Constant Rate Production: DOE Approach to Meeting NASA Needs for RPS for Nuclear-Enabled Launches.
The use of radioisotope power systems (RPS) for nuclear-enabled NASA missions is a long-standing arrangement between DOE and NASA. The requirements for the power system come from NASA, while DOE performs the procurement, fueling, testing and delivery. Recent examples include Mars Science Laboratory and New Horizons. A challenge has been interplay between the schedule for RPS availability from DOE versus the schedule NASA has for competitively selected missions. By mutual agreement, the actual operations to procure an RPS and prepare it for fueling, has always waited until the final selection of a mission. This timeline for a New Frontiers class mission leaves approximately 5-6 years from the time of final mission selection to the actual launch date. The number of RPS used for a Frontier class mission can be 1 to 3 units, i.e., the recent New Frontiers-2025 announcement of opportunity published in December 2016. If 1 or 2 units are needed for a specific mission, the timeline from the decision point to the launch date is a challenge, but doable. The activities taking place in this timeframe would include manufacturing the power system, producing the fuel, and performing the assembly/testing and delivery operations. If the mission selected requires 3 RPS the logistics of accomplishing all activities during the 5-6 years is problematic. The challenge involves appropriate resourcing for plutonium production, heat source production and assembly/testing operations. Typically, the time between RPS-enabled missions involve staffing attrition and reduction at the heat source production and the assembly/testing facilities that can be down to 60-75 percent of peak staffing levels to reduce costs. The duration for increasing staffing in these areas, which includes hiring, nuclear workforce training and obtaining the appropriate security clearance is 2 years. Taking account for this 2 years and the 6 months prior to launch arrival of the RPS at Kennedy Space Center erodes too much of the 5-6 years to comfortably support the use of 3 RPS on a mission and doesn't leave much schedule margin for a 2 RPS unit mission. To provide better support for NASA nuclear-enabled missions a different approach was devised, constant rate production. This involves a higher level of base capability at Los Alamos National Laboratory (LANL), Idaho National Laboratory (INL) and Oak Ridge National Laboratory (ORNL) to provide a stabilized work force. This will enable 10-15 heat sources to be produced annually at LANL, and subsequently shipped to the INL to be placed into a stable intermediate form that enables storage for up to several years that leads to quick production of general purpose heat source modules when a mission is selected. The up-front production of Pu-238 at ORNL is maintained so that there is material constantly in the pipeline. Production of key specialized components at ORNL is also maintained using this model. This allows for a reduction of risk to the nuclear-enabled missions, yet always having quantities of hardware available “on the shelf” to support production of RPS for NASA.