Safety Process For Navy Gun and Ammunition Systems
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1 Safety Process For Navy Gun and Ammunition Systems Eileen McConkie Naval Surface Warfare Center Dahlgren Division Dennis Bushor Naval Surface Warfare Center Dahlgren Division John Filo Naval Surface Warfare Center Dahlgren Division
2 Agenda Purpose Policies Define Safety Gun System Safety Process Hardware Software Ammunition Safety Hazards Identification Mitigation Risk Acceptance Independent Review Summary 2
3 Purpose Identify safety processes involved in the qualification of all gun systems and their associated ammunition for U.S. Navy Gun System Gun Mount (GM) Fire Control System (FCS) Associated Systems Ammunition Safety Fuze Energetic Transportation and Storage System Safety Program Plan Developed for all Gun and Ammunition Systems 3
4 Safety Process All Gun Systems and Ammunition Need to go Through a Rigorous Safety Process Before Deployment Gun Systems for Navy Platforms New Development Previously Developed Systems New Ammunition for New or Existing Gun Systems Updates/Upgrades to Deployed Systems Deployment of Existing Gun Systems on New Platforms 4
5 Government and Navy Safety Policy DOD DODD DODI DOD R DDESB Service Component Explosives Safety Oversight DOD Acquisition Process Methodology for Implementing Acquisition Procedures Guidebook SECNAVINST C SECNAVINST H OPNAVINST A OPNAVINST Mandatory Procedures for Implementation Policy for Safety, Mishap Prevention, Occupational Health, and Fire Prevention Navy System Safety Program Explosives Safety Policy NAVSEAINST NAVSEAINST E Requirements for System Safety Program Department of the Navy Weapon Systems Explosives Safety Review Board Implementation of Government Safety Policies Ensures Safety of System Onboard Ship 5
6 System Safety Defined What exactly IS a System Safety Issue? A situation in which own-platform, ownplatform personnel, or friendly assets are at risk from onboard equipment / systems. Personnel Own-Ship Damage Friendly Asset Environment What exactly IS NOT a System Safety Issue? Operational Effectiveness and Survivability Issues Operational Effectiveness Survivability 6
7 Gun System Safety Analysis Process Program Definition Detailed Safety Analyses Safety Disposition Top Level Spec. Historical data Interface Design Spec. Computer Program Performance Specification STANAG 4404 Ada Mitre and C/C++ guidelines Critical Functions List Computer Program (CP) Safety Requirements Safety Analyses Safety Testing MIL-STD-882 System Safety Program Requirements Preliminary Hazard Analysis Special Hazard Analyses System Hazard Analysis NAVORD OD Weapons Systems Safety Guidelines Handbook Preliminary Hazard List Subsystem Hazard Analyses Operating & Support Hazard Analysis Safety Disposition 7
8 Gun System Hardware Safety Apply General Guidelines for Electronic Equipment (MIL-HDBK-454). Inspect hardware for validation of hardware safety requirements (regardless of design phase). Analyze equipment motion Identify sources of radiated energy 8
9 System Control Software Safety Main emphasis of gun system safety. Analyze Software IAW NATO Standardization Agreement (STANAG) Apply lessons learned from previous like systems. Adhere to C++ safety coding guidelines Address Safety Concerns with Java Operating System Middleware Firmware Development tools Analyze test environment Determine the Level of Rigor of Software testing 9
10 Ammunition Safety Design to Proven Standards Fuze design MIL-STD-1316 Electronic Safe & Arm Device (ESAD) WSESRB TM Ignition Design MIL-STD-1901 Initiator MIL-DTL Ensure that the Energetic Compounds are Stable NAVSEAINST and STANAG 4170 Analyze Design to Mitigate Hazards Eliminate Single Point Failures MIL-STD-882D Safety Analyses Special Safety Analyses Structural Analyses 10
11 Ammunition Tests Analyze for a variety of environments Transportation (Land, Sea, Air) Storage Handling by service personnel Drop Combat or Terrorist Threats Fire Shock and Vibration Radiation Test ESD / HERO: MIL-STD-464 Insensitive Munitions: MIL-STD-2105 Associated STANAG Shipboard Shock: MIL-S-901 Fuze: MIL-STD-331C Hot Gun Cook-off: NAVSEA SW300-BC-SAF
12 Identify and Categorize Mishaps and Causal Factors Resulting in: Death, injury, illness, equipment loss or damage, environmental violation That may lead to: The unplanned event Produces: Real or potential condition that exists within system that could lead to mishap CAUSAL FACTORS Elements within the system design, implementation, or operation that lead to, or contain, a hazard. 12
