Flight Hardware Hydraulic System Design and Test Requirements.
In addition to the following requirements, flight hardware hydraulic systems shall meet the minimum design fabrication and test requirements of 12.5.1 and 12.5.2.
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12.7.1. Flight Hardware Hydraulic System General Design Requirements
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12.7.1.1. Where necessary, hydraulic system low-points shall be provided a drain fitting (bleed ports) to allow draining of condensates or residue for safety purposes.
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Entrapped air, moisture, and cleaning solvents are examples of foreign substances that may be hazardous to the system, component, or control equipment.
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12.7.1.2. Bleed ports shall be located so that they can be operated without removal of other components and shall permit the attachment of a hose to direct the bleed off material into a container away from the positions of the operators.
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12.7.1.3. Test points shall be provided on hydraulic systems so that disassembly for test is not required.
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12.7.1.4. Test points shall be easily accessible for the attachment of ground test equipment.
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12.7.1.5. For all power-generating components, pump pulsations shall be controlled to a level that does not adversely affect system tubing, components, and support installation.
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12.7.1.6. Where system leakage can expose hydraulic fluid to potential ignition sources, fire resistant, or flameproof hydraulic fluid shall be used.
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12.7.2. Flight Hardware Hydraulic System Accumulators and Reservoirs. All accumulators and reservoirs that are pressurized with gas to pressures greater than 100 psig shall be designed in accordance with 12.2.
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12.7.3. Flight Hardware Hydraulic System Pressure Indicating Devices
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12.7.3.1. A pressure indicating device shall be located on any pressurized storage system with a pressure greater than 100 psig.
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12.7.3.2. These devices shall be designed to be remotely monitored during prelaunch operations.
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12.7.4. Flight Hardware Hydraulic System Pressure Relief Devices
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12.7.4.1. Pressure relief devices shall be installed on all systems having an on-board pressure source that can exceed the MAWP of any component downstream of that source unless the system is single failure tolerant against overpressurization during prelaunch operations.
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12.7.4.2. Flight systems that require on-board pressure relief capability shall meet the following minimum requirements:
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12.7.4.2.1. The pressure relief device shall be installed as close as practical downstream of the pressure sources such as pumps, turbines, or gas generators.
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12.7.4.2.2. Pressure relief devices shall be set to operate at a pressure not to exceed 110 percent of the system MOP.
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12.7.4.2.3. The relieving capacity of the relief device shall be equal to or greater than the maximum flow capability of the upstream pressure source and should prevent the pressure from rising more than 20 percent above the system MOP.
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12.7.4.2.4. The effects of discharge from relief devices shall be assessed and analyzed to ensure that operation of the device shall not be hazardous to personnel or equipment. Items to be analyzed include thrust loads, toxicity, combustibility, flammability, and others as necessary.
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12.7.4.2.5. Relief devices shall be located so that other components cannot render them inoperative.
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12.7.4.2.6. No obstructions shall be placed downstream of the relief valve or burst disk outlet.
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12.7.5. Flight Hardware Hydraulic System Vent and Drain Systems. Hydraulic systems shall be designed so that pressure and fluids cannot be trapped in any part of the system without vent and/or drain capability.
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12.7.6. Testing Flight Hardware Hydraulic System Components Before Assembly. All system elements pressurized with gas to pressures greater than 100 psig shall be qualification tested in accordance with 12.2.4.1 and acceptance tested in accordance with 12.2.4.2 and 12.5.1.17.1.
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12.7.7. Testing Flight Hardware Hydraulic Systems After Assembly
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12.7.7.1. Tests shall meet the requirements of 12.5.1.17.2.
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12.7.7.2. Leak tests shall meet the requirements of 12.5.1.17.3.
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12.7.7.3. System validation and functional tests shall meet requirements of 12.5.1.17.4.
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12.7.7.4. Modified and repaired flight hardware shall meet the requirements of 12.5.1.17.6.
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