to the Office of Primary Responsibility (OPR) using the AF Form 847, Recommendation for Change of Publication; route AF Form 847s from the field through the appropriate functional chain of command.

SUMMARY OF CHANGES

This instruction is substantially revised and must be completely reviewed.

Scientific, Research, and Development

AFRL RESEARCH TEST MANAGEMENT

1022582115C Text Box 12 June 2017

Table of Contents Chapter 1

PURPOSE AND SCOPE

1.1. Purpose

1.2. Scope

1.3. Waivers

Chapter 2

RD ROLES AND RESPONSIBILITIES

2.1. AFRL/RD Director

2.2. RD Chief Scientist

2.3. RD Chief Engineer

2.4. RD Test Office

2.5. Division Chiefs

2.6. Division Chief Engineer (DCE)

2.7. Division Test Lead (DTL)

2.8. Project/Program Managers, Principal Investigators, Scientists, and Engineers

Chapter 3

TEST COORDINATION

3.1. DET/SE - Safety Office Roles and Responsibilities

3.2. Outside Agency Coordination

Chapter 4

TEST PROCESS

4.1. Test Plan Process

4.2. Test Documentation and Collaboration

4.3. Final Test Plan Package (TPP) Review Process

Chapter 5

TEST APPROVAL

5.1 Test Approval Authority (TAA)

Chapter 6

TEST EXECUTION

6.1. Test Execution

6.2. Test Plan Changes/Revisions

6.3. Project Completion or Termination

Chapter 7

PRESCRIBED AND ADOPTED FORMS

7.1. Prescribed Forms

7.2. Adopted Forms

ATTACHMENT 1

GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION

Chapter 1

PURPOSE AND SCOPE

1.1. Purpose. The purpose of this instruction is to establish roles and responsibilities and to standardize the basic process for the conduct of research and development test activities in AFRL Directed Energy Directorate (RD). It is the Director’s goal to establish a clear test process that defines test objectives and measures to provide technical sufficiency and to maintain a safe working environment for all personnel during the conduct of tests, experiments, and demonstrations. To meet this goal, all projects in the Directorate require adequate planning and review prior to test execution, consistent with Air Force guidance. This OI addresses the steps to formalize the test planning process within AFRL/RD. This test planning process applies to other organizations and contractors that perform tests in AF facilities or test sites as required.

1.2. Scope. This instruction applies to all AFRL/RD programs, projects, and personnel involving test, experiment, or demonstration activities at any location including those activities performed at geographically separate units such as Maui. Those experiments, tests, or demonstrations that use RD technology and/or devices (e.g. laser, RF), high voltage sources or other sources that use one or more toxic chemicals or substances to create a directed energy effect must complete the full test review process. For select laboratory R&D efforts, such as 6.1 Basic Research or routine/repetitive measurement efforts, a Standard Operating Procedure (SOP) may be used in lieu of a Test Plan to provide the Researcher with increased flexibility, particularly in those cases where experimentation is directed toward greater understanding of phenomena without specific applications to a process or product.

1.2.1. Test Plan Criteria

Test plans are required for efforts that:

a. Collect data based upon execution plan Technical Performance Measures;

b. Collect data that formulates the design of a DEW device and/or prototype;

c. Evaluates a system or device for analysis of alternatives;

d. Evaluates specific data elements required for major decision points involving selection or qualification of a system or technology

1.2.2. Standard Operating Procedure (SOP) Criteria

SOPs are not safety plans but a document that provides consistent, repetitive procedures to operate or evaluate components, instruments, equipment or apparatus. SOPs must specify tasks, safety warnings, analytical methods and process to ensure Quality Assurance and must meet the following criteria:

a. Well defined routine or repetitive activities that test components, operates instruments, equipment or apparatus that are not developmental.

b. Routine work to calibrate and maintain instrumentation or equipment needed for program objectives

c. Basic 6.1 Research that investigates a phenomena or uncertainty in outcome utilizing a methodical approach to measure performance for research discovery

The RD TL in consultation with the Division Test Lead (DTL) will determine whether an effort qualifies for a SOP. The RD TL and DTL will consult with the Division Chief Engineer (DCE) to make the final determination for those cases where it is unclear whether a formal test plan is required. Test plans and SOPs follow the same process for approvals in that the TAA is the final approval authority. For all non-test efforts (e.g. machine shops) that fall under standard ground safety rules, consult with DET/SE on safety requirements. Test or experimental activities lasting over a year may require annual safety review and renewal of the AFRL Form 5 AFRL Safety Permit, per PRSOI Sup to AFI/AFMC/AFRL 91-202. Test plans and standard operating procedures are valid as long as the scope, objectives and data measures do not change. Annual re-validation, (discussion/e-mail) of these efforts will be performed by the RD Test office and Program Manager (PM)/DTL for concurrence. To eliminate duplication of effort, technical and safety reviews conducted by other organizations partnered with AFRL, possessing mature, well defined, and documented review processes may be considered and accepted at the discretion of the AFRL Test Approval Authority (TAA). This instruction also applies to AFRL/RD activities performed in collaboration with other organizations at any installation, leased government properties, or remote locations.

