4 KSC Motor Integration

7/29/2019 4 KSC Motor Integration

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Motor Integration Team

Presented by:

KSC MotorIntegration


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Motor Integration at KSC and CCAFS


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Russ Bakes

Integration ProgramManager

SteveSchmieder

IntegrationSub-systemManager

Paul Teehan

MSFC ResidentOffice

Ted Shaffner

KSC OperationsManager

Bruce Tams

Integration DesignEngineering Manager

Mike Evans

Quality Manager

Integration Leadership Team


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Interfaces

The integration teams function is to assure ATK and MSFCrequirements are incorporated into the motor processing at KSC

The hands on work, i.e., build up, stack, close out, integrate,

launch and disassemble the boosters is done by USA

Because we work with an integrated vehicle and operate in a

multi contractor environment our communication is with multipleelements


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Recovery

and PostflightEvaluation

Launch

SRB Stacking

KSC Operations

KSC Operations

CCAFS Operations

RSRM Processing


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Jay Jay

Siding

LMF

Segment

Onload

Port

Canaveral

Hangar AF and

Hangar N

VAB/ RPSF/

OSB Area

Pads

SuspectSiding


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SHUTTLELANDING

SRB RETRIEVALSHIP

HANGAR AF

RPSF

SRB STACKING

ET/SRBOPERATIONS

ETSTANDALONE

LCC

INTEGRATEDVEHICLE OPS/VAB

OffloadBuildup

HORIZONTALPAYLOAD INT

PAYLOAD FACILITIESHYPERGOLIC

FACILITY

ORBITER PROCESSING

FACILITY

Pad Ops

VERTICAL

PAYLOAD

INSTALLATION

Design Centers

Element Refurbishment and Manufacturing

Logistics and Shipping

Delivery

Offload and

Inspect

Aft Booster

Build

Field Joint Mate

Leak Test

Field Joint

Protection

System

S&A

SRB Integration

Launch

Recovery

Disassembly andAssessment

Shuttle Vehicle Processing Operations


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Delivery

Segments arrive at Jay Jaysiding via railcar

Cars are 200-ton railcars

with fiberglass covers


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Offload and Inspect

Segments and exit cones are rotated to vertical (flightorientation) in the rotation building at the Rotation, Processingand Surge Facility (RPSF)


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Aft Booster Build-up

Aft skirt mate Exit cone mate

Leak test

Backfill

Nozzle severance connection,

checkout, and close out GEI and heater power cable

installation and test

Stiffener ring installation andclose out

Froth-Pak Application Systems tunnel installation

and close out

Storage until ready to stack


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Aft Skirt Mate

The aft skirt (USA supplied) isplaced in the build up stand and

the segment is mated

177 pins are installed and secured

with a steel retainer strap

The joint is closed out with a pinband and cork

Cork

Pin Retainer Strap

Aft skit clevis


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Exit Cone Mate

Aft exit cone is assembled to theforward exit cone at KSC

(Joint No.1)

Phenolic mating surfaces are

primed with DC1220 primer

prior to assembly

Primary and secondary O-rings

are installed

Exit cone is raised on an

elevator and floated on an air

bearing for mating

The joint is bolted with 96fasteners

Leak test is performed at 83

and 30 psig with the Mass Flow

Meter prior to joint backfill

Backfill

O-rings


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Exit Cone Backfill

Joint gap is backfilled (injected) with RTV sealant Spatulas are used to support the tape and aid in a

deep fill of the joint

Backfill is part of thermal barrier system

Joint 1 is a static joint (opens less than 0.0005 in.)

