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Discovery spent about 15 weeks in the processing facility undergoing about 22 modifications and routine testing. Shown are STS-39 primary payloads installed in Discovery's payload bay in the Orbiter Processing Facility (OPF). Payloads installed in the OPF include the Critical Ionization Velocity payload and the Chemical Release Observatory.
Several safety concerns have occurred during pyro operations at 30% or lower RH in the OPF area based on the increase of electrostatic discharge (ESD). These concerns targeted the safety of personnel, flight hardware, and ground support equipment (GSE). Two proposed methods considered to control ESDs during pyro operations at 30% or lower RH are the use of an ionizer blower and to increase the moisture content. In order to demonstrate that the ionizer is effective in neutralizing static charge, a series of experimental runs were conducted in the Electrostatics Laboratory located in the Operations & Checkout (O&C) Building at NASA Kennedy Space Center (KSC). The effectiveness of the ionizer blower was evaluated based upon the time lapse of a charged metal plate from initial 1000 to 400 volts. Distance, RH, and angle of attack were studied. A full factorial experiment (2(exp 3) = 8) was conducted. Since we did not have a statistical analysis program, such as SAS, available, calculations were done manually based on the method of ANOVA (Analysis of Variances), but R(exp 2) (fitness of curve) was not obtained. As conjectured, distance was found to be the major influencial variable. Therefore, we concluded that the best possible combination of situations would be to position the ionizer blower as close as possible and facing directly into the charged plate. This scenario resulted in the quickest discharge rate, which would be the most beneficial during pyro operations below 30% RH. The second method of increasing the moisture content in the work environment through a modification of the OPF ECS current configuration appeared to be dependent on budget constraints and currently not planned to be modified. Finally, some recommendations are discussed such as to test the ionizer in an actual field experiment with a mockup pyro connector and a technician with all the NASA KSC Safety-compliant PPE to assess the realistic effectiveness of the ionizer blower.
The goals of this research are to: 1) Assess the Theory of Flame Stretch by operating a unique flame-vortex experiment under microgravity conditions in the NASA Glenn 2.2 Second Drop Tower (drops to identify operating conditions have been completed); 2) Obtain high speed shadowgraph images (500-1000 frames/s) using the drop rig (images were obtained at one-g, and the NASA Kodak RO camera is being mounted on the drop rig); 3) Obtain shadowgraph and PIV images at 1-g while varying the effects of buoyancy by controlling the Froude number (completed); 4) Numerically model the inwardly-propagating spherical flame that is observed in the experiment using full chemistry and the RUN 1DL code (completed); 5) Send images of the flame shape to Dr. G. Patniak at NRL who is numerically simulating the entire flame-vortex interaction of the present experiment (data transfer completed); and 6) Assess the feasibility of obtaining PIV velocity field images in the drop rig, which would be useful (but not required) for our assessment of the Theory of Flame Stretch (PIV images were obtained at one-g using same low laser power that is available from fiber optic cable in drop tower). The motivation for the work is to obtain novel measurement needed to develop a physically accurate model of turbulent combustion that can help in the control of engine pollutants. The unique experiment allows, for the first time, the detailed study of a negatively-curved (negatively stretched) flame, which is one of the five fundamental types of premixed flames. While there have been studies of flat flames, positively-curved (outwardly-propagating) cases and positively-strained (counterflow) cases, this is the first detailed study of a negatively-curved (inwardly-propagating) flame. The first set of drops in the 2.2 Second Drop Tower showed that microgravity provides more favorable conditions for achieving inwardly-propagating flames (IPFs) than 1-g. A vortex interacts with a flame and creates a spherical pocket, which burns inwardly. Shadowgraphs at 1000 frames/sec quantify the Markstein number and flame speed. A Low-Laser Power PIV System was developed and is being added to the drop package. Numerical computations were required to explain why the Markstein numbers measured for the inwardly-propagating flames differ from those of outward propagating flames; this is an important research issue in the assessment of the Theory of Flame Stretch. The RUN-1DL code (developed by Prof. B. Rogg) was run for IPF and OPFs with complex methane and propane chemistry. Results confirmed that Ma for the IPFs are larger than for OPFs as was observed experimentally. Physical reasons for these new findings about the Theory of Flame Stretch are being determined from the experiments and the computations. Several journal papers have been published; the drop package is described in the AIAA Journal, while the one-g results appear in three other journal papers.
