MSD Safety Manual.pdf

DIRECTIVE NO. 540-PG-8715.1.2E Page 2 of 92

EFFECTIVE DATE: 08/16/2022

EXPIRATION DATE: 08/16/2027

CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

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

GSFC 3-18 (11/09)

P.4 REFERENCES

Each section lists the unique reference documents applicable for that section. Sections of the ETD Safety Manual are referred to within this document. The ETD Safety Manual lists the general safety requirements to be followed throughout the Directorate.

P.5 CANCELLATION

540-PG-8715.1.1D, MSD Safety Manual

P.6 SAFETY

This Manual describes safety issues associated with specific facilities or process areas within MSD.

This Manual sets forth the requirements for conducting safe operations within the Mechanical Systems Division (MSD), Goddard Space Flight Center (GSFC), Greenbelt, Maryland and Wallops Flight Facility (WFF), Virginia. In general, this includes activities in the follow areas: Buildings 4, 5, 5A, 7, 10, 15, 29, 30, 84, 302, 303, 304, and 305 and WFF D-101, E109, F-7, N-159, V-45/50/55, X-35, and X-55.

Although this Manual does not specifically list the NPR 8715.3, NASA Safety Manual 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. Those referring to sections of the ETD Safety Manual will be noted as ETD SM with the applicable section number.

P.7 TRAINING

Any required training is listed in the applicable section.

P.8 RECORDS

Record Title Record Custodian Non-ionizing Radiation Systems, forms GSFC 23-6RF, 23-28RF, 23-35RF, 23-6L, 23-28L, 23-67A/B, and 23-35LU GSFC Radiation Protection

Office

Ionizing Radiation Systems, forms GSFC 23-6I, 23-28I, 23-35IP, 23-6ID and 23-28ID GSFC Radiation Protection

Office

Pressure Systems Formal Certification Report Pressure Systems Manager

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Hot Work Permit forms GSFC 23-4 and 23-4A and Utility Outage Request Form Issuing Organization

Confined Space Entry Permit form GSFC 23-52 Issuing Organization

Code 200 Electronics Management Services Operations and Information (eMOSI) Portal; Email the Hazardous Waste team at GSFC-HAZWASTE@lists.nasa.gov

Medical and Environmental Management Division

(MEMD)

Safety Data Sheets (SDS) Appropriate Branch Head or Safety Representative

NASA Mishap Information System (NMIS) https://nmis.sma.nasa.gov/ Issuing Organization

