nasa-std-5005d.pdf

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NASA TECHNICAL

STANDARD

NASA-STD-5005D

National Aeronautics and Space Administration Approved: 06-14-2013

Washington, DC 20546-0001 Superseding NASA-STD-5005C

STANDARD FOR THE DESIGN AND FABRICATION OF

GROUND SUPPORT EQUIPMENT

MEASUREMENT SYSTEM IDENTIFICATION:

METRIC/SI (ENGLISH)

DOCUMENT HISTORY LOG

Status Document

Revision

Approval Date Description

Baseline 5-10-1996 Baseline Release

Revision A 5-15-2001 Incorporated numerous updates to applicable and reference documents

Revision B 9-15-2003 Incorporated numerous updates to applicable and reference documents

Interim C 7-20-2007 Interim Revision (General Revision—Document

Completely Rewritten)

Incorporated numerous updates to applicable and reference documents, added M&P Section 5.11, restructured to single verifiable requirement per numbered paragraph, and moved non-verifiable best practices to italicized guidance statements.

Revision C 3-13-2009 General Revision—Document Completely

Rewritten

Transitioned Interim NASA Technical Standard

NASA-STD-(I)-5005C to NASA Technical

Standard NASA-STD-5005C.

Revision D 6-14-2013 General Revision—Document Completely

Rewritten

Incorporated numerous updates to applicable and reference documents, reduced the number of Center-specific standards in lieu of industry standards, and moved M&P requirements from 5.11 to Section 6.

FOREWORD

This Standard is published by the National Aeronautics and Space Administration (NASA) to provide uniform engineering and technical requirements for processes, procedures, practices, and methods that have been endorsed as standard for NASA programs and projects, including requirements for selection, application, and design criteria of an item.

This Standard is approved for use by NASA Headquarters and NASA Centers, including

Component Facilities and Technical and Service Support Centers.

This Standard establishes minimum requirements and engineering best practices for design and development of ground systems and equipment intended for use in preparing space flight systems for flight after acceptance by the Government. This Standard does not apply to facilities or equipment used in the manufacturing of space flight systems.

Individual provisions of this Standard should be and are intended to be tailored (i.e., modified or deleted) by contract or program specifications to meet specific program, project, and Center needs and constraints based on a risk assessment by Safety and Mission

Assurance (S&MA) according to program and Center procedures.

Requests for information, corrections, or additions to this Standard should be submitted via

“Feedback” in the NASA Standards and Technical Assistance Resource Tool at https://standards.nasa.gov.

Origial Signed By: 06-14-2013

Michael G. Ryschkewitsch Approval Date

NASA Chief Engineer

SECTION

TABLE OF CONTENTS

PAGE

DOCUMENT HISTORY LOG

FOREWORD

TABLE OF CONTENTS

1. SCOPE

1.1 Purpose

1.2 Applicability

1.3 Tailoring

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government Documents

2.3 Non-Government Documents

2.4 Order of Precedence

3. ACRONYMS AND DEFINITIONS

3.1 Acronyms and Abbreviations

3.2 Definitions

4. GENERAL REQUIREMENTS

4.1 Commercial Off-The-Shelf (COTS) Equipment

4.2 System Requirements

4.2.1 Performance Requirements

4.2.1.1 Design Life

4.2.1.2 Contamination from GSE

4.2.1.3 GSE Design for Access

4.2.1.4 Interfaces

4.2.2 Heritage GSE

4.2.3 Reliability

4.2.3.1 Redundancy

4.2.3.2 Failure Tolerance

4.2.3.3 Failure Propagation

4.2.4 Environmental Conditions

4.2.4.1 Natural Environment

4.2.4.2 Launch-Induced Environment

4.2.4.3 Controlled Interior Environment

4.2.4.4 Controlled Clean Environment

4.2.4.5 Uncontrolled Interior Environment

TABLE OF CONTENTS (Continued)