The PLB, its cargo, and payload canister must satisfy the cleanliness requirements of visual clean (VC) level 1, 2, 3, or special as stated in NASA document SN-C-0005A. The specific level of cleanliness is chosen by the payload bay customer for their mission. During orbiter turnaround processing at KSC, the payload bay is exposed to the environments of the Orbiter Processing Facility (OPF) and the Payload Changeout Room (PCR). In supportive response to the orbiter payload bay/facility interface, it is necessary that the facility environment be controlled and monitored to protect the cleanliness/environmental integrity of the payload bay and its cargo. Techniques used to meet environmental requirements during orbiter processing are introduced.
The 515-41B National Space Transportation Systems Program Mission Report contains a summary of the major activities and accomplishments of the sixth operational Shuttle flight and fourth flight of the OV-099 vehicle, Challenger. Since this flight was the first to land at Kennedy Space Center, the vehicle was towed directly to the OPF (Orbiter Processing Facility) where preparations for flight STS-41C, scheduled for early April 1984, began immediately. The significant problems that occurred during STS-41B are summarized and a problem tracking list that is a complete list of all problems that occurred during the flight is given. None of the problems will affect the STS 41C flight. The major objectives of flight STS-41B were to successfully deploy the Westar satellite and the Indonesian Communications Satellite-B2 (PALAPA-B2); to evaluate the MMU (Manned Maneuvering Unit) support for EVA (Extravehicular Activities); to exercise the MFR (Manipulator Foot Restraint); to demonstrate a closed loop rendezvous; and to operate the M.R (Monodisperse Latex Reactor), the ACES (Acoustic Containerless Experiment System) and the IEF (Isoelectric Focusing) in cabin experiments; and to obtain photographs with the Cinema 360 Cameras.
The Technology Information Sheet was assembled in database format during Phase I. This document was designed to provide a repository for information pertaining to 144 Operations and Maintenance Instructions (OMI) controlled operations in the Orbiter Processing Facility (OPF), Vehicle Assembly Building (VAB), and PAD. It provides a way to accumulate information about required crew sizes, operations task time duration (serial and/or parallel), special Ground Support Equipment (GSE). required, and identification of a potential application of existing technology or the need for the development of a new technolgoy item.
The goal of this research is to develop a viable NDE technique for the inspection of orbiter thermal protection system (TPS) tile bonds. Phase 2, discussed here, concentrated on developing an empirical understanding of the bonded and unbonded vibration signatures of acreage tiles. Controlled experiments in the laboratory have provided useful information on the dynamic response of TPS tiles. It has been shown that several signatures are common to all the pedigree tiles. This degree of consistency in the tile-SIP (strain isolation pad) dynamic response proves that an unbond can be detected for a known tile and establish the basis for extending the analysis capability to arbitrary tiles for which there are no historical data. The field tests of the noncontacting laser acoustic sensor system, conducted at the Kennedy Space Center (KSC), investigated the vibrational environment of the Orbiter Processing Facility (OPF) and its effect on the measurement and analysis techniques being developed. The data collected showed that for orbiter locations, such as the body flap and elevon, the data analysis scheme, and/or the sensor, will require modification to accommodate the ambient motion. Several methods were identified for accomplishing this, and a solution is seen as readily achievable. It was established that the tile response was similar to that observed in the laboratory. Of most importance, however, is that the field environment will not affect the physics of the dynamic response that is related to bond condition. All of this information is fundamental to any future design and development of a prototype system.
A general purpose scheduling system and its application to Space Shuttle Orbiter Processing at the Kennedy Space Center (KSC) are described. Orbiter processing entails all the inspection, testing, repair, and maintenance necessary to prepare the Shuttle for launch and takes place within the Orbiter Processing Facility (OPF) at KSC, the Vehicle Assembly Building (VAB), and on the launch pad. The problems are extremely combinatoric in that there are thousands of tasks, resources, and other temporal considerations that must be coordinated. Researchers are building a scheduling tool that they hope will be an integral part of automating the planning and scheduling process at KSC. The scheduling engine is domain independent and is also being applied to Space Shuttle cargo processing problems as well as wind tunnel scheduling problems.