P.9 MEASUREMENT/VERIFICATION

None

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Table of Contents

1.0 INTRODUCTION

2.0 FACILITIES REQUIREMENTS

2.1 Acoustic Chamber

2.1.1 Scope

2.1.2 General

2.1.3 Specific Facility Requirements

2.1.4 GSFC Contacts

2.1.5 Reference Documents Unique to this Section

2.2 Cleanrooms

2.2.1 Scope

2.2.2 General

2.2.3 Specific Facility Requirements

2.2.4 GSFC Contacts

2.2.5 Reference Documents Unique to this Section

2.3 Advanced Composite Materials Lab (ACML)

2.3.1 Scope

2.3.2 General

2.3.3 Specific Facility Requirements

2.3.4 GSFC Contacts

2.3.5 Reference Documents Unique to this Section

2.4 Electromagnetic Compatibility

2.4.1 Scope

2.4.2 General

2.4.3 Specific Facility Requirements

2.4.4 GSFC Contacts

2.4.5 Reference Documents Unique to this Section

2.5 High Capacity Centrifuge

2.5.1 Scope

2.5.2 General

2.5.3 Specific Facility Requirements

2.5.4 GSFC Contacts

2.5.5 Reference Documents Unique to this Section

2.6 Mechanical Integration

2.6.1 Scope

2.6.2 General

2.6.3 Design/Operational Requirements

2.6.4 GSFC Contacts

2.6.5 Reference Documents Unique to this Section

2.7 Advanced Manufacturing

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2.7.1 Scope

2.7.2 General

2.7.3 Specific Facility Requirements

2.7.4 GSFC Contacts

2.7.5 Reference Documents Unique to this Section

2.8 Magnetics

2.8.1 Scope

2.8.2 General

2.8.3 Specific Facility Requirements

2.8.4 GSFC Contacts

2.8.5 Reference Documents Unique to this Section

2.9 Mass Properties

2.9.1 Scope

2.9.2 General

2.9.3 Specific Facility Requirements

2.9.4 GSFC Contacts

2.9.5 Reference Documents Unique to this Section

2.10 Modal Survey

2.10.1 Scope

2.10.2 General

2.10.3 Specific Facility Requirements

2.10.4 GSFC Contacts

2.10.5 Reference Documents Unique to this Section

2.11 Plating Facility

2.11.1 Scope

2.11.2 General

2.11.3 Specific Facility Requirements

2.11.4 Hazardous Chemicals Specific to the Plating Facility

2.11.5 GSFC Contacts

2.11.6 Reference Documents Unique to this Section

2.12 Precision Assembly Area

2.12.1 Scope

2.12.2 General

2.12.3 Specific Facility Requirements

2.12.4 GSFC Contacts

2.12.5 Reference Documents Unique to this Section

2.13 Static Test

2.13.1 Scope

2.13.2 General

2.13.3 Specific Facility Requirements

2.13.4 GSFC Contacts

2.13.5 Reference Documents Unique to this Section

2.14 Thermal Vacuum

2.14.1 Scope

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2.14.2 General

2.14.3 Specific Facility Requirements

2.14.4 GSFC Contacts

2.14.5 Reference Documents Unique to this Section

2.15 Vibration Laboratory

2.15.1 Scope

2.15.2 General

2.15.3 Specific Facility Requirements

2.15.4 GSFC Contacts

2.15.5 Reference Documents Unique to this Section

2.16 Computer Aided Design (CAD) Computer Facilities

2.16.1 Scope

2.16.2 General

2.16.3 Specific Facility Requirements

2.16.4 GSFC Contacts

2.16.5 Reference Documents Unique to this Section

2.17 Code 544 Mechanical, Electronical, and Mechanism Assembly and Test Laboratories53

2.17.1 Scope

2.17.2 General

2.17.3 Specific Facility Requirements

2.17.4 GSFC Contacts

2.17.5 Reference Documents Unique to this Section

2.18 Thermal Coating Characterization and Environmental Testing Facility

2.18.1 Scope

2.18.2 General

2.18.3 Specific Facility Requirements

2.18.4 GSFC Contacts

2.18.5 Reference Documents Unique to this Section

2.19 Thermal Technology Development Facility

2.19.1 Scope

2.19.2 General

2.19.3 Specific Facility Requirements

2.19.4 GSFC Contacts

2.19.5 Reference Documents Unique to this Section

2.20 Thin Film Deposition Facility

2.20.1 Scope

2.20.2 General

2.20.3 Specific Facility Requirements

2.20.4 GSFC Contacts

2.20.5 Reference Documents Unique to this Section

2.21 Thermal Coatings Application Facility

2.21.1 Scope

2.21.2 General

2.21.3 Specific Facility Requirements

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2.21.4 GSFC Contacts

2.21.5 Reference Documents Unique to this Section

2.22 Molecular Kinetics Facility

2.22.1 Scope

2.22.2 General

2.22.3 Specific Facility Requirements

2.22.4 GSFC Contacts

2.22.5 Reference Documents Unique to this Section

2.23 BRDF(Bidirectional Reflectance Distribuition Function) and Advanced Techniques for Cleaning, Analysis and Verification (BATCAVE)

2.23.1 Scope

2.23.2 General

2.23.3 Specific Facility Requirements

2.23.4 GSFC Contacts

2.23.5 Reference Documents Unique to this Section

2.24 Pressure Vessel System and Lifting Devices and Equipment Inspection and Testing Laboratories

2.24.1 Scope

2.24.2 General

2.24.3 General Facility Requirements

2.24.4 Specific PVS Lab Requirements

2.24.5 Specific NDT Lab Requirements

2.24.6 Specific LDE Sling Test Lab Requirements

2.24.7 GSFC Contacts

2.24.8 Reference Documents Unique to this Section

2.25 W045 Mechanical Assembly Laboratory, W51 Integration and Test Facility, and W27 Advanced Development Facility

2.25.1 Scope

2.25.2 General

2.25.3 Specific Facility Requirements 74

2.25.4 GSFC Contacts

2.25.5 Reference Documents Unique to this Section

2.26 Materials Engineering Branch Facilities

2.26.1 Scope

2.26.2 General

2.26.3 Specific Facility Requirements

2.26.4 GSFC Contacts

2.26.5 Reference Documents Unique to this Section

2.27 Nanotechnology Facility …………………………………………………………….. 81

2.27.1 Scope …………………………………………………………………………… 81

2.27.2 General …………………………………………………………………………. 81

2.27.3 General Facility Requirements …… …………………………………………. 81

2.27.4 GSFC Contacts ………………………… ……………………………………. 81

2.27.5 Reference Documents Unique to this Section …………………… ………….. 82

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2.28 WFF Facilities

2.28.1 Scope

2.28.2 General

2.28.3 General Facility Requirements

2.28.4 Specific Facility Requirements

2.28.5 WFF Contacts

2.28.6 Reference Documents Unique to this Section

2.29.0 Storm Conditions

2.29.1 Scope

2.29.2 Acronyms/Definitions 86

2.29.3 General

2.29.4 Design/Operational Requirements

2.29.5 GSFC Contacts

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1.0 Introduction

This Manual is designed to provide the specific safety requirements for the facilities within the MSD.

This manual describes the safety issues encountered in each of the various test facilities and labs found in MSD.

In most cases, 540 Branches have detailed safety requirements that apply to work being performed in their labs and facilities. Branch management should be consulted to inquire about these requirements before work is started in any Division lab or facility.

Any remaining questions as to the safety of the test article should be directed toward the Code 360 Safety Division, the MSD Safety Lead, or the ETD Safety Manager

Hazardous situations not resolved, or extremely hazardous situations, will be brought to the attention of the applicable Branch Head.

Problem areas not resolved will call for immediate stoppage of all work.

2.0 Facilities Requirements

2.0.1 Facility General Requirements

2.0.2 Scope

This section is a collection of umbrella requirements which are repetitive in multiple facilities within Code 540/MSD.

2.0.3 General Requirements

All facility managers should be familiar with the requirements in this section as they pertain to various operations throughout the MSD.

1. Storm Warning: A Storm Warning Condition Status 3 will preclude crane lifts, structural dynamics testing, and EMI/EMC testing in the building 7/10/15/29 Integration & Test (I&T) complex unless a waiver has been signed by the Code 549 Branch Head (or designee—this may be the lead Project Test Engineer) and the Project Representative. This requirement refers primarily to work in the Acoustics (Section 2.1), Vibration Testing (Section 2.16), Electromagnetic Compatibility (Section 2.4), High Capacity Centrifuge (Section 2.5) and critical crane operations.

