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B-52H Modification Planning Guide – System Safety Analysis Guide

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Table of Contents

LIST OF FIGURES ....................................................................................................... viii

LIST OF TABLES ........................................................................................................ viii

ABSTRACT ..................................................................................................................... ix

1. INTRODUCTION ..................................................................................... 1-1

1.1 Purpose .............................................................................................................. 1-1

1.2 Scope ................................................................................................................. 1-1

2. REFERENCE DOCUMENTS ................................................................... 2-1

2.1 Government Documents .................................................................................... 2-1

2.2 Non-Government Documents ........................................................................... 2-2

2.3 Other Documents ............................................................................................... 2-3

2.4 Definitions ......................................................................................................... 2-3

3. SYSTEM SAFETY IMPLEMENTATION ............................................... 3-1

3.1 Roles and Responsibilities ................................................................................ 3-1

3.1.1 System Safety Organization ....................................................................... 3-1

3.1.2 Engineering Team ...................................................................................... 3-1

3.2 System Safety Process ....................................................................................... 3-2

3.2.1 System Safety Program .............................................................................. 3-3

3.2.2 Safety Requirements Definition ................................................................. 3-4

3.2.3 System Safety Analysis Process ................................................................ 3-4

3.2.4 Safety Assessment Preparation .................................................................. 3-5

3.2.5 Safety of Flight Clearance .......................................................................... 3-6

4. AIRCRAFT SAFETY REQUIREMENTS ................................................ 4-1

4.1 General Requirements ....................................................................................... 4-1

4.1.1 Effects on Aircraft Performance ................................................................ 4-2

4.1.2 Effects on the Aircraft Weight and Balance .............................................. 4-2

4.1.3 Aircraft Space and Equipment Location .................................................... 4-2

4.1.4 Aircraft Electrical Power............................................................................ 4-2

4.1.5 Aircraft Electromagnetic Compatibility ..................................................... 4-2

4.1.6 Aircraft Thermal Environment ................................................................... 4-3

4.1.7 Aircraft Structures ...................................................................................... 4-3

4.1.8 Aircraft Hydraulic and Fuel Systems ......................................................... 4-3

4.1.9 Aircraft Vibration Environment ................................................................. 4-3 iv D675-60000-28 REV B

4.2 Equipment Safety Requirements ....................................................................... 4-3

4.2.1 Crash Safety ................................................................................................ 4-3

4.2.2 Explosive Atmosphere ................................................................................ 4-4

4.2.3 Vibration ..................................................................................................... 4-4

4.2.4 Electromagnetic Interference ...................................................................... 4-4

4.2.5 Temperature - Altitude ............................................................................... 4-4

4.2.6 Explosive Decompression .......................................................................... 4-4

4.2.7 Personnel Safety ......................................................................................... 4-4

4.2.8 Human Factors ............................................................................................ 4-5

4.2.9 Hazardous Materials ................................................................................... 4-5

4.2.10 Electromagnetic Radiation ......................................................................... 4-5

4.2.11 Lightning Protection ................................................................................... 4-5

4.2.12 Mechanical Design ..................................................................................... 4-5

4.2.13 General Workspace Hazards ...................................................................... 4-5

4.3 Integration of Conventional or Nuclear Weapons ............................................. 4-6

4.3.1 Weapon Certification/Safety Requirements ............................................... 4-6

4.3.2 Aircraft / Stores Compatibility ................................................................... 4-6

4.4 Aircraft Cockpit Requirements .......................................................................... 4-7

4.5 Special B-52H Safety Requirements ................................................................. 4-7

4.5.1 Explosion Hazard Zone Classifications ...................................................... 4-7

4.5.2 B-52H Zone Seals ....................................................................................... 4-8

4.5.3 Electrical Equipment Requirements ........................................................... 4-9

4.5.4 Fire Prevention ......................................................................................... 4-13

4.5.5 Fire Containment ...................................................................................... 4-13

4.5.6 Crew Fire Warning ................................................................................... 4-13

4.5.7 Ejection Clearance .................................................................................... 4-13

4.5.8 Cockpit Circuit Breakers .......................................................................... 4-14

4.5.9 Oxygen System ......................................................................................... 4-14

4.5.10 Magnetic Materials ................................................................................... 4-14

4.5.11 Mercury Usage ......................................................................................... 4-14

5. AIRCRAFT POTENTIAL HAZARDS ..................................................... 5-1

5.1 Potential Generic Hazards ................................................................................. 5-1

5.2 Potential Unique Hazards .................................................................................. 5-4

6. SYSTEM SAFETY TASKS ....................................................................... 6-1

7. AIRCRAFT SYSTEMS ............................................................................. 7-1

7.1 Takeoff Essential Systems ................................................................................. 7-1

7.2 Weapons Control and Delivery System ............................................................. 7-3

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7.3 Electronic Countermeasures Systems ............................................................... 7-3

