sscman91-710v3.pdf

BY ORDER OF THE COMMANDER

SPACE SYSTEMS COMMAND

SPACE SYSTEMS COMMAND MANUAL

91-710, VOLUME 3

27 DECEMBER 2022

Safety

RANGE SAFETY USER

REQUIREMENTS MANUAL - LAUNCH

VEHICLES, PAYLOADS, AND GROUND

SUPPORT SYSTEMS REQUIREMENTS

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for downloading or ordering on the e-

Publishing website at www.e-Publishing.af.mil.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: HQ SSC/SEK Certified by: HQ SSC/SEK

(Mr. John G. Orpen)

Supersedes: AFSPCMAN91-710V3, 15 May 2019 Pages: 239

This manual implements AFI 91-202, The U.S. Air Force Mishap Prevention Program and is consistent with DoDD 3100.10, Space Policy, DoDD 3200.11, Major Range and Test Facility

Base (MRTFB), DoDD 3230.3, DoD Support for Commercial Space Launch Activities, DoDI

3200.18, Management and Operation of the Major Range and Test Facility Base, AFPD 91-1, Nuclear Weapons and Systems Surety, AFPD 91-2, Safety Programs, and the Memorandum of

Agreement between the Department of the Air Force and the Federal Aviation Administration for

Launch and Reentry Activity on Department of the Air Force Ranges and Installations. This volume establishes the system safety program requirements, minimum design, test, inspection, hazard analyses, and data requirements for hazardous and safety critical launch vehicles, payloads, and ground support equipment, systems, and materials for Space Systems Command (SSC) ranges, including the Eastern Range (ER) and Western Range (WR). The following topics are addressed:

general design requirements, documentation requirements, pad safety console, material handling equipment, acoustic hazards, non-ionizing radiation sources, radioactive (ionizing radiation) sources, hazardous materials, ground support pressure systems, flight hardware pressure systems, ordnance systems, electrical and electronic equipment, motor vehicles, computer systems and software, seismic design criteria (WR only), and solid rocket motors and motor segments.

This Volume applies to all Range Users conducting or supporting operations on the SSC ranges.

Range Users include any individual or organization that conducts or supports any activity on resources (land, sea, or air) owned or controlled by SSC ranges. This includes such organizations http://www.e-publishing.af.mil/

2 SSCMAN91-710V3 27 DECEMBER 2022

as the DoD, US government agencies, civilian launch operators, and foreign government agencies and other foreign entities that (1) use SSC range facilities and test equipment; (2) conduct prelaunch and launch operations, including payloads to orbital insertion or impact; and/or (3) require on-orbit or other related support. Commercial users intending to provide launch services from one of the ranges shall have a license or license application in process from the Department of Transportation's Federal Aviation Administration (FAA) or have a DoD sponsorship and be accepted by the DoD to use the ER or WR. Foreign government organizations or other foreign entities shall be sponsored by an appropriate US government organization or be a customer of a

Range User. This volume does not apply to the Air National Guard or Air Force Reserve Command units.

In accordance with SSCI 91-701, The Space Systems Command Launch and Range Safety

Program, all tailored versions of SSCMAN 91-710 are approved by the Space Launch Delta (SLD)

Commander.

The authorities to waive SLD/unit level requirements in this publication are identified with a Tier

(“T-0, T-1, T-2, T-3”) number following the compliance statement. Waiver authority of non-tiered requirements may not be delegated below the Space Launch Delta Commander level unless specifically stated in this publication. See DAFMAN 90-161, Publishing Processes and

Procedures, and any SSC supplements for a description of the authorities associated with the Tier numbers. Submit requests for waivers through the chain of command to the appropriate Tier waiver approval authority, or alternately, to the Publication OPR. Ensure all records generated as a result of processes prescribed in this publication adhere to AFI 33-322, Records Management and Information Governance Program, and are disposed IAW the Air Force Records Disposition

Schedule, which is located in the Air Force Records Information Management System. Refer to

SSCMAN 91-710, Volume 1, Attachment 6 for submitting/recommended supplemented changes and questions to HQ SSC Directorate of Safety (HQ SSC/SE) using the Range Safety approved change request form or DAF Form 847, Recommendation for Change of Publication. Route the change request form through the appropriate functional chain of command.

This publication may be supplemented, but all supplements must be approved by HQ SSC/SE prior to certification and approval for publishing. Each range may incorporate range-unique or program-unique requirements into documents other than a supplement, such as an operating instruction, which is only required to be coordinated internally within the local Range Safety organization structure and approved at the local level by the Chief of Safety.

Note: SSCMAN 91-710, Volume 7, contains a glossary of references, acronyms and abbreviations, and terms for use with all the volumes. Special publication formatting features are described in paragraph 1.2 of this volume.

SUMMARY OF CHANGES

This document has been updated primarily to reflect organizational changes associated with the establishment of SSC as a USSF Field Command (FLDCOM), and the re-alignment of launch and range safety program management from the former Air Force Space Command publication to an

SSC publication.

