Ed E. 1 t I 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

F 

MANNED ORBITING LABORATORY (MOL) 

EXPLOSIVE ORDNANCE SYSTEMS REQUIREMENTS 

SAFSL EXHIBIT 30060 

6 JUNE 1968 

N 

7:in 7) 

OL.o j 

SPECIAL - 

• HANDLING 

6007 

• Page L-bf jj 

ropy ?of 

7-1 
IMP 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

1. 0 SCOPE 

2. 0 APPLICABLE DOCUMENTS 

3, 0 REQUIREMENTS 

3. 1 Design Requirements 

3. 1. 1 General 

3. 1. 2 Compatibility 

3. 1 3. 1. 3 Standardization 

3. 1. 4 Interchangeability 

3. 1. 5 Materials 

3. 1. 5. 1 Standard Parts and Materials 

3. 1. 5. 2 Shelf Life 

3.1.6 Metals 

3. 1. 7 Explosive 

3. 1. 7. 1 

3. 1. 7. 2 

3. 1. 7. 3 

3. 1. 7. 4 

3. 1. 7. 5 

3. 1. 8 Electrical 

3. 1. 8. 1 

3. 1. 8. 2 

3. 1. 8. 3 

Materials 

Single Batch 

Temper.ature 

Specifications and Standaids 

Explosive Compatibility 

Sensitive Explosives 

Characteristics 

Electromagnetic Compatibility 

Static Charge 

Firing Current 

3. 1. 9 Percussion Initiators 

3. 1. 9. 1 Firing Probability 

3. 1. 9. 2 Blown or Pierced Primers 

3. 2 Performance Requirements 

3. 2. 1 Over capability 

3. 2. 1. 1 Severing Charges 

3. 2. 1. 2 Cartridge Actuated Devices 

3.2. 1.3 Detonation Transfer 

3. 2. 2 Reliability 

3. 2. 3 Redundancy 

3. 2. 3. 1 Explosive Functions 

3. 2. 3. 2 Cartridge Actuated Devices 

SPECIAL • 

1-1 A DI. I G 

• , • 

L - 6 0 0. 7 

Copy apof 

Page ti.shf 
i'9 s 11 s.✓ 16. • s •:r env 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

3.2:4 

3.2.5 

Proof Pressure 

Burst Pressure 

3, 2, 6 Leakage 

3, 2. 7 Fragmentation 

3, 2. 8 Contamination 

3. 2, 9 Environment 

3. 2. 10 Shelf Life 

3, 3 Safety Requirements 

3. 3. 1 General 

3.3. 2 System Safety Engineering 

3. 3. 2. 1 Integration of Effort 

3. 3. 2. 2 Safing Devices 

3. 3, 2. 2, 1 Safe-Arm Devices 

3.3.2.2.2 Electrical Arm-Disarm Devices 

3.3.2.2.3 Arming and Disarming 

3. 3. 2, 2.4 Monitoring 

3. 3. 3 Safety 

3. 3. 4 Emergency/Backout Procedures 

• 3. 3..5 Assignment of Lot Numbers and the Submission of 

Data Cards and Motor Log Books 

3. 3. 6 • Color Coding 

3. 3. 7 Accident/Incident Reports 

3. 4 Installation and Checkout Requirements 

3. 5 Training Requirements 

4. 0 QUALITY ASSURANCE PROVISIONS 

4. 1 Developmental Testing 

4. 1. 1 Testing Parameters 

4, I.2 New Materials' 

4.1.3 • RF Susceptibility 

4, 2 Qualification Testing 

4. 2. 1 Environmental Conditions 

4, 2.2 Functioning 

-4.2, 3 Firing Characteristics 

4. 2.4 Number of Units 

S i 

SPECIAL 

HANDLING 

L-6007 

Copy Aaof 

Pa7g-e-3.:'bf Lei 
\e• 1114r4 IJCJIG.1 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

4.3 Acceptance Testing 

4. 3. 1 Non-Destructive Tests 

4. 3. 2 Lot Sample Test Firing 

4.4 . Verification Testing 

4. 4. 1 Test Program 

4.4. 2 Test Site 

5. 0. PREPARATION FOR DELIVERY 

6.0 DEFINITIONS 

SPECI4 

HANDLING 

L - 6007 

Copy as of 10 

Page 412,10,147 

(PI r.■ " ( 
Management of Contractor Data end Report 

dated 3-14-64 

System Test and Operations Plan, dated 

6 June 1968. 

Safety and Accident Prevention dated 

March 1966 

SSD-CR-65-275A, Environmental Test Plan dated 9-1-66 

'Volume 6 (contractor 

applicable'document) 

trvizanrN7c73 

. 2 

tri

V A 

‘',.7 

\ t 

to LIM It■ 

SPECIAL. 

HANDLING 

L-6007 

Copy -2of 0_10 

Pa ge.5bif ;1:M 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

'NW 

1.0 SCOPE 

This document establishes and defines the minimum acceptable requirements 

for design, testing, safety and transportation of explosive ordnance 

systems used on the Manned Orbiting Laboratory System. 

