Flight Termination Systems Commonality Standard

Range Safety Group

DOCUMENT 319-14

FLIGHT TERMINATION SYSTEMS

COMMONALITY STANDARD

(ABERDEEN TEST CENTERDUGWAY PROVING GROUNDREAGAN TEST SITEWHITE SANDS MISSILE RANGEYUMA PROVING GROUNDNAVAL AIR WARFARE CENTER AIRCRAFT DIVISIONNAVAL AIR WARFARE CENTER WEAPONS DIVISIONNAVAL UNDERSEA WARFARE CENTER DIVISION, KEYPORTNAVAL UNDERSEA WARFARE CENTER DIVISION, NEWPORTPACIFIC MISSILE RANGE FACILITY30TH SPACE WING45TH SPACE WING96TH TEST WING412TH TEST WINGARNOLD ENGINEERING DEVELOPMENT COMPLEXNATIONAL AERONAUTICS AND SPACE ADMINISTRATION)

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED

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DOCUMENT 319-14

FLIGHT TERMINATION SYSTEMS

COMMONALITY STANDARD

September 2014

Prepared by

RANGE SAFETY GROUP

Published by

Secretariat

Range Commanders Council

US Army White Sands Missile Range

New Mexico 88002-5110

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TABLE OF CONTENTS

PREFACExi

ACRONYMSxiii

Chapter 1. Introduction1-1

1.1Background1-1

1.2Basis of Authority1-3

1.3Scope1-3

1.4Acceptability at any Test Range within the Major Range and Test Facility Bases1-4

1.5Lead Range Safety Office1-4

1.6Operational Constraints1-5

1.7Procurement of Flight Termination System-Peculiar Test Equipment1-6

1.8Tailoring1-6

1.9Waivers and Equivalent Level of Safety Certifications1-7

1.10Grandfathering1-8

1.11Range User-Provided Hardware1-8

1.12Responsibilities and Authorities1-8

Chapter 2.Tailoring2-1

2.1Tailoring Overview2-1

2.2Tailoring Process2-1

Chapter 3.Common Flight Termination System and Component Performance Requirements3-1

3.1Flight Termination System Functional Requirements3-1

3.2Flight Termination System Design3-4

3.3Environmental Design3-11

3.4Command Termination System3-19

3.5Automatic, Inadvertent-Separation, Fail-Safe, or Autonomous Flight Termination System3-19

3.6Flight Termination System Safing and Arming Devices3-26

3.7Liquid Propellant Shutdown3-27

3.8Flight Termination System Monitoring3-28

3.9Flight Termination System Electrical Components and Electronic Circuitry3-29

3.10Flight Termination System Monitor, Checkout, and Control Circuits3-36

3.11Flight Termination System Ordnance Path3-37

3.12Radio Frequency Receiving System3-38

3.13Flight Termination Receiver3-40

3.14Wiring and Connectors3-54

3.15Laser-Initiated Ordnance Fiber-Optic Cable Assembly3-57

3.16Batteries3-58

3.17Electromechanical Safe-and-Arm Devices with a Low-Voltage Initiator3-67

3.18High-Energy Electronic Initiator Firing Unit3-71

3.19Laser Firing Unit3-73

3.20Ordnance Interrupter3-76

3.21Ordnance Initiators3-79

3.22Devices Containing Percussion Initiators3-83

3.23Propellant-Actuated Devices/Cartridge-Actuated Devices3-85

3.24Explosive Transfer System3-86

3.25Destruct/Terminate Charge3-87

3.26Parachute Systems3-89

3.27Flight Termination System Shutdown Valves3-89

3.28Vibration and Shock Isolators3-93

3.29Autonomous Flight Termination Unit3-93

3.30Miscellaneous Components3-97

Chapter 4.Flight Termination System Component Test and Analysis Requirements4-1

4.1Scope and Compliance4-1

4.2Component Tests and Analyses4-1

4.3Test Plans and Procedures4-1

4.4Test Anomalies and Failures4-1

4.5Failure Analysis4-2

4.6Test Tolerances4-3

4.7Test Equipment4-4

4.8Rework and Repair of Components4-10

4.9Test and Analysis Reports4-10

4.10Component Test and Analysis Tables4-11

4.11Component Examination4-15

4.12Acceptance Testing and Analysis4-16

4.13General Qualification Testing and Analysis Requirements4-26

4.14Qualification Non-Operating Environments4-28

4.15Qualification Operating Environments4-34

4.16Radio Frequency Receiving System4-54

4.17Flight Termination Receiver - Analog/Tone-Based4-58

4.18Enhanced Flight Termination Receiver4-72

4.19Autonomous Flight Termination Unit4-87

4.20Flight Termination System Shutdown Valves4-94

4.21Miscellaneous Components4-105

4.22Electrical Connectors and Harnesses4-107

4.23Remotely Activated Silver-Zinc Batteries4-109

4.24Thermal Batteries4-116

4.25Manually Activated Silver-Zinc Batteries4-123

4.26Nickel-Cadmium Batteries4-134

4.27Lithium-Ion Batteries4-152

4.28Lead-Acid Batteries4-168

4.29Safe-and-Arm Devices, Low-Voltage Initiators, Rotor Leads, and Booster Charges4-184