SSCMAN91-710V3 27 DECEMBER 2022 3

Chapter 1—INTRODUCTION 8

1.1. General

1.2. Organization of the Volume

Chapter 2—RESPONSIBILITIES AND AUTHORITIES 10

2.1. Range Safety, SLD 30 and SLD 45

2.2. Range User Responsibilities

Chapter 3—GENERAL DESIGN REQUIREMENTS 11

3.1. General

3.2. Systems Without Specific Design Criteria

Chapter 4—DOCUMENTATION REQUIREMENTS 12

4.1. System Safety Program Plan (SSPP) and Hazard Analyses

4.2. Missile System Prelaunch Safety Package (MSPSP)

4.3. Missile System Prelaunch Safety Package (MSPSP) Associated Test Plans and

Test Results

4.4. Nondestructive Examination (NDE) Plans

Chapter 5—PAD SAFETY CONSOLE 14

5.1. Pad Safety Console General Design Requirements

5.2. Pad Safety Console Controls, Monitors, and Communication Lines

5.3. Pad Safety Console Color Television System

5.4. Pad Safety Console Communication and Video Recording

5.5. Pad Safety Console Validation and Test Requirements

5.6. Pad Safety Console Data Requirements

Chapter 6—MATERIAL HANDLING EQUIPMENT, CRANES AND HOISTS, AND

PERSONNEL WORK PLATFORMS 17

6.1. Overview

6.2. Material Handling Equipment (MHE)

Table 6.1. Attachment Point Preferences

6.3. Cranes and Hoists

Table 6.2. California Occupational Safety and Health Administration Requirements

Table 6.3. Smart Crane Controls

Table 6.4. Hoist Emergency Lowering

Table 6.5. Existing Real Property Installed Equipment (RPIE) Cranes and Hoists

6.4. Removable, Extendible, and Hinged Personnel Work Platforms

4 SSCMAN91-710V3 27 DECEMBER 2022

6.5. Man-Rated Baskets

6.6. Flight Hardware Used to Lift Critical Loads

Chapter 7—ACOUSTIC HAZARDS 40

7.1. Acoustic Design Standards

7.2. Acoustic Data Requirements

Chapter 8—NON-IONIZING RADIATION SOURCES 41

8.1. Electromagnetic Frequency Radiation (EMFR) Emitters

8.2. Laser Systems (Class 1M, 2M, 3B, and 4)

Chapter 9—RADIOACTIVE (IONIZING) RADIATION SOURCES 44

9.1. Radioactive Source Design Standards and Controls

9.2. Radioactive Sources Carried on Launch Vehicles and Payloads

Table 9.1. Range Safety Support to Interagency Nuclear Safety Review Board

Chapter 10—HAZARDOUS MATERIALS 47

10.1. Hazardous Materials Selection Criteria

10.2. Hazardous Materials Test Requirements

Table 10.1. Potential Sources of Hazardous Material Information

10.3. Hazardous Materials Environmental Requirements

10.4. Hazardous Material Data Requirements

10.5. Process Safety Management and Risk Management Plan

Chapter 11—GROUND SUPPORT PRESSURE, VACUUM, AND HAZARDOUS

STORAGE SYSTEMS 50

11.1. Overview

11.2. Ground Support Pressure, Vacuum, and Storage Systems Requirements

11.3. Ground Support Pressure Systems Requirements

Table 11.1. Material Selection and Testing

Table 11.2. Corrosion Control Guidance

Table 11.3. Additional Analysis Lessons Learned

Table 11.4. Steel Types for Pressure System Tubing

Table 11.5. Steel Types for Pressure Relief Devices

Table 11.6. Spacing for Tubing Supports Within Consoles or Modules

Table 11.7. Spacing for Tubing Supports Between Consoles or Modules

Table 11.8. Steel Types for Cryogenic Equipment

SSCMAN91-710V3 27 DECEMBER 2022 5

Table 11.9. In-service Operating, Maintenance, and Inspection Plan Guidance

11.4. Ground Support Pressure Systems Certification Data

Chapter 12—FLIGHT HARDWARE PRESSURE SYSTEMS AND PRESSURIZED

STRUCTURES 89

12.1. Overview

12.2. Flight Hardware Pressure System and Pressurized Structure General

Requirements

Table 12.1. Flexible Hose Guidance

12.3. Flight Hardware Pressure Vessel Design, Analysis, and Test Requirements

Figure 12.1. Pressure Vessel Design Verification Approach

Table 12.2. Qualification Pressure Test Requirements

Table 12.3. Minimum Proof Pressure

12.4. Flight Hardware Metallic Pressurized Structure Analysis and Test Requirements. 120

12.5. Flight Hardware Special Pressurized Equipment Design, Analysis, and Test

Requirements

12.6. Flight Hardware Pressure System Component Design and Test Requirements

Table 12.4. Pressure Components Safety Factors

Table 12.5. Design Considerations for Addressing Contamination

Table 12.6. Limit Torque Requirements

12.7. Flight Hardware Pneumatic System Design Requirements

12.8. Flight Hardware Hydraulic System Design and Test Requirements

12.9. Flight Hardware Hypergolic Propellant System Design and Test Requirements

12.10. Flight Hardware Cryogenic Systems Design and Test Requirements

12.11. Flight Hardware Pressure Systems Data Requirements

Chapter 13—ORDNANCE SYSTEMS 155

13.1. Ordnance Hazard Classification

13.2. Ordnance System General Requirements

13.3. Ordnance Electrical and Optical Circuits

13.4. Initiator Electrical and Optical Circuits

Table 13.1. Clarification on Valid and Independent Inhibits

13.5. Ordnance Safety Devices

Table 13.2. Fault Tolerance Clarifications

13.6. Ordnance Initiating Devices

6 SSCMAN91-710V3 27 DECEMBER 2022

Table 13.3. Exploding Bridgewire (EBW) RF Sensitivity

Table 13.4. Exploding Foil Initiator (EFI) RF Sensitivity

13.7. Explosive Transfer Systems and Receptor Ordnance

13.8. Ordnance Test Equipment

13.9. Ordnance Data Requirements

Chapter 14—ELECTRICAL AND ELECTRONIC EQUIPMENT 182

14.1. Electrical and Electronic Ground Support Equipment and Flight Hardware

General Design Requirements and Standards

Table 14.1. Safety Devices for Lithium Battery Design

Table 14.2. Li Ion Battery Maximum Expected Operating Pressure (MEOP) Clarification