All deliverable data and/or documentation specified in this exhibit shall 

-be in accordance with the respective contractor's CDRL (0 1423) as 

detailed by Forms 9 or equivalent. 

2.0 APPLICABLE DOCUMENTS 

The following documents are applicable to the extent specified in this 

- document. This document is to take precedence in the event. of a conflict 

Of requirements. 

Ammunition Color Coding dated 27 June 1960 

Metals,.Definition of Dissimilar dated 

16 December 1958 

Electromagnetic Compatibility Requirements, 

Orbiting Vehicle, General Specification for 

the MOL Program dated 6 June 1968. 

MOL Program Effectiveness Exhibit dated 

6:June 1968 

MOL Logistics Plan dated 6 June 1968 

Agent T. C. George's Rules and Regulations 

for Transportation.of Explosives and Other 

Dangerous Articles 

MIL--STD-709 

• 

MS 33586A 

SAFSL Exhibit 

3 0005 

SAIL Exhibit 

30002 

SAFSL Exhibit 

30025 

ICC Tariff f19 

AFSCM/AFLCM 310-1, 

_volume II, Change J 

dated 11-1-67 

SAFSL Exhibit 

30020 

AFPI 7=4047 
NRO APPROVED FOR • 

RELEASE 1 JULY 2015 

—*Electromagnetic Control Plan dated 

9-1-66 

EMC Control Plan 

TIII/M Program Plan, Seven Segment, 

120 Inch Diameter, Solid Rocket Motor 

(EMC) Control Plan ' 

SSD-CR-65-334A 

(contractor applicable 

document) 

SP.ECIAL 

HANDLING 

IJLi 6 I t ,.V.40 

AGC so-cR-65-8180-150 

tec-m-o-4801-66-9 

L - 6007 

Copy -22,i 

Page L-bfal 
clftiY7) -SPECIAL 

• HANDLING 

El M 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

3.0 REQUIREMENTS 

These provisions shall establish the minimum acceptable requirements for 

the design of explosive ordnance systems, subsystems and components. 

3.1 Design Reauirements 

(R) 3.1.1 General 

It shall be a prime objective to obtain maximum safety and 

reliability by designing the following into each explosive 

ordnance' system: 

a) Simplicity 

b) Minimization of explosive charges consistent with 

reliability. 

• c) Ruggedness of construction 

d) Minimization of opportunity for human errors 

*e) Desensitization to initiation by spurious energy 

- sources. 

3.1.2 Compatibility 

The design of all explosive ordnance systems shall be mutually 

compatible with other systems and subsystems. The functioning of any explosive system shall have no detrimental effect 

on components designed to function subsequent to the explosive 

operation. 

(R) . 3.1.3 Standardization 

The design of all explosive ordnance systems shall incorporate 

the maximum use of existing qualified items. 

(R) 3.1.4 Interchangeability 

All lowest order assembly items installed on the vehicle 

having the same part number shall be interchangeable. 

CR) 3.1.5 Materials 

All materials used shall be of high quality, light weight, 

suitable for the purpose to which applied and shall be . 

certified as conforming to applicable contractually identified 

specifications. 

• 

L - 6007 

Copy rzof yo 

Page -.11•6f4:24 
tcii :4 is i t c..9 

NRO APPROVED FOR • 

RELEASE 1-JULY 2015 

3.1.5.1 Standard Parts and Materials 

Standard Parts and Materials as defined in paragraph 

4.1.3 of SAFSL Exhibit 30002 shall be used in the 

design and construction of explosive ordnance 

devices to the extent that performince is not 

adversely affected. 

3.1.5.2 Shelf Life 

All materials used in the explosive ordnance syste;-S 

shall be selected and controlled to insure a fabricated product consistent with paragraph 3.2.10 

herein. 

(11) 3.1.6 Metals 

Dissimilar metals, as defined by MS-33586, shall not be used 

in intimate contact unless suitably protected against 

electrolytic corrosion. Any protective coating used shall 

mot preclude provisions for obtaining electrical bonding. 

. 3.1.7 Explosive Materials 

'All explosive materials shall conform to the following 

requirements: 

(R) 3.1.7.1 Single Batch 

All charges of the same design in a lot of explosive 

components shall be loaded from the same batch of 

:material. - The batch shall be handled, tested and 

•. stored so as to maintain its separate identity. 

(R) 3.1.7.2 Temperature 

Explosive ordnance devices shall be designed to 

perform satisfactorily during or after exposure to 

a temperature 50°F higher than the maximum predicted 

environmental temperature to which the material will 

be exposed during storage, handling, installation 

and operation. 

(R) 3.1.7.3 Specifications and Standards 

Where Military or Federal Specifications and/or 

Standards are applicable, explosive materials shall 

comply with such specifications or standards unless 

compliance with other material specifications will 

result in equal or superior performance. Attainment 

of qualification status shall constitute adequate 

demonstration of such performance. 

