Saturn IB Orientation

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CHRYSLER CORPORAT ION SPA CE DIVISIONSATURN IB ORIENTATIONTRAINING MANUAL 85 1-0

This publ ica t ion pr ese nt s a br ie f de sc r ip t ive sum mar y of the Sa turn IBve h i c le a nd C h r ys l e r C o r por a t i on ' s a c c om pl i s hm e s t s i n t he m i s s i l e s a ndspace f ie ld .

The Sa tu r n IB i n f o r m a tion p r e s e n t e d he r e in i s ba s e d on c u r r e n t p l a nsfor ea ch of the s ta ges . Al though the re may be des ign changes f ro m vehicleto vehic le , the bas ic components , sy s te ms , and ope ra ting pr inc ip le s wi l l r e -m a i n s i m i l a r t o p re v i o u s m o d e ls .

PRE PAR ED THROUGH JOINT EFFO RTS O FPe r s on ne l D e pa r tm en t

Educat ion and Development Bran chSys tem s Tra in ing Uni t

Michoud OperationsAND

Enginee r ing Communica t ions Depar tmentTechnica l Informat ion Branch

Applied Communica t ions Engineer ing Sect ion

Huntsvi l le Opera t ions

Date: 15 F e b r u a r y 1 9 6 5


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Sect ionT A B L E O F C ONT EN TS

P a g eINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . 1A . HISTORY . . . . . . . . . . . . . . . . . . . . . . . 2B . SATURN FAMILY AND MISSIONS . . . . . . . . . . 10. . . . . .HRYSLER CORPORAT ION SP AC E DIVISION 15A . MICHOUD OPERATIONS . . . . . . . . . . . . . . . 17B . HUNTSVILLE OPERATIONS . . . . . . . . . . . . . 19C. FLORIDA OPERATIONS . . . . . . . . . . . . . . . 2 3

I11. SATURN IB VEHICLE DESCRIPTION . . . . . . . . . . 25GENERAL DESCRIPTION . . . . . . . . . . . . . . 25. . . . . . . . . . . .EHICLES NOMENCLATURE 2 6UNIT NUMBERING AND COMPONENT

DESIGNATION . . . . . . . . . . . . . . . . . . . 29. . . . . . . . . . . . . . . . . . . . . ..IBSTAGE 31. . . . . . . . . . . . . . . . . . . . .-IVB STAGE 45INSTRUMENT UNIT . . . . . . . . . . . . . . . . . 48PAYLOAD . . . . . . . . . . . . . . . . . . . . . . . 49PROPELLANT DISPERSION SYSTEM (DESTRUCT

SYSTEM) . . . . . . . . . . . . . . . . . . . . . . 50EMERGENCY DETECTION SYSTEM . . . . . . . . 52

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G - 1

iii


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F i g u r eF r o n t i s p i e c e

T a b le

LIST O F ILLUSTRATIONSTi t le

. . . . . . . . . . . . . . . . . . . . . . . .eds tone. . . . . . . . . . . . . . . . . . . . . . . . .u p i t e r . . . . . . . . . . .- 1. C.2. and E a r l ie r Vehi c les . . . . . . . . . . . .h e S a tu rn F a m i ly of Ve h ic l e sS a tu r n I / IB L a u n c h Co m p lex e s . . . . . . . . . . . .Defense -Space Group Oper a t ion s . . . . . . . . . . .. . . . . . . . . . . . .pace Div is ion Organ iza t ionHuntsv i l le Opera t ions Organ iza t ion . . . . . . . . . .Sat u rn IB Conf igura t ions . . . . . . . . . . . . . . .. . . . . . . .a tu rn IB S tage and Unit Des igna t ions. . . . . . . . . . . . . . . . . . . . . . .-IB StageT a i l Un it As s e m b ly . . . . . . . . . . . . . . . . . .. . . . . . . .a i l Are a . Ou tb oa rd E n g in e s Re m o v e dT a i l Are a . Co m p let e . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .r o p e l l a n t C o n t a i n e rs . . . . . . . . . . .p id e r Be a m a n d T o p T an k Are a. . . . . . . . . . . . . . . . . . . . . .-IVB StageIn s t ru m e n t Un it . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .pollo PayloadBloc k D ia g ra m S a tu r n IB E DS . . . . . . . . . . . .

LIST OF TA BLESTi t le . . . . . . . . . .eds tone and Jup i te r C Highlights . . . . . . . . . .ro u nd T e s t Ve h ic l e No m e n c la tu r e. . . . . . . . . . . . .l ig h t Veh ic le s Nomenc la tu re. . . . . . . . . . . . . .- IB S tage S ta t i s t ica l Da taMajo r S im i la r i t i e s and Dif fe rences of Con ta ine rs . .. . . . . . . . . . . . . . . .onta iner Ident i f ica t ion

P a g e

P a g e


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A. HISTORYD r . von B rau n ' s r e m a rk s , a s D i rec to r of the G eorge C . M ar sha l l Space

Fl igh t C en te r (M SFC ) , w er e m ade a t the ce rem ony m ark ing the com ple tionof production of the f i r s t Chr ysle r-bu il t S atu rn I S-I s t age and the p rese n ta t ionof the boo ster to the National Aer ona utic s and Space Adm inis trat ion (NASA)a t the NASA-Michoud plant. H is r e m a r k s a r e a t hu m bn ai l h i s t o r y of C h r y s l e r t spa r t i c ipa t ion in the na t ion t s m is s i l e and space e f fo rt and cha rac t e r i ze ourre la t ionship with var ious g overnmenta l agencies over a good numb er of y ea rs .

As a r es ul t of Ch ry s l er ' s except ional World War I1 wa r ef for t under thelead ersh ip of K. T. Ke lle r , o n October 24, 1950 Pr es id en t Tr um an appointedMr. Kel ler , pre s ide nt and cha i rma n of the board of Chr ys ler Corpora t io n , tothe newly cr ea te d positio n of Dir ec tor of Guided Mi ss il es for the U. S. A rm edF o r c e s . Shor t ly af ter h i s appointment to th is pos i tion , wi th cha rac ter i s t icfo res igh t , M r . K e l l e r ins is t ed to the C hrys le r boa rd of d i r e c to r s tha t C hr ys le ren te r the m iss i l e bus iness . A n A dvanced Pro jec t s G roup fo r m is s i l e s andspace was for me d wi th in the Defense Divis ion . Th i s g roup l a t e r fu rn i shedthe nuc lei of both the Mis sil e Division and the Space Division.

In the Su mm er of 1952, the Army Ball is t ic Mis si le Agency (ABMA) wasseek ing a p r im e con t rac to r fo r the R edstone m iss i l e . Tea m s w ere se n t tota lk to the manag ements of v ar ious corpora t ions tha t had the potentia l to be-come pr im e con t rac tors . In October , 1952, the Depar tment of Defenseawarde d Ch rys ler a con t rac t to as s i s t ABMA with the des ign and product ion ofR edstone m is s i l e s . The jet engine plant that Chr ys ler had buil t during theKorean War fo r the Navy, and which had nev er been use d because of c on tra ctcancella t ion , was conver ted in to a mi ss i le manufactur ing fac i l i ty . Ch ry s le renginee rs were a lso in tegra ted in to impor ta nt seg ments of the RedstoneArse nal a t Huntsvil le , Alabama.

