500-PG-8715.1.2D Applied Engineering and Technology Directorate Safety Manual.pdf

DIRECTIVE NO. 500-PG-8715.1.2D APPROVED BY Signature: Original signed by:

EFFECTIVE DATE: June 16, 2020 NAME: Felicia Jones

EXPIRATION DATE: June 16, 2025 TITLE: ETD Director

CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

08/16

Procedures and Guidelines (PG)

COMPLIANCE IS MANDATORY

Responsible Office: 500/Engineering and Technology Directorate (ETD) Title: Engineering and Technology Directorate Safety Manual

PREFACE

P.1 PURPOSE

The Engineering and Technology Directorate (ETD) Safety Manual is intended to establish the safety requirements of the ETD safety program, and to provide GSFC personnel contacts on specific subjects.

It summarizes the required safety information needed to conduct activities in ETD facilities. This Manual lists the pertinent NASA, GSFC, and Occupational Safety and Health Act (OSHA) requirement documents. It is not intended to replace any of the above documents. For more detailed information, the reference documents listed in each section can be consulted. For specific requirements for operations within each Division, refer to the specific Division/Branch Safety Manual.

P.2 APPLICABILITY

This Manual applies to all GSFC organizational elements, contractors, commercial projects, and personnel from other Government agencies while in ETD facilities.

a. In this document citations are assumed to be the latest version unless otherwise noted.

b. In this document, all mandatory actions (i.e., requirements) are denoted by statements containing the term “shall.” The terms “may” or “can” denote discretionary privilege or permission; “should” denotes a good practice and is recommended but not required; “will” denotes expected outcome; and “are/is” denotes descriptive material.

P.3 AUTHORITY

OSHA 29 CFR 1910 and 1926, Occupational Safety and Health Standards NPR 8715.1, NASA Occupational Safety and Health Programs NPR 8715.3, NASA General Safety Program Requirements GPR 1700.1, Occupational Safety and Health Program at Goddard Space Flight Center NPD 8700.1, NASA Policy for Safety and Mission Success

P.4 APPLICABLE DOCUMENTS AND FORMS

DIRECTIVE NO. 500-PG-8715.1.2D Page 2 of 112

EFFECTIVE DATE: 06/16/2020

EXPIRATION DATE: 06/16/2025

a. 29 CFR 1910, Safety and Health Regulations for General Industry

b. 29 CFR 1926, Safety and Health Regulations for Construction

c. 500-PG-8621.4.1, ETD Mishap and Close Call Investigation, Reporting and Corrective Actions

d. 500-PG-8715.1.1, ETD Safety Plan

e. 540-PG-8700.2.1, Design of Dollies, Stands and Spacecraft Shipping Containers

f. 540-PG-8719.1.1, Lift Sling Design

g. 800-PG-8710.3.1, Wallops Flight Facility Flex Hose Handling and Installation

h. ACGIH Threshold Limit Values for Chemical Substances and Physical Agents and Biological

Exposure Indices

i. ANSI Z359 series, Fall Protection Standards

j. ANSI Z41-1991, American National Standards for Personal Protection—Protective Footwear

k. ANSI Z87.1-1989, American National Standard Practice for Occupational and Educational Eye and Face Protection

l. ANSI/AIAA S-081, Space Systems- Composite Overwrapped Pressure Vessels (COPV)

m. ANSI/AISS S-080, Space Systems-Metallic Pressure Vessels, Pressurized Structures, Pressure

Components

n. ASME B30 series, Mobile Cranes and Hoists

o. ASME- B56, Low Lift and High Lift Trucks

p. ASME Boiler Pressure Vessel Code

q. GPR 1400.1, Waiver Processing

r. GPR 1700.2, GSFC’s Chemical Hygiene Program

s. GPR 1700.6, Confined Space Program at GSFC

t. GPR 1700.7, Electrical Safety

u. GPR 1700.8, GSFC Hazard Communication Program

v. GPR 1800.1, Goddard Space Flight Center Smoking Guidelines

w. GPR 1840.1, Asbestos Management Program

x. GPR 8500.1, Environmental Planning and Impact Assessment

y. GPR 8500.3, Waste Management

z. GPR 8621.4, GSFC Mishap Preparedness and Contingency Plan

aa. GPR 8710.3, Certification and Recertification of Ground-Based Pressure Vessels and

Pressurized Systems

bb. GPR 8710.7, Cryogenic Safety

cc. GPR 8715.5, Fire Protection at GSFC/Greenbelt

dd. GPR 8719.1, Certification and Recertification of Lifting Devices and Equipment

ee. GPR 8730.7 Laboratory Management Program

ff. GPR 8800.2, Local Exhaust Ventilation (LEV) System Maintenance and Repair Management

gg. GSFC-STD-8715.1, Goddard Technical Standard Explosive Safety Program

hh. NASA Reference Publication 1099, Lithium/Sulfur Dioxide Cell and Battery Safety

ii. NASA-STD-5005, Standard for The Design and Fabrication of Ground Support Equipment

jj. NASA-STD-5006, General Welding Requirements for Aerospace Materials

kk. NASA-STD-8719.9, Standard for Lifting Devices and Equipment, DIRECTIVE NO. 500-PG-8715.1.2D Page 3 of 112

ll. NFPA 101, Life Safety Code

mm. NFPA 70, National Electrical Code

nn. NFPA 79, Electrical Standard for Industrial Machinery

oo. NIOSH Work Practices Guide for Manual Lifting

pp. NPD 8710.5 Policy for Pressure Vessels and Pressurized Systems

qq. NPR 1800.1, NASA Occupational Health Program Procedures

rr. NPR 8715.3, NASA General Safety Program Requirements

P.5 CANCELLATION

500-PG-8715.1.2C, ETD Safety Manual

P.6 SAFETY

Each section specifies required training for that type of task.