(R) 

(R) 
L- 600 7 

Copy-2R_ of Y.L0 

Page 3_1)/44 

SPECIAL 

• •• • • • • "•• %AO .• • 'ad 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 • 

3.1.7.4 Explosive Compatibility 

Explosive materials in contact in an explosive 

train shall be compatible with each other and with 

the non-explosive components they contact. 

("-=-.!• 3.1.7.5 Sensitive Explosives 

The use of sensitive primary explosives shall be 

kept to a minimum consistent with achieving relialale 

performance. 

3.1.8 Electrical Characteristics 

(Z..) 3.1.8.1 Electromagnetic Compatibility 

All electrically activated explosive ordnance 

systems shall comply with the requirements of 

paragraph 3.3.1.3 of SAFSL Exhibit 3.0005. 

Deviations - M-SC. 

"'N 3:1.8.2 Static Charge 

Electric Initiators shall not fire, dud, or deteriorate in performance as a result of being subjected 

to an electrostatic discharge in the pin to case 

mode from a 500 picofarad capacitor charged to 

25,000 volts. A 5000 ohm resistor shall be connected 

in series with the discharge path. 

Deviations - GE and MAC 

:.••••••• 

3.1.8.3 Firing Current 

All electric initiators shall fire within the 

. specified time upon application of 5.0 amperes DC 

with a probability of at least 0.999 at 95% confidence. 

3.1.9 Percussion Initiators 

All percussion initiators shall meet the following requirements: 

3.1.9.1 Firing Probability 

Percussion initiators shall fire with a probability 

of 0.999 at 95% confidence when 50% of the minimum 

!specified input energy is applied. 
L - 6007 

Copy -23..of #.0 

Pageienf 

NROAPPROVEDFOR 

RELEASE. 1 JULY 2015 

( a ) 

$ C.11 IS I e, 11.7 

- 3:1.9.2 Blown or Pierced Primers 

There shall be no blown or pierced primers that 

adversely effect performance of the device when 

the primers are fired with the maximum input energy. 

3.2 Performance Reauirements 

The following performance requirements shall be considered minimum 

-for'the MOL Program. 

(a) 3.2.1 Overcapability 

Unless safety or operational restrictions dictate otherwise 

the design of all explosive ordnance shall be such that the 

performance of the end function shall be accomplished with an 

established overcapability as follows: 

3.2.1.1 Severing Charges 

• 

The overcapability of severing charges shall have: 

a) The capability of severing or rupturing 1.3 

times the required thickness of the 

specified material or 

The capability of severing or rupturing the 

required thickness of the specified, material. 

with an explosive charge which-is 75% by 

. veight of the minimum specified charge. 

Deviation - MAC 

(a) 3.2.1.2 Cartridge Actuated Devices 

Cartridge actuated devices shall perform their end 

functions satisfactorily when actuated by a single 

cartridge containing an output charge which is 80% 

by veight of the minimum specified charge, and with 

no decrease in the initial unoccupied burning 

chamber volume. Deviation - MAC, MMC 

(11) . 3.2.1.3 Detonation Transfer 

Where detonation is required to propagate from one 

explosive component of an explosive train to the 

next explosive component, the detonation shall 

propagate across an in-line gap 1.5 times the 

maximum design tolerance with a probability of at 

least 0.995 at 90% confidence or shall propagate 

across an in-line gap that is 5 times the maximum 

. design tolerance gap. Deviation - MAC, MMC 

c.7) 7E7 

al .3 tAl 

. _ 

SPECIAL - 

• - HANDLING 

• • ■ 
3.2.2 Reliability 

L - 6007 

Copy-z--2of 

Page itbf,02 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CIO 

• 

All explosive ordnance components shall be classified as 

Reliability Critical Items as defined in paragraph 5.3.1 of 

SAYSL Exhibit 30002. The reliability of each explosive 

ordnance function shall be compatible with the MOL System 

RequirementA Allocations. 

(B) 

(B) 

(R) 

(R) 

3.2.3 Redundancy 

• 

All explosive ordnance functions required for mission success 

shall be redundant. Deviation - MAC ' 

3.2.3.1 Explosive Functions 

The explosive function redundancy shall be provided 

to the following extent: 

• . . 

a) Preferable two (2) output charges or 

explosives trains, independently initiated 

or 

b) One (1) output charge or explosive train 

redundantly initiated. Deviation - MAC 

7• - 

3.2.3.2 Cartridge Actuated Devices 

In all instances where one cartridge actuated device 

is used to perform an end function, the device shall 

contain dual cartridges, either one of Which will 

produce sufficient energy to operate the device. 

Where redundant cartridge actuated devices are used 

to perform an end function, the devices may use 

single cartridges. 

