SAFETY DATA PACKAGE (MISSILE SYSTEM PRELAUNCH SAFETY PACKAGE)
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Introduction
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A1.1.1. Purpose. The Safety Data Package (SDP) or equivalent of the Missile System Prelaunch Safety Package (MSPSP) is a documentation data submittal that provides a detailed description of hazardous and safety critical ground support and flight hardware equipment, systems, and materials and their interfaces used in the launch of launch vehicles and payloads. It is one of the media through which missile system prelaunch safety approval is obtained. NPR 8715.7 provides the payload safety review and approval process including required safety documentation and SDP submittal time line for the Payload Safety Introduction Briefing, Safety Review I (project’s mission PDR time frame), Safety Review II (project’s mission CDR time frame) and Safety Review III (prior to payload shipping reviews).
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A1.1.2. Content. This attachment contains the content preparation instructions for the data generated by the requirements specified in Volume 3.
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A1.1.3. Applicability. The requirements in this attachment are applicable to all NASA ELV payloads, and related ground support systems, including AGE, GSE, and facilities.
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A1.1.4. Submittal Process. A Safety Data Package (SDP) (MSPSP) shall be submitted to the PSWG in conjunction with Range Safety by the payload project with overall responsibility for the payload systems for review and approval by the PSWG and Range Safety.
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A1.1.5. Final Approval. A final SDP (MSPSP) that satisfies all PSWG and Range Safety concerns addressed at the project’s mission CDR shall be submitted to the PSWG for review and approval by the PSWG and Range Safety at least 90 calendar days prior to payload (spacecraft) shipment or as determined by the PSWG.
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Preparation Instructions
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A1.2.1. Content
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A1.2.1.1. The SDP (MSPSP) contains technical information concerning hazardous and safety critical equipment, systems, and materials and their interfaces used in the pre-launch processing and launch of payloads.
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A1.2.1.2. The SDP (MSPSP) is a detailed description of the design, test, and inspection requirements for all ground support systems and flight hardware and materials and their interfaces used in the pre-launch and launch of payloads. Hazard Analyses and Hazard Reports shall be contained in the SDP or provided separately and submitted with the SDPs (see A1.2.4.1.9 and A1.2.4.4). All schematics, functional diagrams, and operational manuals shall have well defined, standard IEEE or Mil-Spec terminology and symbols.
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A1.2.1.3. The payload project shall develop the SDP and submit it in three phases (SDP I, II, and III) unless agreed to otherwise by the PSWG and Range Safety.
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A1.2.1.3.1. SDP I is due no later than 30 days prior to the project’s mission PDR (see NPR 8715.7). SDP I shall contain technical information, hazard analysis and hazard reports commensurate with PDR-level design and operations. For a project utilizing a previously launched payload bus SDP I shall include identification and description of any payload safety-related problems, mishaps, or failures that occurred during fabrication, testing, processing, or integration that could affect the safety of the flight hardware or software, ground support equipment, personnel, or other NASA concerns.
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A1.2.1.3.2. SDP II is due no later than 30 days prior to the project’s mission CDR (see NPR 8715.7). SDP II shall contain updated technical information from SDP I commensurate with CDR-level design and operations. A cross-reference shall be provided identifying the disposition of review comments of SDP I indicating where changes were made.
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A1.2.1.3.3. SDP III is the Final SDP and is due no later than 90 days prior to the payload shipment to the processing site (see NPR 8715.7). SDP III shall address all comments and incorporate all changes reflecting the as-built configuration and planned processing activities. A cross-reference shall be provided identifying the disposition of review comments since the last SDP submittal to indicate where incorporated changes to the SDP were made. SDP III shall contain final hazard reports, the Final GOP (in SDP III or as a stand-alone document), and a signed copy of any approved safety waivers (with attachments provided upon request). SDP III shall also contain a record of test failures, anomalies and mishaps involving qualification hardware, flight hardware, ground support equipment, and software (if used for hazard control), and an assessment of the resolution and safety implications of these events.
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A1.2.2. Format. The payload project format is acceptable provided the information described below is provided. Suggested formats are shown as applicable. The format presented in this attachment provides two distinct sections: Flight Hardware Systems and Ground Support Systems.
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A1.2.2.1. Table of Contents and Glossary. The SDP (MSPSP) shall contain a table of contents and a glossary.
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A1.2.2.2. Introduction. The “introduction” section shall address the scope and purpose of the SDP (MSPSP).
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A1.2.3. General Description. The “general description” section provides an overview of the payload or ground support system as a prologue to the subsystem descriptions. The following information is included in this section:
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A1.2.3.1. Physical dimensions and weight.