Joint

Interface

Backfill

Nozzle


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Stiffener Ring Installation and Close-out

The function of the stiffenerrings is to prevent case

damage from splashdown due

to cavity collapse

Stiffener rings have no flight

function

Three sections are bolted to the

integral stub and joined

together by splice plates

RT-455 is used to protect

fasteners and the paintedhardware from heat loads

The foam ramp helps deflect

the water geyser at splashdown

3 Stiffener

Rings

Foam

RT-455

Ablative

Stiffener

Ring


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Systems Tunnel

The aft segment systems tunnel iscompleted at the RPSF up to the ETA

ring prior to transfer to storage

Cables are run and secured

Connections are checked

Covers are installed and closed out

Systems

Tunnel

Stiffener Ring


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Segment Storage

All segments remainvertical on their pallets

until they are transferred

to the VAB for stack

A KAMAG is used to pick

up and transport thepallet

Surges protect the

hardware from rain, wind,

etc.

Not climate controlled.

Segments have weather

proof covers on top


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SHUTTLELANDING

SRB RETRIEVALSHIP

HANGAR AF

RPSF

SRB STACKING

ET/SRBOPERATIONS

ETSTANDALONE

LCC


OffloadBuildup



FACILITY

ORBITER PROCESSINGFACILITY

Pad Ops

VERTICAL

PAYLOAD

INSTALLATION

Design Centers



Delivery

Offload and

Inspect

Aft Booster

Build

Field Joint Mate

Leak Test

Field Joint

Protection

System

S&A

SRB Integration

Launch

Recovery




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RSRM Field Joint Mate

Current joint mate process wasdeveloped through testingduring the RSRM redesignprogram

Joint assembly objective is toprevent tang/clevis flat-on-flatand protect the o-rings frombeing cut or damaged: capturefeature O-ring is mostsusceptible

Calculations are performedbased on case diameter data todetermine proper Field Joint

Assembly Fixture (FJAF)configuration for each joint mate

Interference Fit

Maintains O-ring

Squeeze and Restricts

Joint RotationClevis

Tang


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Joint Mate Preparations

Pressure Sensitive Adhesive(PSA) is applied to the

insulation interfaces

Metal parts are inspected and

greased

O-rings are installed

FJAF configured and

installed

Cases are measured to

determine the relative shapes

Requirement is for shapes to

be within +/-0.210 in. fornominal mate

Shape can be improved by

adjusting the 4 point beam

load distribution

Tang

Clevis

J-Joint


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RSRM Field Joint Mate

Crane lowering rate iscontrolled to 0.060 in./minute

maximum

Levelness and rate of

engagement are continually

monitored during segmentlowering

FJAF contact with the case is

monitored during maximum

engagement

Leak test of the joint and thevent port plug are the final

acceptance of a successful

joint mate

Field Joint Assembly

Fixture Acts to

Shoehorn the

Segments Together

Temposonics to Measure

Rate of Engagement,

Parallelism, and DistanceFrom Mate


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Field Joint Protection System (FJPS)

The purposes of the FJPS are: Maintain an optimal temperature for

O-ring tracking

Prevent environmental

contaminants such as rainwater

from entering the joint area

Final product is painted with white

Acrymax paint

Cork

Heater Retainer

Strap and ThermalBarrier

JointTemperature

Sensor

JointHeater

Pin RetainerBand

RT-455Ablative

RT-455Ablative

Cork


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Skirt Joint Protection System (JPS)