3.2.4 Proof Pressure 

Cartridge actuated devices shall perform their end functions 

satisfactorily when actuated by cartridges containing output 

charges which are 120 percent by weight of the maximum specified charges, and with no increase in the initial unoccupied 

burning chamber volume. Deviation - MAC, MMC 

3.2.5 Burst Pressure 

Cartridge actuated devices shall not rupture or fragment when 

actuated by cartridges containing output charges which are 

150 percent by weight of the maximum specified charges, and 

with no increase in the initial unoccupied burning chamber 

volume. r Deviation - MAC, MMC 

FF 

1/4.) LJ.3 

SPECIAL -• , 

1-1 A .DL I N G 
[ L-6007 

Copy'.2.?-of 

Paged'bf 

SPECIAL 

IA A NOLA NG 

• p'Y Q "4 II 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

3.2.6 Leakage 

All initiators shall be sealed to withstand a pressure 

differential of at least 1/2 atmosphere. The leak rate 

at 1/2 atmosphere differential shall not exceed 1 X 10-5 

standard cubic centimeters of helium per second. 

3.2.7 Fragmentation 

The design of all explosive ordnance systems shall be such 

that norpal functioning produces no deleterious fragmentation. 

3.2.8 .Contamination 

The design of all explosive ordnance systems shall be such 

that prior to, during or subsequent to functioning, any 

contamination produced shall not result in deleterious 

degradation of vehicle performance. Contamination levels 

and operational requirements of.adjacent components shall 

be mutually compatible. 

3.2.9 Environment 

All explosive ordnance systems shall be designed to function 

within specification limits under their operating environments after exposure to the applicable environmental conditions 

defined in the appropriate document as follows: 

a) Douglas - SAFSL Exhibit 10003 

b) GE - SAFSL Exhibit 10003 

c) MAC - SAFSL Exhibit 12003 

d) }IMC - SSD-CR-65-275, Volume No. 6 

e) SS-TIII/M - System Performance/Design Requirements 

ti 

3.2.10 Shelf Life 

All explosive ordnance components shall be designed for a 

minimum shelf life of 3 years from date of manufacture to 

date, of firing, during which period they shall be capable 

of surviving applicable environmental conditions and thereafter of meeting their specified performance characteristics. 
# 

NRO APPROVED FOR 

RELEASE 1- JULY 2015 

(RAP) 

. 3.3 Safety Requirements 

3.3.1 General 

Safety requirements shall be in accordance with paragraph 

5.3.10 of SAFSL Exhibit 30002. System-Safety features 

and procedures shall be developed to assure maximum freedom 

from hazard Attributable to facilities, equipment or 

personnel. \ 

3.3.2 System Safety Engineering 

(T) 3.3.2.1 Integration of Effort 

System safety requirements relating to facilities, 

herein shall not result in duplicate effort perequipment, procedures and personnel as detailed 

formed in accordance with other specifications or 

exhibits but shall be integral and concurrent with 

such efforts. 

3.3.2.2 Sating Devices 

(R) 3.3.2.2.1 Safe-Arm Devices 

Safe-Arm devices which effect the 

physical interruption of the explosive 

train plus electrical sating of the 

ordnance circuitry shall be mandatory 

on the following operations: • 

a) Destruct Systems/Thrust Termination Systems. 

Large Solid Motor Ignition 

Systems weighing in excess of 

100 pounds. 

(R) 3.3.2.2.2 Electrical Arm-Disarm Devices 

Electrical Ara-Disarm Switches or similar 

devicei shall be used on all electrically 

initiated ordnance functions not using 

Safe-Arm devices. 

3.3.2.2.3 Arming and Disarming 

Electrical Safe-Arm and the Arm-Disarm 

devices shall provide means for remote 

arming and disarming as well as for 

manual disarming by ground personnel, 

prior to launch. In the safe condition): 

SPECIAL 

I-1 A IMIL I •NG 

- 6007 

Copyz-z- of 

Page 3'b 

(R) 
i.1 161 It. 

NRO APPROVED FOR 

RELEASE 1-JULY 2015 

..these devices shall interrupt, short, 

. and ground the electric firing initiator 

bridge circuits. 

(B) 

Deviation.- MAC 

3.3.2.2.4 Monitoring 

The Safe Ara and Arm-Disarm devices shall 

provide for remote electrical monitoring 

of the status of the arming circuit. A 

means shall be provided on the safe arm 

devices to visually determine their status. 

(R,T) 3.3.3 

(R,T) 3.3.4 

(R) 3.3.5 

(R,T) 3.3.6 

(T) 3.3.7 

Safety 

Military hazard classifications for handling and storage 

purposes shall be assigned to all explosive ordnance. The 

contractor shall secure the ICC shipping hazard classification 

for each individual explosive item/component or will be 

allowed to ship MOL Program ouantities of explosive ordnance 

items with an ICC Class "A" hazard classification. 

Emergency/Backout Procedures 

Procedures shall be developed for VAFB emergency/backout for 

disarming/safing actions and explosive ordnance disposal. 

Assignment of Lot Numbers .and the Submission of Data Cards 

and Motor Log Books 

Lot numbers shall be assigned to all lots of explosive 

ordnance components. Data cards for explosive ordnance 

components shall be maintained. Motor Log Books shall be 

maintained for all solid propellant motors weighing in 

excess of 100 pounds. 