4.2.4.6 Environmental Test Methods

4.2.4.7 Seismic Environment

4.3 Documentation

4.3.1 Drawings and Specifications

4.3.2 Technical Documentation

4.4 Logistics

4.5 Limited-Life Items

4.6 Quality Assurance

4.6.1 Quality Requirements Definition

4.6.2 Testing

4.6.2.1 Load Test

4.6.2.2 Metrology and Calibration

4.7 Packaging, Handling, and Transportation

5. DESIGN AND FABRICATION REQUIREMENTS

5.1 Structural Design

5.1.1 GSE Structures and Equipment

5.1.1.1 Steel Structures

5.1.1.2 Aluminum Structures

5.1.2 Factor of Safety

5.1.3 Structural Design Loads

5.2 Mechanical Design

5.2.1 Pneumatics

5.2.1.1 Breathing Air

5.2.1.2 Interfaces to Hypergol Systems

5.2.2 Cryogenics

5.2.3 Hypergols

5.2.4 Hydrocarbons

5.2.5 Hydraulics

5.2.6 Environmental Control Systems (ECS)

5.2.7 Lifting Devices

5.2.8 Threaded Fasteners

5.2.9 Tethering Provisions

5.2.10 Transportation Loads

5.2.11 Pressure Systems

5.2.11.1 Code-Stamped Vessel Registration

5.2.11.2 Transporting Hazardous Commodities

5.3 Electrical/Electronic Design

5.3.1 Electrical Control and Monitor Equipment

5.3.2 Electrical Design of Pneumatic and Hydraulic Components

5.3.3 Pyrotechnic Systems

5.3.4 Electrical Power Systems

5.3.5 Bonding, Grounding, and Lightning Protection

5.3.6 Electrostatic Discharge

5.3.7 Hazard Proofing

5.3.8 Software

5.4 Parts

5.4.1 GSE Fasteners

5.4.1.1 Reuse of Self-Locking Fasteners

5.4.1.2 Liquid-Locking Compounds

5.4.1.3 Critical GSE Fasteners

5.4.2 Stainless Steel Tubing

5.4.3 Pipe

5.4.3.1 Stainless Steel Pipe

5.4.3.2 Aluminum Pipe

5.4.3.3 Expansion Joints

5.4.4 Fluid Fittings

5.4.5 Fluid System Protective Covers

5.4.6 Fluid System Components

5.4.7 Electrical Power Receptacles and Plugs

5.4.8 Electrical Power Cable

5.4.9 Electrical Cable and Harnesses

5.4.9.1 Electrical Cables and Harnesses for Critical Applications

5.4.9.2 Electrical Cables and Harnesses for Noncritical Applications

5.4.10 Fiber Optics

5.4.10.1 Fiber-Optic Protective Caps

5.4.10.2 Fiber-Optic Cable Assemblies

5.4.10.3 Underground Fiber-Optic Cable

5.4.10.4 Intra-Building Fiber-Optic Cable

5.4.10.5 Single-Mode Fiber-Optic Cable

5.4.10.6 Multimode Fiber-Optic Cable

5.4.11 Electrical Hookup Wire

5.4.12 Connectors

5.4.13 Coaxial Radio Frequency (RF) Connectors

5.4.14 Electrical Connector Protective Covers or Dust Caps

5.4.15 Optical Covers or Caps

5.4.16 Sensors and Transducers

5.4.17 Purged Electrical Enclosures

5.4.18 Racks, Panels, and Modular Enclosures

5.4.19 Printed Circuit Boards (PCBs)

5.4.19.1 PCB Design

5.4.19.2 PCB Fabrication and Acceptance

5.4.19.3 Printed Circuit Assembly (PCA) Fabrication and Acceptance

5.4.20 Electric Motors

5.5 Electromagnetic Interference (EMI)

5.6 Identification Markings and Labels

5.6.1 Systems and Equipment

5.6.2 Load Test Marking

5.6.3 Compressed Gas Cylinders

5.6.4 Handling Equipment

5.6.5 Electrical Cable and Harness Assemblies

5.6.6 Serial Numbers

5.7 Interchangeability

5.8 Safety

5.9 Human Factors

5.10 Security of Information Technology

6. MATERIALS AND PROCESSES (M&P) REQUIREMENTS

6.1 Material Properties Design Data

6.2 M&P Controls

6.3 Materials

6.3.1 Flammability and Compatibility Requirements

6.3.1.1 Flammability Control

6.3.1.2 Electrical Wire Insulation Materials

6.3.1.3 Fluid Compatibility

6.3.1.3.1 Fluids Other than Oxygen

6.3.1.3.2 Oxygen Systems

6.3.1.4 Metals

6.3.1.4.1 Steel

6.3.1.4.2 Corrosion-Resistant Steel

6.3.1.4.3 Aluminum

6.3.1.4.4 Nickel-Based Alloys

6.3.1.4.5 Titanium

6.3.1.4.6 Copper Alloys

6.3.1.4.7 Beryllium and Beryllium Alloys

6.3.1.4.8 Tin

6.3.1.5 Nonmetals

6.3.1.5.1 Elastomers

6.3.1.5.2 Composite Materials

6.3.1.5.3 Lubricants

6.3.1.5.4 Limited-Life Materials

6.3.1.5.5 Plastic Films, Foams, and Adhesive Tapes

6.3.1.5.6 Fungus Resistance

6.4 Processes

6.4.1 Welding

6.4.1.1 Welding Procedure Qualification

6.4.1.2 Welder/Welding Operator Performance Qualification

6.4.1.3 Weld Classification and Inspection

6.4.2 Brazing

6.4.3 Soldering

6.4.4 Heat Treating and Plating

6.4.5 Forging

6.4.6 Casting

6.4.7 Adhesive Bonding

6.4.8 Fluid System Cleanliness

6.4.9 Crimping

6.4.10 Potting and Molding of Cable Assemblies

6.4.11 Corrosion Control

6.4.12 Stress Corrosion Cracking

6.4.13 Material NDE

6.4.14 Chemical Etching

6.4.15 Hydrogen Embrittlement

6.4.16 Contamination Control

APPENDICES

A GSE Identification Colors

B Deliverables

C Reference Documents and Database

STANDARD FOR THE DESIGN AND FABRICATION OF

GROUND SUPPORT EQUIPMENT

1. SCOPE

1.1 Purpose

The purpose of this Standard is to establish requirements and guidance for design and fabrication of ground support equipment (GSE) to assist National Aeronautics and Space Administration

(NASA) space flight programs/projects in providing robust, safe, reliable, maintainable, supportable, and cost-effective GSE.