1.3. Waivers

1.3.1. Waiver authority for the contents of this document is the RD Director or to the contents of AFRLI 61-103 is the HQ AFRL/CC.

1.3.2. Coordinate waiver requests with the RD TL for coordination/staffing to the appropriate authorities. Local waivers authorized by the RD Director, will be coordinated with the RD Chief Engineer as the advisor to the test safety process and will require coordination with DET/SE. AFRL Operations/Center Test Authority (AFRL/DO) and AFRL Safety (AFRL/SE) will be consulted when PMs request waiver from AFRL 61-103 requirements.

1.3.3. For waiver requests to higher level instructions (AFMC, HAF, SAF, DoD, etc.), coordinate with local RD TL and DET/SE for staffing through AFRL/DO and AFRL/SE to the appropriate OPR, as necessary.

Chapter 2

RD ROLES AND RESPONSIBILITIES

2.1. AFRL/RD Director.

2.1.1. Implement AFMC and AFRL test policies within the Directorate.

2.1.2. Ensure compliance with the research test processes as defined in this instruction and associated volumes and AFI 91-202, The US Air Force Mishap Prevention Program and associated AFMC and AFRL Supplements.

2.1.3. Authorize the use of any RD system for demonstration, extended user evaluation, operational assessment, or deployment prior to system delivery or action.

2.1.4. Approve the Lead Development Test Organization (LDTO) (e.g. Responsible Test Organization (RTO) for flight tests) for programs that require an external organization to lead the test effort, based on the recommendation of the PM. The LDTO is the lead government developmental test organization that is qualified to conduct and/or be responsible for overseeing developmental RD Test activities. A memorandum of understanding (MOU), a memorandum of agreement (MOA), or an Integrated Test Team (ITT) Charter would be used to document specific LDTO and participating test organization(s) (PTO), roles and responsibilities. Typically, LDTO designation, MOU and/or ITT Charter is required for efforts involving aerial vehicles.

2.1.5. Designate the Lead Test Organization (LTO) for programs in their Directorate when working with other organizations. The LTO is the lead government entity that is qualified and responsible for the planning, execution, and reporting on research and development testing. Formal designation of LTO is not required for all in-house RD test efforts where AFRL/RD serves as the LTO.

2.1.6. Act as the Test Approval Authority (TAA) for new, unique, or complex Medium level risk activities as determined by the System Safety Manager (SSM), the RD TL and/or Technical Review or Safety Review Boards. See details for TAA, Chapter 5 of this instruction.

2.1.6.1 Delegates, via this instruction, unique or complex residual Medium risk TAA signature authority to Deputy Director for all activities requiring RD signature in RD’s absence.

2.1.6.2 Delegates, via this instruction, routine Medium residual risk TAA signature authority to RD Division Chiefs.

2.1.6.3. Delegates, via this instruction, routine Low residual risk TAA signature authority to RD Branch Chiefs

2.1.7. Appoint in writing a RD Test Lead.

2.1.8. In conjunction with the AFRL Center Test Authority (CTA), ensure local processes and procedures are established and coordinated with Detachment Chiefs of Safety, RD Chief Engineer, Chief Scientist to include: the need for formal Technical Review Boards (TRBs) and Safety Review Boards (SRBs), the participation on these boards (to include the chairperson), the streamlined review process when formal boards are determined not necessary, and the local test approval process. Recommend participants and chairperson for Technical and Safety Reviews.

2.1.9. Coordinates on High Safety Risk AFRL review packages prior to presentation to the AFRL commander.

2.2. RD Chief Scientist. Coordinate TRB chair assignments with RD Chief Engineer (CE).

2.3. RD Chief Engineer. Oversee the AFRLI 61-104, S&E Systems Engineering and Technical Management for RD.

2.3.1. Ensure the PM, DCE and supporting scientists and engineers apply systems engineering and program management fundamentals to test and safety planning and execution. This includes, but is not limited to, ensuring test objectives are validated, test plans are developed, technical and operational risks are identified and mitigated and residual risks are accepted by the AFRL TAA at the appropriate level.

2.3.2. Conducts all RD aircraft and/or air systems safe-to-fly or airworthiness assessments/determinations prior to flight test. Ensure the test plan describes the system and subsystem requirements and methods of compliance to validate and verify the aircraft is safe-to-fly and is airworthy.

2.3.3. Ensure programs employ the correct disciplines and resources necessary to achieve their technical objectives safely in accordance with this instruction.

2.3.4. Ensure the test plan defines methods to control the configuration of the test article, per applicable configuration management processes.

2.3.5. Chair the TRB. Coordinate TRB chair assignments with Chief Scientist. The RD Chief Engineer can also delegate TRB chairmanship to an individual that is independent from the program but also possess technical expertise to review the program.

2.3.6. Serve as an advisor to the test and safety process.

2.3.7. Participate in safety review boards when requested by the SRB chair for RD activities projected to be potential medium risk or higher.

2.3.8. Chair Test Readiness Reviews (TRR) for all High or Medium Risk test effort as identified during the formal TRB chaired by the RD/CE. The RD Chief Engineer can also delegate TRR chairmanship to an individual that is independent from the program but also possess technical expertise to review the program. The RD/CE will perform TRRs for new unique system/prototype developments that pursue transition or demonstration; extended user evaluation; operational assessment; Joint Concept Technology Demonstration (JCTD); or Advanced Technology Demonstration (ATD).