13 Hazard Mitigation Mitigation Methods (In order of precedence) Design out hazard Incorporate safety devices Provide warning devices Develop procedures and training 13
14 Mishap Risk Acceptance Matrix FREQUENCY OF OCCURRENCE 1 CATASTROPHIC MISHAP SEVERITY CATEGORIES 2 CRITICAL 3 MARGINAL 4 NEGLIGIBLE A FREQUENT B PROBABLE C OCCASIONAL D REMOTE E IMPROBABLE Cells: Risk Level & Acceptance Authority: 1-5: HIGH (UNACCEPTABLE) Acceptance of risk by Component Acquisition Executive. 6-9: SERIOUS (UNDESIREABLE) Acceptance of risk by the Program Executive Officer : MEDIUM (Acceptable with review) Acceptance of risk by the Program Manager : LOW (Acceptable with review) Acceptance of risk by the Program Manager. 14
15 Navy Safety Review Boards Weapon System Explosives Safety Review Board (WSESRB) SECNAVINST C Establishes the WSESRB as the Navy s independent agent for reviewing weapon system safety programs OPNAVINST /MCO P Specifies requirements for WSESRB review NAVSEAINST E Establishes WSESRB policies and procedures Software System Safety Technical Review Panel (SSSTRP) Established by WSESRB to review software safety More thorough review by technical experts Fuze & Initiation Safety Technical Review Panel (FISTRP) Established by WSESRB to review fuze/initiation systems safety More thorough review by technical experts Lithium Battery Review Board Insensitive Munition Review Board (IMRB) Ordnance Hazard Evaluation Board (OHEB) Bureau of Medicine (BUMED) Laser Safety Review Board (LSRB) 15
16 Safety Process Summary Apply Mandated Policies Follow System Safety Program Plan Identify, Mitigate and Accept risk Present Safety Process to Safety Review Board Present Analysis to Safety Review Board All Gun Systems and Ammunition Need to go Through a Rigorous Safety Process Before Deployment. 16
17 BACK UP 17
18 Web Site for Further Interest Digital Engineering Institute fications.htm System Safety Handbook htm Joint Weapon Safety Review Process for USSOCOM Program 18
19 Ammunition Qualification Tests PVAT Sequential Environment 28-Day Temperature and Humidity (T&H) Transportation Vibration Shipboard Vibration 4-Day T&H Fast Cook-Off Slow Cook-Off Bullet Impact Fragment Impact Sympathetic Detonation Shaped Charge Jet Impact Salt Fog Sand and Dust Arena 5-Foot Drop 40-Foot Drop Shipboard Shock Waterproof Energetics Qualification Function and Casualty Fuze Function Fuze Arming Distance Jumble Jolt Missing Interrupter Thermal Shock Detonator Safety Lead Azide HERO ESD EMV Lightning Progressive Arming Primary Explosive Component Safety Test Bonfire Test Stack Test POP Unit Load 19
20 Joint Systems JOINT WEAPON SYSTEMS HAVE JOINT REVIEWS Office of the Secretary of Defense (OSD) Joint Weapon, Munitions, and Laser SOCOM Weapon Safety Review Process USD AT&L Memo implementing the Joint USSOCOM Process, 9 November 07 MEMORANDUM OF AGREEMENT AMONG United States Special Operations, Command (USSOCOM), OSD AT&L, OSD Environmental Readiness and Safety, Department of the Army, Department of the Navy, Department of the Air Force In support of USSOCOM Acquisitions Collaborative process supported by each Service s CAE and Safety review authorities Convenes as necessary to review Joint USSOCOM Weapon Programs Incorporates the Joint Laser Safety Review Board (JLSRB) Participants Navy WSESRB USAF NON-NUCLEAR MUNITIONS SAFETY BOARD (NNMSB) US ARMY FUZE SAFETY REVIEW BOARD (AFSRB) MEMBERS OF EACH BOARD HAVE PARTICIPATED IN MEETINGS OF THE OTHER BOARD 20
21 System Acquisition & System Safety A B Program Initiation C IOC FOC Concept & Technology Development System Development & Demonstration OT&E Production & Deployment Operations & Support Critical Design Review FRP Decision Review Pre-Systems Acquisition Systems Acquisition Sustainment PHL System Safety Management Plan - Guidelines for Conducting the System Safety Program PHA System Safety Program Plan, updated as required through the life of the program Safety Test Plan SRCA SSHA O&SHA SHA HHA Hazard Tracking Database Change Reviews & Analyses Repeated as necessary to support follow-on Block developments Safety Assessment Reports and Formal WSESRB Reviews As-occurring, prior to at-sea testing Introductory Pre-CDR Pre-FRP Pre-Deployment 21
22 MIL-HDBK-454 Electromagnetic environment effects Shipboard bonding and grounding Laser safety requirements Human engineering Hazardous Materials Radiation protections and signs Radio frequency protections and signs Safety colors Other safety signs, labels, and barriers Safety tags 22
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