1.2 Applicability

a. This Standard is applicable to NASA space flight programs and its use is at the discretion of each program. This Standard establishes a set of GSE design requirements for

NASA programs and projects. This Standard is intended for use in establishing uniform engineering practices and methods and ensuring that essential requirements are included in the design, procurement, and fabrication of GSE used to support the operations of receiving, storage, transportation, handling, assembly, inspection, test, checkout, service, launch, and recovery of space vehicles and payloads at NASA’s launch, landing, or retrieval locations. GSE must also meet the requirements for the location of its intended use (e.g. AFSPCMAN 91-710, Range

Safety User Requirements Manual, for the Eastern and Western Test Ranges).

b. This Standard is approved for use by NASA Headquarters and NASA Centers, including

Component Facilities and Technical and Service Support Centers, and may be cited in contract, program, and other Agency documents as a technical requirement. This Standard may also apply to the Jet Propulsion Laboratory or to other contractors, grant recipients, or parties to agreements only to the extent specified or referenced in their contracts, grants, or agreements.

c. Requirements are numbered and indicated by the word “shall.” Explanatory or guidance text is indicated in italics beginning in section 4.

d. Programs, projects, and elements are responsible for flowing requirements down to contractors, subcontractors, and suppliers of components at the lowest level.

e. Programs, in conjunction with Engineering and Safety and Mission Assurance

(S&MA) organizations, have the responsibility to do the following:

(1) Determine categories or types of GSE based on risk and any additional requirements resulting from these categories or types.

(2) Establish and define where this Standard will be applied and when such boundaries require clarification.

(3) Establish program- and project-specific requirements.

(4) Establish minimum configuration management systems to retain the required documentation.

f. This Standard does not apply to the following unless specified by a program, project or Center:

(1) Equipment that is used solely during the manufacturing of flight hardware.

(2) Ground support systems (GSS) that interface with GSE.

(3) Facilities.

(4) Tools.

1.3 Tailoring

Tailoring of this Standard for application to a specific program or project shall be formally documented as part of program or project requirements and approved by the Technical Authority.

2. APPLICABLE DOCUMENTS

2.1 General

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

2.1.1 The latest issuances of cited documents shall apply unless specific versions are designated.

2.1.2 Non-use of specific versions as designated shall be approved by the responsible Technical

Authority.

The applicable documents are accessible via the NASA Standards and Technical Assistance

Resource Tool at https://standards.nasa.gov or may be obtained directly from the Standards

Developing Organizations or other document distributors.

2.2 Government Documents

Department of Defense

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

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

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

Specification for

MIL-DTL-38999 Connectors, Electrical, Circular, Miniature, High

Density, Quick Disconnect (Bayonet, Threaded and

Breech Coupling), Environment Resistant, Removable

Crimp and Hermetic Solder Contacts, General

MIL-HDBK-6870 Inspection Program Requirements, Nondestructive for

Aircraft and Missile Materials and Parts

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

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-461 Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and

Equipment

MIL-STD-810 Environmental Engineering Considerations and

Laboratory Tests

MIL-STD-889 Dissimilar Metals

Federal (FED)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.1200 Hazard Communication and Center Requirements

49 CFR 171 thru 180 Hazardous Materials Regulations (Department of

Transportation)

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

Administration)

NASA

NASA-HDBK-1001 Terrestrial Environment (Climatic) Criteria Handbook for Use in Aerospace Vehicle Development

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

NASA-STD-5008 Protective Coating of Carbon Steel, Stainless Steel, and

Aluminum on Launch Structures, Facilities, and

Ground Support Equipment

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

Metallic Components

NASA-STD-6001 Flammability, Offgassing, and Compatibility

Requirements and Test Procedures

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

Parts

NASA-STD-8719.9 Standard for Lifting Devices and Equipment

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

NASA-STD-8719.17 NASA Requirements for Ground-Based Pressure Vessels and

Pressure Systems (PVS)

NASA-STD-8739.1 Workmanship Standard for Polymeric Application on

Electronic Assemblies

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

Wiring

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

Installation

NPD 8730.1 Metrology and Calibration

NPR 2810.1 Security of Information Technology

NPR 6000.1 Requirements for Packaging, Handling, and

Transportation for Aeronautical and Space Systems, Equipment, and Associated Components

NPR 7150.2 NASA Software Engineering Requirements

NPR 8715.3 NASA General Safety Program Requirements

NASA Centers

George C. Marshall Space Flight Center (MSFC)

MSFC-STD-3029 Guidelines for the Selection of Metallic Materials for

Stress Corrosion Cracking Resistance in Sodium

Chloride Environments

John F. Kennedy Space Center (KSC)

KSC-GP-425 Fluid Fitting Engineering Standards

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

MMA-1985-79 Standard Test Method for Evaluating Triboelectric Charge

Generation and Decay

2.3 Non-Government Documents

Aerospace Industries Association (AIA)/National Aerospace Standards

(NAS)

AIA/NAS 410 NAS Certification & Qualification of Nondestructive

Test Personnel

Aluminum Association (AA)

ADM Aluminum Design Manual

American Institute of Steel Construction (AISC)

AISC 325 Steel Construction Manual

American Society of Civil Engineers (ASCE)

ASCE-7 Minimum Design Loads for Buildings and Other Structures

American Society of Heating, Refrigerating and Air-Conditioning Engineers

(ASHRAE)

ASHRAE Handbook—Fundamentals, Chapter 39

American Society for Testing and Materials (ASTM)

ASTM A123 Standard Specification for Zinc (Hot-Dip Galvanized)

Coatings on Iron and Steel Products

ASTM A153 Standard Specification for Zinc Coating (Hot-Dip) on

Iron and Steel Hardware

ASTM A249 Standard Specification for Welded Austenitic Steel Boiler, Superheater, Heat- Exchanger, and Condenser Tubes

ASTM A269 Standard Specification for Seamless and Welded Austenitic

Stainless Steel Tubing for General Service

ASTM A312 Standard Specification for Seamless, Welded, and Heavily

Cold Worked Austenitic Stainless Steel Pipes

ASTM A380 Standard Practice for Cleaning, Descaling, and

Passivation of Stainless Steel Parts, Equipment, and

Systems

ASTM A653 Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM A780 Standard Practice for Repair of Damaged and Uncoated

