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NASA NTRS2008

The Summer of Hydrogen

Ground crew veterans at Kennedy Space Center still talk about what they call "the summer of hydrogen"-the long, frustrating months in 1990 when the shuttle fleet was grounded by an elusive hydrogen leak that foiled our efforts to fill the orbiter's external fuel tank. Columbia (STS-35) was on Launch Pad A for a scheduled May 30 launch when we discovered the hydrogen leak during - tanking. The external fuel tank is loaded through the orbiter. Liquid hydrogen flows through a 17-inch umbilical between the orbiter and the tank. During fueling, we purge the aft fuselage with gaseous nitrogen to reduce the risk of fire, and we have a leak-detection system in the mobile launch platform, which samples (via tygon tubing) the atmosphere in and around the vehicle, drawing it down to a mass spectrometer that analyzes its composition. When we progressed to the stage of tanking where liquid hydrogen flows through the vehicle, the concentration of hydrogen approached four percent-the limit above which it would be dangerously flammable. We had a leak. We did everything we could think of to find it, and the contractor who supplied the flight hardware was there every day, working alongside us. We did tanking tests, which involved instrumenting the suspected leak sources, and cryo-loaded the external tank to try to isolate precisely where the leak originated. We switched out umbilicals; we replaced the seals between the umbilical and the orbiter. We inspected the seals microscopically and found no flaws. We replaced the recirculation pumps, and we found and replaced a damaged teflon seal in a main propulsion system detent cover, which holds the prevalve-the main valve supplying hydrogen to Space Shuttle Main Engine 3 -in the open position. The seal passed leak tests at ambient temperature but leaked when cryogenic temperatures were applied. We added new leak sensors-up to twenty at a time and tried to be methodical in our placements to narrow down the possible sources of the problem. We even switched orbiters, sending Columbia back to the Vehicle Assembly Building and bringing out Atlantis, scheduled to fly as STS-38. Two shuttles on their mobile launchers passing in the night was a majestic sight, but not one you want to see if you're trying to get an orbiter launched. None of this told us where the leak was, or if we were dealing with more than one leak source.

Weber, Philip↗
NASA NTRS2008

The Astronaut Glove Challenge: Big Innovation from a (Very) Small Team

Many measurements were taken by test engineers from Hamilton Sundstrand, the prime contractor for the current EVA suit. Because the raw measurements needed to be converted to torques and combined into a final score, it was impossible to keep track of who was ahead in this phase. The final comfort and dexterity test was performed in a depressurized glove box to simulate real on-orbit conditions. Each competitor was required to exercise the glove through a defined set of finger, thumb, and wrist motions without any sign of abrasion or bruising of the competitor's hand. I learned a lot about arm fatigue! This was a pass-fail event, and both of the remaining competitors came through intact. After taking what seemed like an eternity to tally the final scores, the judges announced that I had won the competition. My glove was the only one to have achieved lower finger-bending torques than the Phase VI glove. Looking back, I see three sources of the success of this project that I believe also operate in other programs where small teams have broken new ground in aerospace technologies. These are awareness, failure, and trust. By remaining aware of the big picture, continuously asking myself, "Am I converging on a solution?" and "Am I converging fast enough?" I was able to see that my original design was not going to succeed, leading to the decision to start over. I was also aware that, had I lingered over this choice or taken time to analyze it, I would not have been ready on the first day of competition. Failure forced me to look outside conventional thinking and opened the door to innovation. Choosing to make incremental failures enabled me to rapidly climb the learning curve. Trusting my "gut" feelings-which are really an internalized accumulation of experiences-and my newly acquired skills allowed me to devise new technologies rapidly and complete both gloves just in time. Awareness, failure, and trust are intertwined: failure provides experiences that inform awareness and provide decision-making opportunities that build trust among team members and managers while opening minds to new pathways for development. All three are necessary for teams-large or small-to achieve big innovation.