Color Coding 

A11 explosive assemblies/subassemblies or parts shall be 

color coded in accordance with MIL-STD-709 or a MOL Systems 

Office approved document developed for a particular segment. 

Accident/Incident Reuorts 

The MOL Systems Office shall be promptly notified of any 

ordnance accident/incident per AFT' 7-4047. 

^1 l 

, '""*.---7-,Ft 

• 

• 

SPECIAL 

• HAIlDsLING 

Copy a-2 -of 

:115ageLtbf, 1 • 
(P,T). 3.5 Training Reouirements . 

All personnel involved in the installation of explosive ordnance 

shall be given a thorough training course by a qualified instructor 

and certified prior to handling any explosives. The training and 

certification shall be accomplished in accordance with SAFSL Exhibit 

30020. 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

(P,R) 

- Explosive ordnance systems shall- be designed to facilitate installation and checkout. Provisions shall be made for installing all 

explosive ordnance as late in the flight vehicle buildup as practical 

and consistent with operational and safety requirements. All 

explosive ordnance installation and checkout at VAFB shall be in 

accordance with approved procedures. 

t7711777777737- 

3.4 Installation and Checkout Requirements 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

(J) 4.0 QUALITY ASSURANCE PROVISIONS 

• ", Ia.. YID • • ••• •••■ 

-5,0.77.27:7-7.Z,74.•.7g77721.1 

priiinn 

The following requirements shall be specifically implemented in appropriate 

CEI Specifications and contractor test plans. The testing of explosive 

ordnance shall be divided into four categories: 

a) Developmental 

. • 

'<lb) Qualification 

0) Acceptance 

cl) Verification 

4.1 Develouriental Testing 

.Developmental testing is defined as that testing performed on all 

preliminary experimental designs plus the testing necessary to 

demonstrate the capability of the final design to perform its 

function. This shall include, but not necessarily be limited to 

the following: 

Testing Parameters 

Design requirements as specified in the following paragraphs 

of Section 3.0 shall be demonstrated in Developmental Testing: 

Deviation - MAC 

3.1.2 Compatibility 

3.1.9.1 Firing Probability 

(except for the demonstration of Probability 

Levels) 

3.1.9.2 Blown or Pierced Primers 

3.2.1.1 Severing Charges 

3.2.1.2 Cartridge Actuated Devices 

• 3.2.1.3 Detonation Transfer 

(Demonstration of reliability and confidence 

levels shall be in accordance with NAV ORD. 

12101 BRUCETOIT TESTING). 

3.2,4 Proof Pressure 

3.2.5 Burst Pressure 

- 3.2.7 Fragmentation 

• 

3.2.8 Contamination 

L - 6007 

Copy Zz of yo 

F'age /kW' ati 

•• _ • . 

SPECIAL. 

A D L I G 

• 
(1) The DC all fire/no fire characteristics of all electric 

initiators have been determined by Bruceton Testing per 

NAV.ORD 2101. 

(2) The all fire energy level of nereussion initiators has 

been ddtermined by statistical testing. 

SPCIAL .t. - 

HANDIING 

L-6007 

Copy 22of t mil) 

Page Erbf.2.4 

is 4 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 • 

(T) 4.1.2 New Materials 

• 

Developmental testing shall-also include a determination that 

all new materials meet their environmental requireMents. 

(T) 4.1.3 BF Suscentibilit 

Tests shall be conducted on each type of electroexplosive. 

initiator per requirements of SAFSL Exhibit 30005. • 

(T) 4.2 Qualification Testing 

- Qualification Testing is defined as that testing which is necessary 

to demonstrate that the device or system is capable of surviving 

..conditions which each device will encounter during its life. Qualifunder specified operating environments. The qualification test, 

procedures shall be formulated to exceed the predicted environmental 

specified non-operating environments and will function successfully 

ication by similarity shall be permitted only with the concurrence 

of the MX, Systems Office. All qualification lots shall have passed 

. the non-destructive acceptance tests. 

(T) 4.2.1 Environmental Conditions 

The explosive ordnance systems and/or components shall be 

tested under the appropriate environments and environmental 

. conditions as specified in Paragraph 3.2.9 herein. 

(T) 4.2.2 Functioning. 

All explosive ordnance systems shall function in the prescribed 

manner under their operating environments after exposure to 

environmental conditions as specified in Paragraph 3.2.9 

herein. Only those conditions and sequences which the unit 

may normally encounter need be included in the testing. 

Safe-Arm devices shall be tested in the safe position for the 

transportation environment and in the applicable safe and/or 

armed positions for the flight environment. 

(T) 4.2.3 Firin Characteristics 

The qualification program shall include the following certification as applicable: 

_ 
11 • 4-1 :•+s 

1••• 

• 

- . • • • 

Ira ra IC"S 

6 0 0 7 

Copy-2_of 

4 dif 

SPECIAL 

HANDLING 

(T) 4.2.4 Number of Units 

The qualification program for initiators shall include 

the environmental testing of at least 180 units. The 

qualification program of all other explosive ordnance devices 

and systems shall include the environmental testing of at 

least 20 items which shall include full assemblies or, on 

larger systems, partial assemblies. Partial' assemblies shall 

include each type of explosive interface and shortened 

linear or main charges. Deviation - MAC 

NRO APPROVED FOR . 