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A1.2.3.2. Nomenclature and description of major subsystems.
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A1.2.3.3. Types of motors and propellants to be used.
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A1.2.3.4. Sketches and/or photographs of the launch vehicle, payload, or ground support system.
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A1.2.3.5. Synopsis of each hazardous and safety critical subsystem.
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A1.2.3.6. A list of hazardous subsystems addressed in Volume 3 of this publication that are not present in the launch vehicle or payload system.
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A1.2.4. Flight Hardware Subsystems
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A1.2.4.1. At a minimum, the “flight hardware subsystems” section shall include the following information and the specific data requirements listed in A1.2.4.6 through A1.2.4.14 below:
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A1.2.4.1.1. Subsystem overview.
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A1.2.4.1.2. Nomenclature of major subsystems.
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A1.2.4.1.3. Function of the subsystem.
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A1.2.4.1.4. Location of the subsystem.
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A1.2.4.1.5. Operation of the subsystem.
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A1.2.4.1.6. Subsystem design parameters.
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A1.2.4.1.7. Subsystem test requirements.
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A1.2.4.1.8. Subsystem operating parameters.
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A1.2.4.1.9. Summaries of any PSWG and Range Safety required hazard analyses conducted.
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A1.2.4.2. Supporting data shall be included or summarized and referenced as appropriate with availability to the PSWG and Range Safety upon request.
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A1.2.4.3. Tables, matrixes, and sketches are required for systems and component data. (See A1.2.4.7.2 and A1.2.4.7.3 below for suggestions.)
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A1.2.4.4. Required analyses, test plans, and test results may be included in the SDP (MSPSP) as appendixes or submitted separately. At a minimum, analyses, test plans, and test reports shall be listed, referenced, and summarized in the SDP (MSPSP).
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A1.2.4.5. A list of all the PSWG and Range Safety approved non-compliances.
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A1.2.4.6. Flight Hardware Structures and Mechanisms
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A1.2.4.6.1. Flight Hardware Structures and Mechanisms General Requirements. In addition to the information required in A1.2.4.1, the material properties of the main structures, mechanisms, and deployables used on launch vehicles and payloads shall be included in the SDP (MSPSP).
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A1.2.4.6.2. Flight Hardware Used in Lifting Critical Loads. At a minimum, the following documentation is required:
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A1.2.4.6.2.1. SFP analysis.
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A1.2.4.6.2.2. NDE plan and test results for SFP components and SFP welds. A1.2.4.6.2.3. Initial proof load test plan and test results.
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A1.2.4.6.2.4. Stress analysis.
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A1.2.4.7. Flight Hardware Pressure, Propellant, and Propulsion Systems
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A1.2.4.7.1. General Data. A detailed description of the pressure, propellant, and propulsion systems of the payload shall be provided. The description shall include the information identified in A1.2.4.1 plus the following:
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A1.2.4.7.1.1. Material compatibility analysis.
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A1.2.4.7.1.2. Physical and chemical properties and general characteristics of the propellant, test fluid, and gases.
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A1.2.4.7.1.3. For hazardous propellants, fluids, and gases, the following shall be submitted:
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A1.2.4.7.1.3.1. Specific health hazards such as toxicity and physiological effects.
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A1.2.4.7.1.3.2. Threshold limit value (TLV) and maximum allowable concentration (MAC) for eight-hour day, five-day week of continuous exposure.
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A1.2.4.7.1.3.3. Emergency tolerance limits including length of time of exposure and authority for limits (for example, Surgeon General, National Institute for Occupational Safety and Health [NIOSH], independent study).
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A1.2.4.7.1.3.4. Maximum credible spill size including volume and surface area and supporting analyses.
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A1.2.4.7.1.3.5. Description of hazards other than toxicity such as flammability and reactivity.
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A1.2.4.7.1.3.6. Personal protective equipment to be used in handling and using the propellants when this equipment will be used during an operation, and the manufacturer, model number, and other identifying data.
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A1.2.4.7.1.3.7. Manufacturer, model number, specifications, operating limits, type of certification, and general description of vapor detecting equipment.
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A1.2.4.7.1.3.8. Identification of material incompatibility problems in the event of a spill.
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A1.2.4.7.1.3.9. Recommended methods and techniques for decontamination of areas affected by spills or vapor clouds and hazardous waste disposal procedures.
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A1.2.4.7.2. Flight Hardware Pressure, Propellant, and Propulsion System Data. A schematic diagram shall be submitted for all systems: The schematic shall present the system in a clear and easily readable form with complete subsystems grouped and labeled accordingly. The schematic or a corresponding data sheet shall provide the following information:
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