4.30High-Energy Firing Units4-201

4.31Laser Firing Units, Fiber-Optic Cable Energy Transfer Systems, and Laser-Initiated Detonators4-215

4.32Ordnance Interrupters4-231

4.33Percussion-Initiated Device4-239

4.34Explosive Transfer System, Ordnance Manifolds, and Destruct Charges4-246

4.35Ordnance Interfaces and Manifold Qualification4-251

4.36Shock and Vibration Isolators4-253

Chapter 5.Flight Termination System Component, Subsystem, and System Prelaunch Test and Launch Requirements5-1

5.1General5-1

5.2Pre-flight Component Tests5-4

5.3Pre-launch Subsystem and System-Level Tests5-10

5.4Range and Vehicle Compatibility5-16

5.5Special Tests5-16

5.6Post-Mission Data Analysis5-16

Chapter 6.Flight Termination System Ground Support and Monitoring Equipment Design Requirements6-1

6.1General6-1

6.2Ordnance Initiator Simulator6-1

6.3Laser Test Equipment6-2

6.4Range Safety Console6-2

6.5Ground Support Equipment Provided by the Range User6-4

Chapter 7.Flight Termination System Analysis7-1

7.1General7-1

7.2System Reliability7-1

7.3Single-Point Failure7-1

7.4Fratricide7-2

7.5Bent Pin7-2

7.6Radio Frequency Link7-2

7.7Sneak Circuit7-2

7.8Software and Firmware7-2

7.9Battery Capacity7-3

7.10Component Maximum Predicted Environment7-3

7.11Failure Analysis7-4

7.12Qualification-by-Similarity Analysis7-5

7.13Vehicle Power Analysis7-5

7.14Radio Frequency Radiation Analysis7-5

7.15Flight Termination System Breakup Analysis7-5

7.16Tip-Off Analysis7-6

7.17Automatic Destruct System Timing Analysis7-6

7.18Ordnance Initiator Simulator Analysis7-6

7.19In-Flight Flight Termination System Analysis7-6

7.20Flight Termination System Laser-Initiated Detonator Heat Dissipation Analysis7-6

Chapter 8.Documentation8-1

8.1General8-1

8.2Flight Termination System Report8-1

8.3Flight Termination System Report Submittal Process8-2

8.4Final Approval8-2

8.5Flight Termination System Report Format8-2

8.6Telemetry Measurement8-5

8.7Flight Termination System Report Appendixes8-6

Appendix A.Software/Firmware Independent Verification and ValidationA-1

A.1Independent Verification and Validation Analysis SupportA-1

A.2RequirementsA-1

A.3Design and DevelopmentA-1

A.4Operational Evaluation and TestA-2

A.5Reporting AnomaliesA-3

A.6ReviewsA-5

A.7Configuration AuditA-5

A.8Reliability AnalysisA-5

A.9Human Factors AnalysisA-5

Appendix B.Electronic Piece-Part Procurement RequirementsB-1

B.1Piece-Part Program PlanB-1

B.2US Military-Quality Piece-partsB-1

B.3Custom or Non-Military Piece-partsB-2

Appendix C.Electronic Piece-Part Derating RequirementsC-1

C.1GeneralC-1

C.2CapacitorsC-1

C.3Connectors Reliability Application Derating GuidelinesC-7

C.4Crystal Reliability Application Derating GuidelinesC-8

C.5Diode Reliability Application Derating GuidelinesC-8

C.6Electromagnetic Interference Filters - Reliability Application Derating GuidelinesC-10

C.7Fuses - Reliability Application Derating GuidelinesC-10

C.8Inductor and Transformer Reliability Application Derating GuidelinesC-11

C.9Integrated CircuitsC-13

C.10Motors - Derating CriteriaC-15

C.11Printed Wiring Boards and Printed Circuit BoardsC-15

C.12Relays Derating CriteriaC-18

C.13ResistorsC-19

C.14Slip Rings - Derating CriteriaC-25

C.15Substrates - Derating CriteriaC-25

C.16Switches - Derating CriteriaC-25

C.17Transistors - Derating CriteriaC-26

C.18Wire and Cable - Derating CriteriaC-27

Appendix D.GlossaryD-1

Appendix E.ReferencesE-1

LIST OF FIGURES

Figure 11.Typical Flight Safety System with Flight Termination System1-1

Figure 31.Battery Performance Operational Capacity Overview3-61

Figure 41.Example of Allowable Spikes4-6

Figure 42.Example Cross-Talk Response Acceptable Region4-7

Figure 43.Acceptance Thermal Cycle Temperatures - Non-Ordnance4-18

Figure 44.Workmanship Random Vibration Profile4-23

Figure 45.Qualification Thermal Cycle Temperature Requirements - Non-Ordnance, Upper Maximum Predicted Environment4-35

Figure 46.Qualification Thermal Cycle Temperature Requirements - Non-Ordnance, Lower Maximum Predicted Environment4-35

Figure 47.Pressure Lapse Rate for the Altitude (Low Pressure) Step4-42

Figure 48.Temperature/Humidity/Altitude Test Profile4-44

Figure 49.Procedure for Hardmount Qualification of Components on Vibration Isolators4-49

Figure 410.Elect