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Introduction
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A2.1.1. Determination of Hazardous and Safety Critical Procedures. The Ground Operations Plan (GOP) (Attachment 1 of this volume) is the basic document used to initially determine the classification of a procedure. Specifically all procedure description and task summaries along with the associated Operating & Support Hazard Analyses (O&SHAs) are reviewed. This review validates the payload project’s determination of hazardous, non-hazardous, and safety critical procedures. Once the classification of hazardous, non-hazardous, and safety critical is determined, the procedures are submitted to the local safety authorityfor review and approval as described in the documentation part of this volume. The PSWG and Range Safety shall determine if select local safety authority notification or attendance shall be required during review of the initial draft procedures. During review of the initial draft procedures that will take place on an Air Force range, Range Safety shall determine if Pad Safety notification or attendance shall be required. The review of the draft procedures allows a second opportunity to ensure the classification is appropriate.
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A2.1.2. Purpose. Hazardous and safety critical procedures provide a detailed, step-by-step description of the manner in which hazardous and safety critical operations will be accomplished. The procedures are the medium from which approval to start any hazardous or safety critical operation is obtained from the appropriate safety authority.
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A2.1.3. Content. This attachment contains the content preparation instructions for the data generated by the requirements delineated in Volume 6 of this document.
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A2.1.4. Applicability. This attachment is applicable to the following:
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A2.1.4.1. All launch vehicle, payload, or service contractors performing hazardous or safety critical operations at the payload processing facility and launch site area.
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A2.1.4.2. Construction and management contracts for hazardous facilities.
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A2.1.5. Submittal Process. The hazardous procedure submittal, review, and approval process is in accordance with the safety requirements and processes of the specific operating location. For operations in areas under KSC jurisdiction KNPR 8715.3 shall be followed. For Air Force Ranges, the hazardous procedure submittal process is as follows:
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A2.1.5.1. One copy of procedures involving hazardous or safety critical operations shall be submitted to Range Safety for review and approval 55 days prior to the operation. For operations on Air Force Ranges, one copy of the procedures shall be submitted to Range Safety and one copy to Pad Safety for review and approval 55 days prior to the operation. The Range User shall review, approve, and sign the final procedures to be submitted to Range Safety or the appropriate local safety authority for approval.
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A2.1.5.2. Final Pad Safety and Range Safety comments, reviews, and approvals shall be provided to the Range User 45 calendar days after receipt of the procedure.
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A2.1.6. Final Approval. Hazardous and safety critical procedures shall be approved before starting any hazardous or safety critical operations at the payload processing facility and launch site area.
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Preparation Instructions
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A2.2.1. Content. Hazardous or safety critical procedures shall be written in a manner complying with local requirements. Hazardous or safety critical procedures shall be written in a logical format with clear instructions as to the tasks to be performed and hazards and precautions involved.
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A2.2.2. Cover Page
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A2.2.2.1. A cover page with the procedure title and required approval signatures, to include the Payload Organization Safety Engineer and date shall be provided. The signature page shall contain a block for signature approval by the appropriate safety authority.
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A2.2.2.2. The words Draft or Preliminary shall appear on any signed procedure that does not have the required safety approval.
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A2.2.2.3. The cover sheet shall state “Warning: This Procedure Contains Hazardous (or Safety Critical) Operations” and shall be outlined with a border and marked in bold print.
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A2.2.2.4. The cover sheet shall indicate revision level.
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A2.2.3. Purpose Section
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A2.2.3.1. The “purpose” section shall provide a brief synopsis of all major tasks in each operating procedure.
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A2.2.3.2. The synopsis shall include the following information:
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A2.2.3.2.1. A brief description of the tasks, operations, tests, or checkouts to be performed.
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A2.2.3.2.2. The facility and area where the procedure is to take place.
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A2.2.3.2.3. The departure and arrival locations if transportation is required.
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A2.2.3.2.4. For launch vehicle and payload tests, when the test is normally performed in relation to launch day (for example, L-5).
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A2.2.4. Identification of Specific Hazards. The following specific hazards shall be identified in each procedure:
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A2.2.4.1. The quantity and hazard classification of ordnance and propellants involved.