P.7 TRAINING

Required training is listed in the applicable section

P.8 RECORDS

None directly associated with this PG.

P.9 MEASUREMENT/VERIFICATION

ETD considers the safety program a living program and strives to continuously improve the safety and health protection for employees. In order to do this, ETD has implemented area inspections, safety discussions, review of mishaps/close calls lessons learned, and surveys to ensure the safety of personnel, equipment, and facilities. Each branch shall report inspection findings in the SHEtrak database as required in the ETD Safety Plan (500-PG-8715.1.1). If employees are observed violating safety requirements, not only should that employee’s behavior be corrected, but the overall program should be evaluated to determine where improvements are needed. Mishap/close call investigations are used as a tool to identify deficiencies within the program. Lessons learned from investigations should be shared with all Divisions. Periodic discussions are held on safety topics, including close call/mishap reports, survey results, and inspection results. All inspections, audits, and surveys are available in the SHEtrak database, mishap action items are tracked in the NMIS system. SHEtrak can track metrics, such as the number of findings by Risk Assessment Code (RAC), the number of days open and category of findings. Metrics are gathered from the database showing the average days open of findings, numbers of findings by a RAC, and percent of each type

DIRECTIVE NO. 500-PG-8715.1.2D Page 4 of 112 of finding. These are used as a data point to determine the health of the Program. On a periodic basis metrics are presented to the Directorate management.

PROCEDURES

This Manual sets forth the requirements for conducting safe operations within the Engineering and Technology Directorate, Goddard Space Flight Center (GSFC), Greenbelt, Maryland and Wallops Flight Facility (WFF), Wallops Island, Virginia. It defines the requirements, responsibilities, and authorities for all activities conducted within the ETD facilities, and it delineates policies, processes, and approvals for those activities.

Although this ETD Manual does not specifically list the NPR 8715.3, NASA General Safety Program Requirements in each section of the Manual, it is understood that NPR 8715.3 sets the requirements for the overall safety program, which will always be followed. Cross-referenced section numbers, which point to more detailed information on a subject within the document, are enclosed in parentheses. The reader should check the table of contents.

This Manual is arranged to benefit both local facility users and personnel coming into ETD from outside the organization. It is divided into sections to help the reader. These sections contain the following information:

Section 1.0 is an overview of responsibilities and generic information that applies throughout the Manual.

Section 2.0 provides safety information strongly associated with test articles being brought into facilities Section 3.0 describes other ETD general operating/safety requirements over and above those specific topics addressed in section 2.0.

DIRECTIVE NO. 500-PG-8715.1.2D Page 5 of 112

Table of Contents

1.1 Policies

1.2 Responsibility

1.3 Personnel Certification/Qualification Definitions

1.4 Safety Variance

1.5 Mishaps

1.6 Emergency Evacuation

1.7 Construction

1.8 Housekeeping

1.9 Buddy System

1.10 Powered Vehicles

1.11 Joint Occupied Areas

1.12 Procedural Requirements

1.13 Extended Work Hours

1.15 Environmental

1.16 Access Requirements

Specific Safety Requirements

2.1 Mechanical Handling

2.2 Explosives, Propellants, and Pyrotechnics

2.3 Pressure & Vacuum Systems

2.4 Stored Energy Devices

2.5 Hazardous Materials and Hazardous Waste

2.6 Non-Ionizing Radiation Systems

2.7 Ionizing Radiation Systems

2.8 Electrical Systems and Equipment

2.9 Noise

2.10 Unique/Experimental Systems

2.11 Confined Spaces

General Safety Requirements

3.1 Working at Heights

3.2 Hand Tools and Miscellaneous Powered Equipment

3.3 Machine Shops

3.4 Welding, Brazing, Cutting and Hot Work

3.5 Smoking/Vaping

3.6 Personal Protective Equipment

3.7 Office Safety

3.8 Lockout/Tagout

3.9 Thermal and Other Heating Devices

3.10 Trailers

3.11 Industrial Hygiene Program

3.12 Nanotechnology

3.13 Extraterrestrial Dust

DIRECTIVE NO. 500-PG-8715.1.2D Page 6 of 112

3.14 Roll-Up Door Safety

3.15 Mercury Containing Devices

DIRECTIVE NO. 500-PG-8715.1.2D Page 7 of 112

1.1 Policies

It is the policy of the ETD to provide a safe work place for all personnel and operations. ETD strives to eliminate or reduce all potential hazards, thereby avoiding undue risk and accidents that can result in loss of life, injury to personnel, and damage to property, or loss of operating time and effectiveness. Where hazards cannot be eliminated, engineering controls, administrative controls and personal protective equipment (PPE) will be used to protect personnel, equipment, and facilities.

1.2 Responsibility

Safety is everyone’s responsibility. 500-PG-8715.1.1, ETD Safety Plan, lists the responsibilities of the Directorate Office, ETD Safety Manager, Division Offices, Branch Heads, Safety Representatives, and employees.

Each building or complex has an appointed Facility Operations Manager (FOM). The FOM’s responsibilities are delineated in, GPR 8830.1, Facilities Operations Manager.

Each individual—including GSFC government personnel, personnel from other government agencies, contractors and visitors—is responsible for complying with this Manual and identifying and correcting hazardous situations when noted. Individuals need to:

• Correct unsafe conditions if it is within their ability to do so.

• Secure the area to prevent harming others or damaging equipment and notify their supervisor.