8. SAFETY OF FLIGHT (SOF) QUALIFICATION .................................... 8-1

8.1 Vibration/Acoustics ........................................................................................... 8-1

8.2 Temperature-Altitude ........................................................................................ 8-1

8.3 Explosive Atmosphere ...................................................................................... 8-2

8.3.1 Qualification for Explosive Atmosphere Operation .................................. 8-2

8.3.2 Qualification for Explosive Containment .................................................. 8-2

8.4 Explosive Decompression ................................................................................. 8-2

8.5 Crash Safety ...................................................................................................... 8-2

8.5.1 Forward Facing Crewmembers .................................................................. 8-3

8.5.2 Aft Facing Crew Members ......................................................................... 8-3

8.6 Aircraft Ground SOF - EMC Test ..................................................................... 8-3

8.6.1 Guidelines for Determining Extent of Testing Required ........................... 8-3

8.6.2 Analysis Capability and Limitations .......................................................... 8-4

8.6.3 Special Purpose Aircraft - Not Carrying Weapons .................................... 8-4

8.6.4 Minimum Test Required ............................................................................ 8-4

8.7 Restrictions and Limitations .............................................................................. 8-7

8.8 Qualification Tracking ...................................................................................... 8-7

9. SPECIAL EQUIPMENT SAFETY CRITERIA ........................................ 9-1

9.1 Non-Production Equipment ............................................................................... 9-1

9.1.1 Test Instrumentation................................................................................... 9-1

9.1.2 Instrumentation Installation Criteria .......................................................... 9-3

9.1.3 Prototype or Non Production Qualified Components ................................ 9-5

9.1.4 Carry on Equipment (Non-Installed) ......................................................... 9-5

9.2 Ground Test Equipment .................................................................................... 9-5

9.3 Other Support Equipment .................................................................................. 9-5

9.4 Certification of Government Furnished Equipment (GFE) ............................... 9-6

9.5 Commercial Off the Shelf (COTS) Equipment ................................................. 9-6

10. SYSTEM SAFETY SIGN-OFF REQUIREMENTS ............................... 10-1

11. BIBLIOGRAPHY OF B-52H SAFETY REPORTS ............................... 11-1

12. NOTES ..................................................................................................... 12-1

12.1 Abbreviations and Acronyms ....................................................................... 12-1

Appendix A. PRELIMINARY HAZARD ANALYSIS CHECK LIST ................... A-1 vi D675-60000-28 REV B

Appendix B. GENERIC SYSTEM SAFETY PROGRAM PLAN FOR

ENGINEERING ASSIGNMENTS .............................................................................. B-1

B.1 Introduction .................................................................................................... B-1

B.2 Scope .............................................................................................................. B-1

B.3 Objective ........................................................................................................ B-1

B.4 Tasks ............................................................................................................... B-2

Appendix C. GENERIC SOF - EMC TEST PROCEDURES ................................... C-1

C.1 Introduction .................................................................................................... C-1

C.1.1 Purpose ...................................................................................................... C-1

C.1.2 Scope ......................................................................................................... C-1

C.2 Objective And Test Requirements ................................................................. C-1

C.2.1 Objective .................................................................................................... C-1

C.2.2 Test Requirements ..................................................................................... C-1

C.3 Test Personnel ................................................................................................ C-2

C.3.1 Test Director .............................................................................................. C-2

C.3.2 Test Conductor .......................................................................................... C-3

C.3.3 Log Keeper ................................................................................................ C-3

C.3.4 Aircraft Systems Operators and Observers ............................................... C-4

C.3.5 Frequency Coordinator .............................................................................. C-4

C.4 Support And Test Equipment ......................................................................... C-4

C.4.1 Ground Support Equipment ....................................................................... C-4

C.4.2 Test Equipment .......................................................................................... C-5

C.5 ECM Test Procedures ..................................................................................... C-5

C.5.1 Flight Essential Systems Susceptibility Test ............................................. C-5

C.6 Equipment Operating Procedures ................................................................... C-5

C.6.1 Operating Procedure for Source Systems .................................................. C-5

C.6.2 AN/AIC-18 Interphone as a Receptor ....................................................... C-7

C.6.3 AN/ARC-164 UHF Radio as a Receptor ................................................... C-8

C.6.4 AN/ASC-19 AFSATCOM / AN/ARC-171 Radio as a Receptor .............. C-9

C.6.5 AN/ARC-210 V/UHF Radio as a Receptor ............................................. C-11

C.6.6 AN/ARC-190 HF Radio as a Receptor ................................................... C-13

C.6.7 AN/ARN-151 GPS Receiver as a Receptor ............................................ C-14