On the STS-32 shuttle mission, a space flight experiment provided an understanding of the effects of the space environment on the Long Duration Exposure Facility (LDEF) from rendezvous with the shuttle until removal from the payload bay at the Orbiter Processing Facility (OPF) at KSC. The Interim Operational Contamination Monitor (IOCM) is an attached shuttle payload that has been used on two earlier flights (STS 51C and STS 28) to quantify the contamination deposited during the course of the mission. The IOCM can characterize by direct measurement, the deposition of molecular and particulate contamination during any phase of flight. In addition to these principal measurements, the IOCM actively measures the thermophysical properties of thermal control surfaces by calorimetry, the flux of the ambient atomic oxygen environment, the incident solar flux, and the absolute ambient pressure in the payload bay. The IOCM also provides a structure and sample holders for the exposure of passive material samples to the space environment, e.g. thermal cycling, atomic oxygen, and micrometeoroids and/or orbital debris, etc. One of the more salient results from the STS-32 flight suggests that the LDEF emitted a large number of particulates after berthing into the shuttle. The mission atomic oxygen fluence was also calculated. Although the fluence was low by normal standards, the Kapton passive samples exhibited the onset of erosion. Orbital debris and micrometeoroid impacts also occurred during the retrieval mission. The average perforation diameter was approximately 12.5 microns. The largest perforation diameter was measured at 65 microns.
Hypergolic fuels and oxidizer are emitted to the environment during fueling and deservicing shuttle and other spacecraft. Such emissions are difficult to measure due to the intermittent purge flow and to the presence of suspended scrubber liquor. A new method for emissions monitoring was introduced in a previous paper. This paper is a summary of the results of a one-year study of shuttle launch pads and orbiter processing facilities (OPF's) which proved that emissions can be determined from field scrubbers without direct measurement of vent flow rate and hypergol concentration. This new approach is based on the scrubber efficiency, which was measured during normal operations, and on the accumulated weight of hypergol captured in the scrubber liquor, which is part of the routine monitoring data of scrubber liquors. To validate this concept, three qualification tests were performed, logs were prepared for each of 16 hypergol scrubbers at KSC, the efficiencies of KSC scrubbers were measured during normal operations, and an estimate of the annual emissions was made based on the efficiencies and the propellant buildup data. The results have confirmed that the emissions from the KSC scrubbers can be monitored by measuring the buildup of hypergol propellant in the liquor, and then using the appropriate efficiency to calculate the emissions. There was good agreement between the calculated emissions based on outlet concentration and flow rate, and the emissions calculated from the propellant buildup and efficiency. The efficiencies of 12 KSC scrubbers, measured under actual servicing operations and special test conditions, were assumed to be valid for all subsequent operations until a significant change in hardware occurred. An estimate of the total emissions from 16 scrubbers for three years showed that 0.3 kg/yr of fuel and 234 kg/yr of oxidizer were emitted.
Hardware was developed to dilute vapor samples of purged hypergolic propellants (with air) into the range of existing instruments for detection of such toxic vapors. Since these detectors are normally used to monitor at the threshold limit value (TLV), most do not have quantitative capability at percent levels which relate to lower explosion limit (LEL) and fire hazards. For example, the upper limits of Energetic Sciences (ESI) 6000 series detectors used at KSC are 200 parts per million (ppm) for monomethyl hydrazine (MMH) and 500 ppm for nitrogen dioxide (NO2) arising from decomposition of nitrogen tetroxide (N2O4). Orbiter Processing Facility (OPF) personnel servicing Shuttle thrusters need to measure up to 250 ppm MMH and 7,500 ppm NO2 with portable, intrinsically safe instruments. Our objective was to quickly fabricate a sample diluter out of existing materials as a temporary measure while other parallel efforts were conducted to provide a commercial or in-house-developed instrument to detect high propellant levels. A 3 to 1 diluter would bring 500 ppm MMH into the range of the existing fuel ESI, and a 30 to 1 diluter would do the same for NO2. In this way, familiar equipment already available would be used, resulting in minimal paperwork, safety, and training impacts and low cost. An MMH vapor sample-diluter was constructed from a 1/4-inch Kynar tee, along with specially designed lengths of sample and dilution tubing. The sample line was 3 feet of Bev-A-Line 4, 1/4-inch tube leading to the straight run of the tee. The side run of the tee had a 17-inch length of Bev-A-Line 4, 1/4-inch tube, for nominal 3 to 1 dilution. A gas sample bag was prepared and assayed at 113 ppm ppm MMH, and diluted vapor samples were assayed at 39.5 ppm, or a measured dilution of 2.9 to 1. For NO2, a 316 stainless steel (SS) 1/8-inch tee with 49.5 inches of coiled, 1/8-inch outside diameter (OD) 316 SS tubing was used as the sampling end of the dilution system. The side run of the tee was open. The measured dilution ratio, based on the input value of 6,480 ppm NO2, and the average output value of 233 ppm, was 28 to 1. Thus, sample-diluters were successful in diluting concentrated hypergolic propellant vapors, both MMH and N2O4 into the ranges of existing TLV detectors.
