Specific Hazard Report Comments

1. Specific Hazard Report Comments Structures Materials Electrical Procedures & Operational Controls Crew Hazards Radiation Other

2. HR Preparation Typical comments related to payload hazards Based on Statistics from PSRP

3. SDP & HR COMMENTS - Structures

4. SDP & HR COMMENTS - Structures • General Structures & Collision • Reference review of fracture control plan in the safety verification methods • References Material Usage Agreements (MUAs) when none have been identified • Address composite/bonded structures testing and analyses in verification • Reference materials certification in verifications • Address interface load verifications • Summarize vibration test and analysis details • Address fastener integrity documentation • Provide consistent factor of safety numbers • Provide testing and analyses detail to demonstrate controls • Provide complete limited life item assessments

5. SDP & HR COMMENTS - Structures • Structures/Mechanisms • Provide data to identify that safety critical mechanism meets TA-94-041 criteria • Include drawings that detail safety devices • Summarize development/qualification testing • Provide details for tolerances within the mechanism guides & attach points • Provide details pertaining to launch lock data • Assess mechanisms failures based on worst case loads • Assure that safety margin/factor terminology are used appropriately in analysis • Assess both fault tolerance to inadvertent operation and failure-to-operate hazards • Identify methods to clearly define positive indication of mechanism status • Assure that force and torque margins are accounted for in assessment • Include summary analysis, tests, and inspections used to meet TA-94-041 • Provide system descriptions in PSDP that address design requirements and environment • Address functional testing before and after exposure to acceptance/qualification testing

6. SDP & HR COMMENTS - Structures • Rotating Equipment • Provide details regarding worst case speeds of flywheels, centrifuges, and fan blades • Identification of all rotating equipment • Provide fan specification sheets • Use worst case voltage to determine maximum fan speed • Provide containment analysis for fan blades. • Fasteners: • Summarize fastener control requirements • Provide fastener integrity plans • Assure combinations of lot testing, manufacturer and distributor audits, and verification tests for mechanical properties are addressed • Provide certificates and manufacturer test reports for fracture critical and low-risk parts

7. SDP & HR COMMENTS - Structures • Fracture Control • Provide fracture control summaries and parts classifications • Provide definition of maximum rotating component speeds and manufacture tables • Vented and Sealed Containers • Identify and assess sealed containers • Try not to confuse pressure systems and sealed containers • Address venting requirements in Interface Control Document requirements • Interface Hazards • Clearly define use of STS/ISS controls that provide safety features • Assure that ISS rack safety assessments address different payload configurations • Define Extravehicular Activity (EVA) interfaces

8. SDP & HR COMMENTS - Materials

9. SDP & HR COMMENTS - Materials • General Materials • Provide data to address susceptibility to stress corrosion cracking in support brackets, mounting hardware, or other payload structure • Provide MUAs for stress corrosion cracking • Toxicity • Provide complete current list of sample materials • Provide hazard level, concentration, volume, and/or number in material list • Provide summary of conditions and configurations of materials used in experiment • Identify controls and verifications to demonstrate independent levels of containment • Containment • Develop verifications to demonstrate independence of containment levels in HRs • Provide assessments that show containment at reduced pressures for EVAs and bailout

10. SDP & HR COMMENTS - Materials • Offgassing • Address offgassing test plans in HR controls and verifications • Address materials selection criteria in HR controls and verifications • Provide MUAs with HR support data • Flammability/Flammable Atmospheres/ Flammable Materials/Ignition Sources • Identify areas that may collect flammable gasses • Address electric static discharge (ESD) in flammable atmosphere assessment • Provide materials compatibility assessment of interfacing materials • Clearly define testing, ESD controls, and grounding techniques in SDPs/HRs • Develop flammability assessments • Identify operational controls for flammable material usage • Provide MUAs in the SDPs/HRs • Develop controls and verifications to control ignition sources

11. SDP & HR COMMENTS - Electrical

12. SDP & HR COMMENTS - Electrical • Electrical Power Distribution Circuitry • Provide schematics to identify wire size/fusing for appropriate wire derating provisions • Provide up-to-date schematics that identify circuit protection devices • Assure circuit protection devices are rated for wire size • Electric Shock and High Voltage • Assess electric shock hazards during payload operations • Identify worst case voltages and currents within the equipment electrical systems • Describe verifications for inspections/testing of chassis ground • Describe bonding and grounding techniques in verifications • Identify high voltages of electrical systems in SDPs/HRs

