1. By: Shawn M. Laabs, Dae Kim, and Stephen Seidl
Hazard Considerations for Atlas V and Delta IV Integrated Space Vehicle and Launch Vehicle Operations
By: Shawn M. Laabs, Dae Kim, and Stephen Seidl

2. Who / What is ULA? United Launch Alliance
Formed in 2006, ULA is the nation’s most experienced and reliable launch service provider
Delivered more than 129 satellites to orbit with 100 percent mission success
Provides Two World Class Launch Systems Operating as a Single Provider to the U.S. Government
More Than a Century of Combined Experience in Expendable Launch System Production & Operation Providing Assured Access to Space
Pooled Experience of Nearly 1300 Launches
Legacy Reaching Back to 1950s
Denver, CO
Pueblo, CO
Decatur, AL
Cape Canaveral
Air Force Station
(CCAFS), FL
Harlingen, TX
Vandenberg Air
Force Base
(VAFB), CA

3. Agenda Background – System Safety Process Presentation Scope
System Safety Mission Integration Scope
Range Safety Requirements Summary
Summary

4. Background – System Safety Process
The ULA System Safety process covers both ground personnel and public safety from concept design through the end of mission.
It is important to establish and involve a System Safety program in the early stages of the rocket development program
Early engagement ensures that all launch vehicle systems, subsystems, components, integrations, and operations are assessed to ensure ground and public safety risks are controlled to acceptable levels
This presentation will focus on the integration between a Launch Vehicle (LV) and a Space Vehicle (SV), which can also present significant hazards to ground personnel during integrated (SV-LV) operations.
Hazard considerations will be explored for these integrated operations using applicable Range Safety requirements as a guide.
The Atlas V / Delta IV System Safety Program has been designed to be compliant with Air Force (MIL-STD-882E) and Range Safety (EWR and RCC 324) requirements

5. Presentation Scope
To properly scope this presentation, it is important to note the following points:
This presentation will not discuss Federal safety requirements (e.g. OSHA, FAA)
This presentation will not discuss MIL-STD-882 requirements.
This presentation will not discuss the SS-LV process.
This presentation will not discuss flight or public safety.
This presentation will not discuss product safety.
This presentation will not discuss human spaceflight.
This presentation will not discuss facility safety.

6. System Safety mission integration scope

7. Range safety requirements summary
Requirement Document / Section
Requirement Scope
EWR Chapter 1 (ref. 5)
Range Safety Policies and Processes
EWR Chapter 2 (ref. 5)
Flight Analysis Requirements
EWR Chapter 3 (ref. 5)
Launch Vehicle, Payload, and Ground Support Equipment Documentation, Design, and Test Requirements
EWR Chapter 4 (ref. 5)
Airborne Range Safety System Documentation, Design, and Test Requirements
EWR Chapter 5 (ref. 5)
Facilities and Structures Documentation, Design, Construction, Test,
and Inspection Requirements
EWR Chapter 6 (ref. 5)
Ground Personnel, Equipment, Systems, and Materials Operations Safety Requirements
EWR Chapter 7 (ref. 5)
Flight Control Documentation, Systems, and Procedural Requirements
RCC 324 (ref. 6)
Global Positioning and Inertial Measurements Range Safety Tracking Systems
Integrated hazard considerations will focus on EWR 127-1

8. Material handling equipment Controls
Requirement Document / Section
Required Controls
Cranes and Hoists
Minimization / Elimination of Single Failure Points (SFPs)
Design Factors of Safety
Elimination of Brittle Materials
Positive Latching Mechanisms
Reeving
Limit Switches
Dead Man Type Movement Controls
Load Visibility
Bonding, Grounding, and Electrical Insulation
Emergency Brakes
Initial and Periodic Load Tests
Initial and Periodic Non-Destructive Evaluation
Sling Assemblies
Initial and Recurring Proof Load Tests
Hydrasets and Loadcells
Handling Structures
Flight Hardware Lift Points
Removable, Extendible, and Hinged Work Platforms
Fall Protection

9. Non-ionizing radiation Controls
Requirement Document / Section
Required Controls
Radio Frequency Emitters
Fault Tolerance to Preclude Inadvertent Radiation
RF Hats During Ground Operations
Personnel Exposure Below 10 mW/cm2
Personnel Clear Zones During Radiation
Electromagnetic Interference Safety Margin for Ordnance and Avionics