2.3.9. Provide subject matter expertise, guidance, and assistance to all AFRL personnel engaged in test activities associated with RD’s research specialty.

2.3.10. Develop technical review processes with the TL to ensure that each RD’s test activity has a test plan reviewed for technical adequacy and assigned a technical risk level.

2.3.11. Review, publish, and keep current test policy, process, and procedures tailored to the RD unique technology activities and operating environment.

2.3.12. Review all RD test and safety packages prior to submittal for RD Director signature.

2.3.13. Provide input and guidance to the TAA for his/her approval to return to operations.

2.4. RD Test Office.

2.4.1. RD Test Lead (TL) Responsibilities.

2.4.1.1. TL will act as the Director’s focal point for all test processes/procedures and provide guidance and training to PMs.

2.4.1.2. The RD TL in consultation with the DTL will determine whether or not an effort qualifies for a SOP. The RD TL and DTL will consult with the DCE to make the final determination for those cases where it is unclear whether or not a formal test plan is required.

2.4.1.3 The RD TL provides the independent residual technical risk assessment of test efforts that do not require a formal TRB. The TL determines the residual technical risk for the test based upon test plan technical risk assessment and input from Division Chief Engineer

2.4.1.4. Conduct Annual re-validation of Test Plans and SOPs. Approve on-going efforts with discussion/e-mail of these efforts with test team and DTL.

2.4.2. Test Office Responsibilities.

2.4.2.1. Provide independent oversight, review, and guidance for projects undergoing transition, demonstration, extended user evaluation, or deployment (see para. 4.3.3 below);

test strategies; test scope; documentation; suitability; and effectiveness.

2.4.2.2. Attend PM/DTL “kick-off” meetings to coordinate on overall test strategy for each project.

2.4.2.3. Coordinate on all test plans and consult with RD Chief Engineer and/or Chief Scientist to determine if a formal Technical Review Board (TRB) is required based on the scope, complexity, similarity to previous tests, and anticipated risk level.

2.4.2.4. Contact the DET Safety Office and provide information concerning test requirements and data to support the independent safety review.

2.4.2.5. Assist the PM/PI in the development of the safety plan as part of the test plan IAW AFI 91-202_AFMCSUP 13.3.5.2 and 13.5.4, AFRLSUP1 13.3.6.2. Perform calculations and analyses to assist PM and test team in determining test hazards. Coordinate with DET/SE to ensure installation functional entities: Bioenvironmental; Fire; Safety; Range;

Spectrum; Security; and Range Management Offices are informed of hazards and installation requirements are incorporated into test plans.

2.4.2.6. Conduct technical review for projects/programs not needing a formal TRB.

2.4.2.7. Ensure all signed test documents are located in the RD Test Collaboration Share Point site.

2.4.2.8. Assist the test team, planner/manager to certify the test plan documentation and coordination is complete. The RD Test Office will provide support to activities that utilize fuses for energetics and/or fire directed energy systems that require Non-Nuclear board, Directed Energy Weapon (DEW), or Joint Board certifications IAW AF requirements.

2.4.2.9. Serve as the AFRL focal point for teaming and collaboration agreements with the T&E community.

2.4.2.10. Participate on all Technical Review Boards (TRB) and provide input on all Safety Review Boards (SRB) for RD activities IAW AFI 91-202 AFMC/AFRLSUP1 13.3.6.6. Assist in identifying and coordinating appropriate membership and provide technical expertise to the

SRB.

2.4.2.11. Conduct directorate test meetings with DTLs on an as needed basis.

2.4.2.12. Assist RD Chief Engineer to prepare local RD Test Policies for indoor and outdoor test activities using protocols derived from appropriate Air Force Instructions and military and civilian standards.

2.4.2.13. Coordinate with AFRL headquarters and external agencies, e.g. FAA, AFSMO, and Kirtland/Hickam AFB Functional Offices to obtain necessary permits, equipment registration, frequency assignments, and flight authorizations needed to accomplish RD testing.

2.4.2.14. Conduct dry-runs or walk-through verifications of all indoor and outdoor test/SOP efforts, as needed. Work closely with the PMs and DTLs to ensure seamless transition to actual testing.

2.4.3. RD Range Staff Responsibilities.

2.4.3.1. RD Range Management will be responsible for management of the Directorate’s munitions account; acquiring munitions and munitions hardware for test; frequency assignments; range safety officer; and range resource management. The Range Manager will provide guidance to all PMs on proper field test procedures, explosive handling procedures, and assist in field test execution.

2.4.3.2. Provide assistance, control and/or supervise test execution of outdoor test(s) to ensure that testing is conducted according to the approved test plan.

2.4.3.3. Act as liaison between AFRL/RD and proposed managers of range(s) or test site(s) when AFRL/RD uses directed energy devices outdoors or in the field. Assist project personnel in obtaining appropriate permission for access to property, range assets, facilities and targets.

2.4.3.4. Perform DEW range evaluation for all RD activities that would be performed on any DoD range or leased site. A Range Evaluation would be an analysis of adequacy of a range to support a DEW test. This encompasses physical resources, personnel, logistics support, infrastructure, equipment, power, communications, security, etc. needed to support a test.