Note: When referring to individuals from other agencies, academia and visitors we are referring to individuals that are on temporary assignment (Greater than X days) to GSFC for, but not limited to, ongoing Project work, in support of research science, and so on. In addition, there will need to be some level of training awareness with regards to GSFC safety requirements.

Flight project management or Product Development Leads (PDL) are responsible for assuring their team’s safety when working within ETD facilities. Individuals need to assess the hazards inherent in their operations and hardware and impacts they may have on others in the adjacent areas to their operations/hardware, mitigating all hazards to the lowest level. They are responsible for informing all other groups working on or within close proximity of their operations or hardware of any known hazards.

Laboratory Manager responsibilities are described in GPR 8730.7 Laboratory Management Program. In general Laboratory Managers serve as the liaison between government, contractor, and project personnel. They should be knowledgeable about safety requirements for operations in their labs and request compliance with those requirements.

1.3 Personnel Certification/Qualification Definitions

Personnel will be trained in the special skills, technical knowledge, and safety requirements necessary to perform their jobs and operate facilities, systems, and machines within ETD. Unless

DIRECTIVE NO. 500-PG-8715.1.2D Page 8 of 112 specifically noted otherwise, the following personnel certification and qualification definitions apply throughout this Manual:

• Authorized or Designated—An individual who has been selected or assigned by their employer or supervisor as being qualified to perform specific duties.

• Certified—An individual who has completed required training and physical examination as applicable and whose specific knowledge or proficiency in a skill has been demonstrated and documented.

• Competent—An individual who is capable of identifying existing and predictable hazards in the working environment, or working conditions which are dangerous to personnel, and who has authorization to take prompt corrective measures to eliminate them.

• Critical—An individual who has the duties and responsibility to make decisions that could affect the safety of personnel, hardware, or facilities; or one who is working critical operations, such as assembling high dollar value equipment. Examples of critical persons are task leaders and critical crane operators.

• Qualified—An individual who, by possession of a recognized degree, certificate, or professional standing, or knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems related to the subject matter, the work, or the project, or to satisfactorily operate a facility, system, or machine.

• Training—An organized and documented program of activities designed to impart the knowledge and skills required to be qualified to perform specific duties.

1.4 Safety Variance

Compliance with the requirements of this Manual is mandatory unless an approved variance has been obtained. A variance consists of documented and approved permission for relief from an established safety requirement. Variance approval must be consistent with the requirement level (The Code 500 Director approves Code 500 requirements, the Center Direct approves Center requirements, etc.). NPR 8715.3, Section 1.13 Safety Variances describes in detail requirements for obtaining relief from safety requirements and which type is appropriate to use. To process a variance refer to GPR 1400.1, Waiver Processing.

1.5 Mishaps

All mishaps (property damage greater than $20,000 or any injury/illness that requires more than first aid) and close calls (first aid cases or could have caused an injury or damage) shall be reported to the Branch Head, Division Safety Representative, Division Chief, Directorate Office and Code 360 (Greenbelt) or Code 800 Wallops) Safety Division (SD). Reporting to SD (Greenbelt & WFF) will be in NASA Mishap Information System (NMIS).

Definitions of mishaps, investigation requirements, and instructions for completing the required forms may be found in GPR 8621.4, GSFC Mishap Preparedness and Contingency Plan. All mishaps and close calls are assessed to determine where improvements in the safety program are required. Lessons Learned should be reported to the ETD Safety Committee. Section 1.14 describes the continuous improvement process. Mishaps

DIRECTIVE NO. 500-PG-8715.1.2D Page 9 of 112 within ETD are managed in accordance with 500-PG-8621.4.1, ETD Mishap and Close Call Investigation, Reporting and Corrective Actions

1.6 Emergency Evacuation

Any time evacuation alarms sound in the facilities, personnel are to evacuate.

Facility specific Emergency Building Plans (BEP) can be located at https://gs240sharepointeoc.gsfc.nasa.gov/sites/eoc/SitePages/Home.aspx .

Duties should be executed in accordance with the BEP training.

If critical operations are planned that would require employees to remain at their workstation during an evacuation event a separate evacuation plan must be submitted and approved by the GSFC Emergency Preparedness Coordinator (EPC) or the Wallops Emergency Preparedness Manager and the WFF Fire Department. The plan must reduce personnel on station and when imminent danger exists totally shut down and evacuate. All personnel shall be briefed on this plan prior to start of operation.

1.7 Construction

Code 500 performs, on a limited basis, activities that qualify as construction work per the OSHA definition. Primarily construction work performed within Code 500 affects our technical equipment such as thermal vacuum chambers, DI water systems or other equipment specific to our operations.

For all construction work regardless of impact, a GSFC Environmental & Safety Project Review Checklist will be submitted at the following link:

https://mosi.ndc.nasa.gov/EnvironmentalSafetyReview/

Where Code 500 performs construction work that has the potential to affect systems that Code 200, The Management Operations Directorate, maintains, owns, or is responsible for, Code 500 will coordinate with Code 224 to ensure our modifications comply with the GSFC Facility Specification and prevent unintended negative consequences to Code 200 supplied services. To submit projects to Code 224, use the “Consulting Services for Construction Activities” MOSI request, https://mosi.ndc.nasa.gov/services/new/services.xhtml

There are at least four instances where Code 500 construction work will be coordinated with FMD:

1. Infrastructure Changes – Modifications to any FMD supplied services (electrical, chilled water, steam, sanitary drains, potable water, etc.)

a. Code 500 will not modify fire suppression or fire alarm systems. Any modifications to fire suppression or fire alarms systems will be performed by FMD via a MOSI request.