Hardware was developed to dilute vapor samples of purged hypergolic propellants (with air) into the range of existing instruments for detection of such toxic vapors. Since these detectors are normally used to monitor at the threshold limit value (TLV), most do not have quantitative capability at percent levels which relate to lower explosion limit (LEL) and fire hazards. For example, the upper limits of Energetic Sciences (ESI) 6000 series detectors used at KSC are 200 parts per million (ppm) for monomethyl hydrazine (MMH) and 500 ppm for nitrogen dioxide (NO2) arising from decomposition of nitrogen tetroxide (N2O4). Orbiter Processing Facility (OPF) personnel servicing Shuttle thrusters need to measure up to 250 ppm MMH and 7500 ppm NO2 with portable, intrinsically safe instruments. Our objective was to quickly fabricate a sample diluter out of existing materials as a temporary measure while other parallel efforts were conducted to provide a commercial or in-house-developed instrument to detect high propellant levels. A 3 to 1 diluter would bring 500 ppm MMH into the range of the existing fuel ESI, and a 30 to 1 diluter would do the same for NO2. In this way, familiar equipment already available would be used, resulting in minimal paperwork, safety, and training impacts and low cost. An MMH vapor sample-diluter was constructed from a 1/4-inch Kynar tee, along with specially designed lengths of sample and dilution tubing. The sample line was 3 feet of Bev-A-Line 4, 1/4 inch tube leading to the straight run of the tee. The side run of the tee had a 17-inch length of Bev-A-Line 4, 1/4-inch tube, for nominal 3 to 1 dilution. A gas sample bag was prepared and assayed at 113 ppm MMH, and diluted vapor sarnples were assayed at 39.5 ppm, or a measured dilution of 2.9 to 1. For NO2, a 316 stainless steel (SS) 1/8-inch tee with 49.5 inches of coiled, 1/8-inch outside diameter (OD) 316 SS tubing was used as the sarnpling end of the dilution system. The side run of the tee was open. The measured dilution ratio, based on the input value of 6,480 ppm NO2 and the average output value of 233 ppm, was 28 to 1. Thus, sample-diluters were successful in diluting concentrated hypergolic propellant vapors, both MMH and N2O4, into the ranges of existing TLV detectors.
In order to characterize the behavior of tunable diode lasers (TDL), the first step in the project involved the redesign of the TDL system here at the University of Tennessee Molecular Systems Laboratory (UTMSL). Having made these changes it was next necessary to optimize the new optical system. This involved the fine adjustments to the optical components, particularly in the monochromator, to minimize the aberrations of coma and astigmatism and to assure that the energy from the beam is focused properly on the detector element. The next step involved the taking of preliminary data. We were then ready for the analysis of the preliminary data. This required the development of computer programs that use mathematical techniques to look for signatures of chaos. Commercial programs were also employed. We discovered some indication of high dimensional chaos, but were hampered by the low sample rate of 200 KSPS (kilosamples/sec) and even more by our sample size of 1024 (1K) data points. These limitations were expected and we added a high speed data acquisition board. We incorporated into the system a computer with a 40 MSPS (million samples/sec) data acquisition board. This board can also capture 64K of data points so that were then able to perform the more accurate tests for chaos. The results were dramatic and compelling, we had demonstrated that the lead salt diode laser had a chaotic frequency output. Having identified the chaotic character in our TDL data, we proceeded to stage two as outlined in our original proposal. This required the use of an Occasional Proportional Feedback (OPF) controller to facilitate the control and stabilization of the TDL system output. The controller was designed and fabricated at GSFC and debugged in our laboratories. After some trial and error efforts, we achieved chaos control of the frequency emissions of the laser. The two publications appended to this introduction detail the entire project and its results.