14.2. Electronic Ground Support Equipment (EGSE) Design Requirements

Table 14.3. Class I, Division 2 Hazardous Locations

Table 14.4. Exposed Solid Rocket Motors

14.3. Electrical and Electronic Flight Hardware

14.4. Test Requirements for Lithium Batteries

Table 14.5. Lithium Batteries

14.5. Electrical and Electronic Equipment Data Requirements

Chapter 15—MOTOR VEHICLES 197

15.1. General

15.2. Motor Vehicles Other Than Lift Trucks

15.3. Lift Trucks

Chapter 16—COMPUTER SYSTEMS AND SOFTWARE 199

16.1. General

Table 16.1. Firmware, COTS, GOTS and Reused Software

16.2. Determination of Safety Significant Software Functions and Level of Rigor

Table 16.2. Safety Significant Software Functions

Table 16.3. Level of Rigor Lessons Learned

16.3. Hardware and Software Safety Design Requirements

Table 16.4. Anomaly and Failure Detection Alerts

Table 16.5. Safety Critical Function (SCF) Display Alerts

16.4. Software Requirements

Table 16.6. Examples of Acceptable Actions to Initiate a Hazardous Operation

16.5. Computer System and Software Data Requirements

SSCMAN91-710V3 27 DECEMBER 2022 7

16.6. Independent Verification and Validation (IV&V) Analysis Support

Table 16.7. Independent Verification and Validation (IV&V) Analysis Support

Chapter 17—WR SEISMIC DESIGN 208

17.1. Western Range (WR) Seismic Design Requirement Overview

17.2. Applicability of Design and/or Anchorage or Restraint Requirements

17.3. Basis for Design

17.4. WR Seismic Data Requirements

Chapter 18—SOLID ROCKET MOTORS AND ROCKET MOTOR SEGMENTS 211

18.1. General

18.2. Failure Mode Effects and Criticality Analysis (FMECA)

18.3. Lightning Effects Hazard Analysis

18.4. Solid Rocket Motor and Motor Segment Data Requirements

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 212

Attachment 2—MISSILE SYSTEM PRELAUNCH SAFETY PACKAGE. 213

8 SSCMAN91-710V3 27 DECEMBER 2022

Chapter 1

INTRODUCTION

1.1. General.

1.1.1. For unique hazards not covered by the Occupational Safety and Health Administration

(OSHA), and hazardous operations with potential to endanger beyond the boundaries of the launch complex or processing area, all Range Users operating on the SSC ranges, including the ER and WR, are subject to the personnel and resource protection requirements of this volume to ensure safety by design, testing, inspection, and hazard analysis. Department of the

Air Force occupational safety and health standards do not apply to contractors or contractor employees except where Department of the Air Force personnel or property are endangered or if specifically required by contract.

1.1.2. When hazards from Range User operations or activities are contained within the boundary of their operations space and do not impact areas outside of their control, deviation from these requirements through the tailoring process is permitted.

1.2. Organization of the Volume.

1.2.1. Main Chapters. The main chapters of this volume include common requirements for all vehicle classes. Attachments include additional requirements to supplement the main chapters.

1.2.2. Open Text. The open text contains the actual mandatory performance-based requirements. Tailoring expected for these requirements includes the deletion of non-applicable requirements, changes to an existing requirement due to a different design or process with rationale acceptable to Range Safety, or addition to a requirement when there are no existing requirements addressing a new technology, when unforeseen hazards are discovered, when federal or industry standards change and for similar reasons. For example, solid rocket motor performance requirements would be deleted for launch systems that do not use solid rocket motors.

1.2.3. Bordered Paragraphs.

1.2.3.1. Bordered paragraphs, or text boxes, identified as tables and notes in this document, are non-mandatory and are used to identify some of the potential detailed technical solutions that meet the performance requirements. In addition, the bordered paragraphs contain lessons learned from previous applications of the performance requirement, where a certain design may have been found successful, or have been tried and failed to meet the requirement. These technical solutions are provided for the following reasons:

1.2.3.1.1. To aid the tailoring process between Range Safety and Range Users in evaluating a potential system against all the performance requirements.

1.2.3.1.2. To aid Range Safety and Range Users in implementing lessons learned.

1.2.3.1.3. To provide benchmarks that demonstrate what Range Safety considers an acceptable technical solution/implementation of the performance requirement and to help convey the level of safety the performance requirement is intended to achieve.

1.2.3.2. The technical solutions in the bordered paragraphs may be adopted into the tailored version of the requirements for a specific program when the Range User intends

SSCMAN91-710V3 27 DECEMBER 2022 9

to use that solution to meet the performance requirement. At this point, they become mandatory requirements to obtain Range Safety approval. This process is done to:

1.2.3.2.1. Provide an appropriate level of detail necessary for contractual efforts and to promote efficiency in the design process.

1.2.3.2.2. Avoid contractual misunderstandings that experience has shown often occur if an appropriate level of detail is not agreed to. The level of detail in the bordered paragraphs is necessary to avoid costly out-of-scope contractual changes and to prevent inadvertently overlooking a critical technical requirement.

1.2.3.3. The Range User always has the option to propose alternatives to the bordered paragraph solutions. Range User proposed alternative solutions shall achieve an equivalent level of safety and be approved by Range Safety. After meeting these two requirements, the Range User proposed solutions become part of the tailored SSCMAN 91-710 for that specific program.

1.2.3.4. Range Safety has final decision authority in determining whether Range User proposed detailed technical solutions meet SSCMAN 91-710 performance requirements.

10 SSCMAN91-710V3 27 DECEMBER 2022

Chapter 2

RESPONSIBILITIES AND AUTHORITIES

2.1. Range Safety, SLD 30 and SLD 45.

2.1.1. Unless otherwise noted, all references to SLD/SE in this volume refer to the Systems

Safety organizations at SLD 30/SE and SLD 45/SE. SLD/SE is also commonly referred to as

Range Safety. The Range Safety offices are responsible for the review and approval of the design, inspection, and testing of all hazardous and safety critical launch vehicles, payloads, and ground support equipment, systems, subsystems, and material to be used at the ER and

WR in accordance with the requirements of this volume. The responsibilities of Range Safety at SLD 45 may also encompass designs of launch vehicles, payloads, ground support equipment, systems, subsystems, and material used at the National Aeronautics and Space

Administration (NASA) Kennedy Space Center (KSC). Specific responsibilities of Range

Safety include review and approval of documents such as Missile System Prelaunch Safety

Packages (MSPSP), System Safety Program Plans (SSPP), test plans, test reports, and other documents as specified in this manual.