2.4.3.5. Perform DEW range evaluation for all programs of record DEW devices and certify the operational use of that device on major AF ranges in accordance with AFI 13-212 V1 Range Planning and Operations.

2.4.3.7. Manage the Directorate’s Outdoor Test and Experiment Activity Calendar and provide input to AFRL Center Test Authority in accordance with AFRLI 61-103 when appropriate. Coordinate RD test range schedule with the appropriate range authority.

2.4.3.8. Review all test and safety plans involving outdoor testing and/or explosives use.

2.4.3.9. Assist in the preparation of explosive SOP’s that support test plans.

2.4.3.10. Manage the Directorates Training and Certification Program for Explosive Handling.

2.4.3.11. Provide qualified explosive handlers and explosive safety monitors to support programs using explosives and explosive components.

2.4.3.12. When available, and if requested, provide assistance with outdoor test operations such as road guards, lookouts, FAA radar monitor, etc.

2.4.3.13 Perform test director duties on a case by case basis for outdoor field tests, advanced technology demonstrations, prototype transition testing as required.

2.4.3.14. Assist Divisions with logistics for all outdoor field tests, advanced technology demonstrations, prototype transition testing both at Kirtland AFB and other locations.

2.4.3.15 Provide support and documents to enable both manned and unmanned flight test activities. This includes coordination with AFRL/DO for designation of LDTO, SEEK EAGLE Coordination for programs utilizing stores, Non-Nuclear Munitions Safety Board analyses and presentations, SRB support and coordination with ranges and aircraft Program Offices to assist in flight test planning and assistance to the RD Chief Engineer in airworthiness and safety of flight determinations.

2.4.3.16 Facilitate coordination with AFRL/DO and directorate projects requiring in-flight duties under Maintenance/Engineering Support Personnel (MESP) approvals. When required, a qualified Flight Test Engineer will be provided to programs to assist in flight test planning and execution.

2.4.4. RD Environmental Responsibilities.

2.4.4.1. Review all contracts to ensure adequacy of test and environmental requirements and sign the AFRL Form 4, Initial Safety Assessment (AFI 91-202 AFRLSUP1). The AFRL Form 4 must be submitted to contracting office to ensure incorporation of specific language prior to award.

2.4.4.2. Coordinate local, state, and federal environmental compliance issues associated with RD test activities.

2.4.4.3. Inspect test set-up prior to test execution.

2.4.4.4. Conduct annual environmental review of all test plans for currency and compliance with environmental regulations.

2.4.4.5. Act as directorate Human Use Resource Coordinator.

2.4.4.6. Sign all RD AF Form 813s, Request for Environmental Impact Analysis and/or coordinate environmental documentation with the appropriate organization. Provide PM guidance on more detailed environmental assessments and environmental impact statements.

2.4.4.7 Manage the environmental program for RD. Provide guidance, inspection and assistance to ensure compliance with environmental requirements.

2.5. Division Chiefs.

2.5.1. Responsible for the implementation of test process for Division activities. Ensure all Project/PMs conducting test activities follow the procedures published in this instruction and associated published AFRLI 61-103 test volumes. Flight related test activities can be found in AFRLMAN 99-103; procedures for human use related test activities must be obtained from AFRLI 40-402; and systems engineering processes defined in AFRLI 61-104 and AFMCI 63- 1201.

2.5.2. Serve as the TAA of any test activity with Medium residual risk that is not managed at the Directorate level.

2.5.3. Appoint a DTL to manage Division test activities. Submit Division representative’s name to AFRL/RD Test Office.

2.5.4. Attend or designate representative to participate in technical reviews for their Division activities.

2.6. Division Chief Engineer (DCE). The DCE is responsible for the Division’s overall compliance with this Instruction.

2.6.1. Responsible for Division test activities. Ensures activities, within the scope of this OI, have completed required documentation (test and safety plans), assists RD Test Office in determining appropriate technical review requirements, and ensures approvals, in the form of signed Test Plans and Safety Permits/Forms, have been obtained prior to test conduct.

2.6.2. The DCE will assess the technical risk associated with test efforts to ensure test execution meets plans and strategic goals of the division. PMs should consult with the DCE to ensure test efforts are technically sound. The RD/TL will evaluate technical risk and mitigations submitted in the test plan to independently determine the residual risk for each test effort based upon input from DCE/PM for efforts that do not require a formal TRB.

2.6.3. DCE chairs the division TRRs as delegated by the RD Chief Engineer and/or chairs all of the Division Low Risk TRRs. The DCE can delegate the chairmanship of Low Risk TRRs to the Branch Chief.

2.6.4. Attend Directorate test meetings.

2.6.5. Determine when the TAA, CE, RD Test Office, and DET/SE must be re-engaged for changes in scope of PM test activities.

2.7. Division Test Lead (DTL) The DTL must be appointed in writing by the Division Chief.

2.7.1. DTL works with DCE and PMs in the identification of scope and content required for Division test plans.

2.7.2The DTL schedules “kick-off” meetings with the RD Test Office, DCE and Det Safety Office to ensure early planning and to identify long-lead test items.