RELEASE 1 JULY 2015 

4.3 Acceptance Testing 

Acceptance tests are those tests performed on each lot of explosive 

components to verify that the physical, electrical, and performance 

. characterisitcs comply with the design specification requirements 

and that quality is maintained. 

CT) 4.3.1 Non-Destructive Testing 

The acceptance requiremeats shall include the following 

nondestructive tests on 100 percent of each manufactured 

lot: 

a) Electric-Explosive Initiator 

•Radiographic inspection 

•Leak Test 

*Bridge Circuit Resistance Measurement 

*Insulation resistance and/or dielectric 

strength tests 

oElectrostatic discharge test 

Deviation - MAC 

(T) Other Explosive Components 

(T) 

eliadiographic Inspection: 

all integral explosive interfaces, including 

relay fittings on linear charge and all explosive 

loadings except swaged or drawn linear charge. 

•Leak Test (where applicable) 

4.3.2 Lot Sample Test Firing 

Lot-sample firing tests shall be conducted after subjecting 

the samples to vibration at the critical environmental . 

temperature. Those portions of the samples used for the all 
• - 

••••• • 

Erst ri) r 

;.; 

SPECIAL - 

s 

HANDL! G 

L - 6007 

Copy sof 

Page &Vogl 

ler■ellr-erm-s-rirgr— 

V • i--4 • J Cr! fir. U I +4 '4■10 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

fire/no fire tests shall not be subjected to environmental 

exposure prior to firing. All test firing shall include 

suitable verification of explosive output performance. 

Deviation - MAC, MMC 

a) Electric Initiators 

Ten percent of each manufactured lot, but never 

less than 180 samples, shall be test fired. - 

This sample number shall include 1/3 fired fof 

verification (ion-statistical) of all fire/no fire 

design levels, and 2/3 for tests subsequent to 

environment exposure. 

Percussion Initiators 

Manufactures test data will be considered to be 

acceptable for verification of design all fire 

energy levels. 

v) Linear Charges 

Total strand as manufactured: at least two 

samples, one from each end shall be test fired 

before the strand is used for lot fabrication. 

(r) 4.4 Verification Testing. 

Verification testing shall be conducted within a period of three (3) 

months prior to each launch to insure that the explosive ordnance 

critical component has not detezlorated between the time of, 

acceptance testing and launch. Deviation - MMC 

4.14.1 Test Program 

The verification test program shall include the firing and 

measurement of the output characteristics of at least one (1) 

sample of the following items selected from the lot planned 

for flight: 

(T) 

(T) 

(T) 

a) Initiators 

b) Linear Explosive Components (short-length samples may 

used). 

(T) 4.4.2 Test Site 

Verification testing shall be conducted at the launch base or 

installation point using components shich have been stored 

with flighti hardware. 
11-4 E4 io,.!2d1". N tJ17 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 • 

CT) 5.0 PREPARATION FOR DELIVERY 

Explosive ordnance assemblies and/or components shall be prepared fdr 

delivery in accordnance with Section 6 of SAFSL Exhibit 30025. 

:6.0 DEFINITIONS 

All-Fire Current The minimum current which, when applied . 

to an initiator for a given time, insures 

initiation. 

All-Fire Energy 

Arms Disarm Device 

Batch 

Cartridge 

Cartridge - Actuated Device 

Charge 

Deflagration 

The minimum energy applied at a given 

rate to a percussion initiator which 

assures initiation of the explosive 

train. 

To make explosive devices ready for 

firing. 

- - 

An electrical switch which interrupts 

the ordnance circuitry, thus rendering 

the system electrically safe. 

A quantity of explosive material produced 

in one single manufacturing Output cycle 

and controlled as a separate entity. 

A. batch shall be identified by a 

separate explosive lot number. 

An assemblage of components designed to 

yield gaseous energy from a chemical 

reaction (i.e. deflagration) which 

is used to perform mechanical work. 

A device which converts gaseous energy 

produced by a cartridge into mechanical 

work. Examples are ejection mechanisms, 

explosive valves, thrusters, guillotines, 

and pyrosvitches. Excluded are linear 

charge systems. 

The quantity of explosive used in a 

cartridge, shaped charge or other 

explosive item. 

Rapid combustion at less than detonation 

rates. 

-6007 

Copy Daof 

Pa geolailbf at/ 

SPECIAL. 

HANDLII1G 
i —1 5 d ftsi 

Initiation 

Initiator 

cl 77) rinr-7 

')1 

.i 2.va 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

Destruct System 

Detonation 

An explosive ordnance system capable of 

destroying a missile or system in- the 

event of a malfunction during or after 

launch. 

An exothermic chemical explosive reaction 

that propagates with such rapidity that 

the rate of advance of the reaction zone 

into the unreacted material exceeds the-- . 