2. Custodial Interaction: Once shop personnel, machine operators and/or technicians have ensured that potential hazards have been removed, they may allow custodial personnel to clean floor and office areas.

3. Cleaning with Compressed Air: House-supplied compressed air used for cleaning will be set to 30 psi (207 kpa).

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4. Standard Personal Protection for Machinery: When operating machinery, personnel will wear approved eye protection, such as safety glasses, goggles, or full-face shield with goggles/glasses, as well as ear defenders or plugs as necessary, and safety shoes. Follow the guidance as per the ETD Safety Manual and OSHA Requirements. This requirement refers primarily to machinery as shown in the Composite Materials Shop (Section 2.3), Precision Assembly Area (Section 2.13), Electronic Test & Assembly Lab (Section 2.19), and Contamination Engineering Analysis Facility (Section 2.26).

5. Standard Personal Protection Equipment (PPE) for other applications: All personnel will wear PPE appropriate for the activity at hand.

6. Lifting Devices and Equipment Operations: Only certified operators shall operate cranes, mobile aerial platforms and/or powered industrial trucks.

7. Suspended Load Operations: The crane operator will ensure that no personnel are beneath the suspended load at any time.

2.1 Acoustic Chamber

2.1.1 Scope

This section covers the acoustic reverberation chamber and its subsystems, located in Buildings 7/10.

2.1.2 General

Facilities and subsystems covered in this section are:

1. Acoustic Reverberation Chamber: The 40,000 ft3 (1,100 m3) reverberation chamber located adjacent to the Building 7 truck lock and Building 10 High Bay.

2. GN2 Supply for the Acoustic Horns: The GN2 storage system located on the Building 7 parking lot, which supplies the GN2 needed to drive the acoustic generators and horns inside the acoustic chamber.

3. Chamber Air Handling System: The chamber air handling system either recirculates Building 10 conditioned air within the chamber, or exhausts nitrogen-rich chamber air to the outside atmosphere atop the chamber.

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2.1.3 Specific Facility Requirements

The purpose of acoustic testing is to verify that test articles can withstand sound pressure levels up to 154 dB overall, in the frequency range of 25 Hz to 10 kHz. These noise levels are high enough to cause damage to equipment and personnel. Acoustic generators that drive the horns in the reverberation chamber are electro-pneumatically activated. The generators modulate nitrogen gas, which vents through the horns into the chamber. Nitrogen gas depletes oxygen inside the chamber, so special procedures are necessary to protect personnel who enter the chamber.

If necessary, the chamber can be cleaned and maintained as a Class 100 K (M6.5) cleanroom environment. Also, the chamber can be used as a controlled access facility for conducting deployment and shock separation testing. This shock testing requires the handling and firing of electro-explosive ordnance devices.

Special procedures for this facility are as follows:

1. The qualifications of the acoustic control system operators are determined by the facility supervisor.

Only qualified operators, who can demonstrate their ability to operate the control system, are approved to operate the acoustic control system. The facility supervisor maintains and controls appropriate training records.

2. Personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #1 - Storm Warning.

3. Notify the building Facility Operations Manager (FOM) prior to testing so that they can notify occupants of the building.

4. Authorized personnel enter the reverberation chamber either through the personnel door located in the anteroom in the Building 7 truck lock, or through the main doors located in Building 10 (when they are unlocked). Before entering, each person notifies the facility engineer of the intent and purpose of the visit. This ensures that personnel do not walk into hazardous situations.

5. Extra ventilation/air flow may be required to remove contaminants from inside the chamber at the conclusion of the test.

6. The facility engineer determines the appropriate opened or closed configuration of the chamber’s two main access doors, and what other access controls and rope cordons are needed, depending on individual test circumstances.

7. During setup operations, visitors are not permitted inside the chamber, or inside the perimeter of controlled/roped off areas, unless they have been authorized by the facility engineer. Personnel are not allowed to enter the chamber while the red flashing warning lights are on. The console operator is the last person to check the chamber before he/she locks the chamber personnel door. As a fail-safe measure, the console operator will keep the key to the chamber door in his/her possession at all times during the acoustic test so that no one else has the means to enter the chamber. This ensures that personnel are not exposed to high noise levels and possible oxygen deficient atmospheres.

8. The console operator sounds the klaxon warning horn three times before starting the test and inform the personnel working in the Building 7 truck lock, truck lock offices, and the Building 10 High Bay

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that testing is about to begin and to expect high noise. Upon such notification, personnel in the Building 7 truck lock and truck lock offices will vacate the area for the duration of the acoustic test.

9. During testing operations, nitrogen gas enters the chamber through the horns, depleting the oxygen content inside the chamber. Therefore, post-test, exhaust fans will be activated to remove nitrogen in the chamber. The console operator, with a buddy, will unlock the chamber personnel door and check the oxygen level with a calibrated oxygen monitor. Nobody is allowed entry to the chamber until its atmosphere has been checked for a safe oxygen level – at least 19.5%. When the environment is safe inside the chamber, the red flashing warning lights will be shut off.

10. Access will be restricted directly in front of the chamber by prohibiting access from building 10 and from the building 29 high bay area.

11. The maintenance team responsible for the horn servicing platform and the nitrogen supply system consists of at least two members.

