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11.3.1. Procedures shall be prepared governing the safe operation, testing, maintenance, and installation of pressurized systems by the agency performing the specific task.
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11.3.2. Procedures shall be developed for all operations involving propellants and the checkout of propulsion systems.
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11.3.3. Off-loading procedures for payloads shall be made available at any time propellant is loaded in flight hardware. Off-loading design as outlined in Volume 3, Chapter 11 and Chapter 12 of this publication addresses the complete system during the complete processing flow. The off-loading procedures shall include integration of the following:
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11.3.3.1. Hardware:
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11.3.3.1.1. Launch vehicle.
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11.3.3.1.2. Launch vehicle fairing.
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11.3.3.1.3. Spacecraft.
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11.3.3.1.4. Launch complex.
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11.3.3.1.5. Process facility.
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11.3.3.1.6. Transport vehicle.
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11.3.3.1.7. Fixed GSE.
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11.3.3.1.8. Portable GSE.
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11.3.3.2. Software Command Capability:
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11.3.3.2.1. Flight Hardware.
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11.3.3.2.2. GSE:
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11.3.3.3. Personnel Capability:
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11.3.3.3.1. Remote.
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11.3.3.3.2. SCAPE.
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11.3.3.3.3. Combination of both.
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Pressure Systems Test, Inspection, and Maintenance Requirements |
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11.4.1. General Test Requirements
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11.4.1.1. Pressure systems shall be initially tested in accordance with Volume 3, Chapter 11 or Chapter 12.
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11.4.1.2. Any system that has been opened shall be leak tested at 100 percent maximum operating pressure (MOP) with an inert medium.
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11.4.1.3. Pressure relief valves and flex hoses shall be retested within one year of intended use.
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11.4.1.4. Pressure gauges and transducers shall be calibrated annually.
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11.4.1.5. After any disconnection, modification, or repair of a system, the affected part of the system shall be leak tested.
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11.4.1.6. Any component that has been damaged, potentially damaged, repaired, replaced, or modified shall be proof tested in accordance with Volume 3.
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11.4.1.7. After the component proof test, the system or subsystem shall be proof tested, functionally tested, and leak tested. The determination for system proof testing shall be made on a case-by-case basis.
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11.4.1.8. New, modified, or repaired propellant systems shall be tested in accordance with Volume 3, Chapter 11 or Chapter 12.
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11.4.1.9. A log shall be kept on propellant systems to keep track of use, maintenance, modification, testing, and inspection.
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11.4.2. Ground Support Pressure Systems General Inspection Requirements
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11.4.2.1. Before use and each operation, facilities and equipment shall be inspected by the payload project and the appropriate local safety authority to ensure a safe configuration for the facilities, equipment, and propellants involved.
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11.4.2.2. Propellant transfer and storage areas shall be spot checked by the appropriate local safety authority, the Fire Department, and Environmental Health. The appropriate area supervisor shall be advised of any discrepancies noted.
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11.4.2.3. Periodic inspections shall be performed on all ground pressure systems in accordance with applicable procedures.
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11.4.2.4. Periodic inspections shall be performed on ground based pressure vessels and liquid holding tanks in accordance with the ISI Plan in Volume 3. These inspections shall be performed during the following periods:
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11.4.2.4.1. Certification Period. Period from the initial operational use of the vessel and/or system until the vessel and/or system requires recertification.
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11.4.2.4.2. First Certification Period. Period from the first recertification effort until second recertification.
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11.4.2.4.3. All subsequent Recertification Periods.
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11.4.2.4.4. The hazardous pressure system operator shall retain all documentation generated as a result of the recertification effort and place this documentation in the system ISI certification and recertification file.
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11.4.3. Pressure Systems General Maintenance
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11.4.3.1. Before replacement, storage, or repair of hypergolic or toxic propellant or fluid system components, the system shall be purged and flushed of all residual contaminants. System connections and removed components shall be appropriately capped, bagged, and labeled before moving the component.
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11.4.3.2. A record shall be kept on the certification of system and component cleanliness.
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11.4.3.3. When it is necessary to remove flight hardware components from the system, all broken connections shall be bagged and tagged to prevent moisture or particle contamination from outside sources.
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11.4.4. Pressure Systems Tests. Tests performed shall meet the requirements as outlined in Volume 3, Chapter 11 and Chapter 12.
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11.4.4.1. Periodic Test Requirements for Pressure System Components:
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11.4.4.1.1. Flexible hoses shall be hydrostatically proof tested to 1.5 times their MAWP once a year unless otherwise approved by the PSWG and Range Safety.
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11.4.4.1.2. All permanently installed flexible hoses shall be visually inspected over their entire length at least annually for damaged fittings, broken braid, kinks, flattened areas, or other evidence of degradation.
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11.4.4.1.3. Pressure gauges and transducers shall be calibrated once a year.
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11.4.4.1.4. Pressure relief valves shall be tested for proper setting and operation once a year.
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11.4.4.2. Testing Modified and Repaired Pressure Systems. Tests performed shall meet the requirements as outlined in Volume 3, Chapter 11 and Chapter 12.
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11.4.4.3. Pressure Systems Tagging
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11.4.4.3.1. After test and inspection, pressure system components shall be tagged.
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11.4.4.3.2. Tags shall provide the date of the last inspection and proof-load test and the component MAWP.
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11.4.5. Ground Support Pressure Vessels and Liquid Holding Tanks Recertification. Recertification data shall be submitted as part of the SDP (MSPSP) as required in Volume 3, Chapter 11 and Chapter 12.
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11.4.6. Pressure Vessel and Liquid Holding Tank Recertification Documentation. Documentation shall be recorded and maintained in accordance with Volume 3. Chapter 11.
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