On September 29 , 1954, Chr ys le r Corpora t ion was g ranted the cont r ac tto produce the Redstone miss i le .

M as s p roduc tion concept s s t em m ing f ro m au tom otive exper i ence w ereemployed by C hry s le r in the development of fabr ica t ion and ass em bly o per a-t ions for the Redstone . The Chry s ler - ope ra te d Michigan Ordnance Mis s i lePlan t was the only one of i t s kind ope ra ted by a moto r c a r ma nufa ctur er , andC hrys le r i s s a id to be the f i r s t U. S. mis s i l e builder to p lace la r ge ba l l i s t icm iss i l e s in schedu led p roduc tion. C hrys le r m ade enorm ous s t r id es in thedevelopment of fac i l i t ie s , method s, and tooling in the plant. The highlyorganized fac i li ty was comple te wi th equipment for manufactur ing , tes t ing ,qual ity con tro l , and a l l t he e l em ent s r eq u i red to p roduce a m iss i l e r eady fo rdeploym ent to the a rm ed fo rce s . M oreover , a t ea m ca l l ed the A dvance Pr o j -ec ts Organiza t ion was formed wi th in the Ch rys l er Defense Group to spec ia l izein the concept and planning of new weapon and sp ace sy st em proj ect s .


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F IGURE 1. REDSTONE

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The vehic le was pow ered by a s ing le b ipropel lant l iquid roc ket enginedeveloping 78, 000 pounds of thr us t . The mi ss i l e was d i re c te d in f l ight f r o ml if t-of f to impac t by an ine r t i a l guidance and cont r o l sy s te m.

In addi t ion to the Mercu ry-Re dston e pro jec t , which i s wel l known his tory ,some of the h ighlights of the Redstone and Jup i ter C pr og ra m a r e shown inTable 1.

TAB LE 1. REDSTONE AND JUP ITE R C HIGHLIGHTS

2 . J u p i t e r . T h e J u p i t e r m i s s i l e ( F i g . 2) w a s a n i n t e r m e d i a t e r a n g eba l l i s t i c m i ss i l e ( IR B M) conce ived by the A rm y and des igned to pe r fo rm au to -m at i c a l ly the checkou t , fue l ing , t a rg e t a l ignm ent , i gn it ion , and l aunch to theta rg e t w i th in a spe c i f i c t im e l im i t a f t e r t he f i r ing com m and w as g iven.Approval fo r the development was grant ed by the Se cr e t ary of Defense onNovember 8 , 1955. This appro val was base d on the exper ienc e ga ined by theR e ds to n e A r s e n a l t e a m f r o m V-2 and R eds tone . By th i s t im e , C hry s le r

M iss i l e1

13

27

32

404229

1002445051

Even tF i r s t R ed st on e f i r e dF i r s t C h r y s l er - b u i lt m i s s i l e ( d e li v e re d

14 November 1955)F i r s t deep pene t ra t ion of space

( J u p i t e r C )F i r s t C h r y s l e r m i s s i l e s hip pe d

di r ec t ly to AMRF i r s t no s e c o ne r e c o v e r y ( J u p i te r C )F i r s t ta c t i c a l to p ( w a rh e a d )E x p l o r e r I ( J u p i t e r C )F i r s t t r o o p f ir i ngE x p l o r e r IV ( J u p i t e r C )

H ard tack (h igh a l t i tude nuc lea r t e s t s )

D at e F i r e d20 August 1953

19 Ju ly 1956

20 September 1956

14 M a rch 19578 August 195710 D ece m ber 195731 Jan uar y 195816 May 195826 July 19581 August 195812 Augus.t 1958


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F IGURE 2. J U P I T ER

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h c tobe r 1958, ARPA ord e r 14-59 was amended to requ i re the deve lop-ment of a r e l i ab le h igh-p e r forman ce boos te r to se rv e a s the f i r s t s t age of amul t i s tage vehic le capable of pe r forming advanced spac e miss ion s . ARPAals o reques ted a s tudy of a com ple te vehic le sy s te m so tha t upp e r - s t agese lec t ion and development could begin and the launch fac i l i t ie s a t the Atlant icMis s i le Range (AMR) could be de termin ed.

In re sp ons e to the ARPA o rd e r , cons t ruc t ion of the ABMA s ta t ic t e s ts tand for l a rg e boos te r s began on Janu a ry 16 , 1959 a t Reds tone Arsen a l . ByFe br ua r y 1959 , a cont rac t had been awarded for cons t ruc t ion of the fac i l i t i e sa t La unc h C om ple x 34 , a nd a de s ign c on t r a c t w a s a l s o a w a r de d f o r a m ova b l es e r v i c e s t r uc tu r e , w h ic h w ou ld be us e d t o a s s e m b le a nd s e r v i c e the vehic leon the launch pad.

O n Fe br u a r y 3 , 1959, a n AR PA m e m or a ndu m o ff ic ia ll y r e na m e d thepro jec t Sa tu rn, cancel l ing the for m er ident i f ica t ion of Juno V.

Dur ing the ea r ly and middle p a r t of 1959, num erous S a turn sy s te msstud ies wer e pres en ted to NASA and ARPA out l ining var i ous upper s tag econf igura t ions . On November 18 , 1959, NASA as su me d technica l di rec t ionof the Sa turn pro jec t , pending i t s form a l t r a ns f e r f ro m ARPA, On D e c e m be r1 5 , 1959, the S a turn Vehic le Eva lua t ion Com mit tee rea ched a dec i s ion onSa turn uppe r s tage conf igura t ions . The comm it tee , composed of r epre sen ta -t ives f r o m NASA, ARPA, DOD, and USAF, reco mm end ed a long rang e de-ve lopment pr og ra m for Sa turn , including uppe r s tage engines burn ing l iqu idhydrogen (LH2) and LOX. The C- 1 conf igura t ion , se lec ted a s the in i t i a lvehic le to be developed, wa s to be a s tepping s tone to the C-2 vehic le a sshown in f igure 3. A bui lding-block concept was pro pos ed tha t would yie lda var ie ty of Sa tu rn conf ig ura t ion s , each us ing previously prov en develop-m e n ts a s f a r a s p o ss ib le . As these recommenda t ions w ere accepted by theNASA Ad min is t ra tor , Decemb er 31 , 1959, a t en-vehic le R &D pr og ra m wases tabl ish ed. The C-1 conf igura t ion inc luded the S-I , S-IV, and the S-Vs tages . The S- I s tage was to have e ight H-1 engines c lus t e red , us ing LOX/RP - 1 prope l lants capable of producing a to ta l of 1 , 50 0, 000 pounds of t hr us t .The S- IV s tage was to have four engines us ing LOX/LH2 prope l lan t s pro -ducing a tota l of 8 0, 000 pou nds of t h ru st . The S-V stag e would us e two ofthe sa me engines a s the S-IV s tag e , producing a tota l of 40,00 0 pounds oft h r us t . The Sa tu r n p r o j e c t w a s a pp r ove d on J a nua r y 1960, a s a p r og r a m ofthe h ighes t na t iona l pr ior i t y .