C.6.8 AN/ARN-32 Marker Beacon as a Receptor ............................................ C-16

C.6.9 AN/ARN-14 VOR as a Receptor ............................................................ C-17

C.6.10 AN/ARN-14 Localizer as a Receptor...................................................... C-18

C.6.11 AN/ARN-67 Glidepath Receiver as a Receptor ...................................... C-19

C.6.12 AN/ARN-118 TACAN as a Receptor ..................................................... C-20

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C.6.13 AN/APN-69A Rendezvous Beacon as a Receptor .................................. C-22

C.6.14 AN/APX-64 IFF Transponder as a Receptor ........................................... C-24

C.6.15 AN/APN-224 Radar Altimeter as a Receptor .......................................... C-26

C.6.16 AN/APN-218 Doppler Radar as a Receptor ............................................ C-28

C.6.17 SAS as a Receptor .................................................................................... C-29

C.6.18 AN/ASW-49 Autopilot as a Receptor ..................................................... C-30

C.6.19 ASQ-175, AAQ-6 & ASQ-151 EVS as a Receptor ................................. C-31

C.6.20 AN/ASQ-176 OAS as a Receptor ............................................................ C-32

C.6.21 AN/APQ-166 STRATEGIC RADAR (SR) as a Receptor ...................... C-35

C.6.22 AN/ARR-85 MINIATURE RECEIVE TERMINAL (MRT) as a

Receptor .................................................................................................. C-37

C.6.23 GROUP II Receptors ............................................................................... C-38

Appendix D. EMC TEST GUIDLINES .................................................................... D-1

D.1 Introduction .................................................................................................... D-1

D.1.1 Purpose ...................................................................................................... D-1

D.1.2 Scope ......................................................................................................... D-1

D.2 EMC Program ................................................................................................ D-1

D.3 EMI Laboratory Test...................................................................................... D-2

D.3.1 Definition .................................................................................................. D-2

D.3.2 Purpose ...................................................................................................... D-3

D.3.3 EMI Test Applicability ............................................................................. D-4

D.4 SOF EMC Tests ............................................................................................. D-5

D.4.1 Definition .................................................................................................. D-5

D.4.2 Methodology ............................................................................................. D-5

D.4.3 Purpose ...................................................................................................... D-5

D.4.4 Applicability .............................................................................................. D-6

D.5 System Level EMC Tests............................................................................... D-7

D.5.1 Definition .................................................................................................. D-7

D.5.2 Methodology ............................................................................................. D-8

D.5.3 Purpose ...................................................................................................... D-8

D.5.4 Applicability .............................................................................................. D-8

D.5.5 System Level EMC Test Options .............................................................. D-8

Active Page Record .................................................. APR-Error! Bookmark not defined.

Revision Record ............................................. Rev Record-Error! Bookmark not defined.

viii D675-60000-28 REV B

LIST OF FIGURES

Figure 3-1 B-52H System Safety Process ........................................................................ 3-3

Figure 4-1 Maximum Safe Surface Temperature............................................................. 4-9

Figure 5-1 System Safety Analysis Flowchart ................................................................. 5-1

Figure A-1 Preliminary Hazard Analysis ........................................................................ A-2

Figure C-1 APM-123 Altitude to Code Conversion ..................................................... C-25

Figure C-2 AN/APN-224 Test Setup ........................................................................... C-27

LIST OF TABLES

Table 4-1 Wire Size Current Ratings ............................................................................. 4-11

Table 5-1 Alphabetical Listing of Generic Hazards ........................................................ 5-2

Table 6-1 System Safety Tasks (Sheet 1 of 3) ................................................................. 6-2

Table 7-1 Takeoff Essential Systems for the B-52H (Sheet 1 of 3)................................. 7-1

Table 8-1 B-52H FES Susceptible to EMI ....................................................................... 8-6

Table D-1 MIL-STD-461 Test Methods Applicable to B-52H Equipment .................... D-3

Table D-2 Sources and Receptors For SOF EMC Tests ................................................. D-6

Table D-3 Sources and Receptors For System Level EMC Tests .................................. D-9

Table D-4 System Level EMC Test Options ................................................................ D-12

Table D-5 Significant EMC Test Scenarios .................................................................. D-12

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ABSTRACT

This document is one volume of the B-52H Modification Planning Guide series being developed by Boeing Wichita Development and Modification Center (WD-MC) under

Contract to Oklahoma City Air Logistics Center (OC-ALC).

Included herein is guidance on implementing the System Safety Program on the B-52H and establishment of safety requirements for follow-on modifications. Also included is the methodology for system safety hazard analysis as set forth in MIL-STD-882 and other related documents. It is intended that this information will facilitate initial design decisions for installation of future modifications, allowing timely resolution of safety issues with minimum impact on cost and schedules.