Areas of Hot-Dip Galvanized Coatings

ASTM A1016 Standard Specification for General Requirements for Ferritic

Alloy Steel, Austenitic Alloy Steel, and Stainless Steel Tubes

ASTM B241 Standard Specification for Aluminum and Aluminum-Alloy

Seamless Pipe and Seamless Extruded Tube

ASTM D4174 Standard Practice for Cleaning, Flushing, and Purification of

Petroleum Fluid Hydraulic Systems

ASTM D7194 Standard Specification for Aerospace Parts Machined from Polychlorotrifluoroethylene (PCTFE)

ASTM E426 Standard Practice for Electromagnetic (Eddy-Current)

Examination of Seamless and Welded Tubular Products, Austenitic Stainless Steel and Similar Alloys

ASTM E1548 Standard Practice for Preparation of Aerospace

Contamination Control Plans

ASTM E2217 Standard Practice for Design and Construction of Aerospace

Cleanrooms and Contamination Controlled Areas

American Society of Mechanical Engineers (ASME)

ASME Y14.100 Engineering Drawing Practices

ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24

Metric/Inch Standard

ASME B16.9 Factory-Made Wrought Buttwelding Fittings

ASME B31.3 Process Piping

ASME Boiler and Rules for Construction of Pressure Vessels

Pressure Vessel

Code, Section VIII, Divisions 1, 2, and 3

ASME Boiler and Fiber-Reinforced Plastic Pressure Vessels

Pressure Vessel

Code, Section X

American Welding Society (AWS)

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

Joints

AWS C3.4 Specification for Torch Brazing

AWS C3.5 Specification for Induction Brazing

AWS C3.6 Specification for Furnace Brazing

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

AWS D17.1 Specification for Fusion Welding for Aerospace Applications

Electronic Industries Association (EIA)/Electronic Components Association (ECA)

EIA/ECA 310 Cabinets, Racks, Panels, and Associated Equipment

International Electrotechnical Commission (IEC)

IEC 60807 Rectangular Connectors for Frequencies Below 3 MHz

International Organization for Standardization (ISO)

ISO 14952 Space Systems Surface Cleanliness of Fluid Systems

International Telecommunication Union (ITU)

ITU-T G.651 Characteristics of a 50/125 Micrometer Multimode Graded

Index Optical Fibre Cable

ITU-T G.652 Characteristics of a Single-Mode Optical Fibre and Cable

IPC – Association Connecting Electronics’ Industries

IPC-2221 Generic Standard on Printed Board Design

IPC-2222 Sectional Design Standard for Rigid Organic Printed Boards

IPC-2223 Sectional Design Standard for Flexible Printed Boards

IPC-2252 Design Guide for RF/Microwave Circuit Boards

IPC-6011 Generic Performance Specification for Printed Boards, IPC-6012 Qualification and Performance Specification for Rigid Printed

Boards

IPC-6013 Qualification and Performance Specification for Flexible

Printed Boards

IPC-6018 Microwave End Product Board Inspection and Test

IPC J-STD-001 Requirements for Soldered Electrical and Electronic

Assemblies

IPC J-STD-001ES Space Applications Electronic Hardware Addendum to J-STD-

001 Requirements for Soldered Electrical and Electronic

IPC-WHMA-A-620 Requirements and Acceptance for Cable and Wire Harness

National Electrical Manufacturers Association (NEMA)

NEMA ICS 2 Industrial Control and Systems: Controllers, Contactors, and Overload Relays Rated 600 Volts

NEMA MG 1 Motors and Generators

National Fire Protection Association (NFPA)

NFPA 55 Compressed Gases and Cryogenic Fluids Code

NFPA 59A Standard for the Production, Storage, and Handling of

Liquefied Natural Gas (LNG)

NFPA 70 National Electrical Code

NFPA 70E Standard for Electrical Safety in the Workplace

NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical

Equipment

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

SMACNA1958 HVAC Systems - Duct Design

Society of Automotive Engineers (SAE)

SAE AIR 4071 Lubricants for Oxygen Use

SAE AMS 2175 Castings, Classification and Inspection of

SAE AMS 2403 Plating, Nickel General Purpose

SAE AMS 2404 Plating, Electroless Nickel

SAE AMS 2423 Plating, Nickel Hard Deposit

SAE AMS 2488 Anodic Treatment – Titanium and Titanium Alloys

Solution pH 13 or Higher

SAE AMS 2759 Heat Treatment of Steel Parts, General Requirements

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

SAE AMS 2770 Heat Treatment of Wrought Aluminum Alloy Parts

SAE AMS 2771 Heat Treatment of Aluminum Alloy Castings

SAE AMS 2772 Heat Treatment of Aluminum Alloy Raw Materials

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

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

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

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

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

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

Copper Alloy

Telcordia

GR-20 Generic Requirements for Optical Fiber and Optical Fiber Cable

GR-409 Generic Requirements for Premises Fiber Optic Cable

2.4 Order of Precedence

This Standard establishes requirements and guidance for design and fabrication of GSE to assist

NASA space flight programs/projects in providing robust, safe, reliable, maintainable, supportable, and cost-effective GSE but does not supersede nor waive established Agency requirements found in other documentation.

2.4.1 Conflicts between this Standard and other requirements documents shall be resolved by the responsible Technical Authority.