2.1.2. During the review and approval process, both Range Safety and the Range User shall assure timely coordination with other SLD agencies as appropriate. Other SLD agencies include, but are not limited to, Radiation Safety Officer, Bioenvironmental Engineering, Civil

Engineering, Environmental Planning, Explosive Ordnance Disposal, and the Fire Department.

2.2. Range User Responsibilities. Range Users are responsible for establishing and maintaining a system safety program in accordance with SSCMAN 91-710 Volume 1, paragraph 2.5.2 (as described in SSCMAN 91-710 Volume 1 Attachment 3 and Chapter 4 of this volume). The design, inspection, and testing of all hazardous and safety critical launch vehicle, payload, and ground support equipment, systems, subsystems, and materials to be used at the ranges shall be in accordance with the requirements of this volume, to include documentation as described in

Chapter 4 and Attachment 2 of this volume. These responsibilities include the following:

2.2.1. Timely submission of an SSPP.

2.2.2. Timely submission of hazard analyses.

2.2.3. Timely submission of all required MSPSPs.

2.2.4. Timely submission of all MSPSP associated test plans and reports.

2.2.5. Coordinating with and supporting Range Safety in carrying out tasks necessary for

SLD/SE approval of design, inspection, and testing.

SSCMAN91-710V3 27 DECEMBER 2022 11

Chapter 3

GENERAL DESIGN REQUIREMENTS

3.1. General.

3.1.1. All systems shall be designed to tolerate a minimum number of credible failures, based on the degree of fault tolerance required.

3.1.2. The number of design inhibits required to prevent an overall system failure or mishap is based on the failure or mishap result. Specific inhibit requirements are addressed in the design criteria for each of the systems addressed in this volume.

3.2. Systems Without Specific Design Criteria. Those systems that do not have specific design criteria or systems not addressed in this volume shall be designed to the following general criteria:

(See SSCMAN 91-710, Volume 1, Chapter 3, Table 3.2 for guidance on consequence categorization)

3.2.1. If a system failure may lead to a catastrophic hazard, the system shall have three inhibits

(dual fault tolerant).

3.2.2. If a system failure may lead to a critical hazard, the system shall have two inhibits

(single fault tolerant).

3.2.3. If a system failure may lead to a marginal hazard, the system shall have a single inhibit

(no fault tolerant).

3.2.4. Probabilities of hazard occurrence associated with launch and reentry that can endanger a population shall be taken into consideration when determining the number of required inhibits. (See SSCMAN 91-710, Volume 1, Chapter 3, Table 3.1.)

3.2.5. Systems shall be able to be brought to a safe state with the loss of an inhibit.

3.2.6. All inhibits shall be independent and verifiable. Common cause failures shall be assessed in determining inhibit independence.

3.2.7. Design inhibits shall consist of electrical and/or mechanical hardware.

3.2.8. Operator controls shall not be considered a design inhibit. Operator controls are considered a control of an inhibit.

12 SSCMAN91-710V3 27 DECEMBER 2022

Chapter 4

DOCUMENTATION REQUIREMENTS

4.1. System Safety Program Plan (SSPP) and Hazard Analyses.

4.1.1. Range Users shall develop a preliminary SSPP in accordance with SSCMAN 91-710

Volume 1, Attachment 3 and submit to Range Safety for review and approval within 45 calendar days of the Program Introduction (PI) and a final SSPP at least 45 calendar days before any System Requirements Review (SRR) or equivalent program activity. Note: Range

Users should submit the preliminary SSPP and Preliminary Hazard List (PHL) to Range Safety prior to the commencement of the tailoring process or prior to the SRR, whichever occurs first.

4.1.2. Range Users shall develop and submit hazard analyses to Range Safety for review and approval in accordance with SSCMAN 91-710 Volume 1, Attachment 3.

4.1.2.1. Range Safety shall review and provide comments to each of the hazard analyses submittals at or before the appropriate SRR, Preliminary Design Review (PDR), and

Critical Design Review (CDR).

4.1.2.2. Range Users shall not transport hazardous materials to the installation or commence hazardous operations prior to receiving final approval of hazard analysis reports.

4.1.2.3. SSPPs and hazard analyses for DoD programs shall comply with MIL-STD-882, Department of Defense Standard Practice for System Safety, data requirements, or commercial equivalent for commercial FAA-licensed programs.

4.2. Missile System Prelaunch Safety Package (MSPSP).

4.2.1. MSPSP Submittal, Review, and Approval Process.

4.2.1.1. Range Users with overall responsibility for the launch vehicle, reusable launch vehicle, payload, or ground support systems shall submit an MSPSP; for commercial payloads, the payload MSPSP is normally submitted to Range Safety through the launch vehicle contractor.

4.2.1.2. Incremental draft versions of the MSPSP shall be delivered to Range Safety at least 45 days prior to the SRR, PDR, and CDR, or equivalent program activities.

4.2.1.3. Range Safety shall review and provide comments to each of the MSPSP submittals at or before the appropriate SRR, PDR, and CDR, or equivalent program activities.

4.2.1.4. A final MSPSP that satisfies all Range Safety concerns addressed at the CDR shall be submitted to Range Safety at least 45 calendar days prior to the Pre-Ship Review (PSR) or equivalent program activity.

4.2.1.5. Range Safety shall review the final MSPSP and if the MSPSP is found to be satisfactory, approve it within 10 calendar days of receipt. The final MSPSP shall be approved before shipment of associated hardware to the ranges.

4.2.2. MSPSP Preparation. Requirements for preparing an MSPSP can be found in

Attachment 2 of this volume.

SSCMAN91-710V3 27 DECEMBER 2022 13

4.3. Missile System Prelaunch Safety Package (MSPSP) Associated Test Plans and Test

Results.

4.3.1. All MSPSP associated test plans shall be submitted at least 45 calendar days before the intended test plan use. Range User requests to eliminate or reduce testing shall be justified with clear and convincing evidence presented to the SLD Commander (SLD/CC) for approval. The

SLD/CC may delegate approval authority to Range Safety.