D ur ing Ma r c h 1960, t he e xec u ti ve o r de r t r a ns f e r r i n g the Sa tu r n p r og r a mto NASA bec ame effective. Af te r rev iew of the S-IV pr op os al s , Douglas Ai r -c ra f t Corpora t ion was awarde d , on Ap r i l 26 , 1960, a co nt rac t to deve lop andbui ld the s tage , us ing s ix L H ~ / L O X ngines . On May 26, 1960 as se mb ly ofthe boos te r for the f i r s t Sa turn fl igh t vehic le was begun. On July 1, 1960,


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REDSTONE

JUPITER

UPITER-C

JUNO I I

MREDSTONE

C-H 9044FIGURE 3. C - 1, C-2 , AND EARLIER VEHICLES

t h e S a t u r n p r o g r a m w a s f o r m a l l y t r a n s f - r r e d t o t h e G eo r ge C . M a r s h a l lS p a c e F l i g h t C e n t e r ( M S F C ) .

I n J a n u a r y 1 96 1, Dr . von Braun prop osed tha t the C- 1 veh ic le be changedf r o m a th r ee -s ta ge to a two-s tage conf igura t ion in suppor t of the Apollo p ro -g r a m . T h e c h an g e d e l et e d r e q u i r e m e n t s f o r t h e S - V s tage on th e C - 1 v e -h i c l e s . Du ring May 1961, MSFC began re- ex am ina t io n of the capa bi l i t ie s oft h e S a tu r n C - 2 conf igura tion . Res u l t s of th i s examina t ion ind ica ted tha t , a sl u n a r m i s s io n r e q u i r e m e n t s h a d i n c r e a s e d , a S a tu r n v e h ic l e of e v en g r e a t e rp e r f o r m a n c e w o uld be d e s i r a b l e . A s a r e s u l t of s t u d i e s i n i t ia t e d a t M SF C inMay, D r . von Brau n announced , Jun e 23 , 1961, tha t fu r the r eng ineer ing de-s ign wo rk on the C-2 conf igurat ion would be d iscont inued, and effor t wouldi n s t e a d b e r e d i r e c t e d t o w a r d c l a r if i c a ti o n of the Sat urn C-3 a nd Nova c onceptsI n v e s t i g at i o n s w e r e s p e c i f i ca l l y d i r e c t e d t o w a r d d e t e r m in in g c a p a b i l i t i e s ofthe p rop ose d C-3 conf igura tion in suppor t ing the Apollo miss io n .

Dur ing the of Sa tu rn deve lopment f r o m 1958 to 1961 , Ch rys le re n g i n e e r s w o r k in g w ith t he v o n B r a u n t e a m , though off ic ia l ly in s upp ort oft h e R e d s to n e a n d J u p i t e r p r o g r a m s , w e r e a c t i v e ly e ng a ge d i n t he d e ve lo p-m e n t of t h e S a t u r n p r o g r a m . D u r ing t h e l a s t w e ek i n J u n e 1 96 1, a c o n t r a c tw a s a w a r d e d t o C h r y s l e r C o r p o r a t i o n f o r p e r f o r m a n c e of q u a l if ic a ti o n an d


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r e l iab i li t y t e s ti ng on va r i ous eng i ne, hyd rau l i c , m echan i ca l , and s t r uc t u r a lcomponents of the Satu rn booster . T h i s c o n t r a c t m a r k e d C h r y s l e r ' s o f f i ci a len t ry i n to t he Sa t u rn p rog ram .

On September 7, 1961, the government-ow ned Michoud Ordn ance Pla nta t New Orle ans was sele cted by NASA a s the s i te fo r indus t r ia l product io n ofthe S- I s t age . The plant would be operate d by indus t ry under th e techn icaldi rect ion of MSFC. Simul taneously, MSFC cont inued pr ep ara t io ns fo r a con-fe renc e t o s e cu re R eques t s fo r Q uot at ions f r om i ndus t ry on p roduc t i on ofthe S- I s t age . On September 26, 1961, a p roposa l con fe rence w as he l d a tNew Or leans to s ec ur e b ids fo r indus t r i a l p roduc tion of the S- I s t ag e , and onNovember 17, 1961, NASA announced the select ion of Ch ry sl er C orp ora t ionto negot ia t e a con t rac t t o bu ild, check ou t , and t e s t 20 S- I boos te rs . Thecont ra c t was s igned in mid-J anuar y 1962.

On July 11, 1962, NASA announced that a new two-stage Sa tur n cla ssvehic le would be developed for manned ea r t h orb i t a l mis s io ns wi th fu l l - sca leApol lo s pac ecr af t and assoc i a t ed equipment . The C-1 boos te r and the C-5thi rd s tage would be adapted to provide a vehic le capable of perf orm ing the sem i s s i o n s . Thi s veh ic l e was iden t if i ed a s the S a turn C-IB. On August 6,1962, NASA and Chr ys ler s igned a co nt r ac t fo r product ion of 21 C-1 bo os ter s ,wi th de l ivery to be mad e be tween l a t e 1964 and ear ly 1966. The s t a ges wouldbe produced by Ch rys le r a t the Michoud P la n t .

Dur ing the f i r s t week of Fe br ua ry 1963 , NASA announ ced that S at ur nvehic le nome ncla ture had been changed f r om C- l t o Sa t u rn I , f r om C - IB t oSa t u rn IB , and f r om C -5 t o Sa t u rn V . On F eb ru ar y 20, 1963, NASA ap -proved the procu rem ent p l an for modi f ica t ion of the bas i c C hr ys le r con t rac t ,fo r redes ign ing the S- I s t age to the S- IB conf igura tion , and fo r the de l ive ryof twelve S-IB sta ges and eight S-I s tag es. S-IB con t ra ct negot ia t ions wi thChr ys le r a t Michoud we re comple ted on Augus t 5 , 1963. In ea r l y N ovem ber1963, S-I- 111 t h rough S-I- 116 s t ages we re cance l l ed and ex i s t ing ha rd wa red iver t ed to S- IB manufac ture .B. SATURN FAM ILY AND MISSIONS

The Saturn IB i s one of the Sa turn launch vehicle fami ly c om pr ise d ofthe four c onfigurat ions shown in f igure 4.The four S- I B lock I f l i gh t veh ic l es (SA- 1 th rough SA-4) wer e u sed pr i -

ma r i l y to t e s t and va l ida te the mult i -eng ine and c lus t e red prope l l an t t ankconcepts . These veh ic l es fea tur ed 165 ,000-pound th ru s t (165 K ) engines anddummy upper s t ages . A s impl i f i ed gu idance s ys t e m was u sed because of thel imi t ed t ra j ec tor i es f lown by these ve h ic l es .