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1. INTRODUCTION

Topics covered include the system safety process, safety design requirements (criteria) for installing new equipment or modifying existing equipment on the B-52H aircraft, hazards to consider for each modification, guidelines for determining system safety tasks to be performed for new projects, a preliminary hazard checklist, a generic B-52H System Safety Program Plan

(SSPP) for engineering assignments and minimum Safety of Flight (SOF) / Electromagnetic

Interference (EMI) / Electromagnetic Compatibility (EMC) tests required for various modifications.

For each Engineering Manufacturing and Development (EMD) program, a unique SSPP shall be prepared that defines the B-52H System Safety organization, outlines the approach for system safety implementation, safety methodologies and analysis techniques and a safety schedule used to ensure satisfactory levels of safety to personnel and the aircraft throughout all phases of the program.

1.1 Purpose

The purpose of this document is to provide planning guidelines for accomplishing both temporary modifications to the B-52H aircraft and permanent changes, e.g., modernization of basic aircraft systems, to ensure the safety of the airplane is maintained. This document also provides guidance on the safety considerations for installation of Group B equipment on the

B-52H. Any change to the aircraft configuration requires assessment as to the impact of the change on existing aircraft systems as well as the effects existing aircraft systems may have on the added or modified items.

In addition, any changes to the aircraft configuration require an assessment of the impact on the existing nuclear certified aircraft systems. Both temporary and permanent changes to the B-52H aircraft must be analyzed to ensure the current nuclear certification of the aircraft is not altered or degraded. For more information on B-52H Nuclear Surety Certification refer to B-52H

Modification Planning Guide, D675-60000-10, Design and Evaluation Criteria for Nuclear

Safety/Certification.

1.2 Scope

The B-52H is a complex weapon system due to the diverse weapons and missions assigned to the aircraft. It is not practical to define all safety requirements for any combination of proposed changes to the aircraft. The normal safety approach in the planning phase for an aircraft modification is to have an early assessment conducted by System Safety to determine the safety requirements necessary for the program.

This document provides the process to assure that changes to the aircraft configuration do not degrade the current level of safety of the B-52H aircraft or its systems. It outlines system safety engineering requirements, identifies system safety activities required in conjunction with a modification, describes the system safety process, identifies generic and unique hazards to

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consider, and describes methods for determining and documenting safety of flight qualification, including EMI/EMC Safety of Flight.

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2. REFERENCE DOCUMENTS

2.1 Government Documents

STANDARDS:

FED-STD-313D

Chg Notice 1

Material Safety Data, Transportation Data and

Disposal Data for Hazardous Material Furnished to

Government Activities

03 Apr 1996

21 Mar 2000

MIL-HDBK-244A Guide To Aircraft/Stores Compatibility 06 Apr 1990

MIL-HDBK-454A General Guidelines For Electronic Equipment 03 Nov 2000

MIL-HDBK-1763 Aircraft/Stores Compatibility: Systems Engineering

Data Requirements And Test Procedures

15 Jun 1998

MIL-STD-704E Aircraft Electrical Power Characteristics 01 May 1991

MIL-STD-461E Requirements For The Control of Electromagnetic

Interference Characteristics Of Subsystems And

Equipment

20 Aug 1999

MIL-STD-810F

Chg. Notice 3

Environmental Engineering Considerations and

Laboratory Tests

01 Jan 2000

05 May 2003

MIL-STD-882D Standard Practice For System Safety 10 Feb 2000

MIL-STD-1472F Human Engineering 23 Aug 1999

MILITARY:

AFI33-118 Radio Frequency Spectrum Management 03 Apr 2002

AFI63-104 The Seek Eagle Program 19 Jul 1994

AFI91-102

Nuclear Weapon System Safety Studies, Operational

Safety Reviews, And Safety Rules

01 May 1999

AFI91-103 Air Force Nuclear Safety Certification Program 26 Jun 2001

AFI91-107 Design, Evaluation, Troubleshooting, And

Maintenance Criteria For Nuclear Weapon Systems

06 Apr 1994

AFI91-108 Air Force Nuclear Weapons Intrinsic Radiation

Safety Program

29 Nov 1993

AFI91-204 Safety Investigations And Reports 11 Dec 2001

AFI91-205 Non Nuclear Munitions Safety Board 01 Jul 1998

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AFI91-301 Air Force Occupational And Environmental Safety, Fire Protection, And Health (AFOSH) Program

01 Jun 1996

AFI91-302 Air Force Occupational And Environmental Safety, Fire Protection, And Health (AFOSH) Standards