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A2.2.4.2. The hazardous and non-hazardous configurations of the system before, during, and upon completion of the operation.
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A2.2.5. Safety Precautions. As applicable, the following precautions shall be incorporated in each procedure at the beginning of the procedure as well as at the applicable step in the body of the procedure:
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A2.2.5.1. Warnings.
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A2.2.5.2. Cautions.
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A2.2.5.3. Note inhibits.
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A2.2.5.4. Safety devices.
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A2.2.5.5. Control areas.
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A2.2.6. Facility Configuration Inspections. The procedure shall indicate the specific facility and safety clearance zone control area to be used.
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A2.2.6.1. The requirements for the performance of facility configuration inspections shall be incorporated in the procedures.
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A2.2.6.2. The facility configuration inspection requirements shall address verification of the following:
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A2.2.6.2.1. Facility explosive limits.
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A2.2.6.2.2. Facility personnel limits.
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A2.2.6.2.3. Posting of fire symbols when ordnance and propellants are moved into or out of a facility.
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A2.2.7. PPE and Emergency Equipment
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A2.2.7.1. PPE, fit testing, and emergency equipment requirements for each operation shall be incorporated in hazardous procedures.
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A2.2.7.2. The PPE and emergency equipment shall address the following:
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A2.2.7.2.1. PPE requirements according to the manufacturer model number, MIL-SPEC, or standard for compliance.
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A2.2.7.2.2. The occasions for the use of PPE.
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A2.2.7.2.3. Types of emergency equipment required.
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A2.2.7.2.4. Location of the emergency equipment during the operation.
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A2.2.7.2.5. The number of emergency equipment units required. No substitution or configuration alteration of PPE shall be allowed without specific appropriate local safety approval.
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A2.2.8. Pre-Operational Checklist of Required Tools and Equipment
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A2.2.8.1. A pre-operational checklist of all tools and equipment required for safe operations shall be incorporated in the procedures.
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A2.2.8.2. For safety critical equipment, the following information shall be included:
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A2.2.8.2.1. Manufacturer, model, and serial number.
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A2.2.8.2.2. Location of the equipment during the operation.
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A2.2.8.2.3. The number of units required.
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A2.2.8.2.4. The required monitoring devices and their alarm settings.
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A2.2.8.2.5. Proof test requirements.
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A2.2.8.2.6. Nondestructive examination requirements.
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A2.2.8.2.7. Calibration requirements.
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A2.2.9. Support Personnel Requirements
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A2.2.9.1. Payload project and any support personnel requirements such as Pad Safety, Fire, Medical, and Security/HOS personnel shall be incorporated in the procedures. In a multi-task procedure, the times these support personnel are needed shall be stipulated.
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A2.2.9.2. The following support personnel requirements shall be addressed:
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A2.2.9.2.1. The hazardous periods when personnel limits shall be enforced.
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A2.2.9.2.2. The minimum essential personnel by functional title and number required.
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A2.2.9.2.3. The Pad Safety or local safety authority notification in all cases. In accordance with local safety requirements, local safety authority or Pad Safety presence and concurrence is required before beginning all hazardous operations.
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A2.2.9.2.4. Special training, certifications, or experience requirements.
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A2.2.10. References to Applicable Documents
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A2.2.10.1. All applicable documents, drawings, and specifications shall be referenced in the procedures.
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A2.2.10.2. If a specific operations safety plan or other safety plans apply to the procedure, they shall be listed in the procedure reference section.
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A2.2.10.3. This document and AFSPCMAN 91-710 shall be listed in the procedures.
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A2.2.10.4. Procedures shall not use excessive second tier references.
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Use of excessive second tier references means to incorporate references in such volume that the meaning is lost and use of the procedure becomes confusing, unnecessarily complex, or irrelevant.
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A2.2.11. CCAFS Cape Support and WR Range Scheduling Notification. Notification of the local safety authority at least 24 hours before the planned start of an operation is required to ensure appropriate support is provided and shall be incorporated in the procedures. The PSWG shall provide the notification information. CCAFS Cape Support (321-853-5211) and Range Scheduling (321-853-5941) on the ER and Range Scheduling (805-606-8825) on the WR.