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ffi3uH


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The Satu rn I Block I1 f l ight vehicles (SA-5 through SA- 10) have l ivesecond s t age s , i n s t rum e n t un i t s , and a r e adapt ed fo r a t t a chm en t of bo i l e r -p la t e o r p ro to type Apollo sp acecraf t . Engine s for the S-I stag e of the BlockI1 veh ic l es a r e upra ted to 188 K . Six LH2/LOX fue led engines power theS-IV s t age . The se veh ic l es a r e be ing used to conduct per form anc e t es t s ofthe in t egra ted S- I/S- IV s t ag es , p rove the LH2/ LOX propel lant combinat ion,f l igh t - t es t t he pro to type Apol lo sp acecra f t , and conduct micr ome teor o idm e a s u r e m e n t e x p e ri m e n ts .

The Sa turn IB veh ic l e as shown re pre sen t s the mos t advanced of a s e r i e sof 22 Satur n I / I B tes t and f l ight vehicles to be produced. The fl igh t ve rs i on sof thes e vehicle s inco rpo rate components of the Satu rn I and Sa t u rn V ve -h ic l es . The eigh t eng ines used for the S-IB boos te r a r e ra t ed a t 200 K each ;the S- IVB s t age s ing le LHz/LOX fue led J -2 engine i s ra t ed a t 200 K. T hepr im ar y opera t iona l miss ion of the Sa turn IB f ligh t veh ic l es wi l l be to p l aceunmanned and manned Apollo spa cec raf t in to ear th or b i t s i n acc ord ance wi thspec i f i c miss ion req ui re men t s . A var i e ty of t es t s wil l be conducted dur ingthese f l igh t s , i ncluding space docking and lunar l and ing maneuver ex er c i se s ,and f l ight test in g of the S-IVB stage for Sa turn V and other h eav ier com -ponents of the Apollo pro gr am .

The Sa turn V configurat ion shown in f igure 4 i s a m ul t i s t age l aunch ve-h ic l e used fo r the Apollo manned lunar and p lane ta ry explora t ion pro gr am .Five engine s, each wi th a t hr us t of 1 , 500, 000 pounds and fueled wi th a m ix-tur e of R P - 1 die se l and LOX, p ower the S-IC f i rs t s tag e of the launch ve-hicle . Engine s, fueled wi th a mixture of LH2 and LOX, pow er the S-I1(secon d) s tag e, and the S-IVB ( thi rd ) s tage of the vehicle . A n i n s t rum en tuni t i s located between the S-IVB stage and the Apol lo payload. The payloadcons i s t s of the lunar excurs ion module (LE M) , the se rv i ce module (SM), andthe command module (CM).

T he Sa t u rn I / I B veh ic l e s a r e l aunched f ro m tw o pads a t A MR , l aunchcomplexes 34 and 37B. Sa turn I B lock I veh ic l es wer e l aunched f r o m launchcomplex 34. This Complex ha s been modif ied and wi l l be used to launchSaturn IB vehicles . Complex 37B i s the launching s i te fo r the Sa tur n I BlockI1 vehic l es . I t wi l l be modif ied to launch Saturn IB vehicles . The launchcomplexes (F ig . 5 ) p rov ide fue l , pneumat i c , l aunch cont ro l cen te r , se rv i ces t ruc t u re , l aunch pedes t a l , and um bi li ca l t ow er f ac i l i ti e s t o e re c t and se rv -i ce the veh ic l e in p repa ra t ion fo r l aunching .

Launching of the Saturn V wi l l occur fr om Comp lex 39 a t the AMR. Thecomplex fac i l i t i es p rov ide the f i r ing s i t es , ver t i ca l a sse mb ly bu i ld ing (VAB),l aunche r -um bi l i ca l t ow er (L U T ) , m ob il e a rm i ng t ow er , and c raw l e r t r an s -po r te r fo r the ass emb ly , checkout , t ran spor t a t ion , and f i r ing of the Sa tu rnV vehicle . Becau se of the eno rmo us si ze of the Satu rn V, mat ing of the st ag es


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and check out of the veh icle w ill be ac co mp lis he d on the LUT in the VAB.The LUT with the er ec t , as se mb led vehicle wi l l be then t ra nsp or t ed to thef ir ing s i t e by the c raw ler t r an spo r t e r .

FIGURE 5. SATURN I / I B LAUNCH COMPLEXES


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SECTION 11. CHRYSLER CORPORATION SPACE DIVISION

F r o m i t s h u m b l e b eg in n in g s a s a n a d v an c e d p r o j e c t s w o r ki ng g r o u p i nt h e D e f e ns e D iv i si o n, C h r y s l e r C o r p o r a t i o n ' s m i s s i l e s a n d s p a c e e f fo r t h a sevolved unt i l it i s two d iv i s ion s (Mis s i l e Divi s ion and Space Divi s ion) wi th inthe Defen se-Sp ace Group. The Defense-Space Group ha s of f i ces and fac i l i -t i e s p rov i d ing l i a i s on and d i r ec t suppor t of the ma j o r mi s s i l e s and spacef ac i l i t i e s i n t he Un i ted S t a t e s a s shown i n f i gu r e 6.

Our Washington, D. C . off ice ma i n t a i ns l i a i son w i th gover nmen t age nc i ese n g ag e d i n m i s s i l e s a n d s p a c e a c t i v i t i e s a nd p a r t i c ip a t e s i n c o n t r a c t n e -g o ti at io n s a t th e p r o g r a m l e v e l.The D e t r o i t o f f ices p r ov i de adm i n i s t r a t i ve suppor t f o r t he Def ense - SpaceGr oup , p r ov i de d i r e c t eng i nee r ing suppor t to t he Space and M i s s i l e sDi v i s i ons , and d i r e c t eng i nee r ing suppor t and l i a i son f o r the Lewi s Re -s e a r c h C e n t e r a n d W r i g h t- P a tt e rs o n A i r F o r c e R e s e a r c h C e n t e r.Bo t h the M i ss i l e and t he Space D i v i s ions ma i n t a i n launch sup por t ope r a -t i ons a t t he F l o r i da Oper a t i ons p l an t a t Cape Kennedy i n eng i nee ri ng andtech nic al s up po r t of both NASA and the A ir F o rc e . These ope r a t i onspa r t i c i pa t e i n compl ex f ac i li t y equ ipmen t i n s a l l a ti on , l aunch p r ep a r a -t ion s , and refurb i sh ing of launch com plexes af t e r launch.The Houston off i ce main ta ins l i a i son and engineer ing suppo r t for theM anned Space Cen t e r .The Whi te Sands of f ice provides t echnica l and engineer ing supp or t forr ock e t and mi s s i l e weapon sy s t em s t e s t i ng conduc t ed by t he Ar m y a t t heWhi te Sands Miss i l e Range .The W es t Coas t o ff ice ma i n t a i ns l i a i son w i th Edwar ds A i r Fo r c e Ba se ,Vandenburg A i r F or ce B ase , and manuf ac tu r i ng compan i es engaged i nt he m i s s i l e a n d s p a c e b u s i n e s s .By fa r the l a rg es t of the orga niza t ions tha t comp ose the Space Divi siona r e the Michoud and Huntsv il le Ope ra t ions engaged in engineer ing sup-po r t and boos t e r manuf ac t u r e f o r M SFC and the Sa t u r n I / I B p r o j e c t .