2. Structural Changes – Modifications to the existing structure including: existing walls coming down, new walls going up, modifications to floors, ceilings, or walls.

a. Code 500 will not submit wall penetrations for conduit but will properly fire stop all penetrations regardless of the wall rating.

b. Floor and wall coating changes will not be submitted to FMD

3. Occupancy Changes – Modifications that would change the intended use and NFPA 101 classification of the space

DIRECTIVE NO. 500-PG-8715.1.2D Page 10 of 112

a. For example: changing an office into a lab space would require FMD review.

4. Installation or modification of equipment that FMD is expected to service or maintain.

When construction work is performed under the direction of any division within Code 500, this document and 29 CFR 1926, Safety and Health Regulations for Construction, apply.

1.8 Housekeeping

Although not specifically mentioned in each section, housekeeping is important to the safety of the overall operation. Each person is responsible for cleaning up the work area as part of their normal operations. Areas not adequately maintained in a clean state not only add to an unsafe condition, but normally affect the quality of the work product. As part of maintaining the work area, outside doors should be kept closed as much as possible. Fire doors shall never be propped open.

1.9 Buddy System

The buddy system is established for work in hazardous situations so that immediate help and assistance can be provided in case of an emergency. The buddy system requires that at least two employees are present during the performance of the task while at least one individual is remains unexposed to the hazard.

The buddy system shall be used on all jobs that involve high voltage, confined spaces, hazardous materials (i.e. chemicals, radiation sources) used near or above Immediately Dangerous to Life and Health levels, or any other task that places personnel at extreme risk.

1.10 Powered Vehicles

Petroleum powered vehicles and fuel containers require Branch Head or designee and SD approval prior to being stored or operated inside of a building. Petroleum includes but is not limited to, gasoline, diesel and propane fuels.

1.11 Joint Occupied Areas

The safety responsibility for jointly occupied work areas (Code 500 personnel and other groups) shall be the responsibility of the facility owner unless a Memorandum of Understand (MOU) is developed to identify the responsible party. Appendix D provides a MOU template that may be used to establish safety responsibility. Code 500 expects all groups working in Code 500 areas to comply with this Manual at a minimum.

If an occasion exists that an ETD safety requirement cannot be met, a safety variance will be processed in accordance with GPR 1400.1.

1.12 Procedural Requirements

Hazardous operations are those tasks that potentially have an immediate danger to the individual (death or serious injury) if not performed correctly, could create a danger to other individuals in the immediate area, or are a danger to the environment. These types of operations shall have written procedures, which are approved by the appropriate Line Manager or designee and safety representative. The procedures must be written in detailed steps to provide maximum protection to personnel, prevent procedural error, and minimize misinterpretation and include appropriate warnings and cautions where malfunctions or errors may cause injury or damage. Prior to the start of any hazardous portion of a procedure, the task leader holds a pre-task briefing with all personnel involved with the task to discuss the hazards, precautions, and required personal protective equipment

DIRECTIVE NO. 500-PG-8715.1.2D Page 11 of 112

1.13 Extended Work Hours

It is NASA policy that consideration of the potentially detrimental impacts of unusual shifts and prolonged work-times be given a high priority to prevent worker psychological and physiological stress and undesirable outcomes. Work-rest cycles shall take into consideration and make proper allowances for the work environment, including temperature extremes. NPR 1800.1, NASA Occupational Health Program Procedures, Section 2.15, Balancing Work-Rest Cycles states the NASA work hour requirements for critical and non-critical positions. A Critical Position is one in which at any time during the work day/week a worker's job performance can directly impact ground safety, flight safety, or mission success. All other positions are considered non-critical. Deviations from these maximum work times require approval by a designated supervisor.

1.15 Environmental

When planning a new task or modification to an existing task (i.e. process, project, lab, facility work, etc.). Code 250, Environmental Team should be consulted to ensure compliance with existing environmental laws and regulations. This should be completed early in the planning stages to avoid cost and schedule impacts and to minimize impacts to the environment. In accordance with GPR 8500.1, Environmental Planning and Impact Assessment, complete the Environmental Checklist (GSFC Form 23-75) through the Management Operations Services and Information System at https://mosi.ndc.nasa.gov/EnvironmentalSafetyReview/. Further information can be obtained by calling the Environmental Team at 6-0469 or 6-4693 at Greenbelt or 7-2319 at Wallops.

If handling, storing, transferring, or using petroleum-based oils (i.e., gasoline, #2 fuel oil, hydraulic fluid) and non-petroleum oils (i.e., animal fats, vegetable oils), or hazardous materials outside buildings, personnel shall complete GSFC Integrated Contingency Plan (ICP) training annually. The course is available in the classroom only during Safety Awareness Campaign or upon request. Containers with a shell capacity equal to or greater than 55 gallons must be managed in accordance with the GSFC ICP.

An electronic copy of the GSFC ICP may be found at Code 250 Medical and Environmental Management Division website at https://code200-external.gsfc.nasa.gov/250/environmental/documents under “Emergency Response Planning.” Access to the document is restricted to GSFC personnel.

1.16 Access Requirements

Certain ETD facilities require additional training to access and work in those areas without an escort.

Examples of these types of areas include the Integration & Test (I&T) Complex (Buildings 7/10/15/29) lab floor, the Detector Development Lab (DDL) (Building 30), clean rooms used to process flight hardware, and laboratories with Electrostatic Discharge (ESD) requirements. For specific requirements coordinate with the applicable building FOM or Lab Manager prior to entry.

Specific Safety Requirements This section of the Manual is designed to summarize Federal Agency and local requirements and to specify the requirements to be used when working in ETD facilities. This is not meant to replace existing documents, but to help the reader locate the knowledge needed to work safely.