Homer, Peter↗
NASA NTRS2008

Achieving Workplace Health through Application of Wellness Strategies

Purpose: 1) Understand and measure JSC workplace health: a) levels, sources, indicators & effects of negative, work-related stress; b) define leading indicators of emerging issues. 2 Provide linkage to outcomes: a) Focus application of wellness strategies & HR tools; b) Increase quality of work life and productivity. 3) Current effort will result in: a) Online assessment tool; b) Assessment of total JSC population (civil service & contractors); c) Application of mitigation tools and strategies. 4) Product of the JSC Employee Wellness Program. 5) Collaboration with Corporate Health Improvement Program/University of Arizona.

Robinson, Judith L.↗
NASA NTRS2008

Future Aeronautical Communication Infrastructure Technology Investigation

This National Aeronautics and Space Administration (NASA) Contractor Report summarizes and documents the work performed to investigate technologies that could support long-term aeronautical mobile communications operating concepts for air traffic management (ATM) in the timeframe of 2020 and beyond, and includes the associated findings and recommendations made by ITT Corporation and NASA Glenn Research Center to the Federal Aviation Administration (FAA). The work was completed as the final phase of a multiyear NASA contract in support of the Future Communication Study (FCS), a cooperative research and development program of the United States FAA, NASA, and EUROCONTROL. This final report focuses on an assessment of final five candidate technologies, and also provides an overview of the entire technology assessment process, including final recommendations.

Gilbert, Tricia↗
NASA NTRS2008

On the Application of a Response Surface Technique to Analyze Roll-over Stability of Capsules with Airbags Using LS-Dyna

As NASA moves towards developing technologies needed to implement its new Exploration program, studies conducted for Apollo in the 1960's to understand the rollover stability of capsules landing are being revisited. Although rigid body kinematics analyses of the roll-over behavior of capsules on impact provided critical insight to the Apollo problem, extensive ground test programs were also used. For the new Orion spacecraft being developed to implement today's Exploration program, new air-bag designs have improved sufficiently for NASA to consider their use to mitigate landing loads to ensure crew safety and to enable re-usability of the capsule. Simple kinematics models provide only limited understanding of the behavior of these air bag systems, and more sophisticated tools must be used. In particular, NASA and its contractors are using the LS-Dyna nonlinear simulation code for impact response predictions of the full Orion vehicle with air bags by leveraging the extensive air bag prediction work previously done by the automotive industry. However, even in today's computational environment, these analyses are still high-dimensional, time consuming, and computationally intensive. To alleviate the computational burden, this paper presents an approach that uses deterministic sampling techniques and an adaptive response surface method to not only use existing LS-Dyna solutions but also to interpolate from LS-Dyna solutions to predict the stability boundaries for a capsule on airbags. Results for the stability boundary in terms of impact velocities, capsule attitude, impact plane orientation, and impact surface friction are discussed.

Horta, Lucas G.↗
NASA NTRS2008

A Computational Approach for Model Update of an LS-DYNA Energy Absorbing Cell

NASA and its contractors are working on structural concepts for absorbing impact energy of aerospace vehicles. Recently, concepts in the form of multi-cell honeycomb-like structures designed to crush under load have been investigated for both space and aeronautics applications. Efforts to understand these concepts are progressing from tests of individual cells to tests of systems with hundreds of cells. Because of fabrication irregularities, geometry irregularities, and material properties uncertainties, the problem of reconciling analytical models, in particular LS-DYNA models, with experimental data is a challenge. A first look at the correlation results between single cell load/deflection data with LS-DYNA predictions showed problems which prompted additional work in this area. This paper describes a computational approach that uses analysis of variance, deterministic sampling techniques, response surface modeling, and genetic optimization to reconcile test with analysis results. Analysis of variance provides a screening technique for selection of critical parameters used when reconciling test with analysis. In this study, complete ignorance of the parameter distribution is assumed and, therefore, the value of any parameter within the range that is computed using the optimization procedure is considered to be equally likely. Mean values from tests are matched against LS-DYNA solutions by minimizing the square error using a genetic optimization. The paper presents the computational methodology along with results obtained using this approach.