This NASA Kennedy Space Center two-part video release is comprised of footage covering STS-26 launch preparations from the arrival of the Tracking and Data Relay Satellite (TDRS) at the Orbiter Processing Facility (OPF) to the lift and mate of the external tanks. The STS-26 flight crew include: Frederick H. (Rick) Hauck, mission commander; Richard O. Covey, pilot; John M. (Mike) Lounge, mission specialist; David C. Hilmers, mission specialist; and George D. (Pinky) Nelson, mission specialist. The primary payload of STS-26 is the TDRS while the secondary payloads include the Physical Vapor Transport of Organic Solids (PVTOS); Protein Crystal Growth (PCG); Infrared Communications Flight Experiment (IRCFE); Aggregation of Red Blood Cells (ARC); Isoelectric Focusing Experiment (IFE); Mesoscale Lightning Experiment (MLE); Phase Partitioning Experiment (PPE); Earth-Limb Radiance Experiment (ELRAD); Automated Directional Solidification Furnace (ADSF) and two Shuttle Student Involvement Program (SSIP) experiments. Launch preparation footage includes flight crew arrival at KSC, rollout of Discovery to Pad B, OV-103 Discovery power-up, main engine unpacking and installation, solid rocket boosters' arrival prep and stacking, and aft skirt to aft segment mating.
Preparations for launch of STS-26 are shown. They include: (1) VAB to OPF high bay rollover; (2) Main engine unpacking and installation; (3) OMS pod installation; (4) Crew hatch removal; (5) Modified crew hatch installation; (6) Nose cap installation; (7) 17 inch disconnect work; (8) Ku-band antenna stow and deploy; (9) Tile work; (10) Oasis payload installation; (11) Solid rocket boosters arrival, preps and stacking; (13) Modified SRB segments: Arrival via train at KSC RPSF; (14) AFT segment rotation to vertical in RPSF; (15) AFT skirt to AFT segment mating; (16) SRB grain inspection; (17) Lift AFT segment; and (18) Lift and mate external tank.
Live footage shows the rollback of STS-39 to the VAB (Vehicle Assembly Building), the rollback of Discovery to the OPF (Orbiter Processing Facility) High Bay 2, Discovery ET Disconnect Door Hinges (Cracks), Discovery ET Disconnect Door Hinges (Edited) and Discovery in the VAB.
Live footage shows preparation for the Astro-1 mission. Scenes include Payload Bay door closing, Rollover to the Vehicle Assembly Building (VAB) from OPF, the STS-35/Astro rollout to Pad-A, Broad Band X-Ray Telescope (BBXRT) Servicing, and crew arrival for the Terminal Countdown Demonstration Tests (TCDT). The crewmembers of STS-35, Commander Vance D. Brand, Pilot Guy S. Gardner, and Mission Specialists Jeffrey A. Hoffman, John M. Lounge, Robert A. Parker, Samuel T. Durrance, and Ronald A. Parise, are shown participating in various training activities. Activities include driving the M113 vehicle, participating in emergency training, and addressing the press upon arrival at Kennedy Space Center.
During processing work on the orbiter Discovery at Pad A, significant cracks were found on all four lug hinges on the two external tank umbilical door drive mechanisms. NASA managers opted to roll back the vehicle to the Vehicle Assembly Building (VAB) on March 7, and then to the Orbiter Processing Facility (OPF) for repair. Hinges were replaced with units taken from orbiter COLUMBIA, and reinforced. Discovery returned to the pad on April 1. Shown are the cracked orbiter umbilical door hinges.