Velocity of sound in the unreacted 

material. 

Detonator A high explosive device, initiated:by 

either electrical or mechanical means, 

which produces a shock front and/or 

shrapnel pattern capable of satisfactorily 

propagating detonation in the next high 

explosive element in the explosive l train. 

Disarm The normal method of returning ordnance 

systems or components to a safe status. 

Explosive A substance or mixture of substances 

which can be made to undergo a rapid 

chemical change, without an outside 

supply of oxygen, with the liberation of 

large quantities of energy and generally 

accompanied by the evolution of hot gases. 

• 

Explosive Component A separately packaged explosive assembly. 

Explosive Ordnance Components, devices and assemblies 

which contain explosives. 

Explosive Train An assembly of combustible and/or explosive 

charges in series. 

Flexible Linear Shaped Charge FLSC is a linear cutting charge. It 

(FLSC) consists of a high explosive contained 

in a metal casing which is formed into a 

chevron-or "V" shape. FLSC is used to 

cut metal or other material to effect 

stage separation, hatch opening, vehicle 

destruct, etc. 

The process of starting an explosive 

chemical reaction. 

The first element in an explosive train 

which, upon receipt of the proper 

mechanical or electrical impulse, produces 

a deflagrating or detonating action. 

SPECIAL • - . 

HANDLING 

L - 6007 

Copy of 

Page4grbf#1A 
HA NDLI C1G 

NRO APPROVED FOR 

RELEASE 1 JULY 2615 

'The amount of externally applied energy 

to an explosive which will cause -

initiation. 

An explosive charge contained in a metal 

or plastic sheath. Examples are linear 

shaped charge, flexible linear shaped 

charge, and mild detonating fuse. 

That collection of items produced in a 

continuous production run utilizing the 

same batch (explosive lot) of explosive 

materials. A continuous production run 

shall be defined as production of Units 

utilizing the same procedures, tooling, 

processes, and controls without changes 

or interruptions other than normal,shift 

operations. 

Mild Detonating Fuse (MDF) A small.diameter column of explosive 

material contained in a metal sheath. 

lib-Fire Current The. maximum current which can be applied 

to an initiator for a given length of 

time without causing initiation of the 

explosive train. This is normally 

expressed at a reliability and confidence 

level. 

Input Energy 

Linear Charge 

• Lot 

Output Characteristics The characteristics of an explosive 

component which describe the form and 

magnitude of the energy release when the 

component functions. 

Percussions The method of initiating an explosiveloaded item by impact or a sudden 

crushing or pinching of the explosive 

material as between a blunt firing pin 

and en anvil. 

Relay, Explosive An explosiVe-train component that provides 

the required explosive energy to reliably 

initiate the next element in the train. 

Remote Arming & Disarming Arming and disarming without physical. 

accessibility to the device. 

Safe 7 The condition of an explosive ordnance 

system Where the explosive train and/or 

electrical circuitry is interrupted to 

prevent initiation. 

L - 6007 

- - spgiciAL 

H A. NG rith 

Copy ,P,D of .41) 

Page aptbf oldtt 
Safe-Arm Device. 

Sensitivity 

energy. 

Severing The process of linear cutting or 

rupturing by the use of linear charges. 

•A device which, in the safe condition, 

renders the ordnance system mechanically 

safe.byinterrupting the explosive train. 

The characteristic of an explosive 

component which expresses its susceptibility 

to initiation by externally applied 

k-1 r. I 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

• 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

. NONE 

• 

- • k 

• 

. 

a .1 

;a .1 

. . 

SPECIAL z 

• HANDLING 

L-6007 

Copy a, aof 

Pa g 64:tbf00 

•Oao.e a. 4... .,•11, 60 UN 

APPENDIX A 

DAC DEVIATIONS 
APPENDIX B 

GE DEVIATIONS 

L-6007 

Copy -.2.of 

Page4rf 4,19 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

3.2. I .2 Cartridge Actuated Devices' 

The existing pyrotechnic initiators on the DRV shall be exempt from 

the requirements of this paragraph. Actual performance data shall be provided 

to the MOL System Office. 

3.2.4 Proof- Pressure 

The existing pyrotechnic initiators on the DRV shall be exempt from 

the requirements of this paragraph. Actual performance data shall be provided 

to the MOL Systems Office. 

• 

3.2.5 Burst Pressure 

The existing pyrotechnic initiators on the DRV shall be exempt from 

the requirements of this paragraph. Actual performance data shall be provided 

to the MOL Systems Office. 

3.2.6 Leakage 

The existing pyrotechnic initiators on the DRV shall be exempt from_ 

the requirements of this paragraph. Actual performance data shall be provided 

to the MOL Systems Office. 

3.2.9 Environment 

(f) GE-DRV (TBD) 

3. 3. 2. 2 Clarification 

The safe and arm provisions contained in the present DRV design meets 

the requirement of this paragraph. 

an r) SPECIAL 

,..3.„12,, ' • I-1 A 
11 1; fAcY lb> 

MAC DEVIATIONS 

3.1.8.2 Static Charge 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

• The Gemini B segment, explosive ordnance devices shall 

• not be required to withstand the stated static charge 

requirement. 