13. SDP & HR COMMENTS - Electrical • Connector Mate/Demate • Develop verifications to demonstrate compliance with MA2-99-170 • Assess and determine applicability of connectormate/demating hazards • Bonding and Grounding • Provide schematics to demonstrate accurate grounding provisions • Assess and develop verifications to demonstrate compliance with MA2-99-142

14. SDP & HR COMMENTS – Procedures & Operational Controls

15. SDP & HR COMMENTS – Procedures & Operational Controls • Procedures and Operations • Develop a rapid safing assessment • Address crew procedures used to control payload hazards in SDP/HRs • Identify maintenance procedures in HR controls and verifications • Address manufacturing and processing procedures used to verify controls • Assess and summarize whether computer processing may result in a catastrophic hazard • Provide fire detection and suppression approach in SDP • Assess and determine if EVA procedures are required for control of a hazard • Assure that hazardous commanding and hazardous command tables are accurate • Address anomalies related to design, manufacturing, and handling procedures

16. SDP & HR COMMENTS – Crew Hazards

17. SDP & HR COMMENTS – Crew Hazards • Shatterable Materials and Debris • Assess potential shatterable materials/debris and potential escape paths • Provide shatterable materials list and identify method of containment • Identify if optical glass is used • Develop verifications to demonstrate controls for each component • Sharp Edges • Assure verifications to assess sharp edges caused by manufacturing processes • Identify if use of protective covers are required and address in controls and verifications • Lasers • Identify use of lasers in PSDP and provide specifications including power, wavelength, category, type, and classification • Pinch Hazard and Crew Injury • Address whether procedural controls are required to preclude pinch points

18. SDP & HR COMMENTS – Radiation

19. SDP & HR COMMENTS – Radiation • Electromagnetic Interference (EMI) • Provide a summary of the EMI source in SDP • Assess hazards related to EMI susceptibility • Address EMI waivers in HR verifications • Radio Frequency • Reference waivers to ICD in SDP/ HRs • Assess whether the ICD violations are hazardous to other payloads or STS/ISS • Provide schematics to demonstrate safety devices to preclude RF threat • Ionizing Radiation • Assess whether there are any radio isotopes, if none then state so in the SDP • Provide JSC Form 44 to identify total radioactivity units per sample (uCi/sample)

20. SDP & HR COMMENTS – Other Categories

21. SDP & HR COMMENTS – Other Categories • Pressure Systems • Determine Maximum Design Pressure (MDP) by defining the two worst case failures • Address freeze/thaw cycles of cryogenic and hypergolic systems • Identify ground filling procedures in HR causes, controls, and verifications • Assure lines, fitting, and components factors of safety are determined • Address materials compatibility and material failures (e.g., corrosion) in components • Provide pressure system tables to address pressure ratings of all lines, fittings, and components • Provide pressure system diagrams that detail the geometry of system • Develop and provide pressure vessel qualification program summaries

22. SDP & HR COMMENTS – Other Categories • Batteries • Address all batteries in SDP/HRs including those in memory and circuit cards • Provide details such as cell size, number, current, chemistry, type, capacity, serial/parallel circuitry, and vendor specification sheets • Provide schematics to show controls for leakage, short circuit, and overcharging • Provide acceptance testing plans and include as HR verification support data • Address testing to demonstrate no leakage concerns • Identify cell materials on the hazardous material summary table • Assure battery boxes include absorbent material to preclude electrolyte leakage hazards

23. SDP & HR COMMENTS – Other Categories • Thermal Extremes • Provide IVA/EVA touch temperatures assessments and determine EVA keep-out zones • Develop thermal analysis/testing summaries to address worst case thermal profile • Include use of temperature strips as applicable

24. SDP & HR COMMENTS – Other Categories • Verifications • Provide verifications that correlate with controls • Develop verifications that demonstrate controls by identifying test, analysis, inspection, or procedures to clearly discern pass/fail criteria • Assure verification items clearly show independence for each control • Assure schedules for completion of verifications are consistent with processing of hardware at KSC • Provide description of reverification activities in RAs • Assure on-orbit verification is considered in PSDP and HRs

25. SDP & HR COMMENTS – Other Categories • Document Enhancements • Verifications should be developed to clearly demonstrate methods to assure controls • Provide HR support data, including schematics, drawings, and analyses to support controls and verifications • Assure Phase III HRs do not contain TBDs • Ensure RAs address hardware changes • Provide a VTL to identify open verification activity • Develop and include an operational control list in the PSDP • JSC Form 1230 should not be not used as a checklist, rather it is 16 hazard reports