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A. MICHOUD OPE RAT ION SIn N ovem ber 1961 , the C hr ys le r C orpora t ion Space D iv i s ion w as fo rm ed

to negotia te a co nt r ac t wi th NASA, a c iv i l ian organiza t ion engaged in thepeaceful explora t ion of spa ce , to bui ld the boo s ter s tage of the Satu rn I ve-hicle . In Jan uary 1962, 46 key s ta ff pe r s onne l f ro m bo th the D e t ro i t andHuntsvi l le Ope rat io ns of the M iss i le D ivision moved into the Michoud plan tto begin the op era t ion of the Ch rys ler Cor pora t ion Space Division. Todayt h er e a r e m o r e t h a n 4, 600 pe r sonne l in the d iv i s ion ( approx im ate ly 3 , 1 50 a tMichoud Opera t io ns and 1 , 500 a t Huntsvi lle Opera t io ns) .

The Space Divis ion (Fig . 7) i s com posed of 12 depar tm en t s , ea ch o fwhich pe rf or ms a v i ta l funct ion . The Michoud Op era t ion while pe r fo rmi ngthe adm in i s t r a t ion fo r the Space D iv i s ion p rov ides the eng inee r ing andm anufac tu r ing suppor t fo r p roducing the S- I / IB boos te r s , p rov ides e ng inee r -ing su ppor t for the Huntsvi l le Ope ra t io ns , and provide s e ngineer ing and oth ersupport s e r v i ce s fo r the H ous ton o ff i ce .

The Pr o g ra m C ont ro l Of fi ce d i r ec t s the deve lopm ent of approp r i a t e w orkproposa l s and m on i to r s and coord ina tes the ac t iv i t i e s of a l l depa r tm en t s toe n s u r e t h at t h e i r e f f o r t s a r e p r o ce e d i ng a c c o r d i n g t o th e r e q u i r e m e n t s of o u rcont rac t .

T h e E n g i n e er i n g D e p a r t m e n t d e f in e s a l l s y s t e m e l e m e n t s t o b e b u i lt ,ana lyzes r e li ab i l i t y of s ys t em s and to t a l s t age s , p ropose s com ponen t r e -design, conduc ts inve s t iga t ion in to new space m iss io ns , and p rov ides v a r io uss u pp o rt s e r v i c e s .

T h e S y s t e m s T e s t D e p a r t m e n t , w h ic h s t a t i c - f i r e s t h e s t a g e , p r o v i d e sl aunch and eng inee r ing suppor t t o the J . F. Kennedy Space Center , ands u p e r v i s e s s t a g e t r a n s p o r t a t i o n b e t w e e n m a n u fa c t u ri n g l o c a ti o n a n d t e s ts i t e s .

The Dir ec tor of Opera t ion s coordin ates the ac t iv i t i es of four opera t in ggroups: Qual ity Contro l , Manufactur ing , Ma ter ia l s , and Huntsvi l leOpera t ions .

The Q ua l ity C on t ro l D epar tm en t t e s t s and inspec t s p roduc t sys t em s ,com ponent s , and the com ple ted veh ic le , and es t a b l i s hes qua l ity s t anda rdsand inspec tion m e thods fo r the d iv i s ion and supp l i e r s .

The M anufac tu ring D epar tm e n t f ab r i c a te s pa r t s and com ponen ts anda s s e m b l e s t h e v e h i c l e ; d ev e lo p s t he m a n u f a c t ur i n g p r o c e s s e s f o r t h e f a b r i -ca t ion and as se m b ly of p roduc t ion i t e m s ; p rov ides cos t e s t im a t ing and


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SPACE DIVIS IO N

IP R O G R A M C O N T R O L

O F F I C E

I i

I

FIGU RE 7. SP AC E DIVISION ORGANIZATION

ADMINISTRATIO N ANDC O M P T R O L L E R

II ' I

I I

SYSTEMS TE STD E P A R T M E N TP E R A T I O N S

H U N T S V I L L ES P A C E O P E R A T I O N S

E N G I N E E R I N GD E P A R T M E N T

M A T E R I A L SD E P A R T M E N T

Q U A L I T Y C O N T R O LD E P A R T M E N T

P U B L I C R E L A T IO N SD E P A R T M E N T

M A N U F A C T U R I N GD E P A R T M E N T

C.H 9042-1

PURCHASINGD E P A R T M E N T

C O N T R A C TADMINISTRATIO N

P E R S O N E LD E P A R T M E N T

C O M P T R O L L E RD E P A R T M E N T


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O P E R A T I O N S

I D I R E C T O R 1I H U N T S V I L L E S PA C E O P E R A T IO N S (

O P E R A T I N G MA N A G E R 1P L A N T C O M P T R O L L E RD E P A R T ME N T N O . 4 0 3 0

MANAGER

P R OG R AM A N D C O N T R A C T SL I A I S O N O F F I C E

D E P A R T ME N T N O . 4 0 0 0

P U R C H AS I N G O F F I C E1 DEPARTMENT NO. 4100 IMA N A G E R

P E R S O N N E LDEPARTMENT NO. 4200 I

MANAGER IO P E R A T I O N S

DEPA RTM ENT NO. 4300MA N A G E R

Q U A L I T Y C O N T R O LDEPA RTME NT NO. 4400

I MANAGER

E N G I N E E R I N G

MA N A G E R

SYSTEMS ENGINEERINGDEPA RTM ENT NO. 4500

C H I E F E N G I N E E R

r E L E C T R I C A L AN D E L E C T R O N I C SE N G I N E E R I N G

DEPA RTM ENT NO. 4700C H I E F E N G I N E E R I

I STRUCTURE S AND MECHANICS 1I E N G I N E E R I N GDEPA RTM ENT NO. 4800I C H I E F E N G I N E E R I

r NGINEERING COMMUNICATIONSDEPA RTME NT NO. 4600I MA N A G E R I

I D R A F T I N G A N D D E SI G NDEPARTMENT NO. 4690 1I MANAGER II SYSTEMS STAT I C TE STL--- --------- DEPA RTME NT NO. 4900 I

I MA N A G E R I

F IG U R E 8. HUNTSVILLE O PERAT IONS ORGANIZATION


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t he Launch Suppor t Equ i pmen t Eng i nee r i ng D i v is i on ( l oca t ed i n H un t sv i l le )of Kennedy Spa ce C ent er .