3.2.1.1 Severing Charges 

The overcapability of severing charges shall provide: 

a. The capability of severing or rupturing at least 

1.2 times the required thickness of the specified 

material. • . . 

3.2.1.2 Cartridge Acuated Devices 

The Gemini "B" segment, devices which are operated by 

gas producing cartridges shall have the capability of 

performing their end function when actuated by a single 

cartridge containing an output charge which is 80% 

by weight of the nominal specified charge with no 

decrease in the initial unoccupied burning chamber.. 

volume. This requirement shall not apply where 

CAD output must be closely controlled as in an 

ejection seat catapult, parachute mortar or where CAD 

operation is not reouired for mission success (as 

in an auxiliary experiment). 

3.2.1.3 Detonation Transfer 

MACASTRO present testing methods will be accepted as 

meeting the requirements of this paragraph. 

3.2.3 Redundaam 

The Gemini B segment abort subsyitem is not required to 

incorporate redundant features. Gemini B segment functions 

associated with experiments are not reouired to be redundant. 

3.2.3.1 Does not apply to electrical switch. 

3.2.4 'Proof Pressure 

Cartridge actuated devices shall be subjected to a proof 

pressure tdst per Table 3.7-1 of SAFSL 12004 :CAD.shall not 

yield or leak as a result of this test. 

• 

I

L-6007 

Copy zzof 4:0 rr'177 SPECIAL L.6,4.1!. al ilDLII1 • (3 Page a 71 fos, -11b 
MACASTRO not required comply to the requirement 

4.1.1 Testing Parameters 

NASA Gemini devices shall be exempt. 

- 

(91 

. SPECIAL . 

.1 , k I-1 A EIDLl [`,1G 

^ - • 

L-6007 

Copy aZof 

Pa g e244,,,,9 

.11 11 4-11a 61,17 Go V i v 1.0 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

3.2.5 Burst Pressure . 

Cartridge actuated devices shall be subjected to a burSt 

pressure test per Table 3.7-1 of SAFSL 12004: CAD shall not 

rupture or frAz^ent as a result of this test. 

• 

3.3.2.2.3 Arming and Disarming 

MACASTRO not required to comply to the requirement. 

3.3.2.2.4 Monitoring 

-4.2.4 Number of Units • • • 

NASA Gemini devices shall be exempt from this requirement. 

MCASTRO has statistically tested 150 units to determine allfire and no-fire characteristics. MCASTRO has environmentally 

tested at least 15 items where the design is similar to NASA 

qualified units. 

4.3.1 Non-Destructive Testing. 

a) Electric-Explosive Initiator 

The Gemini "B" segment is exempt from meeting the 

electro static discharge test requirement. 

4.3.2 Lot Sample Test Firing 

The below listed lot sampling procedure will be accepted for all 

lots procured prior to the effective date of this document. 

All lots of flight explosive ordnance devices other than the 

qualification test lot shall include lot sample firing tests. 

Tests shall demonstrate compliance with previously established 

performance parameters as applicable. Test quantities shall be 

in accordance with Table I. Prior to firing elecric initiators, 

1/2 of the samples shall be subjected to one (1) amp no-fire 

current for five (5) minutes and 1/2 of the samples shall be 

subjected to one (1) vatt no-fire power for five (5) minutes. 

Prior to test firing, all ordnance device samples shall be 

subjected to 'their applicable elevated environmental temperature. 
i3/4 1,4 L$L.1kg 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

• 

-LOT SIZE 

3-10 

11-22 

23-35 

36-52 

53-69 

70-92 

93-120 

121-160 

161 & up 

NOTE:, 

Lot sample quantities for MDF Interconnects shall be 

constant at 10% minimum. For large separation assemblies, 

shortened FLSL segments may be used. 

+ 4.! (".•5 0.71, l'") 

a I ; 

SPECIAL 

H 1115:. .1 11 G .

L - 6 0 0 7 

Copy -P-2-of 

Pa geoliibf 
1.6 C4 14:L.0 1611 ‘.1 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

. APPENDIX D 

T-IIIM DEVIATIONS 

3.1.8.1 Electromagnetic Compatibility 

All electrically activated explosive ordnance systems shall 

comply with the requirements of: 

a) SSD-CR-334 

b) AGC - SSD-CR-65-8180-150 

c) UTC - SSD-CR-4801-66-9 

Items procured prior to the effective date of this document are exempt from 

they "requirements of the following paragraphs: 

/1) 

/ 2) 

3.2.1.2 Cartridge Actuated Devices 

3.2.1.3 Detonation Transfer 

/ 3) 3. 2.4 Proof Pressure 

4) 3. 2. 5 Burst Pressure 

5) 4. 3. 2 Lot Sample Test Firing 

6) 4. 4 Verification Testing 

rTi T7) r; SPECIAL 

HArs,1DLIING 

L - 6007 

Copy 

Page