Forward and aft skirt JPS isprimarily to provide thermal

protection, weather protection and

to retain the pins

A flat steel strap is installed over the

pin heads

Cork is bonded with EA934 andpainted with Acrymax paint

A grease bead is applied to the

clevis/tang exterior interface of the

joint

GreaseBead

Steel Retainer

Strap

Cork


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S&A Installation

The ignition Safe and Arm (S&A)devices are installed after the

RSRM is stacked and the forward

skirt is installed

Fluorocarbon seals contained

within a steel retainer gasket are

placed between the S&A and theigniter adapter surface

Crushable preload measuring

washers are used to control bolt

preload

Leak test is performed with thebolts partially torqued to prevent

false positive due to a metal to

metal seal

Final torque and cable

connections are then performed

S&A

Gasket

S&A


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Vehicle Integration

SRB integration Joint heater and temperature sensor connections

Thrust Vector Control (TVC) actuator to nozzle connections

Chamber pressure and ignition S&A connections

Systems tunnel cable runs

Systems tunnel cove close outs

Extensive checkouts of ground and flight electrical systems

The tank is mated to the SRB

The orbiter is mated to the tank

The assembled vehicle is rolled to the pad


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SHUTTLELANDING

SRB RETRIEVALSHIP

HANGAR AF

RPSF

SRB STACKING

ET/SRBOPERATIONS

ETSTANDALONE

LCC


OffloadBuildup



FACILITY


Pad Ops

VERTICAL

PAYLOAD

INSTALLATION

Design Centers



Delivery

Offload and

Inspect

Aft Booster

Build

Field Joint Mate

Leak Test

Field Joint

Protection

System

S&A

SRB Integration

Launch

Recovery




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Launch

Launch countdown begins about 3days prior to launch

RSRM systems begin to activateapproximately 18 hours prior tolaunch S&A rotation test at Launch (L)-60

hours

The igniter heater is activated at L-18hours

Operational Pressure Transducers(OPTs) are powered up at L-9 hours

Joint heaters are powered up at L-8hours

OPTs are checked out at L-1.5 hours

The igniter heater is deactiviated andthe S&A armed at L-5 minutes

Main engine start is at L-6 sec

SRB ignition and hold-down post-firingat L-0


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SHUTTLELANDING

SRB RETRIEVALSHIP

HANGAR AF

RPSF

SRB STACKING

ET/SRBOPERATIONS

ETSTANDALONE

LCC


OffloadBuildup

HORIZONTAL

PAYLOAD INT


FACILITY


Pad Ops

VERTICAL

PAYLOAD

INSTALLATION

Design Centers



Delivery

Offload and

Inspect

Aft Booster

Build

Field Joint Mate

Leak Test

Field Joint

Protection

System

S&A

SRB Integration

Launch

Recovery




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Recovery

Ships crew gatherparachutes and the frustum

Divers install the Diver

Operated Plug into the

nozzle

The DOP system pumpswater from the interior to get

the booster into log mode

Recovery ships tow the

SRBs back to Hangar AF


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Post Flight Disassembly and Assessment

SRBs are floated into awharf and lifted onto the

disassembly dolly with a

straddle lift

SRB and RSRM

components aredisassembled by USA

Assessments of the flown

hardware are performed

by ATK, USA SRB and

MSFC representatives


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RSRM Postfire Evaluation Process

Purpose of RSRM Postfire Evaluation

The objective of postfire evaluation (disassembly and assessment)

is to verify integrity of recovered RSRM hardware and identify any

anomalous conditions in a timely manner

Did the hardware perform as expected? What is it telling us?

Were engineering requirements violated, and if so how does this effectperformance?

Is the condition in family with past observations?

Does the condition affect subsequent launches or tests?

Impact on future launches is addressed in flight/test readiness review

(FRR/TRR) process


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Postfire Evaluation Requirements Postfire Hardware Evaluation System Operating Plan

Defines system requirements for:

Disassembling, evaluating, documenting, reporting, and databasing the

condition of postfired RSRM hardware

Identifying, reviewing, tracking, and resolving observed abnormal/anomalous

conditions or trends

Postfire Engineering Evaluation Plans

Defines requirements for:

Engineering evaluation, hardware observation limits (allowable and

reportable), and photo/video documentation

Approved by NASA MSFC


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Postflight Evaluation Process and Timeline Launch + 2-21 days, CCAFS Hangar AF (Florida)

Recovered solid rocket boosters initially assessed, including assessment for missing

external insulation

Forward and aft skirts, S&A devices, igniters, nozzles, and exit cones removed and

assessed

Case field joints demated and internal insulation assessed Launch + 8-14 days, ATK Thiokol M-66A Facility (Utah)

S&As disassembled and assessed

Launch + 15-30 days, VACCO vendor facility (California)

Arming-Monitor and Barrier-Booster disassembled and assessed

Launch + 12-18 days, ATK Thiokol Refurbishment Center (Utah)