2.7.3. DTL notifies RD Test Office and DET/SE (organization mailbox) when the Test Plan Package (TPP), all test and safety documents, is loaded on the RD Test Collaboration Share Point site for review and comment. Ensures all modifications and adjudication to comments are managed on the RD Test Collaboration Share Point Site. Requests independent technical and safety risk assessment when the TPP is ready.

2.7.4. DTL works with DCE and PM to ensure results of the executed test and analyses are presented to the applicable TAA and management level. These data reviews, and hot washes will be centrally archived with the approved test plan on the RD Test Collaboration Share Point site as appropriate.

2.7.5. DTL submits and update the Division’s short- and long-term outdoor test and experiments schedule to the Directorate Test and Experiments Activity Calendar on the RD Test Collaboration Share Point Site.

2.7.6. Attend Directorate test meetings.

2.7.7. DTL assists the PM in conducting data reviews at the appropriate level; ensuring all outdoor efforts include communication of test event results to division management, RD Test Office and upper management when appropriate.

2.8. Project/Program Managers, Principal Investigators, Scientists, and Engineers.

2.8.1. Implement this instruction and AFRLI 61-103, AFRL Research Test Management.

Comply with AFRLMAN 99-103, AFRL Flight Test and Evaluation; and AFI/AFMCI 99- 103, Test and Evaluation, Test Management; when activities use flight platforms.

2.8.2. Develop long range test strategy, including early planning for outdoor tests and present information at Execution Plan Reviews.

2.8.3. Develop test plans that include annexes for safety, security, human use, flight, and environmental, as appropriate with integrated test team members (project managers, principal investigators, technical advisors, and participating S&Es…). Coordinate test documents with DTL and Division CE to ensure adequate quality, rigor and completeness as appropriate.

2.8.4. Coordinate with DTL to convene and lead an integrated test plan working group to define test objectives, methodology and exit criteria for proposed tests when appropriate.

Develop Integrated Test Working Group charters for complex tests involving external agencies which have LDTO, LTO, or PTO responsibilities.

2.8.5. Host test team “kick-off meeting” with RD TL, DTL, and DET/SE, RD Environmental and DCE early in the test planning process to obtain specific test guidance for new programs/projects.

2.8.7. Contact DTL and RD TL for any program(s) that are going to pursue transition, deployment or demonstration offsite, early in the program planning phase.

2.8.8. Submit request for munitions, frequency assignments, and FAA letters of non-objection to RD Test Office for coordination and external agency processing, if required. Submit laser certification requests to the appropriate Base Bioengineering Office.

2.8.9. Submit all test plan documentation for review, comment and approval to the RD Test Collaboration SharePoint site. During the collaboration period of the TPP, all reviewing offices and functions (RD Test Office, RD Chief Engineer, DET/SE, Environmental, Division test team etc.) will work directly with the responsible PM/DTL to discuss and apply revisions to draft test package documents on the RD Test Collaboration Share Point site to maintain version control, ensure document consistency, and provide a record of comments/changes.

All test planning members will be used to leverage expertise to ensure all aspects (technical, test, airworthiness, safety, engineering, etc.) of the test package are methodical and comprehensive. The PM has the ultimate responsibility for addressing and adjudicating all comments to the TPP, and publication of the final version. PMs/DTLs are required to keep RD Test and DET/SE informed on schedule changes that impact collaboration comment adjudication and completion of test process.

2.8.10. Develop Division SOPs and coordinate with DTL for submission to the RD Test Collaboration Site for processing.

2.8.11. Present test scope, objectives, and methodology at technical reviews and conduct TRR, data reviews as required. See guidance for TRBs and TRRs on the RD Test Collaboration Share point site, Reference Library.

2.8.12. Conduct all test activities in accordance with approved test plan to include cleanup of test areas upon completion of test activities.

2.8.13. Ensure mishap, security, environmental and operational (OPREP) reporting to the appropriate functional office is determined and documented in the test plan.

2.8.14. Prepare or obtain artifacts needed to support airworthiness determinations.

Coordinate with DTL to load all documents into the test folder established on the RD Test Collaboration SharePoint site.

2.8.15. Submit supporting documents for all requests for LDTO (RTO), aeronautical orders and authorization to perform in-flight duties to DTL and RD Test Office for processing.

2.8.16. Submit all contract Statements of Work or Objectives, AFRL Form 4, Initial Safety Assessment, to the RD Test Collaboration SharePoint site and notify RD Test Office and DET/SE for review and incorporation of specific test/environmental and safety language and deliverables. Provide coordinated document to contracting office for statement of work update.

2.8.17. Comply with indoor and outdoor Test Requirements and locally developed test guidance and policies IAW this OI.

Chapter 3

TEST COORDINATION

3.1. DET/SE - Safety Office Roles and Responsibilities.

3.1.1. In cooperation with RD TL, develop specific test safety standards and independent review and approval processes and procedures tailored to the directorate test activities and operating environments. The RD Director, Detachment Commander, and AFRL/SE will approve these local processes and procedures.