3. ACRONYMS AND DEFINITIONS

3.1 Acronyms and Abbreviations

°C degrees Celsius

°F degrees Fahrenheit

AA Aluminum Association

ADM Aluminum Design Manual

AFSPCMAN Air Force Space Command Manual

AIA Aerospace Industries Association

AIAA American Institute of Aeronautics and Astronautics

AISC American Institute of Steel Construction

AMS Aerospace Material Specification

AS Aerospace Standard

ASCE American Society of Civil Engineers

ASHRAE American Society of Heating, Refrigerating and Air-Conditioning

Engineers

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

AWS American Welding Society

CFR Code of Federal Regulations

CGA Compressed Gas Association

COTS commercial off-the-shelf

DTL detail

ECA Electronic Components, Assemblies & Materials Association

ECS Environmental Control System

EEE electrical, electronic, and electromechanical e.g. for example

EIA Electronic Industries Association

EMC electromagnetic compatibility

EMI electromagnetic interference

ESD electrostatic discharge

ETFE ethylene tetrafluoroethylene

FOD foreign-object debris

GO2 gaseous oxygen

GR generic requirement

GSE ground support equipment

GSS ground support system

HDBK handbook i.e. that is

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronic Engineers in inch

IPC Association Connecting Electronics Industries

ISO International Organization for Standardization

ITU International Telecommunication Union

JSC Lyndon B. Johnson Space Center kPa kilopascal

KSC John F. Kennedy Space Center ksi one thousand pounds per square inch

KTI Kennedy Technical Instruction

LH2 liquid hydrogen

LNG liquefied natural gas

LO2 liquid oxygen

M&P materials and processes

Materials and Processes organization

MAPTIS Materials and Processes Technical Information System

MHz megahertz

MIL military mm millimeter

MMA Malfunction/Materials Analysis

MMH monomethylhydrazine

MMPDS Metallic Materials Properties Development and Standardization

MNL manual

MPa megapascal

MSFC George C. Marshall Space Flight Center

NAFPI National Aerospace FOD Prevention Inc.

NAS National Aerospace Standards

NASA National Aeronautics and Space Administration

NDE nondestructive evaluation

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

NPD NASA Policy Directive

NPR NASA Procedural Requirements

NPT National Pipe Thread Tapered Thread

PC printed circuit

PCA printed circuit assembly

PCB printed circuit board

PCTFE polychlorotrifluoroethylene

PHE propellant handler’s ensemble

PPE personnel protective equipment ppm parts per million

PRF performance specification

PQR procedure qualification record psia pound per square inch absolute psig pounds per square inch gauge

PVS pressure vessels and pressure systems

PTFE polytetrafluoroethylene

QD quick disconnect

RF radio frequency

RH relative humidity

S&MA Safety and Mission Assurance

SAE Society of Automotive Engineers

SCC stress corrosion cracking

SMACNA Sheet Metal and Air Conditioning Contractors’ National

Association

SPEC specification

SSP Space Shuttle Program

STD standard

TM technical memorandum

TP technical procedure

UNS Unified Numbering System

UTS ultimate tensile strength

V/m volts per meter

vs. versus

WPQ welding operator performance qualification

WPS welding procedure specification

3.2 Definitions

Commercial Off-The-Shelf (COTS): Equipment, including hardware and associated software, that is commercially available from the industrial inventory at the time of purchase.

Rationale: Commercial items or components should be used when they satisfy the GSE function and will not degrade the safety or reliability of the ground or flight system. Requirements should be specified in terms of functionality or performance rather than design.

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

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

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

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

The basis for the factor of safety should be stated in the engineering calculations.

Flight Hardware: Hardware intended for launch, including boosters, engines, payloads, and manned or unmanned components.

Fracture-Critical: Classification of hardware where a crack could lead to a failure that results in serious personnel injury, damage to flight hardware, loss of mission, or major damage to a significant ground asset.

Rationale: The term fracture-critical for GSE is used only to determine requirements as specified in this Standard and does not imply additional fracture-critical requirements normally applied to flight hardware.

Ground Support Equipment (GSE): Nonflight equipment, systems, or devices specifically designed and developed for a physical or direct functional interface with flight hardware.

Rationale: GSE is equipment whose failure could propagate into flight hardware or equipment that could prevent the failure of GSS and facility systems from propagating into flight hardware.

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

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

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

Inadvertent Operator Action: A single error by the operator of a GSE control function on a configured system.

Rationale: Operator errors include actions performed at an inappropriate time or to an incorrect degree such as operating a switch, button, valve, knob, lever, or other design feature of the system requiring operator input. This does not include cross-connecting fluid lines/electrical cables or performing unsafe acts not related to operation of the system.

Safe Working Load: The maximum assigned load the device or equipment can operationally handle and maintain. This value is marked on the device indicating maximum working capacity. This is also the load referred to as “rated load” or “working load limit.” If the device has never been downrated or uprated, this also is the “manufacturer’s rated load.”

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

Rationale: Tools are not designed to specifically interface with flight hardware, nor are they designed to perform a function specific to flight hardware. Their design and general use in industry includes a variety of applications that may be required on flight hardware or GSE.

Tools are intended for use by trained technicians and facilitate manual operations, such as torquing fasteners, cutting wire, checking electrical continuity, and verifying surface clearances. Examples of tools include torque wrenches, crow’s feet, voltmeters, go/no-go gages, screwdrivers, wire cutters, and pliers.

4. GENERAL REQUIREMENTS

4.1 Commercial Off-The-Shelf (COTS) Equipment

In order to meet customer requirements, individual system and equipment design projects may need criteria that are more stringent than those specified herein. In such cases, these criteria should be determined by the responsible design organization in consultation with its customers

(e.g., users and operators).

Each program/project has the responsibility to define its own policy for the acceptance of COTS equipment in GSE.

