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Testing is normally conducted to verify performance, i.e. verify that the system meets
design requirements. The data from these tests can also be used for safety purposes.
Examples include, determination of part failure rates which can be used to predict the
probability of failure; testing the strength or compatibility of new materials which can be
used to identify possible hazards; determination of interface problems between integrated
assemblies which can also define hazards; and quality control tests performed by vendors
of subcontractors. Tests performed for purposes other than safety can generate data
useful to the safety process only if the proper data is collected and documented. It is the
job of safety engineering to clearly define the safety program objectives so that test
planners will be aware of the data which will be useful to safety.
11.4 Test Safety Analysis
It is also important to consider the safety of the test itself. Safety engineers need to work
closely with test planners to ensure that the proper precautions are observed during the
testing to prevent personnel injury or equipment damage. Each proposed test needs to be
analyzed by safety personnel to identify hazards inherent in the test and to ensure that
hazard control measures are incorporated into test procedures. It is during the process of
test safety analysis that safety personnel have an opportunity to identify other data that
may be useful to safety and can be produced by the test with little or no additional cost or
schedule impact.
FAA System Safety Handbook, Chapter 11: T&E Safety
December 30, 2000
11 -3
11.4.1 Test And Evaluation Safety Tasks
A comprehensive test and evaluation safety program will involve the following activities:
·  Coordinate with test planning to determine testing milestones in order to
ensure that safety activities are completed in time to support testing.
·  Schedule safety analysis, evaluation and approval of test plans and other
documents to ensure that safety is covered during all testing.
·  Prepare safety inputs to operating and test procedures.
·  Analyze test equipment, installation of test equipment and instrumentation
prior to the start of testing.
·  Identify any hazards unique to the test environment.
·  Identify hazard control measures for hazards of testing.
·  Identify test data that will be of use to safety.
·  Review test documentation to ensure incorporation of safety requirements,
warnings, and cautions.
·  Review test results to determine if safety goals have been met or if any new
hazards have been introduced by the test conditions.
·  Collect data on the effectiveness of operating procedures and any safety
components or controls of the system.
·  Compile safety-related test data.
·  Make a determination about the safety of the system. Determine if the safety
features have been controlled as expected and if identified hazards have been
controlled to an acceptable level of risk.
·  Evaluate compatibility with existing or planned systems or equipment.
·  Identify deficiencies and needs for modifications.
·  Evaluate lessons-learned from previous tests of new or modified systems or
tests of comparable systems to identify possible hazards or restrictions on test
conditions.
·  Document and track all identified hazards to ensure resolution.
FAA System Safety Handbook, Chapter 11: T&E Safety
December 30, 2000
11 -4
11.4.2 Test And Evaluation Safety Results
A comprehensive test and evaluation safety program will produce the following products:
·  Hazard analysis reports.
·  Test safety analysis reports.
·  Hazard tracking and risk resolution system.
·  Safety analysis schedules.
·  List of identified hazards.
·  List of hazard control measures.
·  List of required safety data.
·  List of warnings and cautions.
·  Reports of procedure and test plan reviews.
·  Safety inputs to test planning reviews.
·  Safety inputs to training materials.
·  Safety inputs to operations manuals.
11.5 Other Test And Evaluation Safety Considerations
11.5.1 A system whose safe operation depends upon trained personnel
should not be tested without appropriately trained personnel.
The test personnel should undergo a training program consistent with the anticipated
operator training program. Testing a system in the operational environment using design
　
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