3.1.2. Attend RD “kickoff” meetings for proposed test efforts and provide PM with initial safety risk issues/concerns and make an initial determination as to whether a formal SRB will be required. DET/SE formal SRB determination will be based on the scope, complexity, similarity to previous activities, and anticipated risk level.

3.1.3. Provide input to RD technical review boards.

3.1.4. Assist the RD test team: RD Test Office, PM, scientists and engineers with safety portion of the test plan. Recommend actions or mitigation that could minimize hazards that ultimately reduces the residual risk.

3.1.5. Perform the independent safety review on planned test activities; recommend the residual safety risk level based upon the proposed mitigation as described on the THA IAW AFI 91-202_AFMCSUP; and recommend the overall safety risk for TAA approval.

3.1.6. Notify the DTL upon completion of the independent safety review of submitted documents on the RD Test Collaboration Share Point site. Provide signed AFRL Form 5, a THA residual risk, and any safety recommendations ten working days after independent safety review request.

3.1.7. In conjunction with RD Test Office and RD Chief Engineer develop, publish, and keep current policy, process and procedures tailored to RD unique test activities and operating environment.

3.1.8. If an SRB is required, the Chief of Safety will act as or designate the chairperson for the SRB. Membership and attendees for the RD SRB will be determined by the DET/SE with input from RD Director, Chief Scientist or Chief Engineer. Minimal membership of the SRB will include independent technical and operations representatives, maintenance experts, safety experts, the test manager/planner, and/or other personnel not directly involved in the test.

3.1.9. Notify the RD Chief Engineer of any SRBs for RD activities projected to be potential Medium risk or higher.

3.2. Outside Agency Coordination

3.2.1. Laser

3.2.1.1. Above the horizon laser operations must have a risk analysis to determine coordination with Laser Clearing House IAW DoDI 3100.11, Illumination of Objects in Space with Lasers.

3.2.1.2. All lasers greater than 5mW will be submitted to Host Laser Safety Officer for evaluation.

3.2.2. RF Spectrum and Radiation Hazards.

3.2.2.1. All transmitting RF devices must have an analysis and/or spectrum authorization for the specified operating location. The RD Spectrum Manager will coordinate and obtain spectrum authorizations for all intentional RF radiators.

3.2.2.2. All RF devices that have the capability to emit greater than AFOSH Standard 48-9, Electro-Magnetic Frequency Radiation Occupational Health Program, Lower Tier MPE levels will be coordinated with Base Radiation safety officer to ensure proper safety measures are employed.

3.2.2.3. Any device that has or is suspected to have an ionizing radiation hazard will be submitted to the Base Radiation Safety Officer for hazard evaluation and certification.

3.2.3. Munitions. Tests involving the use of munitions or explosives must have written procedures for the munition/explosive involved. An SOP for explosive operations will normally be added as an annex to the test plan. Explosive SOP’s require DET/SEW and host station SEW approval. In cases involving munition disassembly, AFMC SEW approval of the munition/explosive SOP is required.

3.2.4. Flight

3.2.4.1. Activities involving flight both manned and unmanned will require coordination with AFRL/DO and the RD Test Office and various outside offices depending upon the type and complexity of the activity.

3.2.4.2. The airworthiness and flight release process will follow the AFRLGM2016-62-01 until final policy is endorsed.

3.2.4.3. All activities utilizing AF aircraft platforms will follow AFI 91-205 and/or AFI 91- 401 when DEW is tested. All activities with stores will follow the AF Seek Eagle process to obtain a Seek Eagle recommendation for air worthiness and safety of flight determinations.

3.2.4.4. The RD Test Office will facilitate coordination with the FAA and pertinent test ranges regarding RD flight test activities.

Chapter 4.

TEST PROCESS

4.1. Test Plan Process. All AFRL research and development test activities will follow the top-level process of planning, technical review, safety review, test approval, execution, data analysis, lessons learned, reporting and archiving. Each of these steps can be tailored to the level appropriate for the activity, i.e., a basic research experiment may be conducted with a short test plan or SOP and associated safety documentation; whereas, a flight test may require a formal TRB and flight SRB coordinated with HQ AFRL. Typically the test process requires consideration for test objectives, methods, measures of performance and instrumentation; test unique hazard identification and risk mitigation; airworthiness determinations; transportation plans; security;

spectrum authorizations; and external coordination and approvals. The process, Figure 4.1, is designed to identify the long lead items and potential pitfalls early on in the test planning process, when corrective actions can be taken and test resources can be identified with minimal impact to the test schedule.

Figure 4.1. Research Test Management Process

4.1.1. Each Division or Branch will identify the critical issues and objectives, taking input from the customer requirements and determining if the test is supportable and meets approved execution plans. Once the Division or Branch decides to perform the test, a “kick-off meeting” will be scheduled and hosted by the PM. The meeting will be held with members from RD Test Office, DTL, DCE, and the DET/SE to discuss the detailed requirements to accomplish the test.