The f unc t i ons of t he Hun t sv i l l e ope r a t i ng dep a r t me n t s a r e s i m i l a r t othose of the Michoud Ope ra t ion s .T h e P l a n t C o m p t r o l l e r D e p a r t m e n t i s r e s p o n s i b le f o r t h e d i r e c t io n of a

f i nanc ia l con t r o l p r og r a m inc l ud i ng gene r a t i on and ma i n t enance of r e co r d sand r e po r t s cove r i ng t he accoun ti ng and t r e asu r i n g ac t i v i t i e s of t he Hun t s -v i ll e Oper a t i on .

T h e P r o g r a m s a n d C o n t r a c t s L i a i s o n o ff ic e p ar t i c ip a t e s i n s e c u r i n g n e wb u s i n e s s a n d s e r v i c i n g c u r r e n t b u s i n e s s . Th i s o ff ice ma i n t a i ns con t r o l andp r o g r a m l i a i s o n w it h M S F C , t h e A r m y , M i ch o ud , Kennedy Space Cen t e r ,a nd w it h c o n t r a c t o r s .

T h e P u r c h a s i n g O f fic e p r o c u r e s g o od s , s e r v i c e s fa c i l i ti e s , e q u ip m e n t ,a nd m a t e r i a l s t o c a r r y o n t h e s u p p o r t s e r v i c e s p r o vi d e d b y th e H u n t sv i ll eOper a t i on .

T h e P e r s o n n e l D e p a r t m e n t o b t ai n s a n d m a i n t a i n s a c o m p e t e n t w o r k f o r c ea n d p r o v i d e s f o r t ra i n i n g , s a f e t y , e m p l o ye e r e l a ti o n s , w a g e a n d s a l a r y a d -mi n i s t r a t i on , and t he se cu r i t y of c l a s s i f i ed in f o r ma t i on .

T h e O p e r a t i o n s D e p a r t m e n t m a i n t a i n s a manuf ac t u r i ng f ac i l i ty f o r t hef ab r i ca t i on o f p r o t o t ype ha r dw ar e and too li ng, f o r cus t o m mechan i ca l ande l e c t r i ca l cons t r uc t i on , and f o r s ho r t p r oduc t i on r uns i n sup por t of M SFCl a b o r a t o r i e s . A l so , t h e d e p a r t m e n t f u r n i s h e s t h e p l an t o p er a ti n g a n d e n -g i n e er i ng s e r v i c e s f o r t h e H u n t sv i ll e P l a n t .

T h e Q u a li ty C o n t r o l D e p a r t m e n t m a i n t a i n s a qua l i t y con t r o l eng i nee r i ng ,t e s t , and checkout sup por t ac t iv i ty in suppo r t of MSFC, inc luding the es ta b-l i shm en t and execu t i on of a Qual it y Con t r o l Sys t e m i n compl i ance w i t h ap -p l ic a b l e c o n t r a c t u a l r e q u i r e m e n t s . A l so , t h e d e p a r t m e n t m a i n t a i n s t h equal i ty co nt ro l of all i t e m s m a n u f a c t u r e d b y t h e p l a nt , a n d e s t a b l i s h e s a s y s -t e m of su r ve i l l a nce on a ll p l an t m e a s u r i n g a n d t e s t e q ui p me n t r e q u i ri n g c a l -i b r a t i o n a n d t r a c e a b l e t o t h e B u r e a u of S t a n d a r d s .

T h e S y s t e m s S t a t i c T e s t D e p a r t m e n t i s e ng ag ed i n s t a t i c t e s t i n g of t h eb o o s t e r . T h i s d e p a r t m e n t i s a h y b r id d e p a r t m e n t i n t h a t p e r s o n n e l a d m i n -i s t r a t i on i s p r ov i ded by - t he Hun t sv i ll e Oper a t i on and techn i ca l adm i n i s t r a -t i on i s 2 r ov i ded by t he Sys t em s T es t Depar t m en t of t he M ichoud Oper a t i ons .T h i s d e p a r t m e n t s t a t i c - t e s t s all s t a g e s b u i lt by C h r y s l e r .


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A l l t h e en g i n ee r i n g d ep a r t m en t s of C h r y s l e r H u n t sv il l e r ep o r t t o t h eE n g i n ee r i n g M an ag e r .

T h e S y s t e m s E n g in e e ri n g D e p a r tm e n t p e r f o r m s l a u nc h s y s t e m d e s i g n ,deve lopment , and modi f i ca t ion , inc lud ing l aunch f ac i l i t i es , veh ic le sy s t e m s ,g r o u n d eq ui p m en t, i n s t r u m en t a t i o n , an d au x i l i a r y eq u i p m en t i n s u p p o r t ofboth KSC and MSFC.

T h e E l e c t r i c a l a n d E l e c t r o n i c s E n g i ne e r in g D e p a r t m e n t i s e ng ag ed i n t h eeng ineer ing d es ign of gu idance , co n t r o l , an d b o th a i r b o r n e an d g r o u n d i n s t r u -m e n t at i on s y s t e m s .

T h s S t r u c t u r e s a n d M e ch a n i cs E n g in e e r in g D e p a r t m e n t i s e n ga g ed i n t h een g i n ee r i n g an d d e s i g n of sp ace veh i cl e s t r u c t u r e s an d p r o p u l s i o n sy s t em san d ev a lu a t in g t h e f l ig h t ch a r a c t e r i s t i c s of sp ac e v eh i c l e s .

T h e E n g i ne e r in g C o m m u n i c at i o ns D e p a r t m e n t s u p p o r t s C h r y s l e r a e r o -s p a c e a n d fa b r i c a t io n p r o j e c ts a n d M S F C l a b o r a t o r i e s i n t h e p r e p a r a t i o n a n dreproduc t ion of a var i e ty of t echn ic a l docum ents inc lud ing ma nua l s , hand-b o o k s , p r o c e d u r e s , s p e c i f i ca t i o n s , s t a n d a r d s , p u r c h a s e d e s c r i p t i o n s , r e -p o r t s , s t u d i e s , b r o c h u r e s , c h a r t s , a n d s p e c i a l p r o j e c t s . T h e d e p a r t m e n ta l s o m a i n ta i n s a t e c h n i c a l l i b r a r y a n d m i c r o f i l m f i l e.

The Draf ting and Des ign Dep ar tm ent p rov ides des ign docu menta t ion ofm i s s i l e a n d s p a c e v e hi c le s y s t e m s , c o m p o n en t s , a n d l a u nc h s u p p o r t e qu i p-m en t ; e s t ab l i sh e s en g i n ee r i n g d o cu m ent a ti o n p l an s an d p r o g r am s , an d co -o r d i n a t e s d r a f t i n g an d d e s i g n r e q u i r e m en t s w i th o t h e r en g i n ee r i n g f u n ct i o nsof C h r y s l e r and cu s t o m e r ag en c i e s .C. FLORIDA OPERATIONS

C h r y s l e r F l o r i d a O p e r a t i o n s , m a n n e d by b o th M i s s i l e D i v i si o n a n dSpace Div i s ion per sonne l , p r o v i d es o ne of t h e m o s t c o m p l e t e en g i n ee r i n gan d m an u f ac t u r in g f ac i l i t i e s i n t h e C ap e K en nedy a r e a i n su p p o r t of b o t hNASA and the A i r Fo rc e .