12. For Lifting Devices and Equipment Operations, personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #6

13. For suspended load operations, personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #7. If the load is to remain suspended for acoustics or pyro-shock testing, personnel are not be allowed in the chamber unless a certified LDE operator is manning the crane controls. The Safety Division conducted a noise survey of the acoustic facility. (Appendix D). When the facility was operating, the ambient noise levels surrounding the outside of the chamber walls and doors measured a maximum of 119 dBA for one minute approximately one foot from the doors. The levels dropped to 110 dBA at a distance of 25 feet from the doors. Per NASA Specifications, personnel will use hearing protection when exposed to environments where noise is at or above 85 dBA. The Environmental Test Engineering and Integration Branch, Code 549, provides ear defenders or plugs to personnel and requires their use by personnel that must monitor equipment set up in the vicinity of the chamber. Refer to GPR 1820.1, Hearing Conservation Program for a listing of NASA permissible noise exposure limits.

14. Special procedures are required for deployment and shock separation testing that requires the handling and firing of electro-explosive ordnance devices. The Project is responsible for providing procedures for lifting/crane operations and firing the electro-explosive devices. The Project’s test plan and operating procedures shall be approved by the MSD Project Support Team Lead before setup or testing is permitted. (See Section 2.2 in ETD SM for ordnance handling and operational requirements.)

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2.1.4 GSFC Contacts

Structural Dynamics Test Engineering Group, Lead: (301) 286-9332 Safety Division: (301) 286-6086 ETD Safety Manger: (301) 286-3976 MSD Safety Lead: (301) 286-6458 Support Contractor Safety: (301) 286-2601

2.1.5 Reference Documents Unique to this Section

OSHA 29 CFR Part 1910.179, Overhead and Gantry Cranes OSHA 29 CFR Part 1910.212 and Part 1910.27, Mechanical Equipment OSHA 29 CFR Part 1910.95, Occupational Noise Exposure NPR 1820.1, Hearing Conservation CGA P-14-1983, CGA P-12-1987, CGA P-1, and ASHRAE 15-89, Gaseous Nitrogen

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2.2 Cleanrooms

2.2.1 Scope

This section covers safety issues related to all MSD cleanrooms, clean tents, and support areas.

Some of these cleanrooms include the Spacecraft Systems Development and Integration Facility (SSDIF), the Spacecraft Checkout Area (SCA), the Radio Frequency Interference Room (RFI), the Space Environment Simulator (SES) anteroom, the Calibration & Integration Facility (CAIF), the Whitehouse, B29/160, B29/150, and the Horizontal Flow Facility (HFF), but is applicable to all clean tent/cleanroom environments within the Bldg.7, 10, 15&29 Complex.

2.2.2 General

All the cleanrooms and clean tents listed above are typically operated and maintained as Class 10,000 (ISO-7) environments. They are used primarily for the integration and testing of space flight hardware. As such, strict rules govern the activities within these facilities. Besides the safety issues addressed in this section, clean facilities may also harbor potentially hazardous systems.

2.2.3 Specific Facility Requirements

All personnel who enter a clean facility will wear cleanroom garments including coverall, hood, boots, gloves, and mask. Due to the nature of these garments, certain inherent risks occur with their use. The primary way to avoid an accident when wearing cleanroom garments is to execute work activities in a slow, deliberate manner.

1. Visibility limitations: The hood and mask may restrict an individual’s peripheral vision. Secure the hood firmly to the face by using the adjustable snaps to achieve a snug fit. Fasten the face mask by placing the elastic band behind the head and adjusting the mask so that it does not ride up into the eyes or protrude away from the face a great distance. The hood and mask should not move or shift when the head is turned.

2. Bulkiness: Cleanroom garments are cut full by the manufacturer to allow space for the user’s clothes. This extra bulk means the wearer should exercise caution when working around equipment or passing by obstructions, so as not to snag the garments on these items.

3. Boot hazard: Cleanroom boots are made to envelop the wearer’s shoes, so they have a larger footprint than ordinary shoes. The bootstraps that surround the instep and Achilles heel area fasten the boot to the foot, but only loosely, and have free hanging ends several inches long that can dangle freely. Also, the polyurethane soles are somewhat slippery. Personnel who wear these boots are advised to fasten them as tightly as possible, snap down the dangling ends, and check them for a snug fit in the anteroom before entering the clean facility. Exercise extreme caution when climbing ladders or walking on scaffolding. Personnel who walk on the overhead crane bridge in the SSDIF cleanroom are exempt from wearing cleanroom boots.

4. Garment breathability: Garment material used in the cleanroom facilities is tightly woven polyester. The tight weave of the fabric prohibits most particles from passing through, resulting in a high-quality barrier of protection to the environment. However, the tight weave characteristics of the garments can be uncomfortable or potentially hazardous to the wearer.

Heat and moisture are not dissipated readily, and it is possible for a worker to experience heat exhaustion or fatigue when performing strenuous activities.

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5. Garment flammability: The polyester fabric cleanroom garments are not treated with flame retarding agents. If exposed to extreme heat, the fabric will melt and possibly ignite. Molten or burning polyester emits toxic vapors and will cause severe burns upon contact with the skin. It is important to keep a safe distance between potential heat sources and the cleanroom garment.

6. Work area congestion: The level of work activity in a clean facility can be extremely high, with many people moving about, working on separate projects simultaneously. Personnel could potentially stray into the path of moving hardware, or trip over cables, tubing, and other hardware lying on the floor, and possibly interfere with another worker’s activities. Awareness of the activities of cleanroom workers is critical to avoid unexpected interference with activities.

Working and moving cautiously and deliberately are key to avoiding accidents.