4.1.2. The RD TL will work with the RD Chief Engineer to determine if a formal TRB is required and the DET/SE will determine the need for a formal SRB. Formal TRBs will be chaired by the RD Chief Engineer, Chief Scientist or designee. All test activities involving flight (unmanned air vehicle, aircraft, balloons, or rockets) will convene a TRB and SRB prior to operation. The RD TL in coordination with the DCE, PM and DTL will discuss the requirement for a formal TRB at the “kick-off” meeting. Typically, TRBs will be held on those efforts with extensive scope, complexity, non-similarity to previous tests, and anticipated higher risk levels. Formal TRBs may be held for test efforts with: high value assets; flight; explosives; significant environmental impacts or safety hazards; or high complexity/visibility. An informal technical review will be conducted for all other test efforts and the RD TL will assign the test residual technical risk level.

4.2. Test Documentation and Collaboration. To accomplish a test activity, the PM must prepare test documentation to adequately cover technical, data analysis, safety, security and any other task necessary to accomplish the test. In order to leverage the technical, test, and safety expertise available within AFRL/RD, the RD Test Collaboration Site was established on SharePoint. When the PM deems that a Test Plan Package (TPP) development or SOP is at a point where initial technical and safety review and collaboration are warranted, they can coordinate with the DTL to submit the documents into the SharePoint site. The DTL notifies the RD Test Office and DET/SE that the documents are available for collaboration. The RD Test Office will notify RD test reviewers (DCE, Branch Chiefs, Environmental and those functional members required for review) that documents are ready for comment. All comments and changes to the documents will be submitted by the RD test planning team and DET/SE within 10 working days. To maintain version control, avoid duplication, and ensure timely response for mission accomplishment all documents will be edited on the RD Test Collaboration site. After the collaboration period, the PM is responsible for responding to comments made on the documents. Following adjudication and development of the final TPP draft, the DTL will request the RD Test Office and DET/SE perform final technical and safety reviews of the TPP.

4.2.1. Standardized test plan, SOP, and Safety Package templates are available on the RD Test Collaboration Share Point site. The templates are designed to help the test planners build a TPPs and SOPs with clear objectives and details on how to achieve those objectives. SOPs and appropriate safety packages are submitted to the RD Test Collaboration share point site similar to the submittal of test plans. All paragraphs in the Test Plan template must be addressed except where indicated as optional. Additional paragraphs can be added to the test plan outline to address unique test requirements. The format of the standard test plan/SOPs and other guidance for testing is provided in the Test Reference Folder, available on the RD Test Collaboration Share Point Site.

4.2.1.1. The Safety Package. The typical safety package includes the safety plan annex (Appendix S) that discusses test hazards or THAs, initial safety risk prior to mitigation, and residual safety risk after mitigation; AFRL Safety Permit (AFRL Form 5) identifies risk levels; and AFRL Form 29 AFRL Test Safety Mishap Worksheet may be required for specific tests as defined by DET/SE. Additionally, AFRL Form 12 Test Hazard Analysis are required for any flight test activity. These documents are attached to the test plan and maintained in an established folder on the RD Test Collaboration Share Point Site.

4.2.1.2. The Environmental Package. All test activities must have an AF Form 813, Request for Environmental Impact Analysis. If an action can be excluded from further environmental analysis, the AF Form 813 will receive a categorical exclusion (CATEX) in accordance with 32 CFR 989 and will be signed by the RD Environmental Manager (EM) or appropriate organization. If the action requires further documentation, RD will work with the PM to accomplish an Environmental Assessment or Environmental Impact Statement.

These efforts will most likely require program funds; therefore, it is critical that the PM identify their actions to the RD EM early in the planning phase or at the “kick-off” meeting.

The EM will assist PMs with hazardous material authorization and creation of an initial accumulation point for any generated hazardous waste. Templates for the environmental packages are available on the RD Test Collaboration Share Point Site.

4.2.1.3. Other packages as required. Test activities that require separate airworthiness artifacts, human use, RF spectrum assignment/authorization, security, transportation details or any other applicable attachments shall be attached as appendices and submitted to the RD Test Collaboration SharePoint Site along with the test plan.

4.3. Final Test Plan Package (TPP) Review Process.

The PM must establish and present test objectives; measures of performance; test methods and predictions; and data analysis plans at the TRB for the board to evaluate the technical risk. If a formal review board is not required, the PM/DTL should submit the test plan with their recommended technical risk assessment to RD Test Office for residual technical risk evaluation and TAA level recommendation. Additionally, an independent safety review and associated residual safety risk recommendation from DET/SE will be established for all test efforts.

4.3.1. Submission and Review. The PM/DTL or their representative shall submit final draft TPP including any applicable FAA, Spectrum analysis, RF or Laser certifications, Airworthiness Artifacts, Environmental Appendix, and Safety package to the RD Test Collaboration Share Point site.

The PM/DTL will load the draft Test Plan or SOP, including the Safety Annex and other supporting documentation, to the RD Test Collaboration SharePoint site. The PM/DTL will notify the DET Safety Office organizational mailbox, the RD Test Office that the draft test and safety documents are available for review. DET/SE will initiate the safety review of the draft documents, and the RD Test Office will notify the appropriate RD test planning members (DCE, Branch Chief, Environmental…) that all test documentation is ready for their review and collaboration.

All comments and changes to the complete test and safety document package will be managed on the RD Test Collaboration SharePoint site and completed within 10 working days of notification, to maintain version control, avoid duplication, and ensure timely response for mission accomplishment. The PM/DTL will respond to comments and/or make corrections on the draft package.