E n g in e e ri n g a nd t e c hn i c al p e r s o ~ n e l r e a c t i v e ly e n ga g ed i n la u n c hcomple x des ign , f ac i l i ty equ ipment ins ta l l a t i on and modi fi ca t ion , l au n chf ac i l i ty ch eck o u t, v eh i cl e l au n ch p r ep a r a t i o n , an d f ac i l i ty r e f u r b i sh i n g a f t e rl au n ch f o r t h e S a t u r n I / I B , at la.^, T i t an , M i n u t em an , an d C en t au r v eh i c l e s .T he m a n u fa c t ur i ng f a c i l i t i e s p r o v i de e l e c t r i c a l / e l e c t r o n ic a n d m e t a l f a b r i c a -t i o n cap ab il i t i e s i n su p p o r t of t h e en g in ee r in g se r v i c e s .


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I n c r e a s e d S-IB m i s s i o n c o n t r a c t r e s p on s i b i li t i e s h a ve f u r t h e r b r o a d en e dthe scope of wor k perf or me d and the number of people engaged a t F lo r i daOpe ra tions . With th i s inc re a se d re spons ib i l i ty , a r e o rga n iz a t ion of theF lo r ida Ope ra t ions ha s be e n in i t i a t e d to inc lude se c t ions fo r Pe r son ne l ,Admin i s tra t ion , Me c ha n ic a l Eng ine e r ing , In s t rume n ta t ion Eng ine e ring ,E le c t r i c a l a nd R F Eng ine e r ing , Log i s t i c s Eng ine e r ing , La unc h SupportEquipment Enginee r ing , Qua l i ty Engin eer ing , Tes t ing Engineer ing andOpera t ions Engineer ing . An o rga n iz a t iona l c ha r t w ith we l l de f ine d se c t io nfunc t ional r e spons ib i l i ty ha s not be e n e s ta b l i she d at the t im e of t h is p r in t ing .


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ESCAPE TOWER29.1 ft I i

PAYLOAD

C-H 258

F I G U R E 9 . SATURN I B CONFIGURATIONS


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SECTION 111. SATURN IB VEHICLE DESCRIPTION

A. GENERAL DESCRIPTIONFigu re 9 shows the ma jo r c ha rac t e r i s t i c s of Sa tu rn IB , t he s econd-

genera tion su cc es s o r t o Sa tu rn I , and by f a r t he mo s t power fu l i n i t s pay loadc lass be ing man ufac tured today . The Sa t urn IB two-s tage veh ic le i s capableof inject ing a ba sic payload of ap pro xim ately 3 7,0 00 pounds into a 10 0-naut i -ca l -mi l e o rb i t . With a Cen tau r t h i rd s t ag e , i t i s c apab le of de l ive r ing anear th -esc ape pay load of appro ximate ly 12 ,00 0 pounds , o r a Voyager pay loadof ap pr ox im ate ly 9 , 000 pounds , to the P lan e t Ma rs . The two-s tage veh ic lei s app rox ima te ly 191 f ee t l ong ( inc lud ing the l aunch e scape sys t em ) , app rox i -ma tely 21 f ee t a t t he l a r ge s t d i am e te r , and we ighs app rox ima te ly 1 , 262 ,400pounds a t l i fto f f. E igh t t a i l f ins on the S- IB s tag e provide suppo r t and ho ld-down poin ts fo r l aunch and , u nder c er ta in condi t ions , ae rody namic s tab i l i tyduring f l ight .

Eight l iqu id-fueled Rocketdyne H- 1 eng ines , eac h developing 200, 000pounds of thr u st , pow er the S-IB s tage. The fou r ou tboa rd engines a r e g im-bal moun ted fo r d i r ec t i ona l con t ro l . A s in gle 200, 000-pound t h ru st L H 2 / L O XRocketdyne J - 2 engine power s the S-IVB s tag e . The engine i s g imb al mountedto provide p i tch and yaw cont ro l .

The S-IVB s tage a t tach es to the S- IB s tag e th rough the S-IVB af t in t e r -s tage. The a f t in te r s tage i s bo lted to the sp id er b eam of the S- IB s ta ge , andS-IBIS-IVB sep ara t ion o ccu rs be tween the S- IVB af t sk i r t and the S-IVB af ti n t e r s age .

A 260 - inc h -d i am e te r , 36 -inch -high, unp re s s u r i z ed , i n s t rume n t un i t i sloca ted be tween , and a t tached to , t he S -IVB fo rwa rd sk i r t and the pay loadadap te r a s sem bly . The in s t r um en t un it houses t he veh ic le con t ro l sy s t em ,gu idance and con t ro l sy s t em , t r ack ing sy s t e ms , and power supp l i e s .

A payload asse m bly , cons is t ing of the Apollo spa cec raf t with the launchescape sy s t em a t t ached , m a te s t o the i n s t ru men t un it t h rough the pay loada d ap t er a s s e m b l y . The Apollo spa ce cra f t con s is t s of a comman d module , ase rv i ce modu le , and a l una r ex cu r s ion modu le . T h e se m o d ul es a r e a r r a n g e dso tha t t h r ee a s t ro nau t s can ma ke a l una r o rb i t a l r endezvous app roach to t hemoon , exp lo re i t s su r f ac e , and r e tu rn t o ea r th . One of the Sa tu rn IB ' s mi s -s ions i s t o t r a in a s t ro nau t s i n t h i s te chnique .


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A Saturn IB thr ee- s tage configuration use s the f l ight -proven Centaur a sa th i rd s t age . Two res tar ta ble LH 2/L Ox fueled P ra t t and Whi tney RL-1OA-3engines power the Centau r. Other configurat ions under study for improvingthe capa bil i t ies of the Satu rn IB boos ter include using proven sol id o r l iquidst rap-on uni t s , the mixing of fluorin e with LOX called FLOX, and elongatingthe S-IB propellant containers. The se advanced S -1B sta ge configurat ionscould in cr ea se the payload capa city of the e ntir e vehicle by app roxim ately40 percent.

The black and white painting pat te rn of th e Satu rn IB vehic le a ids groundtrack ing stat ions in establishing o rientat ion of the vehicle durin g i t s ini t ia lsta ge of flight. Bec ause of heat t ra ns fer considerat ions, the fuel conta inersof the S-IB sta ge a r e painted predo minantly black and the LOX co ntaine rs a r epainted white. The launch esca pe tower i s painted red, and a red "UNITEDSTATES" on a white background i s painted on the S-IB stage fuel co ntai ner s.The paint ing adds approxima tely 1, 000 pounds of weight to the ve hic le.B. VEHICLES NOMENCLATURE

The following info rmatio n is fo r or ientat io n and fami l iar izat ion withvariou s Saturn IB vehicles and s tage elemen ts that wi l l be produced. Thedynamic te st vehicle , the faci l i t ies checkout te st vehicle , and the tes t s ta gesassoc iated with each a r e indicated, together wi th a se r i es of spec ial te s tstag es. The thr ee cate go ries of fl ight vehic les (prototype, qualificat ion, andproduct ion) a r e identi f ied, and the s tage elemen ts and inst rume nt uni t s ar edesignated by name and num ber. Table s 2 and 3 show a complete breakdownon the vehicles and stage elem ents.