18 Apr 1994

AFOSHSTD48-9 Radio Frequency Radiation (RFR) Safety Program 01 Aug 1997

AFPD40-2 Radioactive Materials (Non-Nuclear Weapons) 08 Apr 1993

AFPD91-2 Safety Programs 28 Sep 1993

AFPD91-3 Occupational Safety And Health 27 Sep 1993

OC-ALC

MMOI 800-4

System Safety Program

2.2 Non-Government Documents

SPECIFICATIONS:

None

DRAWINGS:

None

OTHER PUBLICATIONS:

D180-28993-101 Defense & Space Group System Safety Instructions -

Definitions

D180-28993-301 Boeing Aerospace System Safety Instructions –

Hazard Identification Guidelines

D180-28993-302 D&SG System Safety Instructions – Introduction to

System Safety Analysis Process

D180-28993-311 D&SG System Safety Instruction – System Safety

Engineering in Software Development

D675-60000-3 Electromagnetic Interference - Book 1

D675-60000-3 (C) Electromagnetic Interference - Book 2 (C)

D675-60000-4 Electrical Power Analysis

D675-60000-6 Thermal Environment Analysis

D675-60000-7 Space (Volumetric) Requirements

D675-60000-10 Design and Evaluation Criteria for Nuclear Safety

/Certification

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D675-60000-12 (C) Electromagnetic Characteristics (C)

D675-60000-13 (C) Existing Systems EMI Index (C)

D675-60000-14 Electric Power Characteristics

D675-60000-15 Random Vibration Requirements

D675-60000-16 Thermal Environments and Equipment Requirements

D675-60000-19 Weapon Compatibility Document

D675-60000-20 Weight Surveillance

D675-60000-21 Fuel and Hydraulic Systems

D675-60000-22 System-To-System Interface & Physical

Characteristics - Book 1

D675-60000-22 (C) System-To-System Interface & Physical

Characteristics - Book 2 (C)

D675-60000-23 Structural Loadability

D675-60000-27 Environmental Qualification Planning Guide

(C) - Classified

2.3 Other Documents

NAS 411 Rev 2 Hazardous Material Management Program 01 Jan 1994

NEMA Z535.1 Safety Color Code 01 Jan 2002

NEMA Z535.3 Criteria for Safety Symbols 01 Jan 2002

NEMA Z535.4 Product Safety Signs and Labels 01 Jan 2002

NEMA Z535.5 Accident Prevention Tags (for Temporary Hazards) 01 Jan 2002

NFPA 70 National Electrical Code 01 Jan 2002

NFPA 407 Aircraft Fuel Servicing 02 Aug 2001

2.4 Definitions

For a complete listing of system safety definitions, refer to D180-28993-101, Boeing Defense &

Space Group (D&SG) System Safety Instructions – Definitions.

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3. SYSTEM SAFETY IMPLEMENTATION

The safety of our products is an essential part of the Boeing goals and objectives. Our B-52H products must have maximum performance capability with maximum safety of design and operation. The task of the system safety function is to implement the engineering process by which maximum safety can be achieved.

Two Boeing D&SG System Safety Instructions are referenced throughout this section. These two instructions provide the basis for the following content and should be used as reference guides for all B-52H modification projects/programs. The two Boeing instructions are

D180-28993-301 and D180-28993-302, Hazard Identification Guidelines and Introduction to

System Safety Analysis Process, respectively.

3.1 Roles and Responsibilities

3.1.1 System Safety Organization

The B–52H system safety lead (SSL) shall be in charge of coordinating and directing the system safety activities with the associated functions of B-52H modification program/project including design, manufacture, test, installation, operation, handing, and maintenance. The SSL is responsible for the implementation and maintenance of this planning guide and is the focal point of all B-52H system safety related activities.

In order to assure the coherence of the design, manufacturing, assembly, integration and test documentation with the associated system safety documentation, the SSL and the appointed system safety engineer(s) (SSE) shall participate in all project reviews as a full member of panels and boards.

The SSL/SSE shall participate in B-52H modification program/project baselining of system and subsystem requirements, supporting design reviews, ensuring safety requirements are implemented within the design and integration of the program/project, and performing risk assessments as required by the contract.

3.1.2 Engineering Team

It is the Project Manager’s/Engineer’s responsibility to ensure the SSL/SSE for the B-52H modification program/project is informed of all the matters with regards to the project including, but not limited to, the following: critical items, problems or failures, non-conformances, design changes, deviations, waivers, actions and/or recommendations resulting from analysis, reviews, inspection and audits, qualification, verification, and acceptance of the project. The Project

Manager/Engineer is responsible for ensuring that the SSL/SSE are informed of all internal/external design meetings and milestone review activities.

The Project Manager/Engineer is responsible for receiving concurrence from the SSL when changes are made to the B-52H modification program/project milestone schedule to ensure that system safety activities remain in accordance with the overall program.

