NASA CR-145185 ROCKET PROPULSION HAZARD SUMMARY: SAFETY CLASSIFICATION, HANDLING EXPERIENCE AND APPLICATION TO SPACE SHUTTLE PAYLOAD by D. F. Pennington T. Man B. Persons MAY 1977 Prepared under Contract No. NAS1-12500 Task R-150 VOUGHT CORPORATION Dallas, Texas for AI/ A National Aeronautics and Space Administration FOREWORD This final report presents the results of a literature survey and study effort performed by Vought Systems Division (VSD) of the Vought Corporation to determine the hazards of Shuttle payload propulsion systems. This report contains a discussion of the methods and purpose of hazard classification for transportation and storage, handling/safety procedures and requirements, quantitative hazard assessment techniques of solid and liquid rocket systems, a preliminary hazard analysis of rocket systems for Shuttle payload, and a hazard comparison of solid and liquid systems. The study was cor,ducted under NASA Contract NAS1-12500, Task R-150. .oo III We express our appreciation for the assistance received from the NASA Aerospace Safety Research and Data Institute, Lewis Research Center, Mr. Solomon Weiss; Safety Office, Kennedy Space Flight Center, Messrs. J. T. Atkins and O. Snellgrove; Safety, Reliability, and Quality Assurance, Johnson Space Center, Messrs. M. Fields and B. Miller; Delta Program, Goddard Space Flight Center, Mr. D. Dembrow; Langley Research Center, Mr. F. P. Crommie; Marshall Space Flight Center, Messrs. W. Clements and B. Rice; Safety-Norton AFB, Space and Missile Systems Organiza- tion, Major J. Mason and Captain D. King; The Boeing Company, Messrs. I. Meyerson and R. Bibeau; Hercules Incorporated Bacchus Works, Mr. B. Brown; Department of the Navy, Messrs. R. Kinert and H. Worthy; in our endeavor to perform a detailed literature search and review. P. N. RANSDELL TECHNICAL PROJECT ENGINEER ADVANCE SPACE PROGRAMS C. F. MACHALA, JR. " PROPULSION PROJECT ENGINEER SCOUT PROGRAM iv TABLE OF CONTENTS Page FOREWORD .............................................................. Itt TABLE OF CONTENTS ...................................................... v LIST OF FIGURES ......................................................... x LIST OF TABLES ......................................................... xiv GLOSSARY OF TERMS ................. ................................... xv 1.0 SUMMARY ............................................................ 1 2.0 INTRODUCTION ....................................................... 3 2.1 Scope ............................................................ 3 2.2 Study Objectives .................................................... 4 3.0 HAZARD CLASSIFICATION FOR ROCKET PROPELLANTS .................... 5 3.1 Introduction ....................................................... 5 3.2 Responsible Federal Agencies .......................................... 5 3.2.1 Department of Transportation (DOT) .............................. 5 3.2.2 Department of Defense (DOD) ................................... 7 3.3 Classification ....................................................... 7 3.3.1 Testing ..................................................... 8 3.3.1.1 Bulk Solid Propellant ................................... 8 3.3.1.2 Assembled Motors ..................................... 10 3.3.2 Assignment of Classification .................................... 10 3.3.3 Quantity-Distance Standards ................................... 10 3.3.3.1 Solid Propellant Classes ................................. 10 3.3.3.2 Liquid Propellant Classes ................................ 12 3.3.4 Compatibility Groups ......................................... 13 3.4 Validity of Classifications ............................................ 13 3.5 Conclusions ....................................................... 14 4.0 ROCKET SAFETY REQUIREMENTS AND EXPERIENCE ..................... 15 4.1 Introduction ...................................................... 15 4.2 Safety Procedures .................................................. 15 4.2.1 Scout ............................ .......................... 15 4.2.2 Minuteman (MM) ............................................ 18 4.2.3 Delta Program ............................................... 19 V TABLE OF CONTENTS (CONTINUED) Page 4.2.3.1 Receiving and Inspection ................................ 19 4.2.3.2 Launch Preparation Document ........................... 19 4.2.4 Poseidon Program ............................................ 21 4.2.5 Eastern Test Range Requirements ................................ 22 4.2.5.1 AFETRM 127-1 Safety Requirements ...................... 22 4.2.5.1.1 AFETRM 127-1 Chapter 3 ...................... 22 4.2.5.1.2 AFETRM 127-1 Chapter 5 ...................... 23 4.2.5.2 KMI 1718.1B/SF KSC General Safety Plan .................. 