4.3.2. Range Safety shall review and comment on or approve test plans within 45 calendar days of receipt. Disapproved test plans shall be corrected and resubmitted. An approved test plan is required before test performance.

4.3.3. Test reports shall be submitted at least 45 calendar days of intended system use.

4.3.4. Range Safety shall review, comment, and approve test reports within 10 calendar days of receipt. Disapproved test reports shall be corrected and resubmitted. An approved test report is required before system use.

4.4. Nondestructive Examination (NDE) Plans.

4.4.1. Unless otherwise specified in a separate part of this document that addresses a particular class of system or equipment, a nondestructive examination (NDE) plan shall include the following:

4.4.1.1. NDE technique and acceptance criteria to be used on each single failure point

(SFP) component or SFP weld after initial and periodic proof load tests.

4.4.1.2. Detailed engineering rationale for each technique and acceptance criteria. Note:

Detailed engineering rationale may include manufacturer stated requirements/recommendations or recognized industry standards such as American

National Standards Institute (ANSI) and the American Society of Mechanical Engineers

(ASME).

4.4.1.3. A determination of whether the equipment is dedicated to only one function or whether it is multipurpose.

4.4.1.4. The environment and/or conditions under which the equipment will be used and stored.

4.4.1.5. The existence of any SFP component and weld materials susceptible to stress corrosion.

4.4.1.6. Corrosion protection and maintenance plans.

4.4.2. Unless otherwise specified in a separate part of this document that addresses a particular class of system or equipment, the NDE plan shall be submitted to Range Safety for review and approval as soon as developed and no later than the program PDR, unless otherwise agreed to by Range Safety.

14 SSCMAN91-710V3 27 DECEMBER 2022

Chapter 5

PAD SAFETY CONSOLE

5.1. Pad Safety Console General Design Requirements.

5.1.1. Each launch control center, blockhouse, and firing room, as applicable, shall provide for a Pad Safety Console (PSC). MIL-STD-1472, Human Engineering Design Criteria for

Military Systems, Equipment, and Facilities, shall be used as appropriate in designing the PSC.

Note: The term ‘Pad Safety Console’ has also been known in the past as ‘Operations Safety

Console’; the terms shall be considered interchangeable.

5.1.2. The Range User (normally the launch vehicle provider) shall provide an ER/WR PSC unless otherwise agreed to by Range Safety. Range Safety shall approve the design, operation, and maintenance of the PSC.

5.1.3. The Range User shall provide ample and satisfactory space to install and operate the console.

5.1.4. No SFP components shall be in the ground support equipment (GSE) or firing room/launch control center/blockhouse system that will cause the loss of a safety critical system control or monitor (as determined by Range Safety) at the PSC.

5.2. Pad Safety Console Controls, Monitors, and Communication Lines.

5.2.1. The PSC shall be in a dedicated position to provide the Pad Safety Supervisor/Pad

Safety Officer sufficient information and communications capability to convey safety status and conditions to the appropriate authority (e.g., the launch complex control authority for day-to-day operations and the Mission Flight Control Officer [MFCO] during a launch operation).

5.2.2. At a minimum, the controls, monitors, and communication lines listed below are required at the launch complex PSC. These items are general in nature and may vary depending on the launch facility and/or launch vehicle configuration. The monitor circuit shall be designed so that the actual status of the critical parameters can be monitored rather than the command transmittal. It is important that this console does not have any flight termination system (FTS) command transmittal functions.

5.2.2.1. FTS safe and arm status for all FTS safe and arm devices.

5.2.2.2. Ignition safe and arm status for all solid rocket motor safe and arm devices.

5.2.2.3. An enable control switch and status for all solid rocket motor arming devices.

5.2.2.4. Launch vehicle liquid propulsion system inhibits and propellant tank pressure status (psig).

5.2.2.5. Fire suppression system status.

5.2.2.6. Launch complex warning beacon and horn control switch and status.

5.2.2.7. Emergency and normal electrical power status for critical locations.

5.2.2.8. Wind speed and direction readouts.

5.2.2.9. Communications Control Panel.

SSCMAN91-710V3 27 DECEMBER 2022 15

5.2.2.9.1. At least one Class A dial line.

5.2.2.9.2. Audio-selector push buttons for intercom net and direct lines in which four channels can be accessed simultaneously.

5.2.2.9.3. Direct line to the MFCO.

5.2.2.9.4. Direct line to the Range Safety representative.

5.2.2.9.5. Direct lines to Test Conductor and Launch Control Officer.

5.2.2.9.6. Direct line to primary access control point for safety control areas.

5.2.2.9.7. Direct line to facility safety net.

5.2.2.9.8. Direct line to Launch Support Team Chief and fallback area.

5.2.2.9.9. Access to facility public address (PA) system with emergency override capability.

5.2.2.9.10. Radio frequency (RF) nets, as required.

5.2.2.9.11. Direct line to the Launch Director.

5.2.2.9.12. Direct line to the Aerospace Surveillance Officer (ASO).

5.2.2.9.13. Particular communication equipment as specified in applicable Range

Safety Operations Requirements (RSOR).

5.2.2.10. Master countdown status.

5.2.2.11. Holdfire (stop launch sequencer) control switch, for pad launches only, active through T-0 (for ER only).

5.2.2.12. Ignition firing line enable and disable control switch and status.

5.2.2.13. Holdfire status.

5.3. Pad Safety Console Color Television System.

5.3.1. A PSC color television system shall be provided to ensure the coverage necessary to view all hazardous operations in the launch complex. Note: various feeds (e.g., infrared camera) may be desired for monitoring specific hazards.

5.3.2. Control of the television system shall be available at the PSC.

5.4. Pad Safety Console Communication and Video Recording.

5.4.1. The PSC shall be capable of recording and playback of hazardous operations.

5.4.2. Communication and video recording requirements shall be coordinated with the launch controller and test conductor before the start of an operation.

