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operational environment, nor should it be interpreted that all of these example ground tests will be necessary to
validate a specific system.
Mechanical Systems and Components (Vehicle Structure, Pressurization, Propulsion System including
engine frame thrust points, Ground Support Equipment)
Types of Tests: Load, Vibration (dynamic and modal), Shock, Thermal, Acoustic, Hydro-static,
Pressure, Leak, Fatigue, X-ray, Center of Gravity, Mass Properties, Moment of Inertia, Static
Firing, Bruceton Ordnance, Balance, Test to Failure (simulating non-nominal flight conditions),
Non-Destructive Inspections
Electrical/Electronic Systems (Electrical, Guidance, Tracking, Telemetry and Command, Flight Safety
System (FSS), Ordnance, Flight Control and Recovery)
Types of Tests: Functional, Power/Frequency Deviation, Thermal Vacuum, Vibration, Shock,
Acceleration, X-ray, recovery under component failures, abort simulations, TDRSS integration
testing (up to and including pre-launch testing with flight vehicle)
Propulsion Systems (Propulsion, FSS, Ordnance, Flight Control)
Types of Tests: Simulation of nominal launch and abort sequences for engines (including restart,
if applicable), Orbital Maneuvering System (including restart for reentry-burn) and Attitude
Control System; Environmental testing (Thermal, Vibration, Shock, etc.)
Thermal Protection System
Types of Tests (for TPS and bonding material): Thermal, Vibration, Humidity, Vacuum, Shock
Aerodynamics (Structure, Thermal, Recovery)
Types of Tests: Wind Tunnel, Arc Jet, Drop Tests (Landing Systems)
Software (Electrical, Guidance, Tracking, Telemetry, Command, FSS, Ordnance, Flight Control and
Recovery)
Types of Tests: Functional, Fault Tolerance, Cycle Time, Simulation, Fault Response,
Independent Verification and Validation, Timing, Voting Protocol, Abort sequences (flight and
in-orbit) under non-nominal conditions with multiple system failures, Integrated Systems Tests
13.4.5 Flight Tests
If an applicant’s System Safety Plan includes a flight test program, then a considerable amount of
planning is needed to define the flight test program that will establish the performance capabilities of the
vehicle for routine and repetitive commercial operations. When flight testing is indicated, a flight test plan
will be needed to demonstrate that the vehicle’s proposed method of operations is acceptable and will not
be a hazard to the public health and safety, and safety of property.
The purpose of flight-testing is to verify the system performance, validate the design, identify system
deficiencies, and demonstrate safe operations. Experience repeatedly shows that while necessary and
important, analyses and ground tests cannot and do not uncover all potential safety issues associated with
new launch systems. Even in circumstances where all known/identified safety critical functions can be
FAA System Safety Handbook, Chapter 13: Launch Safety
December 30, 2000
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exercised and validated on the ground, there is still the remaining concern with unrecognized or unknown
interactions (“the unknown unknowns”).
The structure of the test program will identify the flight test framework and test objectives, establish the
duration and extent of testing; identify the vehicle’s critical systems, identify the data to be collected, and
detail planned responses to nominal and unsatisfactory test results.
Test flight information includes verification of stability, controllability, and the proper functioning of the
vehicle components throughout the planned sequence of events for the flight. All critical flight parameters
should be recorded during flight. A post-flight comparative analysis of predicted versus actual test flight
data is a crucial tool in validating safety critical performance. Below are examples of items from each test
flight that may be needed to verify the safety of a reusable launch vehicle. Listed with each item are
examples of what test-flight data should be monitored or recorded during the flight and assessed postflight:
Vehicle/stage launch phase: Stability and controllability during powered phase of flight.
· Vehicle stage individual rocket motor ignition timing, updates on propellant flow rates,
chamber temperature, chamber pressure, and burn duration, mixture ratio, thrust, specific
impulse (ISP)
· Vehicle stage trajectory data (vehicle position, velocity, altitudes and attitude rates, roll,
pitch, yaw attitudes)
· Vehicle stage Attitude, Guidance and Control system activities
· Functional performance of the Vehicle Health Monitoring System
· Functional performance of the Flight Safety System/Safe Abort System
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