3-2 D675-60000-28 REV B

The Project Manager/Engineer is responsible for providing the engineering support documentation for each hazard analysis and for reviewing/providing comments to the safety reports to ensure the technical information is commensurate with the design of the project.

3.2 System Safety Process

The ultimate goal of system safety is to ensure that the safety of personnel, the B-52H aircraft and the surrounding environment is maintained during use of the hardware/software produced by and for the B-52H modification project/program. Effective mishap risk identification and commensurate risk reduction can be achieved only if sufficient management emphasis on system safety is applied throughout the development cycle. Therefore, it is essential that the system safety process be initiated at the commencement of a B-52H modification project/program.

The basic information and guidelines for use by System Safety personnel in performing their required tasks and activities for the B-52H aircraft is defined in document D180-28993-302, Boeing Defense & Space Group System Safety Instructions – Introduction to System Safety

Analysis Process. The goal of this instruction is to promote common understanding of the basic system safety analysis task. This task generally consists of the application of analysis methods

(tools) to accomplish the following:

a. Identification of hazards;

b. Evaluation of the hazards in terms of potential mishap risk to the item, elements, or systems being investigated;

c. Recording and tracking of actions taken to eliminate or control the identified hazards;

and reporting to the program and customer the level of mishap risk being accepted.

The D180-28993-302 is not a "how to" instruction, but rather it is an introduction to the understanding of the system safety analysis process.

Process -- n; 1. A particular method of performing a task in which there are a number of steps 2.

A series of actions by which a task is accomplished to bring about a desired result; a methodology

Figure 3-1 shows the process steps to be applied during a B-52H modification program.

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Figure 3-1 B-52H System Safety Process

Early integration of system safety into a project serves to aid engineers in making design decisions that may affect the overall safety of the project. Proactive implementation of system safety can reduce the risk of cost increases or schedule delays that may arise if design changes are required further down the design path.

Continuous involvement of system safety throughout the design (preliminary and critical design stages), fabrication, and test, is also essential so that the project/program can ensure that safety to personnel, the B-52H aircraft and to the surrounding environment (e.g., other equipment or facilities) is maintained during handling, installation, operation, and maintenance of the hardware/software. The following Sections 3.2.1 through 3.2.4 provide an over-view of the major steps of the system safety process.

3.2.1 System Safety Program

The first step of the system safety process is to coordinate with the customer and establish the level of risk acceptable to both the customer and the contractor. This information shall be the start of establishing a system safety program that works toward achieving a safe product acceptable to the contractor and customer. For large-scale or complex B-52H modification projects/programs, the system safety program is specifically tailored to the contract and the

System Safety Program Plan (SSPP) is written, which serves to document the system safety program. The SSPP should be documented via one of the following methods:

Establish System Safety Program

Identify Safety

Criteria /

Requirements

Perform System

Safety Analysis

Process

Prepare Final Safety

Assessment Report /

Memo

Section 3.2.1 Section 3.2.2 Section 3.2.3

Section 3.2.4

3-4 D675-60000-28 REV B

a. Contractually required document

b. Part of another program document

c. A stand alone SSPP

d. Memorandum of Agreement (MOA)

3.2.2 Safety Requirements Definition

For each B-52H modification project/program, system safety shall assist management in the definition of system safety requirements that shall be contained in the System Segment

Specifications (SSS), Statements of Work (SOW) and any sub-level specification required for the project/program. This is a crucial step in the system safety process, because failure to identify safety requirements early in the project/program could result in impacts to cost and schedule should design changes be required further down the development path.

Safety requirements may arise from contractual requirements (e.g., applicable military standards) or derived requirements based on the operation/functionality of the system, system integration issues or lessons learned. For example, a contractual safety requirement may be that new or modified equipment shall not degrade the existing level of safety of the system. A requirement derived from that might be that all new or modified equipment shall be explosion proof or incapable of igniting an explosive mixture.

3.2.3 System Safety Analysis Process

D180-28993-302 defines in detail the system safety analysis process to be performed for any

Boeing project. This process shall be implemented into all B-52H aircraft modification projects/programs. As stated in D180-28993-302, there are six steps of the system safety analysis process: hazard identification, hazard control, hazard reporting, hazard tracking, hazard verification, and finally hazard risk assessment. This system safety analysis process shall be documented in a hazard analysis.

3.2.3.1 Hazard Analyses

For each B-52H modification project/program, system safety engineers shall prepare a hazard analysis, which is a tool for systematically identifying hazards/mishap risks and developing design/operational requirements to reduce these risks. The hazard analysis documents the potential risk to personnel, the B-52H aircraft and surrounding equipment/facilities for the purpose of hazard tracking, reducing The Boeing Company exposure to liability, and historical records. They also provide a vehicle to achieve customer concurrence on safety requirements, hazard control methods and closeout verification.