When a program/project approves the use of COTS equipment in GSE, the following design requirements apply:

a. COTS equipment shall be evaluated for acceptability from a materials and processes

(M&P) standpoint (see section 6).

b. Qualification tests and inspections shall be indicated in the engineering documentation.

c. For COTS used as critical GSE, documentation shall be provided as evidence that the requirements of this document have been met.

d. Modifications to COTS shall be performed in accordance with the design and fabrication requirements in this document.

e. COTS incorporated into GSE shall be selected for use within the limits of the manufacturer's specified ratings (e.g., environmental, mechanical, electrical, electromagnetic compatibility, etc.).

COTS equipment should be used to the maximum extent possible when (1) it satisfies the intended function; (2) it will not degrade the safety or reliability of the flight or ground system;

and (3) it provides a cost savings that exceeds possible cost increases due to unique maintenance or logistics requirements, modifications, or an increase in the complexity of the interfacing equipment. Vendor or contractor documentation and supporting test data should be incorporated into system control documents.

4.2 System Requirements

4.2.1 Performance Requirements

In addition to performance requirements, GSE should be designed for ease of production, manufacture, construction, and inspection. GSE should be designed to minimize the complexity and frequency of maintenance. Close manufacturing tolerances should be avoided unless required by design and performance.

4.2.1.1 Design Life

GSE shall be designed for the operational life specified by program or mission requirements.

Engineering documentation should specify maintenance requirements to meet design life.

4.2.1.2 Contamination from GSE

GSE shall not cause degradation of or contaminate flight systems or ground systems while it is being used, checked out, serviced, or otherwise handled.

4.2.1.3 GSE Design for Access

GSE design shall include access provisions for handling, servicing, calibration, maintenance, repair, and replacement of components and limited-life items.

GSE design should provide for ease of operation, maintenance, servicing, cleaning, and inspection of hardware and software. GSE fault detection and isolation should be considered based on criticality and cost of failures.

4.2.1.4 Interfaces

a. GSE shall meet the requirements of all interfaces with flight hardware or software as specified in interface control documentation.

Interfaces should be verified by test and/or analysis. GSE should be designed to reduce or eliminate the potential for a mating device (fluid, mechanical, or electrical) to be connected to the wrong interface with flight hardware.

b. GSE shall be compatible with all facility interfaces.

An assessment may be required to determine if it is more cost-effective to modify the facility interface or design the GSE to meet the existing facility interface.

4.2.2 Heritage GSE

Heritage GSE is hardware/software that has been fabricated and delivered to a previous program. GSE designs that were not fabricated are not considered Heritage GSE and must meet the requirements of this Standard.

Existing GSE that was verified to meet the GSE design and fabrication requirements of a previous NASA program shall be considered acceptable for use without further verification to the requirements of this Standard, if the following conditions are met:

a. Approval is obtained from the responsible program/project office.

b. Waivers to GSE design and fabrication requirements from the previous NASA program are evaluated and approved by the responsible Technical Authority against the equivalent requirements in this Standard.

c. Existing GSE is verified to meet the performance requirements, interfaces, operational limits, and environments for its intended application.

GSE design and fabrication requirements for previous NASA programs are defined in SW-E-

0002, Ground Support Equipment General Design Requirements: Space Shuttle; KSC-DE-512-

SM, Facility, System, and Equipment General Design Requirements; SSP 50004, Ground

Support Equipment Design Requirements: International Space Station; or a previous version of this Standard.

4.2.3 Reliability

4.2.3.1 Redundancy

When redundancy is required to satisfy failure tolerance:

a. Redundant systems, subsystems, or components shall be designed such that the failure of one will not prevent the other from performing its intended function.

Physically orienting or separating redundant items should be considered to prevent propagation of failures (e.g., routing electrical cables in separate cable trays).

b. Redundant systems, subsystems, or components shall be designed such that common-cause failures (e.g., contamination, common power source, etc.) do not eliminate redundancy.

c. Redundant systems shall be designed such that each independent path can be tested without invalidating the system configuration.

4.2.3.2 Failure Tolerance

a. GSE (except primary structure and pressure vessels, piping, and tubing in rupture mode) shall be designed such that no single failure or inadvertent operator action results in equipment or facility damage or personal injury.

Failure tolerance is not possible for primary structure and pressure vessels/tubing in rupture mode. Safety of these systems is achieved by application of design requirements contained in this standard.

GSE may be designed to terminate operations autonomously after the first failure or inadvertent operator action and in time to preclude any scenario that results in equipment or facility damage or personal injury. This approach is consistent with the historical use of the term “fail-safe” by the GSE design community.

b. GSE shall be designed to sustain a failure or inadvertent operator action and still perform its basic function when necessary to meet either safety or operational requirements.

Purges, ground special power, and launch release systems are examples of systems that interface with other systems whose loss would propagate failures. This approach is consistent with the historical use of the term “fail-operational” by the GSE design community.

4.2.3.3 Failure Propagation

GSE shall be designed to prevent failures from propagating to flight systems.

The design of GSE should consider how flight hardware/software failures could propagate through the GSE and affect other flight systems.

4.2.4 Environmental Conditions

4.2.4.1 Natural Environment

GSE used or stored in an uncontrolled exterior environment shall be designed to function after exposure to the natural environment at its respective geographical location as specified in

NASA-HDBK-1001, Terrestrial Environment (Climatic) Criteria Handbook for Use in

Aerospace Vehicle Development.

Specifications in NASA-HDBK-1001 may be tailored to reflect program-defined risk and exposure times, including operation within the launch commit criteria of the vehicle.