Once the revised Test Plan (including the Safety Annex) is complete, the PM /DTL will email the RD Test Office requesting an independent technical risk assessment, and email the DET/SE requesting an independent safety assessment. If no SRB is required, then DET/SE will sign the safety permit and place it in the RD Test Collaboration SharePoint site within 5 days of the request, and notify the PM / DTL that the safety permit is ready for TAA signature.

Similarly, if no TRB is required the RD Test Office will sign the Test Plan within 5 days of the request. The DTL will notify the required RD division test personnel and TAA that all test documents are ready for signature.

The highest residual technical and safety risk recommendations determine the appropriate TAA management level. Residual risk levels are defined by TRBs/SRBs or by the DET/SE and RD TL in the absence of formal boards. Timing for the test/safety process is dependent on the complexity of the program/projected test effort - as expected the time to accomplish a flight test is much longer than completing documents for basic research on the bench. For planning purposes use the estimates shown in figure 4.3. The RD Test Collaboration Share Point site can be audited to reveal the complete version history for test documents and will function as the staff summary and signature process for each effort.

Individuals required to sign test documentation will be notified via e-mail, no hard copies or staff summary is required.

Figure 4.3. Typical Test Process Timeline

4.3.2. Review of Classified Tests. Classified and Special Access programs are subject to this OI. Equivalent test reviews must be implemented within the security confines of the program. The RD TL or designee will be read into these RD programs unless a waiver is granted by the AFRL/RD Director.

4.3.3. Technology Transition, Demonstrations or Deployments of Research Systems.

When technology development reaches an appropriate level of readiness to initiate transfer or integration in a configuration for the purposes of demonstration, assessment or deployment the PM must implement disciplined Systems Engineering process. At a minimum ATDs and JCTDs will meet the definition of demonstration.

If there is a reasonable expectation of providing a system or end-item as an experimental leave behind capability for operations by the user, the systems engineering process must include documentation pertaining to reliability, safety, suitability, effectiveness characteristics and required certifications of the system or end-item.

4.3.3.1 A readiness review will be convened for RD systems deemed ready for demonstration or transition. The RD Chief Engineer or designee will chair the review. Membership will consist of AFRL/RD Test Office, environmental, and DET/SE. Other members will be designated by the chairman. The review team will make a recommendation to the RD Director that the system is ready for transition, operational assessment, extended user evaluation, demonstration, or deployment.

Chapter 5.

TEST APPROVAL

5.1 Test Approval Authority (TAA). The TAA is the final approval, accepts the residual technical and safety risk, mitigation and methods proposed to execute the test. The TAA is the responsible management level who controls the resources (funding and personnel) to accept the risks associated with test. The TAA is determined based on the recommended technical and safety risks associated with the test. The PM and test planning team will identify mitigation strategies to minimize all risks to the lowest level, consistent with achieving test requirements.

The remaining risk is considered the residual risk, for the TAA levels.

5.1.1. Test Technical Risk Recommendation. The RD TL will manage the test process and will assign the independent test technical risk to recommend the TAA level associated with the residual technical risk. However when a formal TRB is held the test technical residual risk will be assigned by the Board.

5.1.2. Safety Risk Recommendation. The DET/SE will perform the independent safety risk assessment and recommend a TAA level associated with the residual safety risk. However, when a formal SRB is held the Board will recommend the safety residual risk for each hazard, as well as the test as a whole using the Risk Assessment Matrix IAW AFI91- 202/AFMC/AFRL Sup.

5.1.3. Formal TRB or SRB. Board meeting minutes will document any liens or actions required prior to test; identify board members, attendees; and document the overall TRB and SRB risk determined by the board on AFRL Forms 19B Technical Review Board and Form 19A Safety Review Board, respectively.

5.1.4. Personnel authorized to act as TAA are identified in Chapter 2 of this instruction.

AFRL/RD Division Chiefs will be the TAA for activities with Medium residual technical or safety risk that is not managed at the directorate level. Medium risk tests will not be delegated lower than Division Chief. Branch Chiefs will be the TAA for activities with Low residual technical or safety risk. AFRL/RD Director or Deputy Director in the director’s absence will be the TAA for any activity with Medium residual technical or safety risk that is of a complex nature, or has high political sensitivity. High technical residual risk efforts will be approved by the RD Director. Only the AFRL/CC or designee can be the TAA for any activity with a High residual safety risk.

TECHNICAL RISK: Technical risk is defined as follows:

Low Technical Risk. The test process is clearly understood and well known by the program team.

It is very likely that the test objectives can be achieved or the consequences of not achieving the objectives are negligible.

Medium Technical Risk. Portions of the test activities are new or have not been successfully demonstrated in the past. A moderate investment is required to execute the plan. There is a low to medium probability that some test objectives may not be achievable, but the consequences of not achieving them are minimal to moderate. An example would be a test that has a narrow window of opportunity for data collection, but the test could be repeated in a timely manner at a reasonable expense.

High Technical Risk. A significant portion of the planned test has not been successfully demonstrated by the test team. A significant investment is required to execute the test. Careful planning is required to ensure all preparation activities come together to ensure successful execution of the test. One or more organizations have committed significant resources to the test activity.