DIRECTIVE NO. 500-PG-8715.1.2D Page 12 of 112

2.1 Mechanical Handling

2.1.1 Lifting Devices and Equipment (LDE)

2.1.1.1 Scope

This section covers lifting devices, such as overhead cranes, mobile cranes, and hoists.

2.1.1.2 Definitions

1. Critical Lifts—Lifting operations with special, high-dollar items such as spacecraft, one-of-a-kind articles, or major facility components, whose loss would have serious programmatic or institutional impact. Critical lifts also include operations with special personnel and equipment safety concerns beyond normal lifting hazards.

2. Noncritical Lift – Any lifting operation that does not meet the critical lifting definition.

2.1.1.3 General

The Standard for Lifting Devices and Equipment, NASA-STD-8719.9, establishes minimum safety requirements for LDE used for material handling. Compliance with NASA-STD-8719.9 is mandatory for all NASA-owned, NASA contractor, and visitor-supplied equipment to be used in support of NASA operations.

GPR 8719.1 defines the applicability, policy, and requirements to implement NASA-STD-8719.9 at NASA/GSFC in terms of LDE and LDE operator certification, and lifting operational requirements, respectively. The following section summarizes the relevant requirements of the aforementioned documents.

2.1.1.4 Design/Operational Requirements

1. General Safety Rules for Lifting Operations, prior to use the LDE operator will:

• Ensure that the certification is current prior to use for all involved LDE.

• Establish safety zones before initiating operations. Safety zones should have appropriate barriers

(rope, cones, etc.) established prior to an LDE lift.

• Ensure the lifting hook is connected to facility ground before connecting to explosives or EEDs. (See

Section 2.2.4)

• Obtain keys for access to LDE by contacting the Branch Head or the owner of the equipment.

• If radio communications are to be used, test the communication system prior to the operation. Operation will stop immediately upon communication loss, and not continue until communication is restored.

• Ensure loads are secure, balanced, and stabilized with proper slings. (See 540-PG-8719.1.1, Lift Sling

Design for information on sling design.) The use of tag lines may be required to keep the load controlled. Tag line personnel need to use caution not to impart undesirable motion to the load.

• Ensure flight hardware is not hoisted during a storm warning condition Code 3 (power outage could occur) or high winds Code 5, unless the stoppage of cranes and other handling equipment due to a power failure cannot result in a condition unacceptable to the Project or ETD Managers. A variance, which

DIRECTIVE NO. 500-PG-8715.1.2D Page 13 of 112 includes provisions to protect a suspended load will be approved by the cognizant project manager to hoist critical hardware during a Code 3 or 5 storm warning. The approved variance should be provided to the appropriate ETD Branch Manager. If a power failure occurs during a lift notify the LDEM immediately.

2. Safety Variances:

In the event that a NASA LDE requirement cannot be met, the Flight Project/Division Office shall prepare a safety variance request package in accordance with GPR 8719.1.

2.1.1.5 GSFC Contacts

Greenbelt LDE Manager: (301) 286-4209 WFF LDE Manager: (757) 824-1359 ETD Safety Manager: (301) 286-3976

2.1.1.6 Reference Documents Unique to this Section

OSHA 29 CFR 1910.179, Overhead and Gantry Cranes OSHA 29 CFR 1910.184, Slings OSHA 29 CFR 1910.67, Vehicle-Mounted Elevating and Rotating Work Platforms NASA-STD-8719.9, Standard for Lifting Devices and Equipment GPR 8719.1, Certification and Recertification of Lifting Devices and Equipment

2.1.2 Lifting Assemblies/Components and Load Cells

2.1.2.1 Scope

This section covers the safety requirements to be met when using lifting assemblies, load cells and positioning devices. Lifting assemblies include below the hook lifting devices and rigging equipment such as, lift slings, shackles, eyebolts, hoist rings, and turnbuckles.) This section includes those devices as defined by ASME B30 series.

2.1.2.2 Acronyms/Definitions

1. Critical weld—A weld that if removed from the structural sling or component would cause structural failure.

2. Load Positioning Device (Hyrda-set)—A manually operated hydraulic lifting device designed to incrementally lift and lower critical loads such as space flight hardware.

3. Rigging (components)—Components such as wire rope cables, nylon straps, shackles, and hoist rings intended to be used in lifting operations.

4. Load cell—A device used to monitor applied load during lifting operations.

5. Below the Hook Lifting Device (BTH)—a lifting device used for hoisting that employs a beam or beams to span the attached load and may include the use of a lift sling(s) in the assembly.

DIRECTIVE NO. 500-PG-8715.1.2D Page 14 of 112

2.1.2.3 General

Operations employing lifting assemblies (rigging and BTH), load cells, and positioning devices shall be considered hazardous operations, and proper safety precautions adhered to at all times.

Employees need to understand the most common hazards of their operation, such as:

• Injuries from falling items due to equipment or hardware failure.

• Injuries from swinging items due to inattention or poor equipment operation.

• Shock, fire, and electrocution from electrical problems.

2.1.2.4 Design/Operational Requirements

Employees who work with lifting assemblies, load cells, and positioning devices shall inspect them before each use to verify that they are in proper working condition and that they have visible and current certifications. Employees who assemble or use these devices will be a certified crane operator.

Guidelines for the use of this equipment are as follows:

1) Lifting operations require the use of safety shoes and except in specific circumstances described in

Section 3.6.4 Hard Hats. Safety glasses or goggles may be required in the presence of flight hardware containing high-pressure gases or fluids, project safety will make the determination.

2) Lifting assemblies, individual lifting components, shall be certified and affixed with a tag in accordance with GPR 8719.1. All expired equipment will be segregated and positively controlled to preclude inadvertent use by placing in a designated area until recertified. Contact the LDE group to recertify the equipment.