10. Ionizing radiation Controls
Requirement Document / Section
Required Controls
Ionizing Radiation Sources
Design to Prevent Release
Shielding
Compatibility with Ordnance, Propellants, Pressure Systems, and Structures
Late Installation
Interlocks
Leak Tests
Warning Signs and Labels
RF Hats During Ground Operations
Personnel Clear Zones During Radiation
Electromagnetic Interference Safety Margin for Ordnance and Avionics
Personnel Protective Equipment

11. Hazardous Materials Controls
Requirement Document / Section
Required Controls
Hazardous Materials
Elimination of Hazardous Materials
Substitution to Less Toxic Materials
Substitution to the Least Flammable Materials
Material Compatibility
Electrostatic Discharge
Personnel Protective Equipment

12. Flight hw pressure systems Controls
Requirement Document / Section
Required Controls
Flight Hardware Pressure Systems
Fault Tolerance to Preclude Inadvertent Release / Leakage (Solenoids, Pyrovalves, etc.)
Design Factors of Safety
Regulators / Relief Devices / Vents
Initial and Recurring Proof Load Tests
Initial and Periodic Non-Destructive Evaluation
Approved Connections (Tubes / Fittings)
Leak Tests
Functional Tests
Reduced Operating Pressure while Personnel are Exposed
Pressure Indicating Devices
Restraints (Flex Hoses)
Service Life / Safe Life
Material Compatibility
Bonding / Grounding
Personnel Clear Zones During Cryogenic Loading / Operations
Flare Stacks (Hydrogen)
Low Point Drains

13. Ordnance systems Controls
Requirement Document / Section
Required Controls
Ordnance Systems
DOT Compliance (Transportation)
Ordnance Classification (Cat A, Cat B, Non-Explosive Initiators, etc.)
Explosive / Pyrotechnic Mix Integrity
Fault Tolerance to Preclude Inadvertent Initiation (Switches, Relays, SAFE & ARM Devices, Interrupters)
Redundant Circuits
Separate Power Circuits for Initiating Systems
Component Qualification
Lot Acceptance Testing
Wiring (Twisted Shielded Pairs)
Isolation from Energy (Shielded, Filtered, Grounded, etc.)
Electromagnetic Safety Margin
Proper Connections
Bonding / Grounding
End Tip Caps (Pre-Installation)
Late Installation to Reduce Personnel Exposure
ARM / SAFE Status Monitoring

14. Electrical systems Controls
Requirement Document / Section
Required Controls
Electrical and Electronic Systems
Electrical Power OFF Prior to Installation, Repair, and Replacement
Protection from Power Transients
Fuses / Circuit Breakers
Power Cut Off Switches
Power Indicator Lights
Electromagnetic Safety Margin
Keyed, Color Coded, or Design Limited (Mismating Impossible) Connectors
Locking Connectors
Wire Isolation
Bonding / Grounding /Shielding
Material Compatibility
Bent Pin Analysis

15. Seismic design Controls
Requirement Document / Section
Required Controls
Seismic Design
Eliminate or Minimize Designs / Configurations that would Tip Over During a Seismic Event
Seismic Restraints

16. operational Controls Requirement Document / Section Required Controls
Ground Support Personnel, Equipment, Systems, and Material Operations
OSHA Compliance
Periodic Inspections / Audits
Operations Safety Plans
In-Service, Operating, Maintenance, and Inspection Plans
De-conflicting Hazardous Operations
Environmental Restrictions on Operations (e.g. Lightning)
Remote Operations
Warning Lights
Training and Certification
Procedural Controls (Warnings, Cautions, and Notes)
Essential Personnel Only / Clear Non-Essential Personnel
Pre-Task Safety Briefing
Personnel Work Hour Restrictions
Road Blocks
Use of Spotters
PPE (e.g. SCAPE Suits, ESD Wrist-Stats, Fall Protection)
Pathfinder Operations with Less Hazardous Systems
Stop of Operations Command (performable by anyone)
Hot-Work Permits
Lockout/Tagout Program
Grounding / Bonding
Alternate Space Confined Entry Program
Suspended Load Exposure Elimination / Mitigation
Drop Mitigation Program
Drug and Alcohol Free Workplace
Contingency Plans / Emergency Plans
Support Personnel Availability (e.g. Fire, Medical)
Incident Response
Safety Working Group Meetings

17. SUMMARY
Space Launch presents unique hazards to ground operations personnel
Compliance to Range Safety Requirements mitigate hazards to acceptable levels
It is important to mitigate hazards using Safety Order of Precedence

18. Thank You