7. Emergency evacuation: In the event of a fire drill or emergency requiring immediate evacuation, do not remove cleanroom garments or sign out of the cleanroom entry log prior to immediately and quickly exiting the building through the nearest exit. The first person leaving the cleanroom should be responsible for taking the cleanroom entry Log with him/her and presenting it to the fire warden. Individuals who were working in a facility in which they signed in will report immediately to the nearest fire warden to make their presence known so that the warden can account for all personnel not signed out of the cleanroom log.

8. Training: Personnel who need to work in any Bldg#7, 10, 15 & 29, cleanroom\clean tent facility shall undergo cleanroom training that familiarizes them with entry and clean operating procedures as well as safety procedures required for work in the area. This course is: GSFC Code 540 Cleanroom Certification Training and is located on SATERN. Other Project-specific training may also be required prior to entry to a given area.

9. For Lifting Devices and Equipment Operations, personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #6.

10. Mechanical and electrical rooms: These rooms contain systems that service the cleanroom facilities. They may contain electrical service panels, mechanical air handling equipment (fans, blowers, filters, and ducts), hot water pumps, steam pressure regulating stations, chilled water circulating systems, and central vacuum cleaning machinery. General requirements are applicable in these rooms, as well as the following:

a. The maintenance team working in these rooms consists of at least two members.

Individual personnel may enter to perform visual checks only.

b. Use portable light sources to illuminate the work area. Check the area for wasps, birds, or other animals that might startle an employee.

c. Systems may have high voltage/current, high temperature steam and hot water, chilled water and refrigeration systems, high air velocities and air pressure differentials, hydraulic systems, house-supplied air and gaseous nitrogen supplies, and vacuum equipment. Fans, blowers, pumps, and other machinery may be driven by large electrical motors with direct-drive gearing, belt drives, and other coupling mechanisms that present potential hazards. Plumbing systems may have non-insulated pipes that condense water and drip to form puddles. Floors may be slippery from condensates, oils, and other machine fluids. Clean up or rope off any hazardous areas immediately.

d. Always exercise caution when entering or exiting doors in these rooms because of potential air differentials caused by blowers and high velocity air currents. Some doors may need to be opened forcibly and held tightly to prevent them from slamming shut on

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parts of the body. This same precaution holds for panel coverings, machine doors/openings, baffles, etc., that may slam shut.

e. Before working on pipe insulation or other insulating materials, verify that no asbestos is present. If asbestos is present, or if you are not sure of the contents, contact the Safety Division.

2.2.4 GSFC Contacts

Support Contractor Cleanroom Operations Office: (301) 286-8103 Safety Division: (310) 286-6086 ETD Safety Manager: (301) 286-3976 MSD Safety Lead: (301) 286-1034 Support Contractor Safety: (301) 286-6458

2.2.5 Reference Documents Unique to this Section

OSHA 3067, Concepts and Techniques of Machine Safeguarding OSHA 29 CFR Part 1910.242, Hand and Portable Powered Tools and Equipment OSHA 29 CFR Part 1910.243, Guarding of Portable Powered Tools

2.3 Advanced Composite Materials Lab (ACML)

2.3.1 Scope

This section covers the composite materials shop and its subsystems, located in Building 5A.

2.3.2 General

The composite materials shop is designed for process development, prototyping, and spacecraft hardware production in composite materials, primarily fiber-reinforced plastics. Graphite, glass, and Kevlar fibers are the most commonly used reinforcement materials, with epoxies and cyanate-esters as matrices. The raw materials are laid up on a mold and cured with heat and pressure to near-net shape. Then the molded item is machine-finished, and the surface is prepared for bonding, usually adhesive bonding with supplementary mechanical fasteners. The shop contains special purpose facilities, which are described under specific facility requirements below.

2.3.3 Specific Facility Requirements

Special procedures for this shop are as follows:

1. The qualifications of the ACML personnel is determined by the facility supervisor. Only qualified personnel, who can demonstrate their ability in composites material handling and fabrication techniques, are approved to work in the lab.

2. The qualifications of the ACML personnel to operate special purpose facilities, such as the Autoclave pressure chamber and the electric oven, is determined by the facility supervisor.

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3. All shop equipment guards will be installed before operating any equipment. (See ETD Safety Manual for guard information.)

4. Personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #4 - Standard Physical Protection for Machinery.

5. Personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #5 - Standard Physical Protection for other applications. If necessary, approved respirators fitted with the appropriate filter cartridges will be worn when working with vapor emitting materials.

6. For Lifting Devices and Equipment Operations, personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #6.

7. Hazardous wastes, including items such as epoxies, solvents, etc.:

a. For removal of hazardous waste or to create a new hazardous waste stream, submit a request using the eMOSI portal or email the Hazardous Waste team at GSFC- HAZWASTE@lists.nasa.gov.

8. Personnel handling pre-preg materials will wear disposable, powder-free Nitrile gloves for protection. The gloves minimize the possibility of allergic skin reactions and keep body oils from contaminating the materials being handled.

9. Avoid having liquid epoxies and adhesives contact the skin or eyes. In the event of skin or eye contact, rinse the affected areas with water for 15 minutes. The shop contains a permanent eyewash station at the wall near the exit door, by the fume hood.

10. Lab personnel should use caution, and appropriate gloves, when handling or surface-finishing shaped items to avoid being injured by rough and jagged edges of fibers and cured cements and epoxies.

11. Non-hazardous waste materials, except for metal waste, can be discarded in the standard GSFC dumpsters. As appropriate, recycle metal waste. Usually, byproducts from the fabrication process that have been fully cured are non-hazardous.