3) A lift stability analysis and stress analysis shall be required for all critical lifts. See NASA-STD-

8719.9 and/or 540-PG-8719.1.1 for detailed requirements.

4) If replacement of a damaged lifting assembly component is required, the replacement must be identical and individually proof tested.

a) Concurrence of the LDE Manager must be obtained for all proof test procedures performed on

GSFC components.

5) Documentation, including procedures, Non-Destructive Test (NDT) reports, and/or certification of compliance, for hardware that is proof tested and inspected out-of-house is submitted to the LDEM prior to use.

6) Equipment or hardware that is not affixed with a proper certification tag, or has a certification date that has expired is considered uncertified and shall not be used. This equipment needs to be segregated and submitted to the LDEM for certification.

7) Load cells shall be calibrated and tested annually to 100% of safe working load. When using old style load cells with detachable eyebolts, safety wire the eyebolt to the load cell to preclude inadvertent disengagement from the cell during use.

8) Basic safety guidelines: Personnel can prevent injuries and payload damage involving the use of lifting assemblies, load cells, and individual lifting components by obeying the following guidelines:

DIRECTIVE NO. 500-PG-8715.1.2D Page 15 of 112

• Thoroughly inspect each piece of equipment and hardware prior to its use, and report any problems immediately.

• Only operate equipment certified and authorized to use.

• If the equipment or hardware has expired certification, or if the certification tag is missing, do not use it.

• Make sure the equipment or hardware is rated to handle the desired load. If there are any doubts about the rating or the load to be applied, see your supervisor.

• Wear the proper PPE.

2.1.2.5 Load Positioners (Hydrasets)

2.1.2.5.1 Scope

This section covers load positioners (Hydra-sets).

2.1.2.5.2 Acronyms/Definitions

1. Load Positioner—A manually operated hydraulic lifting device designed to incrementally lift and lower critical loads such as spaceflight hardware.

2. Load positioner certification/recertification—A process performed by the LDE Group which leads to the initial certification, or continuation of certification, validating that maintenance, test, or other operational checks have been performed and are current.

2.1.2.5.3 General

Hydra-sets should be used when there is a requirement for precise adjustment when lifting critical hardware and the crane is not capable of providing the precision required.

2.1.2.5.4 Design/Operational Requirements

1. Load positioners that have the necessary design features, maintenance/inspection, and test intervals to lift critical loads shall be conspicuously marked so that the operator and assurance personnel can distinguish that the Hydra-set is qualified for critical lift.

2. For best performance, select a Hydra-set so that the intended load is between 20% and 80% of the Load positioner’s capacity.

3. Exercise Hydra-Sets prior to critical lifts with a dummy load that is at least equivalent to the weight of the item to be lifted.

4. LDE tags are issued and attached to certified/recertified equipment.

5. Only certified (licensed) operators are authorized to operate GSFC Load positioners. Training shall include the properties of Load positioners, operating procedures, hands-on training, and an operational demonstration.

2.1.2.5.5 GSFC Contacts

See Section 2.1.1.5.

DIRECTIVE NO. 500-PG-8715.1.2D Page 16 of 112

2.1.2.5.6 Reference Documents Unique to this Section

DEL PUB 81-1, Model A Hydra-Set DEL PUB 81-2, Model B Hydra-Set DEL PUB 81-3, Model C Hydra-Set DEL PUB 81-4, Model D Hydra-Set DEL PUB 81-5, Model E Hydra-Set DEL PUB 81-6, Model ES Hydra-Set NASA-STD-8719.9, Standard for Lifting Devices and Equipment See also Section 2.1.1.6.

2.1.2.5 GSFC Contacts

See Section 2.1.1.5.

2.1.2.6 Reference Documents Unique to this Section

540-PG-87191.1, Lift Sling Design See Section 2.1.1.6.

2.1.3 Powered Industrial Trucks

2.1.3.1 Scope

This section covers powered industrial trucks (PITs) used for material handling. PITs include forklifts and tugs used for moving equipment and flight hardware.

2.1.3.2 Acronyms/Definitions

None

2.1.3.3 General

For PITs covered by NASA-STD-8719.9, it is GSFC’s policy to follow standard industry/manufacturer recommended practices and applicable Federal, State, and local government regulations. PITs shall be inspected and certified by the LDEM.

2.1.3.4 Design/Operational Requirements

1. Equipment Certification:

a. Only PITs designed and constructed in accordance with ASME- B56 series documents shall be used on ETD properties.

b. Modifications to equipment including the use of fork extensions shall be approved by the Original Equipment Manufacturer (OEM). If the OEM is no longer available, an engineering analysis may be submitted to the LDEM for approval.

DIRECTIVE NO. 500-PG-8715.1.2D Page 17 of 112

c. The owner organization shall perform a safety analysis such as a fault tree analysis, FMEA, O&SHA on all PITs used for critical lifts.

d. The owner organization shall perform maintenance and repairs per OEM recommendations.

2. Operator Training:

a. Only certified by the LDEM shall be authorized to operate PITs.

3. General Requirements and Safety Rules:

a. The operator shall perform an inspection prior to the first use each shift and record the results in the logbook. Defects are to be reported immediately to LDEM.

b. Where provided, seatbelts shall be worn.

c. Diesel-powered or propane-powered vehicles are not allowed inside buildings beyond the truck locks without FOM approval. The use of gasoline-powered vehicles inside the truck locks or buildings are approved by the FOM on a case-by-case basis with appropriate hazard controls in place. Approval must be documented either within the daily logbook or other approved means.

d. Name plates, certification labels and markings shall be maintained in place and in a legible condition.

2.1.3.5 GSFC Contacts

See Section 2.1.1.5.