A hazard analysis shall consist of the following information at minimum:

a. Top-level hazardous events (e.g., fire)

b. Definition of the hazardous event (e.g., Fire in the black box occurring during operational use, test or maintenance activities).

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c. Applicable causes for the top-level event (e.g., arcing/sparking components)

d. Definition of the hazardous effects (e.g., potential loss of life and aircraft if fire occurs without warning or means to suppress fire upon ignition)

e. Identification of hazard controls to eliminate or reduce the probability of occurrence

(e.g., design precluding use of arcing/sparking components)

f. Verification of the hazard control implementation (e.g., review of detailed design drawings and parts lists)

g. Identification of the final hazard risk (e.g., catastrophic with improbable occurrence).

Refer to section 5.0 of this document for more information regarding aircraft potential hazards and reference D180-28993-302, Section 2.0 for detailed guidance on performing the activities of letters “a” through “g” above.

There are several types of hazard analyses that are used to identify all sources of potential hazards. The different types of hazard analyses are the Preliminary Hazard Analysis (PHA), Subsystem Hazard Analysis (SSHA), System Hazard Analysis (SHA), Health Hazard

Assessment (HHA), Operating and Support Hazard Analysis (O&SHA) and the Test Hazard

Analysis (THA). For more information regarding these analyses refer to Section 3.0 of

D180-28993-302 titled, Introduction to Analysis Methods.

When identifying hazard controls during the hazard analysis process, the following hazard reduction precedence sequence shall be used:

h. Design for minimum risk

i. Safety devices

j. Cautions and warnings

k. Procedures and training

3.2.3.2 Hazard Closed-Loop Tracking

For each B-52H modification project/program, a Hazard Control Log (HCL) shall be prepared by the system safety engineer and it shall serve as a closed-loop tracking system used to track open hazards and their controls thus providing an audit trail of hazard resolutions. For more information regarding the closed-loop hazard tracking refer to D180-28993-302, Section 2.3 titled Hazard Reporting, Tracking and Verification.

3.2.4 Safety Assessment Preparation

For each B-52H modification project/program, the system safety engineer shall prepare a final safety assessment. Depending upon the scope of the modification program/project (EMD program or fleet support EA), either a full-scale Safety Assessment Report (SAR) in accordance with MIL-STD-882 or an abbreviated system safety coordination memo shall be prepared. In general, the SAR and safety memos are used to document the purpose of the project, description of the modification, and provide an executive summary of the hazard analysis findings.

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When required by contract the SAR and safety coordination memos shall be submitted to the customer for approval prior to the operational use of the hardware/software in the B-52H aircraft.

In particular, an EMD program SAR shall be delivered to the customer 60 days prior to the start of the first ground test of the hardware/software, unless otherwise stated in the program’s SSPP noted in Section 3.2.1 above.

3.2.5 Safety of Flight Clearance

A Safety Of Flight Clearance Memorandum will be provided to the SPO for all aircraft modifications requiring ground/flight test. The detail of clearance will be dependant on the complexity of the modification, but as a minimum will address the items listed in Sections 9 and

10. This memorandum will include, as necessary, a compatibility matrix for the new/modified items being tested. A major modification can result in an extensive ground/flight test program that requires close coordination between Boeing and the SPO to ensure the test schedule is maintained.

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4. AIRCRAFT SAFETY REQUIREMENTS

4.1 General Requirements

When planning a new modification to the airplane, safety requirements must be considered and established for each phase of the program including design, installation, test, operation and maintenance. The following safety requirements are considered applicable for all B-52H development efforts. Positive action and verified implementation is required in order to prove compliance with each requirement. Failure to comply with the following, if deemed applicable to the program/project, shall be presented to the B-52H program manager for approval and acceptance of the risk:

a. No single component failure, common mode failure, human error, or a design feature shall cause a mishap of Catastrophic or Critical mishap severity categories.

b. No dual independent component failures, dual independent human errors, or a combination of a component failure and a human error involving safety critical command and control functions, shall cause a mishap of Catastrophic or Critical mishap severity categories.

c. The generation of hazardous radiation or energy shall not occur, when no provisions have been made to protect personnel or sensitive subsystems from damage or adverse effects.

d. Packaging or handling procedures and characteristics shall not cause a mishap for which no controls have been provided to protect personnel or sensitive equipment.

Safety Critical and Control Functions -- n; Any function or process that if disrupted or bypassed would likely result in a loss of aircraft control [e.g., power control, attitude control, speed control (air and/or ground), fuel containment].