12. Shop personnel using the appropriate PPE should clean debris and waste materials from surfaces on and around machinery.

13. Personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #2 - Custodial Interaction.

14. Autoclave pressure chamber operation:

a. The pressure chamber is used to cure fiber-reinforced composites. It is capable of controlled heating of a mold and laminate in a pressurized atmosphere.

b. Heat is generated at temperatures up to 177°C (350°F) during the epoxy curing process.

Upon opening the chamber, the operator should allow sufficient time for the item to cool before handling it.

c. The chamber uses GN2 at 1.45 MPa (210 psi) which is supplied from pressurized bottles.

(See Section 2.3 in Volume 1 for GN2 handling information.)

d. The chamber fumes are vented to the outside roof.

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15. General Signal Blue M electric oven operation:

a. The oven is used to dry fiber-reinforced epoxy composites that are curing, and to warm pre-preg materials to ambient temperature.

b. The oven can operate at temperatures up to 427°C (800°F) but is nominally operated up to

204 °C (400 °F). Upon opening the oven, the operator should allow sufficient time for the item to cool before handling it.

c. Oven fumes are vented to the outside roof.

16. Spray booth operation (see appropriate section in the ETD Safety Manual):

a. Fumes are exhausted to the roof.

b. Small quantities of acetone, alcohol, and compatible vapor-emitting (volatile) materials for immediate use are stored on the shelf inside the fume hood. Store larger quantities or not-for-immediate-use vapor-emitting materials in the flammable storage cabinet.

c. Use the fume hood for etching operations, and when applying methyl ethyl ketone (MEK) for epoxy priming or mold release.

d. The permanent eyewash station is located by the exit door, next to the fume hood.

18. Harford freezer:

a. This walk-in freezer is used to store and cool B-staged pre-preg materials, epoxies, and film adhesives at temperatures as low as -23°C (-10°F).

b. Press the manual push button on the inside of the exit door to exit the freezer.

19. Layout room:

a. Rolls of sheet materials such as Teflon, nylon, and polyester, which are stored in this room do not present a hazard. Exercise normal care when unrolling and handling them.

b. Cutting and layout operations require sharp tools, razor knives, scissors, etc. When performing these operations, exercise caution, wear protective gloves, and always cut in a direction away from the body.

2.3.4 GSFC Contacts

Composites and Rapid Prototyping Lab Manager: (301) 286-0101 Safety Division: (301) 286-6086 ETD Safety Manager: (301) 286-3976 MSD Safety Lead: (301) 286-1034 Safety Committee Head: (301) 286-6510 Support Contract Safety: (301) 286-6458

2.3.5 Reference Documents Unique to this Section

N/A

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2.4 Electromagnetic Compatibility

2.4.1 Scope

This section covers the EMC facilities and their subsystems. The Small EMC Test Facility is located in Building 7, Room 8—shielded enclosures 8A, 8B, and 8C. The Large EMC Test Facility is located in Building 7, Rooms N113, N115, N117, and 108A.

2.4.2 General

The shielded enclosures are designed to provide isolated environments for performing radiated and conducted emissions and susceptibility testing. Isolation methods provide quiet electromagnetic environments for the test article and protect personnel from potentially harmful radiation. The isolation methods include using sandwiched steel walls, with the inner wall covered with special ferrite tiles. TDK IP closed cell structure polystyrene absorber is used as an anechoic material on the ceiling/walls of the Small Facility and is carbon loaded conductive polyethylene foam absorber on moveable panels in the Large Facility. Panashield HYB-NF fibrous composite absorber is used as anechoic material on the ceiling/walls of the Large Facility which is Class 10k compliant.

Section 2.4.3, Item 5.a. below contains specifications regarding the shielding effectiveness of the enclosures.

2.4.3 Specific Facility Requirements

Summary of Potential EMC Testing Hazards—Radiated susceptibility test signals can result in exposure to fields marginally equivalent to the maximum safe levels prescribed by IEEE Std.

C95.1™-2005, IEEE Standard for Safety Levels with Respect to Human Exposure to Radio Frequency Electromagnetic Fields, 3 kHz to 300 GHz.

Special procedures for this facility are as follows:

1. The qualifications of the ECM control system operators are determined by the facility supervisor.

Only qualified operators, who can demonstrate their ability to operate the control system, are approved to operate the ECM control system. Personnel involved in performing EMC tests should comply with the requirements specified in IEEE C95.1-2005.

2. Personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #1 - Storm Warning.

3. Personnel should use caution when working inside the Small EMC enclosure to avoid damaging the polystyrene foam that protrudes from the inner walls. A moderate bump against it can dislodge pieces of foam, especially the protruding tips of the foam. Also use caution to avoid damaging the foam when sliding the inner wall payload entry doors open or closed.

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4. The facility engineer is responsible for ensuring that all EMC testing be conducted according to the Code 549 revised safety requirements for testing in the EMI shielded enclosures, effective date May 1, 2014 (or a more recent update, as applicable.) A summary of these requirements follows:

a. Shielded RF Enclosure:

All tests involving electromagnetic radiation are required to be performed inside a shielded enclosure. Radiated interference and susceptibility tests are recommended to be performed inside the shielded enclosures due to the potential for stray pickup of extraneous radiated signals and the general lack of filtered power outside of the enclosures. The shielded enclosures provide typically 85-100 dB shielding effectiveness for containing radiated electric field signals within the enclosures at frequencies from 100-kHz to 10-GHz and provide typically 65-85 dB shielding effectiveness for containing radiated magnetic field signals within the enclosure from 1-10 kHz.