4.2.4.2 Launch-Induced Environment

a. GSE required to function during or after exposure to the launch-induced environment shall be designed to withstand the environment defined in program documents.

b. GSE not required to function after exposure to the launch-induced environment shall not cause damage or create a hazard to flight hardware, facilities, other GSE, personnel, or the environment.

4.2.4.3 Controlled Interior Environment

GSE designed to function within a controlled interior environment shall be designed to the following temperature and humidity requirements:

a. Nominal temperature: +15 °C (60 °F) to +27 °C (80 °F).

b. Extreme temperature: +11 °C (52 °F) to +15 °C (60 °F) or +27 °C (80 °F) to +40 °C

(105 °F) for a maximum of 1 hour.

c. Humidity: nominal 55 percent, within a range of 30 percent to 70 percent.

4.2.4.4 Controlled Clean Environment

Clean rooms and associated controlled environments designated as GSE shall be designed in accordance with ASTM E2217, Standard Practice for Design and Construction of Aerospace

Cleanrooms and Contamination Controlled Areas.

4.2.4.5 Uncontrolled Interior Environment

GSE used in an uncontrolled interior environment shall be designed to meet the most severe exterior environmental conditions for humidity and temperature anticipated at the respective geographical locations, as defined in NASA-HDBK-1001.

Some uncontrolled interior environments can exceed the most severe exterior environment, i.e., an enclosed trailer in a hot (tropical or desert) exterior environment.

4.2.4.6 Environmental Test Methods

Environmental methods and conditions required for testing and qualification of GSE components shall be in accordance with MIL-STD-810, Environmental Engineering Considerations and

Laboratory Tests.

KSC-STD-164, Environmental Test Methods for Ground Support Equipment, Standard for, should be used as a guide to standardize practices.

4.2.4.7 Seismic Environment

GSE used in Zones 3 or 4 as defined in NASA-HDBK-1001 shall be designed to resist the effects of a seismic event using the criteria and guidelines in ASCE-7, Minimum Design Loads for Buildings and Other Structures, Chapter 15, Seismic Design Requirements for Non-Building

Structures.

4.3 Documentation

4.3.1 Drawings and Specifications

Drawings and specifications required for the fabrication, construction, installation, modification, test, operation, maintenance, sustaining, and use of GSE shall be prepared in accordance with drawing practices equal to or more stringent than the engineering drawing practices of ASME

Y14.100, Engineering Drawing Practices.

4.3.2 Technical Documentation

Technical documentation (e.g., manuals and reports) shall be prepared and delivered to the user of the GSE.

Documentation should include applicable deliverables contained in Appendix B.

4.4 Logistics

GSE design documentation shall identify spare parts, components, materials, and items required to support construction, fabrication, installation, activation, test, verification, and operation.

4.5 Limited-Life Items

a. Limited-life items shall be controlled from the date of their manufacture through their period of operational use, including the time they are in storage.

b. The status of limited-life items shall be documented.

c. GSE design documentation shall identify limited-life items and provide instructions for replacement of those parts, components, and materials.

Use of items with a projected lifetime that is less than the design life of the GSE for which the items are intended should be avoided whenever possible. Elapsed time or cycle indicators should be employed to accumulate operational time or cycles for limited-life items. The age of items that are installed in a non-operating mode should also be tracked.

4.6 Quality Assurance

Documentation shall be provided by the design organization to verify compliance with this

Standard (reference Appendix B).

Examinations and tests are recommended to verify that all requirements of this Standard have been achieved. This may include the following:

• Tests and analyses of the performance and reliability requirements.

• Measurement or comparison of specified physical characteristics.

• Verification, with specific criteria, of workmanship.

• Test and inspection methods for ensuring compliance, including environmental.

• Conditions for performance.

4.6.1 Quality Requirements Definition

Quality requirements shall be defined on the engineering drawings or in other technical documents that are included in the design, fabrication, or installation contract.

The design documentation should include any special processes, testing, and inspections to be conducted.

4.6.2 Testing

a. Testing requirements shall be specified in engineering documentation.

b. Critical components shall undergo qualification testing to verify compliance with the applicable specifications and the ability to perform required design functions in the intended environment.

4.6.2.1 Load Test

a. Structural GSE (access platforms, workstands, etc.) shall be load tested to a minimum of 125 percent of the design or working load.

b. Lifting devices and equipment shall be load tested in accordance with NASA-STD-

8719.9, Standard for Lifting Devices and Equipment.

4.6.2.2 Metrology and Calibration

Metrology and calibration of all test equipment and tools used in support of fabrication, assembly, installation, and test of GSE shall be in accordance with NPD 8730.1, Metrology and

Calibration.

4.7 Packaging, Handling, and Transportation

Packaging, transporting, shipping, and handling shall be in accordance with NPR 6000.1, Requirements for Packaging, Handling, and Transportation for Aeronautical and Space Systems, Equipment, and Associated Components.

GSE should be designed so that it can be transported by ground, air, or sea using commercially available methods. Containers should be designed to accommodate all planned transportation, handling, and storage methods. ESD-sensitive components and assemblies should be handled using practices in accordance with ANSI/ESD S20.20, ESD Association Standard for the

Development of an Electrostatic Discharge Control Program for - Protection of Electrical and

Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive

Devices).

5. DESIGN AND FABRICATION REQUIREMENTS

5.1 Structural Design

5.1.1 GSE Structures and Equipment

5.1.1.1 Steel Structures

The design of steel structures fabricated from conventional rolled shapes shall be in accordance with the AISC 325, Steel Construction Manual, using the Allowable Stress Design method.

5.1.1.2 Aluminum Structures

The design of aluminum structures fabricated from conventional rolled or extruded shapes shall be in accordance with Aluminum Association ADM, Aluminum Design Manual.