2.1.3.6 Reference Documents Unique to this Section

OSHA 29 CFR 1910.178, Powered Industrial Trucks ASME B56.1, Part II, Safety Standard for Low Lift and High Lift Trucks ASME B 56.9, Safety Standard for Operator Controlled Industrial Tow Tractors ASME B 56.10, Safety Standard for Manually Propelled High Lift Industrial Trucks Original Equipment Manufacturer’s Maintenance Manuals and Recommendations See also Section 2.1.1.6.

2.1.4 Mechanical Ground Support Equipment (MGSE)

2.1.4.1 Scope

This section covers MGSE such as dollies, tables, jacks, stands, and other hardware used to transport, orient or support payloads/test articles or fixtures.

2.1.4.2 Acronyms/Definitions

None specific for this section.

2.1.4.3 General

Certain MGSE may use mechanical, electrical and/or hydraulic power to orient a payload/test article or fixture that is mounted to it. All MGSE shall be properly certified in accordance with 540-PG-8700.2.1, Design of Dollies, Stands and Spacecraft Shipping Containers and thoroughly

DIRECTIVE NO. 500-PG-8715.1.2D Page 18 of 112 inspected prior to use. The user should be fully cognizant of its proper operation and common hazards of their operation, such as:

a. Injuries from contact with unguarded areas of operation, such as rotating shafts and crush points.

b. Shock, fire, and electrocution from electrical problems.

c. Injury from high-pressure fluids.

d. Injury caused by defective equipment, structural failure, or improper use of the equipment.

MGSE is intended to be moved throughout the facilities on casters or air-bearing support assemblies and to be raised or lowered with jacks. The employee shall understand the most common hazards of these operations, which are:

a. Collision of moving MGSE with the employee and the resultant injury.

b. Collision of moving MGSE with hardware or equipment located in the facility and the resultant personal injury due to indirect causes.

c. Injury from high pressure gases or fluids.

d. Crushing injury caused by defective jacks or stands.

2.1.4.4 Design/Operational Requirements

Employees who work with MGSE shall inspect the equipment before use to verify it is in proper working condition and be familiar with the equipment’s proper operation. Guidelines for the use of MGSE are as follows:

Always wear PPE (Section 3.6) appropriate for the task at hand. Safety glasses or goggles may need to be worn in the presence of high-pressure fluids and gases unless the system/equipment has been proven stable. Garments that protect the body but are not prone to snagging in moving mechanisms are appropriate.

Personnel shall not use MGSE if any of the following applies:

a. The equipment does not have a clearly visible and properly prepared certification tag

b. It is not being used for its intended function

c. It is handling loads greater than it has been certified for

d. It has been damaged or altered and has not been repaired and recertified.

MGSE with pressurized and electrical equipment will follow the safety requirements as stated in the applicable sections of this Manual.

Jacks need to comply with the regulations contained in OSHA 1910.244, NASA-STD-8719.9 and ASME/ANSI B30.1. Observe the following when working with jacks:

a. Jacks used to lift or support flight hardware or where loss of control could damage flight hardware shall be analyzed, tested, inspected, and certified per NASA-STD-8719.9.

b. The jack shall be legibly and permanently marked in a prominent location with its rated load capacity.

c. The manufacturer shall test all new jacks to rated load.

DIRECTIVE NO. 500-PG-8715.1.2D Page 19 of 112

d. The operator shall watch the stop indicator in order to determine the limit of travel. The indicated limit is not to be overrun.

e. Once the load is raised, personnel shall crib, block, or otherwise secure the load. Follow the load with cribbing where practical. Take measures to prevent personnel from working or passing under the load until it is secured.

f. Ensure that there is sufficient swing area for the operating lever(s).

g. Remove operating levers when not in use to avoid accidental dislocation of the jack and to reduce the tripping hazard.

h. Ensure that operators are instructed as to signals and other procedures for multiple jacks or other special lifts.

i. Off-center loading of jacks should be avoided.

j. Extenders shall not be used unless authorized by the LDEM.

All critical fixtures used for environmental testing shall have stress and stability analysis and be approved by the appropriate Branch engineering to verify adequacy for the proposed purpose and proper mating with facility systems. Critical fixtures are those that support or are mounted over critical hardware as defined in NASA-STD-8719.9. All fixtures brought in from outside sources require an independent review by the Environmental Test Engineering & Integration Branch (Code 549).

2.1.4.5 GSFC Contacts

LDE Manager: (301) 286-4209 WFF LDE Manager: (757) 824-1359 ETD Safety Manager: (301) 286-3976 Code 549 Branch Head: (301) 286-2187

2.1.4.6 Reference Documents Unique to this Section

OSHA 1910.244, Other Portable Tools and Equipment ASME/ANSI B30.1, Jacks NASA-STD-8719.9, Standard for Lifting Devices and Equipment

2.2 Explosives, Propellants, and Pyrotechnics

2.2.1 Scope

This section describes the requirements for energetic materials including explosives, propellants, and pyrotechnics brought into or used within ETD facilities.

2.2.2 Acronyms/Definitions

1. Category of Personnel – For the purpose of this explosive site plan, personnel are categorized as followed for the purpose of determining levels of protection:

a. Casuals – Persons not normally part of an operation involving energetic materials but have duties that require their presence, such as quality assurance, safety, etc.

b. Essential Personnel – Individuals identified as such by the program, project, mission, or tenant with responsibility for the operation.