Although minor RF leaks may occur, the RF energy coupled from the interior of the test area to the exterior will be an insignificant fraction of unsafe exposure levels. The responsible EMI Test Engineer will ensure that all access doors to the test enclosure are closed prior to any radiated tests being performed. In addition, the sliding Anechoic Panels in the Small EMI room and the large swinging panels in the Large EMI room should be closed during all radiated tests. Supporting contractor test personnel should check to see if the enclosure doors are closed prior to allowing any signal radiation within the enclosures. It is possible for low frequency magnetic fields radiated in the enclosure to result in a hazardous environment for personnel with specific medical conditions even when the enclosure doors are closed. Project test personnel should be notified of this potential hazard to embedded medical devices by the responsible EMI Test Engineer whenever low frequency (below 10-kHz) magnetic fields are radiated within the enclosures.

b. Fire/Smoke Safety Systems:

The retractable sprinklers, smoke detectors, and fire alarm in the Small EMI enclosure will be operational during all tests. In the event of a fire within the test area, personnel will be immediately evacuated. The ventilation system will automatically convert to a closed-loop system in the event of fire, so that the potentially noxious fumes will not be released within the building but will exhaust directly to the outside.

The Large EMI enclosure fire alarm will be activated and the sprinkler system operational during all tests in this facility. The EMI Test Engineer must be cognizant of the fact that the fire alarm can be falsely triggered by high-power RF transmissions in the facility, and should notify the emergency console operator of this possibility whenever such transmissions may occur during either radiated susceptibility testing or test item operation.

c. Test Area Personnel Ban & Hazardous Warning Posting:

Personnel are not allowed inside the test area during any portion of the radiated susceptibility tests without approval from Code 549 and/or concurrence with the Radiation Safety Office in Code 360. Radiation Hazard signs are posted by the EMI Test Engineer, or their designee, (designating the proper safe/hazardous situation) at the personnel and equipment access doors.

The service area access door for the HEPA filters in the Large EMI enclosure is locked and posted with a Hazardous Warning sign during radiated testing.

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d. Closed Circuit TV Monitoring System:

The EMI Test Engineer, or his designated assistant is responsible for the reasonably continuous monitoring of the test area on the video monitor (for facilities so equipped) to ensure that no personnel are in the testing area during radiated susceptibility or test item RF transmission operations.

e. Unauthorized Operation of Test Item Transmitters:

The EMI Test Engineer is responsible for ensuring that the test article project design lead (PDL) is aware that no radiated operation of any test item transmitters is allowed within the enclosure without the written specific approval of Code 549. In the event the project intends to operate transmitters into dummy loads, hat couplers or other terminating devices during testing, this information must be made known to Code 549 and the enclosure RF levels shall be monitored during such operations to ensure safe termination of the transmitter signals. The Project Test Director will promptly notify the responsible EMI Test Engineer in the event of any inadvertent operation of any transmitters. The Project Test Director will also notify the EMI Test Engineer of any planned operation of transmitters into dummy loads, hat couplers or other load terminating devices with sufficient time to allow monitoring of the RF level in the enclosure during such periods of operation. The EMI Test Engineer will inquire of the Project Test Director as to whether any inadvertent or intended operation of test item transmitters has occurred during each day of testing. In the event of a positive response, details of such transmission shall be recorded in the EMI test data sheets.

f. Monitoring of Enclosure Ambient RF Levels:

At all times when either EMC test equipment or actual test items are located within the enclosures that are capable of transmitting electromagnetic signals at power levels exceeding 0.5 W, the ambient level in the enclosure should be monitored using a broadband triaxial probe, mounted approximately one-meter from the point where the normal EMC instrumentation antenna would be located and in the center of the direction of a typical back-lobe pattern.

The monitoring circuit will be scanned in a broadband mode and generally alarmed for signals exceeding 10-V/m, with the individual test specification customized for optimum alarm setup based on known equipment transmission capabilities and failure potential. Code 549 will be notified in the event the alarm is triggered by unintentional radiation, and a determination made of the source of the triggering signal.

2.4.4 GSFC Contacts

Electromagnetic Test Engineering Group, Lead: (301) 286-0982 Safety Division: (301) 286-6086 ETD Safety Manager: (301) 286-3976

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MSD Safety Lead: (301) 286-1034 Support Contractor Safety: (301) 286-6458

2.4.5 Reference Documents Unique to this Section

IEEE Standard C95.1-2005, IEEE Standard for Safety Levels with Respect to Human Exposure to Radio

Frequency Electromagnetic Fields, 3 kHz to 300 GHz GPR 1860.2, Radiation Safety Radio-Frequency

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2.5 High Capacity Centrifuge

2.5.1 Scope

This section covers the High Capacity Centrifuge and its subsystems, located in Building 15.

2.5.2 General

Facilities and subsystems covered in this section are:

1. High Capacity Centrifuge (HCC): The 120 ft. (36.6 m) diameter centrifuge, located in the Building

15 Rotunda, with test chamber at one end and test platform on the opposite end. The test platform contains a motorized, adjustable tilt fixture for mounting test articles.

2. Centrifuge DC Drive Motors and Motor Generator Set: Two 1250 horsepower (0.93 Mw) DC motors located in the pit area beneath the centrifuge pedestal drive arm. The motor generator set, located in the Building 15 Mechanical Equipment Room, provides the DC power to the drive motors.