5.4.3. Designated recordings shall remain on file for 180 days.

5.5. Pad Safety Console Validation and Test Requirements.

5.5.1. At a minimum, a PSC validation and checkout test shall be performed to demonstrate the following:

5.5.1.1. The correct and reliable operation of PSC functions.

16 SSCMAN91-710V3 27 DECEMBER 2022

5.5.1.2. The validity of PSC outside interfaces.

5.5.1.3. The operating limits of the PSC.

5.5.2. Test plans, procedures, and test results shall be reviewed and approved by Range Safety.

5.6. Pad Safety Console Data Requirements. PSC data requirements are identified in paragraph A2.2.5.16 of this volume.

SSCMAN91-710V3 27 DECEMBER 2022 17

Chapter 6

MATERIAL HANDLING EQUIPMENT, CRANES AND HOISTS, AND PERSONNEL

WORK PLATFORMS

6.1. Overview.

6.1.1. This chapter is divided into three major types of equipment: material handling equipment (MHE), cranes and hoists, and personnel work platforms.

6.1.2. MHE is comprised of below-the-hook lifting devices (BTHLD), handling structures, support structures, slings, load positioning (e.g., Hydra Set ®) and load indicating devices

(LID), lifting assemblies, and rigging hardware. Slings, BTHLDs, lifting assemblies, rigging hardware, and LIDs are governed by industry standards (e.g., Occupational Safety and Health

Administration [OSHA], ASME). Handling structures, support structures, and load positioning devices are governed by accepted engineering practices and requirements of this

Chapter. Data requirements are provided in Attachment 2 of this volume. These requirements are applicable to new or modified MHE. The requirements are also applicable to permanent or short-term use MHE and apply whether the equipment is owned, rented, or leased by the government, contractors, or commercial operators. Periodic/recurring test and inspection requirements are found in SSCMAN 91-710 Volume 6.

6.2. Material Handling Equipment (MHE). The design and initial test requirements for MHE used at the ranges for handling (lifting, supporting, or manipulating) critical and non-critical hardware are included below.

6.2.1. MHE General Requirements.

6.2.1.1. MHE Requirements Validation.

6.2.1.1.1. The Range User shall validate the requirements by providing a Compliance

Check List IAW Attachment 2, A2.3.

6.2.1.1.2. Supporting data for commercial-off-the-shelf (COTS) equipment shall include the following information:

6.2.1.1.2.1. COTS name, description, model number, and part number.

6.2.1.1.2.2. Rated capacity (allowable working load).

6.2.1.1.2.3. Certifications of compliance with industry consensus standards from a

Nationally Recognized Testing Laboratory (NRTL), manufacturer, or other qualified organization.

6.2.1.1.2.4. MHE shall have documented traceability of material, manufacturer, and acceptance testing to required codes and standards (e.g., OSHA, ASME).

6.2.1.2. MHE Single Fault Tolerance.

6.2.1.2.1. Critical MHE shall be designed without single failure points (SFPs).

6.2.1.2.2. Exceptions shall be identified, justified, and submitted to Range Safety for approval. Supporting data shall include the following information: (See also

Attachment 2, A2.2.5.6)

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6.2.1.2.2.1. A list of all identified SFPs.

6.2.1.2.2.2. Risk assessment.

6.2.1.2.2.3. Risk mitigation considerations and inhibits.

6.2.1.2.2.4. A map of SFP locations (for example, weld map, system components).

6.2.1.2.2.5. Inspection and NDE requirements.

6.2.1.2.3. SFP components and welds shall be accessible for nondestructive inspection, maintenance, and repair.

6.2.1.3. MHE Inspection and Test Requirements.

6.2.1.3.1. MHE Test Weights and Load Test Devices.

6.2.1.3.1.1. Load tests shall be conducted with certified weights and/or certified weight fixtures.

6.2.1.3.1.2. These weights shall be identified and permanently and clearly marked with the total weight and owner or agency identification number.

6.2.1.3.1.3. Reinforcing steel (rebar) shall not be used for lift points.

6.2.1.3.1.4. Calibrated load devices such as dynamometers may be used to test slings and other lifting devices except cranes and hoists.

6.2.1.3.1.5. Requirements for Fabrication of New Test Weights and Weight

Fixtures.

6.2.1.3.1.5.1. Weight fixtures shall be designed and load tested IAW requirements contained in paragraph 6.2.3.1.

6.2.1.3.1.5.2. Weight fixtures shall be designed so that the loaded fixture center of gravity is centered below the crane hook for all required weight combinations.

6.2.1.3.1.5.3. Lifting lugs shall be provided if required to enable handling of empty test weight fixtures.

Table 6.1. Attachment Point Preferences.

A single crane hook attachment point on the fixture (e.g., a screw operated pin) is preferable to multiple attachment points that require use of slings.

6.2.1.3.1.5.4. Weight interlocking features shall be provided on both the weight fixture and the weights to help prevent sliding of weights and to help even stacking.

6.2.1.3.1.5.5. Weightlifting lugs shall be proof tested to 125% of the total weight before initial weight use.

6.2.1.3.2. MHE NDE.

6.2.1.3.2.1. NDE plans shall be developed for MHE used to handle critical systems and equipment and MHE containing SFPs.

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6.2.1.3.2.2. The NDE plan shall include detailed methodology, acceptance criteria, frequency of inspection, and a clear schematic showing the exact location of the items to be inspected. For details of the NDE plan, see paragraph 4.4.

6.2.1.3.2.3. NDE shall be performed by qualified and certified personnel IAW the written practices and requirements contained in the American Society for

Nondestructive Testing (ASNT) SNT-TC-1A, Recommended Practice for

Personnel Qualifications and Certification in Nondestructive Testing.