Internal nozzle joints demated and assessed

Launch + 20-160 days, Thiokol Refurbishment Center (Utah)

Nozzle bondlines, nozzle liner char/erosion measurements, case and igniter insulation

measurements, and factory joints demated and assessed


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Barrier-Booster Housing

A041627a1

SAFETY AND ARMING DEVICE

Barrier-BoosterRotor Shaft Seals

Safing Pin

A-M Backfill Port

Visual Indicator

Window

A-M Switch Deck

Motor Field Windings

Motor Armature

A-M Electrical ConnectorGear Reduction (625:1)

Rotor(mechanical barrier)

Perforated PlateFoam Cushion

B-KNO3Granules

B-KNO3Pellets

SII

Safing Arm

Clutch Ass embly

Locking Shaft

EnvironmentalSeals

Booster Basket

Attach Bolt

PLI NestedWasher

Aft Exit Cone Assembly

Cowl Housing

Cowl

A038797aDDB

Vented PositiveStop Set Screw

FlexibleBoot Assembly

Cowl Insulation Segment

Nose InletAssembly

Throat Inlet AssemblyForward Exit Cone Assembly

Fixed HousingAssembly

Snubber Detail:

Ring, Segment,Retainer

Flex Bearing

Flex Bearing Protector

Vented Positive Stop Set Screw

Vented Positive Stop Set Screw



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Postfire Anomaly Record (PFAR) System Any observation that falls outside of established limits or is

unexpected is reported on a Squawk (Florida) or Preliminary PFAR

(Utah, California)

Each Squawk/Preliminary PFAR is presented to SRB/RSRM

Postflight Assessment Team (SPAT Board) for review

SPAT Board consists of NASA, senior contractor management, and

engineering

SPAT Board determines if violation should be elevated to PFAR which

requires corrective actions and further reviews

PFAR corrective actions worked by component teams

PFAR closure rationale approved by ATK Thiokol and MSFC

All PFARs presented in FRR/TRR process including impact and

rationale for upcoming flights/tests


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Postfire

HardwareEvaluationSystem

TWR-16899

Postfire

HardwareEvaluationSystem

TWR-16899

RSRM-XXSpecialIssues

RSRM-XXSpecialIssues

Hardware Disassembly

and Evaluation

Postflight

Observation

Records(PFORS)

Hardware Disassembly

and Evaluation

Postfire

Observation

Records(PFORS)

Squawk

(KSC)

Squawk

(KSC)

Preliminary

Postflight

Anomaly

Record

(Utah)

Preliminary

Postfire

Anomaly

Record

(Utah)

Postflight

Anomaly

Record

(PFAR)

Postfire

Anomaly

Record

(PFAR)

RSRM-XXPostflight

Report

RSRM-XXPostfireReport

Review,Cause,

CorrectiveAction &

DispositionDefines overall

postfire system

Defines motor-set

unique evaluationsbased on specific

changes & issues

PEEP limit

violation or

unexpected condition

Observation

checklist and

recording form

SRB/RSRM

Postfire

Assessment Team

(SPAT) Board

Elevateto PFAR

Dispositionand Close

PostflightEngineeringEvaluation

Plan

(PEEP)

TWR-50051/2

PostfireEngineeringEvaluation

Plans

(PEEPs)

Defines standard

hardware

evaluation

requirements,

observation limits

and photographic

/video coverage

requirements


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Postfire Database, Trending, and Documentation

RSRM postfire data is entered into historical database

Data is trended with historical data to verify performance within

approved limits

Violations of trending limits are reported and investigated asnecessary

Closure of violations is approved by ATK Thiokol management

(and MSFC for significant trends)

Postfire observations and trend data included in final report(s)


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Return to Utah

Segments are loaded ontothe same type railcars as

they were delivered

Nozzle components, igniters,

stiffener rings and other

smaller components areshipped by truck

The joint pins remain at KSC

and are refurbished by ATK

personnel

4 KSC Motor Integration

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