Horta, Lucas G.↗
NASA NTRS2008

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗
NASA NTRS2008

NASA and Superalloys: A Customer, a Participant, and a Referee

NASA has had a long history of research and development in the field of superalloys. These efforts have continued today, where the latest advancements in turbine disk and blade technologies are being developed Although NASA does support military flight systems, it s predominant role is in supporting civilian air transportation systems, and thus has goals for improving fuel efficiency, emissions, noise, and safety of today s aircraft. NASA has traditionally served several distinct but complimentary roles as participants in multi-disciplinary research teams, as customers who fund research and development efforts at industry and universities, and as referees who can address broad issues that affect the entire aeronautics community. Because of our longer range viewpoint, we can take on higher risk, higher reward research topics. NASA can also serve as an intermediary between the basic research performed primarily at universities and the development efforts emphasized by industry. By interacting with individual companies, NASA can identify areas of general interest and problems common to a large portion of the aeronautics community, and devise programs aimed at solving these problems. In space missions, NASA is a direct customer responsible for developing vehicles. In the case of the Space Shuttle, NASA has worked with various contractors to design and build numerous components out of superalloys. Another fascinating area for the use of superalloys is in power systems for long life applications in space. Potential missions include providing electric power for deep space missions, surface rovers, including lunar and Mars, and stationary power generators on the lunar surface.

Nathal, Michael V.↗
NASA NTRS2008

The Ares Project: Building an Exploration Culture from the Inside Up

NASA is building its first new human-rated space exploration vehicles in nearly 40 years. This marks an important operational and cultural change from the Space Shuttle. In the wake of the Columbia disaster, the agency and the nation realized that NASA's goals and culture needed to change. The Ares Project, which is building the launch vehicles that will power human beings to the Moon, Mars, and beyond, is taking a page from the Saturn playbook by having NASA lead both the overall integration and the development of the Ares I upper stage. Ares is also creating a new culture of cooperation, openness, and informed risk taking as we set our sights on other worlds. Ares has established a team environment where issues can be discussed, information is shared, fun and teamwork are encouraged, and constructive conflict and accountability are expected. Following a "One NASA" philosophy, Ares is taking steps to strengthen cooperation among space centers, contractor partners, engineering and scientific communities, and headquarters personnel. As we learn lessons from things that went wrong with the Space Shuttle, we are also borrowing best practices from what has gone right with that program and others. All of these cultural elements will be necessary as we take the next steps beyond Earth orbit.

Cook, Stephan A.↗
NASA NTRS2008

Application of Pi Preform Composite Joints in Fabrication of NASA Composite Crew Module Demonstration Structure

This paper will describe unique and extensive use of pre-woven and impregnated pi cross-sections in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a) To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This paper will focus on the design and fabrication issues supporting selection of the Lockheed Martin patented Pi pre-form to provide sound composite joints a numerous locations in the structure. This abstract is based on Preliminary Design data. The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date.

Higgins, John E.↗
NASA NTRS2008

NASA and Superalloys: A Customer, a Participant, and a Referee

NASA has had a long history of research and development in the field of superalloys. These efforts have continued today, where the latest advancements in turbine disk and blade technologies are being developed. Although NASA does support military flight systems, its predominant role is in supporting civilian air transportation systems, and thus has goals for improving fuel efficiency, emissions, noise, and safety of today s aircraft. NASA has traditionally served several distinct but complimentary roles as participants in multi-disciplinary research teams, as customers who fund research and development efforts at industry and universities, and as referees who can address broad issues that affect the entire aeronautics community. Because of our longer range viewpoint, we can take on higher risk, higher reward research topics. NASA can also serve as an intermediary between the basic research performed primarily at universities and the development efforts emphasized by industry. By interacting with individual companies, NASA can identify areas of general interest and problems common to a large portion of the aeronautics community, and devise programs aimed at solving these problems. In space missions, NASA is a direct customer responsible for developing vehicles. In the case of the Space Shuttle, NASA has worked with various contractors to design and build numerous components out of superalloys. Another fascinating area for the use of superalloys is in power systems for long life applications in space. Potential missions include providing electric power for deep space missions, surface rovers, including lunar and Mars, and stationary power generators on the lunar surface.