In addition, the following general elements should be considered for any aircraft change as a minimum:

e. Effects on Aircraft Performance

f. Effects on the Aircraft Weight and Balance

g. Aircraft Space and Equipment Location

h. Aircraft Electrical Power

i. Aircraft Electromagnetic Compatibility

j. Aircraft Thermal Environment

k. Aircraft Structures

l. Aircraft Hydraulic and Fuel Systems

m. Aircraft Vibration Environment

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4.1.1 Effects on Aircraft Performance

As a general rule most modifications will have some effect on aircraft performance. For example they may increase or decrease weight, increase drag, induce flutter, cause buffet, change environments, or decrease control effectiveness. For this reason every modification which adds or removes equipment, alters the control systems or changes the external aircraft contours should be evaluated by an aerodynamics engineer to assess the potential effects and determine if flight testing is recommended. If such flight testing is recommended, the engineer should develop the test program requirements for customer review and guidance. Further, if the technical uncertainty of the modification is such that airworthiness flight testing is recommended, then the modification should first be developed as a temporary modification and the necessary testing accomplished to remove the uncertainty.

4.1.2 Effects on the Aircraft Weight and Balance

The balance of the aircraft must be maintained within the specified center of gravity (CG) limits for the aircraft. Modification design should attempt to locate the equipment to maintain the CG within limits without adding dead weight ballast or altering the fuel management sequence. As a rule of thumb if the modification exceeds five pounds weight, it should be evaluated by a weights engineer to assess the impact on weight and balance and determine if airworthiness flight testing is recommended. If airworthiness flight-testing is recommended the engineer should develop the test program requirements for customer review and guidance. B-52H MPG

D675-60000-20 contains a discussion of the B-52H drag and weight surveillance program.

4.1.3 Aircraft Space and Equipment Location

Aircraft space for new equipment is limited, which increases the difficulty of the engineering research for available space. To aid in this effort, document B-52H MPG D675-60000-7 contains volumetric data for the current B-52H baseline and candidate upgrades.

4.1.4 Aircraft Electrical Power

Electrical power on the aircraft is limited and the quality does not totally conform to MIL-STD-

704 that is specified for design of most Group B equipment. B-52H MPG D675-60000-4 discuses electrical loading on the aircraft and B-52H MPG D675-60000-14 compares B-52H power quality to the various revisions of MIL-STD-704.

4.1.5 Aircraft Electromagnetic Compatibility

Existing B-52H systems along with a summary of their EMC qualification and operating parameters are maintained in B-52H MPG D675-60000-12 (Classified). Existing known

Electromagnetic Interferences (EMIs) on the B-52H aircraft along with incorporated fixes, if any, are contained in B-52H MPG D675-60000-13 (Classified). In addition OC-ALC maintains a computer program under the fleet support contract at Boeing that can predict antenna-to-antenna EMI for the B-52H, i.e., from an antenna to be installed at a proposed location to existing antennas. This capability is discussed B-52H MPG D675-60000-3.

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4.1.6 Aircraft Thermal Environment

Almost any new electrical or power equipment installed in the aircraft will require either heating or cooling and hence will impact the aircraft temperature environment. B-52H MPG D675-

60000-6 discusses heat loads by aircraft compartment while B-52H MPG D675-60000-16 defines temperature extremes.

4.1.7 Aircraft Structures

B-52H MPG D675-60000-23 contains information on structural loadability by aircraft location.

4.1.8 Aircraft Hydraulic and Fuel Systems

B-52H MPG D675-60000-21 contains a discussion of the theory of operation, testing requirements and current system loading of the hydraulic system. This document also defines the B-52H fuel system, allowable fuels, fuel system configuration, critical components and an overview of service and maintenance.

4.1.9 Aircraft Vibration Environment

Once the Group B equipment is designed and the Group A mounting provisions and location are determined, the zonal not-to-exceed values shown in B-52H MPG D675-60000-15 may be used to define a tailored vibration envelope for equipment qualification rather than using the higher.

4.2 Equipment Safety Requirements

Prior to installation of any new or modified equipment in the B-52H aircraft, the equipment must be certified safe for flight. This will normally be accomplished by the engineering agency responsible for the equipment. Guidelines and methodology for B-52H equipment complete environmental qualification are contained in B-52H MPG D675-60000-27 and should be consulted for more detailed information.

New or modified equipment not fully environmentally qualified may still be certified safe for use during flight test after successfully completing a subset of the environmental qualification requirements developed by the systems engineers in conjunction with agency responsible for the equipment. Section 8.0 of the B-52H MPG D675-60000-27 contains detailed coverage of SOF testing and certification requirements.

4.2.1 Crash Safety

The purpose of this requirement is to ensure that crew zone equipment items shall not break loose from their mounts nor shall internal components break through their equipment case during hard landings, or crash landings until crash load factors have been exceeded.