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A2.2.12. Pre-Task Briefing
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A2.2.12.1. A step for the conduct of a pre-task briefing shall be incorporated in the procedures.
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A2.2.12.2. The following topics shall be addressed:
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A2.2.12.2.1. Operational hazards.
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A2.2.12.2.2. Precautions.
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A2.2.12.2.3. Emergency actions.
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A2.2.12.2.4. Critical task items.
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A2.2.12.2.5. Procedure flow.
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A2.2.12.2.6. Operational discipline.
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A2.2.12.2.7. Communication discipline.
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A2.2.12.3. Specification that the briefing shall be repeated if a shift change is required.
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A2.2.13. Step-by-Step Directions
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A2.2.13.1. Step-by-step directions, written in clear language, with sufficient detail to allow a qualified technician or mechanic to clearly understand and follow them, shall be incorporated.
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A2.2.13.2. The procedure shall contain applicable data sheets, figures, and schematics to document or clarify system parameters and connect points.
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A2.2.14. Identification of Hazardous and Safety Critical Portions of Procedures
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A2.2.14.1. The beginning and end of a hazardous or safety critical portion of a procedure shall be incorporated according to the following criteria:
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A2.2.14.1.1. A “Warning” shall be used to identify hazards to personnel.
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A2.2.14.1.2. A “Caution” shall be used to identify hazards to equipment.
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A2.2.14.1.3. A “Note” shall be used to indicate an operating procedure of such importance that it must be emphasized.
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A2.2.14.2. The activation of warning lights, Public Address (PA) announcements, and notification to Security/HOS of any controlled areas, if not accomplished as a pre-task item, shall be incorporated.
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A2.2.14.3. Safety highlights such as evacuations, safety clearance zones, clearances, activation of aural and visual warnings shall be detailed before the hazardous sequence and in the applicable section of the procedure.
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A2.2.15. Emergency Shutdown and Backout Steps. Emergency shutdown and backout procedures or steps necessary to safe the system or facility in the event of a mishap, incident, or abort shall be incorporated.
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A2.2.16. Transmittal of Procedures. For payloads launched via NASA’s Launch Services Program procedures shall be forwarded to the NASA Launch Site Integration Manager (LSIM) unless otherwise agreed to go to the local safety authority. The PSWG Chairperson is responsible for all safety coordination and the LSIM is responsible for all launch site coordination and Launch Services Program coordination. Transmittal of procedures shall be made with a transmittal letter containing the following information:
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A2.2.16.1. Need Date (minimum of 55 calendar days review time required).
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A2.2.16.2. Procedure title and number.
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A2.2.16.3. Program identified or other identifier to ensure that the proper safety point of contact receives the procedure.
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A2.2.16.4. Special instructions for such items as review and comment and final copy for filing.
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A2.2.16.5. Pertinent information such as “procedure is non-hazardous,” “procedure change does not affect the hazardous portion of the procedure nor otherwise have a safety impact,” or “all previous comments have been incorporated.”
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A2.2.16.6. If the procedure has been previously submitted as a draft or with a different revision number, clarification of the extent of the changes.
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Examples of Hazardous Procedures
Examples of hazardous procedures include, but are not limited to, the following topics:
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Pressurized propellant systems - pressurization (pneumastat and hydrostat), loading and unloading, sampling, leak testing, venting.
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Launch vehicle and payload systems - pressurization, loading and unloading, leak test, erection and lifting with ordnance and/or propellant, application of power with ordnance and/or propellant, safe and arm pin removal, mate and demate operation.
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Hazardous facilities - high pressure systems, propellant flows in ground systems, propellant cart loading, ordnance checkout and installation, X-ray operations, cryogenic operations, fixture proof tests, emergency blackout procedures.
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Ordnance - bore scope, X-ray, continuity test, propellant trimming, installation, electrical connection and disconnection.
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Work involving lasers, high energy RF emissions, radioactive materials, and hazardous materials.
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Changes.
Changes to previously submitted procedures shall be noted with change bars or a similar method of marking.
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