5.1.2 Factor of Safety

a. The following minimum factors of safety shall be used for support structures

(excluding lifting devices and equipment, pressure systems, preload in threaded fasteners, and springs) when not otherwise specified.

(1) GSE structures shall be designed to a minimum factor of safety of 2 against deformation or yielding that impairs the function of the part and a minimum factor of safety of 3 against collapsing, buckling, exceeding the ultimate load, or failing to support the design load.

(2) For brittle materials (less than 5 percent elongation-to-failure) and fiber-reinforced polymers, the factor of safety shall be 5 against exceeding the ultimate tensile strength (UTS).

b. Threaded fasteners shall meet the factors of safety contained in (a) when considering only the operating load, not including preload which is covered in section 5.2.8

c. Springs shall be designed to a minimum factor of safety of 1.4 against exceeding the

UTS.

Due to the nature of their design, springs do not meet the factors of safety specified for other engineering applications and should be designed in accordance with the Handbook of Spring

Design from the Spring Manufacturers Institute.

d. Structures exposed to cyclic loads shall be designed for a minimum service life factor of 4 applied to the design life for fatigue assessments.

5.1.3 Structural Design Loads

Structural design loads shall be specified in the design documentation.

The design should address typical load cases such as the loads created by the assembly, transportation, and operations processes; wind conditions; the structure’s lateral stability; and seismic events.

5.2 Mechanical Design

5.2.1 Pneumatics

a. The design of GSE used for pneumatic servicing, excluding shop air below 1.14 MPa

(165 psia), shall be in accordance with ASME Boiler Pressure Vessel Code, Section VIII and

ASME B31.3, Process Piping, with 100 percent radiography of welded joints.

b. Hoses shall consist of a polytetrafluoroethylene or convoluted 300-series stainless steel inner tube reinforced with a stainless steel wire construction of braid or spiral wrap.

c. Flex hose installations designed for 1.14 MPa (165 psia) or greater shall incorporate hose restraints.

d. For pressurized air systems greater than 1.83 MPa (265 psia) and for all oxygen systems, component bodies and other pressure containing parts shall meet section 6.3.1.3.2.

e. Hydrogen systems shall conform to the requirements of NFPA 55, Compressed Gases and Cryogenic Fluids Code.

5.2.1.1 Breathing Air

Breathing air systems shall conform to 29 CFR 1910, Occupational Safety and Health Standards, Subparts H, I, and M.

KSC-STD-Z-0008, Standard for Design of Ground Life Support Systems and Equipment should be used as a guide to standardize design practices.

5.2.1.2 Interfaces to Hypergol Systems

a. Each pneumatic line that interfaces with a hypergol system shall have a hand-operated shut-off valve upstream of a spring-loaded poppet-type check valve to permit positive shutoff of the pneumatic supply and prevent backflow through the pneumatic line.

b. Each pneumatic line that interfaces with a hypergol system shall be downstream of a pneumatic supply pressure regulator that serves only a fuel or oxidizer system to prevent mixing of combustible vapors.

c. A sampling port shall be provided upstream and downstream of each regulator to permit periodic sampling of the pneumatic fluid for hypergol contamination.

d. A pressure gauge shall be provided downstream of each check valve to indicate the pressure in the hypergol system.

Gauge calibration ports should be designed to limit potential contaminated gas impingement on personnel.

KSC-STD-Z-0005, Design of Pneumatic Ground-Support Equipment, Standard for, should be used as a guide to standardize design practices.

5.2.2 Cryogenics

GSE used for all cryogenic servicing shall be in accordance with ASME Boiler and Pressure

Vessel Code, Section VIII and ASME B31.3 (for Severe Cyclic Conditions).

a. Liquid Hydrogen (LH2) and Liquid Oxygen (LO2) systems shall be designed in accordance with NFPA 55.

b. The design of GSE used for cryogenic servicing with liquid methane shall be in accordance with NFPA 59A Standard for the Production, Storage, and Handling of Liquefied

Natural Gas (LNG).

KSC-STD-Z-0009, Design of Cryogenic Ground Support Equipment Standard for, should be used as a guide for processes, methods, and practices applied to cryogenic GSE at Kennedy

Space Center.

5.2.3 Hypergols

GSE used for hypergolic propellant and monopropellant servicing shall be in accordance with

ASME Boiler Pressure Vessel Code, Section VIII, including lethal service requirements; and

ASME B31.3, including Category M requirements (see 6.3.1.3.1 for material compatibility requirements).

a. Hypergol system design shall preclude the chances of fuel and oxidizer intermixing by the following:

(1) Color coding and marking of hypergol fuels and oxidizer servicing equipment.

(2) Uniquely sizing or using a mechanically different type of connection for each commodity where close proximity creates a potential for cross-connection.

(3) No interconnection between hypergol fuel and oxidizer piping systems.

b. All hypergol servicing equipment shall be designed with spill containment, such as integrated drip pans or drainage to a collection/removal location.

c. Pipe flanges shall be raised face with concentric serrations.

KSC-STD-Z-0006, Hypergolic Propellants Ground Support Equipment, Design of, Standard for, should be used as a guide to standardize design practices. National Pipe Thread Tapered

Thread (NPT) connections should not be used in hypergolic servicing systems. The use of NPT should be restricted to those connections that require conversion from pipe to tube and must have ASME code safeguarding provisions, such as seal welds. GSE used for alternative propellants developed to replace hypergols should meet the requirements of this section.

5.2.4 Hydrocarbons

GSE used for servicing with hydrocarbon fuels shall be in…