3. GN2 Supply for the Load Balance Water Transfer System and Instrumentation Racks: The GN2 storage system, located on the Building 15 parking lot, supplies the GN2 needed to fill the centrifuge’s on-board storage bottles.

4. HCC Pit and Drive Motor Air Handling System: The air handling fans circulate ambient air through either the centrifuge’s drive motors or throughout the HCC pit area.

5. HCC End Cap Loading Vehicle: This vehicle is specially designed for handling, replacing, and removing the HCC chamber end cap. It has systems capable of precisely positioning and aligning the 18,000-lb (8,165 kg) end cap so that it can be bolted and unbolted from the chamber.

2.5.3 Specific Facility Requirements

The HCC simulates launch and landing loads up to 30 g steady state acceleration, depending on payload weight, center of gravity, and test configuration. Test articles are mounted on the platform end using the overhead crane or forklift.

Special procedures for this facility are as follows:

1. The qualifications of the HCC control system operators, and end cap loading vehicle operators, are determined by the facility supervisor. Only operators, that can demonstrate their ability to operate the control system, are approved to operate the HCC control system. Only operators, that can demonstrate their ability to operate the end cap loading vehicle, are approved to operate the end cap loading vehicle.

2. Personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #1 - Storm Warning.

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3. The GSFC power plant will be notified prior to running the centrifuge arm because of the HCC’s high consumption of electrical power and the plant’s concerns about peak energy usage on the center.

4. Visitors are not allowed to walk on the centrifuge arm without permission from the facility engineer.

5. Maximum centrifuge arm speed: The HCC has been stress analyzed and proof tested to the maximum arm speed of 38.3 RPM (March 1997). All permanent fixtures on the arm have been qualified to this speed. If future testing requires a higher arm speed, the facility engineer shall verify that all on-board systems have been stress analyzed and approved for the higher speed. This holds true for the low riding platform, adjustable tilt fixture, and counterbalance structure particularly, because these items have never been qualified at speeds greater than 38.3 RPM.

6. Test platform preparations: The platform’s removable personnel guard railings should be installed during platform preparations. If the railings are removed, or personnel are working at unprotected heights greater than four feet, fall protection equipment will be worn. Permanent structures and the adjustable tilt fixture on board the test platform present tripping and bumping hazards. Personnel should exercise caution when working near the test article and be aware that instrumentation cabling, routed from the payload to junction terminals, may be underfoot or overhead. Often, string potentiometer displacement transducers have fine wires strung at various levels on the platform.

Ribbon tapes should be attached to these wires to alert personnel of their presence.

7. Weight bucket and weight pit: Personnel will refer to the MSD Safety Manual, Section 2.0.3 General Requirements, Item #5 - Standard Physical Protection for other applications (PPE) and (see the ETD Safety Manual), and comply with the mechanical handling requirements in the ETD Safety Manual. Removable portable ladders should be used to climb into the weight bucket and weight pit.

It is helpful to use the motorized personnel lifts to access the weight bucket from the exterior of the arm instead of from the arm’s topside walkway. If personnel must work at unprotected heights greater than four feet, fall protection equipment will be worn.

8. Operations prior to centrifuge running: The facility engineer and control operator will conduct a rotunda and centrifuge arm walkdown prior to running the HCC. Items to be verified include: all payload-specific hardware and instrumentation are secured, crane is stowed with its hook at the highest elevation and crane runway cover plates are secured, platform personnel guard railings are removed, tilt table motor is removed, no extraneous items remain on-board, instrumentation racks are floating, arm access ladder is stowed in the up position, chamber hatch bolted is securely in place, and the rotunda monitor is on station to prevent personnel from entering the rotunda and restricted high bay areas.

9. Operations while the centrifuge is running: Closed circuit television cameras and VCRs will be used to monitor the payload and rotunda area when the arm is running. The control operator should be trained in the alternate methods of “fast” and “emergency” stopping of the centrifuge arm. Static load balance should be verified at 3 RPM. Testing will be accomplished in increments up to the 100% level. As a safeguard to prevent arm speed runaway, no individual increment should exceed 6

RPM.

10. During operations, a test team monitor will be stationed at the rotunda entrance doors to keep all personnel out of the rotunda and away from restricted areas in the Building 15 High Bay and adjacent rooms. While the centrifuge is running, visitors and experimenters should remain in the

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Building 15 hallway and view operations on the video monitors or through the control room observation window. Test team personnel that need to be inside the control room should obtain the facility engineer’s approval.

11. The pit area is a confined space area. Prior to entry call the number listed on the sign posted at the entrance for access. The drive motor blowers will be turned on. During operations when no rotunda floor deck plates have been removed for increased air circulation, an approved confined space entry permit and use of the buddy system are required to enter the pit.

12. During times when a rotunda floor deck plate has been removed for increased air circulation, the drive motor blowers may be switched to circulate air throughout the pit instead of through the drive motors. In this case, perform air monitoring to verify the space is safe and reclassify the space as non-permit required.

13. Personnel teams of two or more are necessary when:

a. Working in the pit, rotunda attic, or inside the centrifuge chamber.

b. Operations involving handling counterbalance weights.

c. Working at heights above 4 ft. (1.2 m).

d. Servicing or repairing electrical equipment or electronic systems with energized circuits.

e. Any non-recurring activity deemed hazardous by the facility supervisor.

14. Personnel should use ear defenders or plugs, at their option, when turning on the lubrication system pumps in the pit or the motor generator set in the Mechanical Equipment Room.