23 4.2.6 Space Transportation System (STS) .............................. 25 4.2.6.1 Introduction ......................................... 25 4.2.6.2 Safety Requirements ................................... 25 4.2.6.2.1 Hazard Analysis, Classification and Control ......... 28 4.2.6.2.2 Safety Reviews ............................... 28 4.2.5.2.3 Safety Compliance and Range Safety (SCRS) ........ 28 4.3 Handling Specifications .............................................. 30 4.3.1 Impact, Shock and Friction ..................................... 30 4.3.2 Static or Stray Electrical Current ................................ 31 4.3.3 Temperatures ............................................... 31 4.4 Hazardous Incidents and Results ....................................... 31 4.4.1 General .................................................... 32 4.4.2 Liquid System Incident Reports ................................. 36 4.4.3 Solid System Incident Reports .................................. 36 4.4.3.1 Polaris and Poseidon Programs ........................... 39 4.4.3.2 Minuteman Program ................................... 41 4.4.3.3 Scout Program ........................................ 41 4.5 Conclusions ....................................................... 41 5.0 ASSESSMENT TECHNIQUES-SOLID AND LIQUID PROPULSION SYSTEMS ..... 43 5.1 Introduction ...................................................... 43 5.2 Findings from Propellant Test Programs ................................. 44 5.2.1 Project Sophy ............................................... 44 5.2.2 Project Pyro ................................................ 44 5.3 Solid Propellant Systems ............................................. 45 5.3.1 Hazard Thresholds ............................................ 46 5.3.1.1 Impact Velocity ...................................... 46 5.3.1.2 Detonation Sustainment-Composite Propellants ............. 50 5.3.1.2.1 Critical Diameter .............................. 50 5.3.1.2.2 Pseudo-Critical Geometry (o c) ................... 50 5.3.1.2.3 Initiation Criterion ............................ 51 vi TABLE OF CONTENTS (CONTINUED) Page 5.3.1.3 Detonation Sustainment--CMDB Propellants ................ 54 5.3.1.3.1 Critical Diameter .............................. 54 5.3.1.3.2 Shotgun Quickness Test ........................ 54 5.3.1.3.3 NOL Card Gap Test ............................ 57 5.3.2 Hazard Effects ............................................... 61 5.3.2.1 General Scaling Laws ................................... 61 5.3.2.2 Peak Side-On Overpressure .............................. 62 5.3.2.3 Positive Phase Impulse .................................. 62 5.3.2.4 TNT Equivalency . .................................... 62 5.3.2.5 Fireball Effects ....................................... 68 5.3.2.6 Firebrand Effects ..................................... 68. 5.3.2.7 Fragmentation ........................................ 72 5.4 Liquid Propellant Systems ............................................ 72 5.4.1 Explosive Yield .............................................. 75 5.4.1.1 Hypergolic (50% N2H4-50°/o UDMH Fuel and N20 4 Oxidizer in Mass Ratio of 1:2) ...................... 76 5.4.1.2 Liquid Oxygen-Hydrocarbon (RP-1 Fuel LO 2 Oxidizer in Mass Ratio of 1:2.25) ..................... 76 5.4.1.3 Liquid Oxygen-Liquid Hydrocarbon (LH 2 Fuel and LO 2 Oxidizer in Mass Ratio of 1:5) ....................... 81 5.4.2 Peak Side-On Overpressure and Impulse ........................... 81 5.4.3 Fireball Effects .............................................. 99 5.4.3.1 Characteristics ........................................ 99 5.4.3.2 Heat Flux Density ..................................... 99 5.4.4 Fragmentation .............................................. 106 5.5 Gas Pressure Vessel Hazards ......................................... 106 5.6 Summary ........................................................ 113 6.0 PRELIMINARY HAZARD ANALYSIS OF ROCKET SYSTEMS FOR SHUTTLE PAYLOAD .......................................................... 115 6.1 Solid Propellants .................................................. 115 6.1.1 Introduction ............................................... 115 6.1.2 System Safety Program ....................................... 115 6.1.2.1 Preliminary Hazard Analysis ............................ 115 6.1.2.2 Operating Hazard Analysis ............................. 115 6.1.2.3 Fault Hazard Analysis ........ ......................... 129 6.1.2.4 Cable Failure Matrix .................................. 129 6.1.2.5 Fault Tree Analysis ................................... 129 6.1.2.6 Software Hazardous Effects Analysis ..................... 129 vii TABLE OF CONTENTS (CONTINUED) Page Scout Vehicle Description ....................................