6.2.1.4. MHE Marking and Tagging Requirements.

6.2.1.4.1. Marking Requirements. All equipment (new and modified) shall be permanently marked IAW applicable codes and standards and have a permanently attached identification tag with the following information:

6.2.1.4.1.1. Manufacturer.

6.2.1.4.1.2. Part number.

6.2.1.4.1.3. Serial number.

6.2.1.4.1.4. Date of manufacture or initial acceptance.

6.2.1.4.1.5. Rated capacity.

6.2.1.4.1.6. Weights of the top assembly and separate subassemblies.

6.2.1.4.1.7. Weight of bridge and trolley (cranes only).

6.2.1.4.2. Tagging Requirements.

6.2.1.4.2.1. Systems/equipment requiring testing shall be tagged and test data included in its data package.

6.2.1.4.2.2. The tags shall be of durable material, preferably corrosion resistant metal, properly secured with corrosion and abrasion resistant wire or string, and marked (stamped or etched) with the following minimum information:

6.2.1.4.2.2.1. Part number, serial number, and other unique identifier

(reference designator).

6.2.1.4.2.2.2. Date of most recent test.

6.2.1.4.2.2.3. Test load.

6.2.1.4.2.2.4. Date of next load test.

6.2.1.4.2.2.5. Date of most recent NDE (if applicable).

6.2.1.4.2.2.6. Date of next NDE (if applicable).

6.2.1.4.2.2.7. A quality assurance or quality control indication certifying data on the tag.

6.2.1.4.2.3. The tags shall be accessible for inspection.

6.2.1.4.2.4. If the assembly is to be disassembled after proof testing, each component and subassembly shall be individually tagged with the reference designator, for example, removal and separate storage of a shackle bolt from the

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shackle after the proof load.

6.2.2. Slings. A sling is a flexible lifting assembly used between the load and hoisting device hook, comprised of alloy steel chain, wire rope, natural or synthetic webbing or synthetic rope, or metal mesh, with supporting fittings and attachment hardware.

6.2.2.1. Sling Design Standards and Requirements.

6.2.2.1.1. Slings shall be designed, manufactured, maintained, and stored in accordance with ASME B30.9, Slings, and 29 Code of Federal Regulations (CFR)

1910.184, Slings.

6.2.2.1.2. Carbon steel or wrought iron chain slings shall not be used.

6.2.2.1.3. Wire rope slings shall be formed with swaged or zinc-poured sockets or spliced eyes.

6.2.2.1.4. Wire rope clips or knots shall not be used to form slings.

6.2.2.1.5. All synthetic slings shall be designed with an ultimate factor of safety of 5 or higher.

6.2.2.1.6. Natural fiber rope or natural fiber web slings shall not be used.

6.2.2.1.7. Rotation resistant rope shall not be used for fabricating slings.

6.2.2.2. Sling Inspection and Test Requirements.

6.2.2.2.1. Before their first operational use at the ranges and following modifications or repairs, slings shall be inspected and tested to 200% of their rated load in accordance with ASME B30.9 and 29 CFR 1910.184.

6.2.2.2.2. For slings used to support critical operations, volumetric and surface NDE testing shall be performed on all sling assembly SFP components, such as pins, bolts, shackles, and links after the proof load test IAW the Range Safety approved NDE plan.

6.2.3. Below-the-Hook Lifting Devices (BTHLD). BTHLDs are structural and mechanical lifting devices and equipment (except for slings, load positioning devices, and load cells) used to connect a crane/hoist hook and a load being lifted, including lifting beams (and arms) and attachment hardware such as bolts and pins (lifting assemblies). Standards for BTHLDs are covered by ASME B30.20, Below-the Hook Lifting Devices, but the device may contain components such as slings, hooks, and rigging hardware addressed by other ASME B30 series standards (Safety Standard for Cableways, Cranes, Derricks, Hoist, Hooks, Jacks, and Slings) or other standards.

6.2.3.1. BTHLD Design Standards and Requirements.

6.2.3.1.1. BTHLDs shall be designed by a structural engineer and manufactured to the specified rated loads and load geometry of Design Category B (with a minimum yield safety factor of 3) in accordance with ASME BTH-1, Design of Below-the-Hook Lifting

Devices, and ASME B30.20.

6.2.3.1.2. Material used in the construction of BTHLDs shall exhibit a ductile failure mode. The intent is to have advanced warning of an upcoming failure via visually detectable deformation of structural components. Use of brittle materials shall require

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Range Safety review and approval, on a case-by-case basis. Higher level NDE requirements, such as volumetric NDE, may be imposed. If brittle materials (less than

5 percent elongation-to-failure) are used, BTHLDs shall be designed to include a safety factor to ultimate of 5 based on rated loads.

6.2.3.2. BTHLD Inspection and Test Requirements.

6.2.3.2.1. Before their first operational use at the ranges and following modifications or repairs, BTHLDs shall be inspected and proof tested to 125% of the rated load in accordance with ASME B30.20 methodology and the Range Safety approved NDE plan. The rated load shall not exceed 80% of the actual test load. If the BTHLD contains components such as slings and shackles, then these components shall be proof tested individually to their respective proof load levels (200% of the rated load for slings and shackles) and the whole assembly then proof tested to 125% of the rated load.

6.2.3.2.2. For BTHLDs used to support critical operations, volumetric and surface

NDE shall be performed on all SFP components and welds after the initial proof load test IAW the Range Safety approved NDE plan.

6.2.4. Handling Structures. Handling structures are those structures used to handle and manipulate hardware or equipment, such as spin tables, equipment racks, and rotating devices.

6.2.4.1. Handling Structure Design Standards and Requirements.

6.2.4.1.1. Handling structures shall be designed with a yield factor of safety of 3 based on rated loads.

6.2.4.1.2. Handling structures whose failure would not result or propagate into a catastrophic event may be designed to a yield factor of safety of 2 based on limit loads.

6.2.4.1.3. Handling structures at the WR shall be designed to accommodate the worst-case seismic load IAW Chapter 17.

6.2.4.1.4. Material (including fittings and attachment hardware) used in the construction of handling structures shall exhibit a ductile failure mode. The intent is to have advanced warning of an upcoming failure via visually detectable plastic deformation of structural components. Use of brittle materials shall require Range

Safety review and approval, on a case-by-case basis. Higher level NDE requirements, such as volumetric NDE, may be imposed. If brittle materials (less than 5 percent elongation-to-failure) are used, handling structures shall be designed to include a safety factor to ultimate of 5 based on rated loads.