Nathal, Michael V.↗
NASA NTRS2006

Incorporating Research Findings into Standards and Requirements for Space Medicine

The Vision for Exploration has been the catalyst for NASA to refocus its life sciences research. In the future, life sciences research funded by NASA will be focused on answering questions that directly impact setting physiological standards and developing effective countermeasures to the undesirable physiological and psychological effects of spaceflight for maintaining the health of the human system. This, in turn, will contribute to the success of exploration class missions. We will show how research will impact setting physiologic standards, such as exposure limits, outcome limits, and accepted performance ranges. We will give examples of how a physiologic standard can eventually be translated into an operational requirement, then a functional requirement, and eventually spaceflight hardware or procedures. This knowledge will be important to the space medicine community as well as to vehicle contractors who, for the first time, must now consider the human system in developing and constructing a vehicle that can achieve the goal of success.

Duncan, J. Michael↗
NASA NTRS2005

Primary Disaster Field Office (DFO), Lufkin, Texas

On February 1, 2003, the Space Shuttle Columbia broke apart during atmospheric re-entry on mission STS-107; the complexity of such an event cannot be underestimated. The Lufkin Disaster Field Office (DFO) served as the primary DFO for all operations, including staging assets and deploying field teams for search, recovery and security. There were many organizations that had operational experience with disaster recovery. Offers to help came from many groups including the White House Liaison Office, the Department of Defense (DOD), branches of local, state and federal government, the Federal Bureau of Investigation (FBI), the Federal Emergency Management Agency (FEMA), the Environmental Protection Agency (EPA), state police, fire departments, the Texas Forestry Service, the Texas Army National Guard, medical groups, various rescue forces, contractor companies, the Salvation Army, local businesses, and citizens of our country and especially East Texas. The challenge was to know how much help to accept and how to efficiently incorporate their valuable assistance into a comprehensive and cohesive operational plan. There were more than 2,000 people involved with search and recovery.

Wetherbee, James D.↗
NASA NTRS2008

The Ares Projects Office: Building an Exploration Culture from the Inside Up

NASA is building its first new human-rated space exploration vehicles in nearly 40 years. This marks an important operational and cultural change from the Space Shuttle. In the wake of the Columbia disaster, the agency and the nation realized that NASA's goals and culture needed to change. The Ares Projects Office (APO), which is building the launch vehicles that will power human beings to the Moon, Mars, and beyond, is taking a page from the Saturn playbook by having NASA lead both the overall integration and the development of the Ares I upper stage. APO is also creating a new culture of cooperation, openness, and informed risk taking as we set our sights on other worlds. APO has established a team environment where issues can be discussed, information is shared, fun and teamwork are encouraged, and constructive conflict and accountability are expected. Following a "One NASA" philosophy, APO is taking steps to strengthen cooperation among space centers, contractor partners, engineering and scientific communities, and headquarters personnel. As we learn lessons from things that Went wrong with the Space Shuttle, we are also borrowing best practices from what has gone right with that program and others. All of these cultural elements will be necessary as we take the next steps beyond Earth orbit.