DIRECTIVE NO. 500-PG-8715.1.2D Page 20 of 112

c. General Public – Persons not associated with a NASA’s mission or operations (e.g., visitors, guests of personnel assigned to the installation, or persons not employed or contracted by NASA or the Center).

d. Non-essential Personnel – Personnel not essential to, or involved with, the immediate operation presenting the energetic materials hazard.

e. Visitors – Visitors are non-essential personnel with limited access. No operations involving energetic materials shall be conducted when visitors are present.

2. Electrically Initiated Device (EID) – Single unit, device, or subassembly that uses electrical energy to produce an explosive, pyrotechnic, thermal, or mechanical output. Examples include: electro-explosive devices (such as hot bridgewire, Semiconductor Bridge, Carbon Bridge, and conductive composition), exploding foil initiators, laser initiators, burn wires, and fusible links.

3. Electrostatic Discharge (ESD) – An arcing of electric charge across a gap between two points not in contact, or through a nonconductor when the voltage exceeds the dielectric breakdown voltage of the nonconductor.

4. Explosive(s) – Any chemical compound or mechanical mixture that, when subjected to heat, impact, friction, detonation, or other suitable initiation, undergoes a very rapid chemical change with the evolution of large volumes of highly heated gases that exert pressures in the surrounding medium.

The term applies to materials that deflagrate, explode, or detonate.

a. Deflagration – Ignition and rapid burning of the confined energetic materials builds up high local pressures leading to nonviolent pressure release as a result of a low strength case or venting through case closures (e.g., loading ports or fuze wells). The case might rupture but does not fragment; closure covers might be expelled, and unburned and burning energetic materials might be thrown about and spread the fire. Propulsion might launch an unsecured test item, causing an additional hazard. No blast or significant fragmentation damage to the surroundings is expected, only heat and smoke damage from the burning explosive substances.

b. Explosion – Ignition and rapid burning of the confined energetic materials builds up high local pressures leading to breakup of the confining structure. Metal cases are fragmented (e.g., brittle fracture) into large pieces that are often thrown long distances. Unreacted or burning energetic materials are also thrown about. Fire and smoke hazards will exist. Air shocks are produced that can cause damage to nearby structures. The blast and high velocity fragments can cause minor ground craters and damage (e.g., breakup, tearing, gouging) to adjacent metal plates. Blast pressures are lower than for a detonation reaction.

c. Detonation – A supersonic decomposition reaction propagates through the energetic materials and produces an intense shock in the surrounding medium and very rapid plastic deformation of metallic cases, followed by extensive fragmentation. All energetic materials will be consumed. Effects will include large ground craters for items on or close to the ground; holing, plastic flow damage, and fragmentation of adjacent metal structures; and blast overpressure damage to nearby structures.

5. Fragmentation – Breaking up of the confining material of a chemical or mechanical mixture when an explosion takes place. Fragments may be complete items, subassemblies, pieces thereof, or pieces of equipment or buildings containing the items.

DIRECTIVE NO. 500-PG-8715.1.2D Page 21 of 112

6. Hazard Classes and Divisions – The DoT hazard classification system consists of nine hazard classes plus a non-regulated category that applies when explosives and hazardous materials are present in an item, but not to a degree that meets the criteria for assignment to one of the nine classes. Class 1 applies to articles where the explosive hazard predominates. Under Class 1, there are six divisions further defining the hazard (four are defined here):

a. Hazard Division 1.1 – Mass explosion.

b. Hazard Division 1.2 – Non-mass explosion, fragment producing.

c. Hazard Division 1.3 – Mass fire, minor blast or fragment.

d. Hazard Division 1.4 – Moderate fire, no significant blast or fragment.

7. Minimum Separation Distance – Minimum distance between Potential Explosion Site(s) and personnel, assets, or structures required to provide the appropriate level of protection from a detonation (either intentional or unintentional) at the Potential Explosion Site.

a. Inhabited Building Distance – minimum distance required to protect facilities and personnel not directly related to explosives storage and operations. Distance to be maintained between explosives areas and administrative areas, operating lines with dissimilar hazards, and explosive areas and Center boundaries.

• Conventional structures can sustain damage up to 5 percent of replacement cost.

• Personnel in buildings are provided a high degree of protection from death or serious injury; however, glass breakage and building debris may still cause some injuries.

• Personnel in the open are not expected to be injured seriously by blast effects, but fragments and debris may cause some injuries.

b. Public Traffic Route Distance – minimum distance required between a Potential Explosion

Site and any public street, road, highway, navigable stream, or passenger railroad. This includes roads on NASA Centers that are open to non-essential personnel or the public for thoroughfare.

• Conventional structures can sustain damage up to 20 percent of replacement cost.

• Occupants of exposed structures may suffer temporary hearing loss or injury from blast effects, building debris, and displacement.

• Personnel in the open are not expected to be killed or seriously injured by blast effects, but fragments and debris may cause some injuries.

• Vehicles on the road may suffer little damage, unless they are hit by a fragment or the blast causes a momentary loss of control.

c. Intra‐Line Distance – minimum distance required to protect activities associated with explosives storage and operations.

• Recognizes operational need for some personnel to be in proximity to explosives while preserving some protection in the event of an explosives accident.

• Conventional structures will be extensively damaged and occupants may be severely injured.

• Should prevent propagation between two explosives locations.

DIRECTIVE NO. 500-PG-8715.1.2D Page 22 of 112

d. Intermagazine Distance – minimum distance between explosive storage sites to prevent an explosion in one explosive storage site from simultaneously detonating an adjacent explosive storage site.

• No guarantee that propagation from one explosive storage site to another will not occur, only that the explosives will not simultaneously detonate.

• Severe structural damage approaching total destruction is expected for conventional structures, and severe personnel injury or death is expected.

2.2.3 General

The greatest hazard to personnel in handling and use of energetic materials is unplanned initiation.

The recognized causes of unplanned…