6.2.4.2. Handling Structure Inspection and Test Requirements.

6.2.4.2.1. Before their first operational use, all new, altered, modified, or repaired handling structures shall be inspected IAW applicable industry methodology and the

Range Safety approved NDE plan and load tested to 150% of the rated load.

6.2.4.2.2. Handling structures designed to a factor of safety less than 3, but greater than or equal to 2, shall be initially inspected and load tested to 125% of rated load.

6.2.4.2.3. For handling structures used to support critical operations, volumetric and surface NDE shall be performed on all SFP components and welds after the initial proof load test IAW the Range Safety approved NDE plan.

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6.2.5. Support Structures. Support structures are those structures used to support hardware or equipment, such as support stands and fixed and portable launch support frames.

6.2.5.1. Support Structure Design Standards and Requirements.

6.2.5.1.1. Support structures shall be designed with a yield safety factor of 3 based on rated loads. Note: For large structures, requirements from American Institute of Steel

Construction (AISC), American Society of Civil Engineers (ASCE) 7 and pertinent building codes may also be considered.

6.2.5.1.2. Support structures whose failure would not result or propagate into a catastrophic event may be designed to a yield safety factor of 2 based on rated loads.

6.2.5.1.3. Material (including fittings and attachment hardware) used in the construction of support structures shall exhibit a ductile failure mode. The intent is to have advanced warning of an upcoming failure via visually detectable deformation of structural components. Use of brittle materials shall require Range Safety review and approval, on a case-by-case basis. Higher level NDE requirements, such as volumetric

NDE, may be imposed. If brittle materials (less than 5 percent elongation-to-failure) are used, support structures shall be designed to include a safety factor to ultimate of 5 based on rated loads.

6.2.5.1.4. Portable ground support equipment, such as equipment racks, shall be designed not to tip when fully loaded and/or moved. For heavy moveable support and handling equipment, lifting lugs and forklift handling, such as fork tubes, shall be incorporated to provide for safe handling.

6.2.5.2. Support Structure Inspection and Test Requirements.

6.2.5.2.1. Before their first operational use, all new, altered, modified, or repaired support structures designed to a yield factor of safety of at least 3 shall be inspected and load tested IAW applicable industry methodology and the Range Safety approved

NDE plan to 150% of rated load.

6.2.5.2.2. Support structures designed to a factor of safety less than 3, but greater than or equal to 2, shall be inspected and load tested to 125% of rated load.

6.2.5.2.3. For support structures used to support critical operations, volumetric and surface NDE shall be performed on all SFP components and welds after the initial proof load test IAW the Range Safety approved NDE plan.

6.2.6. Load Positioning and Load Measuring/Indicating Devices (e.g., Hydra Set ®). Load positioning devices are mechanical devices (e.g., Hydra Set ®), attached to a crane/hoist hook, and used to make fine adjustments to the load position during lifting operations. Load indicating devices (LID) are mechanical devices (e.g., load cells, dynaometers), attached to a crane/hoist hook, and used to measure the weight of the load being lifted.

6.2.6.1. Load Positioning Device and LID Design Standards and Requirements. Load positioning device and LID design allows use for a range of loads, with a specification of not-to-exceed rating. These devices should be used within 20% to 80% range of their rated load capacity due to lower accuracy in the extreme low and high ranges of the rated load.

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6.2.6.1.1. Load positioning device and LID design shall ensure that positive control is maintained at all times, and no actions are initiated or continued without the appropriate controls command being given.

6.2.6.1.2. Failure of the load positioning device or LID shall not result in dropping or un-commanded movement of the suspended or supported load.

6.2.6.1.3. Load positioning devices shall be designed with a minimum ultimate factor of safety of 5.

6.2.6.1.4. LIDs shall be designed in accordance with ASME B30.26, Rigging

Hardware.

6.2.6.1.5. A load positioning device and/or LID inspection plan, identifying all SFP and NDE requirements, methodology, and acceptance criteria, shall be submitted to

Range Safety for review and approval.

6.2.6.2. Load Positioning Device and LID Inspection and Test Requirements.

6.2.6.2.1. Before their first operational use, new, altered, repaired, or modified load positioning devices and LIDs shall be inspected and load tested to 200% of rated load to verify controls and performance (for example, structural, mechanical, electrical).

Load positioning devices and LIDs shall be load tested by the manufacturer or if authorized, IAW the manufacturer instructions to prevent system damage.

6.2.6.2.2. NDE shall be performed during inspection and test per the NDE plan.

6.2.6.2.3. For load positioning devices and LIDs used to support critical operations, volumetric and surface NDE shall be performed on all SFP components and welds after the initial proof load test IAW the Range Safety approved NDE plan.

6.2.7. Rigging Hardware. Rigging hardware consists of shackles, links, rings, swivels, turnbuckles, eyebolts, hoist rings, wire rope clips, wedge sockets, rigging blocks, etc., and may be components of BTHLDs.

6.2.7.1. Rigging Hardware Design Standards and Requirements. All rigging hardware shall be designed, manufactured, handled, and stored in accordance with ASME B30.26.

All hardware will be marked and identified accordingly.

6.2.7.2. Rigging Hardware Inspection and Test Requirements.

6.2.7.2.1. Before first use, all new, modified, or repaired rigging hardware shall be load tested to the proof loads specified in ASME B30.26 prior to initial use.

6.2.7.2.2. For rigging hardware used to support critical operations, volumetric and surface NDE shall be performed on all SFP components and welds after the initial proof load test IAW the Range Safety approved NDE plan. Any rigging hardware meeting removal criteria outlined in ASME B30.26 shall be removed from service.

6.2.8. MHE Data Requirements. MHE initial data requirements shall be submitted IAW paragraphs A2.2.4.6.2 and A2.2.5.6 of this volume. MHE periodic/recurring data requirements shall be submitted IAW requirements in SSCMAN 91-710 Volume 6.

6.2.8.1. For MHE used in safety critical operations, provide initial proof load test plans and test results.

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6.2.8.2. Data Requirements Submission for Major Item MHE Designs.