Leahy, Bartholomew↗
NASA NTRS2007

CompactPCI(Registered TradeMark) Connectors in Space Flight Applications

This report documents the current status of CompactPCI(Registered TradeMark) connectors in GSFC spaceflight applications. To the extent the information is known, this report summarizes to what component quality level each NASA contractor (referred to as OEM in this report) procured the parts, and what board level and system level testing was performed. The report also provides the current status of the reliability assessment for each GSFC project based on the results of testing and FMEA (Failure Mode Effects Analysis). This report addresses how the CompactPCI(Registered TradeMark) connectors came into existence, and how these became the connector style chosen by many designers of space flight hardware. It identifies the design philosophy and the lack of robustness which has led to several known failure modes. These failure modes include fretting of connector pins during vibration, shock and thermal cycling, exposure of underplating, and increased resistance, including brief excursions to very high resistance. Each of these are signs of aging, which becomes an increasing concern for long duration orbiting space flight applications. This report addresses the mitigation strategy to replace CompactPCI(Registered TradeMark) connectors with space qualified Hypertronics 2mm cPCI connectors. The Hypertronics 2mm cPCI connectors are pin-to-pin compatible with the CompactPCI(Registered TradeMark) connectors and meet all of the same technical requirements, except the ability to hot mate, and to mate directly with a CompactPCI of the opposite gender. A detailed comparison of the CompactPCI(Registered TradeMark) connector and the Hypertronics 2mm cPCI connector is provided to describe the ruggedness of Hypertronics connector for space flight applications. Finally, this report makes recommendations for flight hardware for the future missions where the hardware is yet to be built, as well as for the hardware which has already been built with CompactPCI(Registered TradeMark) connectors.

Williams, Richard↗
NASA NTRS2008

GRC Supporting Technology for NASA's Advanced Stirling Radioisotope Generator (ASRG)

From 1999 to 2006, the NASA Glenn Research Center (GRC) supported a NASA project to develop a high-efficiency, nominal 110-We Stirling Radioisotope Generator (SRG110) for potential use on NASA missions. Lockheed Martin was selected as the System Integration Contractor for the SRG110, under contract to the Department of Energy (DOE). The potential applications included deep space missions, and Mars rovers. The project was redirected in 2006 to make use of the Advanced Stirling Convertor (ASC) that was being developed by Sunpower, Inc. under contract to GRC, which would reduce the mass of the generator and increase the power output. This change would approximately double the specific power and result in the Advanced Stirling Radioisotope Generator (ASRG). The SRG110 supporting technology effort at GRC was replanned to support the integration of the Sunpower convertor and the ASRG. This paper describes the ASRG supporting technology effort at GRC and provides details of the contributions in some of the key areas. The GRC tasks include convertor extended-operation testing in air and in thermal vacuum environments, heater head life assessment, materials studies, permanent magnet characterization and aging tests, structural dynamics testing, electromagnetic interference and electromagnetic compatibility characterization, evaluation of organic materials, reliability studies, and analysis to support controller development.

Schreiber, Jeffrey G.↗
NASA NTRS2008

Microfabrication of a Segmented-Involute-Foil Regenerator, Testing in a Sunpower Stirling Convertor and Supporting Modeling and Analysis

Under Phase II of a NASA Research Award contract, a prototype nickel segmented-involute-foil regenerator was microfabricated via LiGA and tested in the NASA/Sunpower oscillating-flow test rig. The resulting figure-of-merit was about twice that of the approx.90% porosity random-fiber material currently used in the small 50-100 W Stirling engines recently manufactured for NASA. That work was reported at the 2007 International Energy Conversion Engineering Conference in St. Louis, was also published as a NASA report, NASA/TM-2007-2149731, and has been more completely described in a recent NASA Contractor Report, NASA/CR-2007-2150062. Under a scaled-back version of the original Phase III plan, a new nickel segmentedinvolute- foil regenerator was microfabricated and has been tested in a Sunpower Frequency-Test-Bed (FTB) Stirling convertor. Testing in the FTB convertor produced about the same efficiency as testing with the original random-fiber regenerator. But the high thermal conductivity of the prototype nickel regenerator was responsible for a significant performance degradation. An efficiency improvement (by a 1.04 factor, according to computer predictions) could have been achieved if the regenerator been made from a low-conductivity material. Also the FTB convertor was not reoptimized to take full advantage of the microfabricated regenerator's low flow resistance; thus the efficiency would likely have been even higher had the FTB been completely reoptimized. This report discusses the regenerator microfabrication process, testing of the regenerator in the Stirling FTB convertor, and the supporting analysis. Results of the pre-test computational fluid dynamics (CFD) modeling of the effects of the regenerator-test-configuration diffusers (located at each end of the regenerator) is included. The report also includes recommendations for accomplishing further development of involute-foil regenerators from a higher-temperature material than nickel.

Ibrahim, Mounir B.↗
NASA NTRS2009

Design Evolution and Verification of the A-3 Chemical Steam Generator

Following is an overview of the Chemical Steam Generator system selected to provide vacuum conditions for a new altitude test facility, the A-3 Test Stand at Stennis Space Center (SSC) in Bay St. Louis, MS. A-3 will serve as NASA s primary facility for altitude testing of the J-2X rocket engine, to be used as the primary propulsion device for the upper stages of the Ares launch vehicles. The Chemical Steam Generators (CSGs) will produce vacuum conditions in the test cell through the production and subsequent supersonic ejection of steam into a diffuser downstream of the J-2X engine nozzle exit. The Chemical Steam Generators chosen have a rich heritage of operation at rocket engine altitude test facilities since the days of the Apollo program and are still in use at NASA White Sands Test Facility (WSTF) in New Mexico. The generators at WSTF have been modified to a degree, but are still very close to the heritage design. The intent for the A-3 implementation is to maintain this heritage design as much as possible, making minimal updates only where necessary to substitute for obsolete parts and to increase reliability. Reliability improvements are especially desired because the proposed system will require 27 generators, which is nine times the largest system installed in the 1960s. Improvements were suggested by the original design firm, Reaction Motors, by NASA SSC and NASA WSTF engineers, and by the A-3 test stand design contractor, Jacobs Technology, Inc. (JTI). This paper describes the range of improvements made to the design to date, starting with the heritage generator and the minor modifications made over time at WSTF, to the modernized configuration which will be used at A-3. The paper will discuss NASA s investment in modifications to SSC s E-2 test facility fire a full-scale Chemical Steam Generator in advance of the larger steam system installation at A-3. Risk mitigation testing will be performed in early 2009 at this test facility to verify that the CSGs operate as expected. The generator which will undergo this testing is of the most recent A-3 configuration, and will be instrumented far in excess of what is normally required for operation. The extra data will allow for easier troubleshooting and more complete knowledge of expected generator performance. In addition, the early testing will give SSC personnel experience in operating the CSG systems, which will expedite the process of installation and activation at A-3. Each Chemical Steam Generator is supported by a complement of valves, instruments, and flow control devices, with the entire assembly called a "module." The generators will be installed in groups of three, historically called "units". A module is so called because of its modular ability to be replaced or serviced without disturbing the other two modules installed on the same unit. A module is pictured in Figure 1, shown with its generator secured by white bands in its shipping (vs. installed) configuration. The heritage system at WSTF is composed of a single unit (three generator modules), pictured in Figure 2 as it was installed in 1965. In contrast, A-3 will have nine units operating in parallel to achieve vacuum conditions appropriate for testing the J-2X engine. Each of the combustors operates in two modes and achieves the so-called "full-steam" mode after all three of its stages ignite. Ignition of the first stage is achieved by exciting a spark plug; the second stage and main stage are lit by the flame front of the previous stage. The main stage burns approximately 97% of the total propellant flow and uses the heat energy to vaporize water into superheated steam. While the main stage remains unlit, the combustor is in so-called "idle" mode. In the WSTF system, this idle mode is not optimized for water usage, and does not need to be, as the water is pumped from a large reservoir. The water supply at A-3 will be contained in tanks with finite volume, so water optimization is preferred for the modnized configuration. Multiple solutions for this issue have been proposed, with the leading concept being a change to the operational definition of "idle mode," with the generator running in a lower heat flux condition.

Kirchner, Casey K.↗