1. Dynamic Te st Vehicle (SA200D). The dynamic te st vehicle wil ldupl ica te the s t ruc ture s , m as s chara c te r i s t i cs , and essen ti a l- sys t em s incor-pora ted in the Saturn IB fl ight configuration. The vehicle, placed in thedynamic te st tower , wil l be used to verify vehicle bending mode s and fr e -quencies under simu lated Iton pad tt and fl ight condit ions. The gr ea t ma jor i tyof engineering changes wil l res ul t f r om findings determined f ro m tes ts con-ducted on this vehicle.

2. Fa ci l i t ie s Checkout Te st Vehicle (SA200F). The fac i l i t ie s checkoutte st vehicle wil l cons ist of the S-IB -F stage and the S-IU-200 V/500 V e le -me nts. The faci l i t ies checkout wil l verify operat iona l stat us of complex 34and i t s compatibi l ity with the fl ight vehicle, This will include handling andere ct io n of the Saturn IB, ser vic e s t ruc ture adjustmen t for enclosing andproviding acc e s s to the veh icle, verific at ion of a l l launch s upp ort equipmentconnections, oper at ion of the pneuma tic sy ste ms , oper at ion of the propellanttr an sf er and loading sys tem s, and checkout of the environm ental contr olsys t em.


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,TABLE 2. GROUND TEST VEHICLE NOMENCLATURE

TEST VEHICLES

IDYNAMIC TEST

VEHICLE

I SPECIA L TEST STAGESI f

FACILITIESCHECKOUTVEHICLE

INSTRUMENT UNITVIBRATION TEST

S-1u-200v1500v

INSTRUMENT UNITASTRIONICS TEST

S-IU-2OOA!BREADBOARD MODEL:

L

1 SA-200D 1 I SA-ZOOF1STAGES STAGES

INSTRUMENT UNITSTRUCTURES TEST

S-Iu-2ooS/5ooS

I 1S-IVB-D

1 S - I B - D 1 wH / 1 fi:E 1 P A Y L O A D 1 I I I 1S-IB-F I S-IVBIIB-F ISATURN

ADAPTER


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3 . Captive F i r i ng s . Ea ch stage (S-IB and S-IVB) of e ac h vehicle w illbe s ta t ic tes ted p r i or to use i n a f l ight vehicle .

4. Fligh t Vehicles . Table 3 pre sen ts the va r ious s tage combina t ionscomprising a given fl ight vehicle.C. UNIT NUMBERING AND COMPONENT DESIGNATION

The vehic le i s d ivided in uni ts for quickly determining the physical loca -tion of el ec tr ic al and mec hani cal com ponents.

The un i t number ing method fo r e lec t r i ca l and mechan ica l re fe rencedesignat ions ( finding num ber s) i s adapted f r om MIL-STD- 16. F igure 10identi f ies the ba si c vehic le uni ts. Uni t locat ions a r e a s foI lows:

Units 1 through 8 - The four inboard and four outboard engines andthe i r imme dia te a r ea be low the fi rewal l .Unit 9 - The th rus t f ram e a re a and a re a be low propel lan t con ta inerbulkheads , including the lower s ki r t s of propel lant tanks .Un i t 10 - Prop el lant conta iner ar ea , upper bulkhead to lowerbulkhead.Unit 11 - The sp ider bea m a re a and a r ea above p ropel lan t con ta inerbulkheads . Also, the antenna panels a r e included i n Uni t 11.Unit 12 - The ins t rument compar tment loca ted in the top s k i r t offuel conta iner number 2.Unit 13 - The ins t rum ent comp artment located in the top s ki r t offuel conta iner number 1 .Units 14 and 15 - deleted.Units 16 through 23 - Eight ta i l f ins .

E lec t r ica l components ins ta l l ed in a g iven uni t a r e des igna ted a s sub-ass em bli es of that unit and a r e ident if ied by means of a coded num be rl le t tercombination.

A typic al compon ent designation code will contain the following: (1) thebas ic re f e re nce un i t (by numb er ) , (2 ) the subassembly (by le t t e r ) , ( 3 ) the


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UNIT-900 PAYLOAD

TANKS

C-H 7887

FI G U RE 10. SATURN IB STA GE AND UNIT DESIGNATIONS

3 0


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number ass ign ed to the su basse mbly (by num ber) , (4 ) the name of the compo-nent (by le t te r) , and (5) the num ber assign ed to the component which differ -entia tes tha t component f ro m identica l unit s in th is or o ther subas semb l ies .EXAMPLE 1 Relay

TSpecif ies that this i s the No. 1 re lay .Indicates that the component is a re lay .

Indicates th is i s the f i r s t "All subas semb ly.

-1ndentifies su ba ss em bl y "A" of the in st ru m en tcompar tment .-Locates th e re la y i n uni t 12, an ins t rum ent com par tm en t.

EXAMPLE 2: Te rm in al E207 of M ain Distr ibu tor

Term ina l num ber.

Ind icate s an e l ec t r i ca l t e rm ina l .Locates the te rm inal in the f i r s t "A" subassembly .

Ind icate s t e rm ina l i s i n a n "A" subassem bly .I Locates the te r min al in uni t 12.

D. S-IB STAGEThe S-IB stage (Fig. 1 ) , manufactured by Chry s ler Corpora tion a t

Michoud, i s approx imately 80 feet long, 21 feet in dia me ter , and has a f inspan of a pprox imately 40 feet . A stage systems simplif icat ion and weightreduct ion ef for t , combined wi th mor e powerful engines , a l lows lar ge r pay-loads to be launched by this s tage than original ly planned. Compared to theS-I stag e, s ignif icant weight reduction ha s been achieved in the S-IB stagethrough des ign mod ification , deletio n of compo nents, and elimina tion ofcomplete sys tem s. The ma jor changes include:


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A N T IE l G H

HE A T

1.

- SLO SH B A F F L E ST 70" D IA . T AN KS

t

!d C-H 8459

F I G U R E 11. S-IB STAGE


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Elim inat ion of the LOX-SOX disposa l s yst em .Elim inat ion of LH2 vent and exhaust syste m.El iminat ion of movie and TV ca m er a sy s te ms .S ix ty p er cen t r educ t ion in in s t rumen ta t ion mea su rem en t s andat tendant equipment .Fo ur la rg e and four s tub ta i l f ins rep laced wi th e igh t swept-de s ignident ical f ins .Tai l sect io n ass em bly modif ied to red uce weight.Prop el lan t container sk i r t s k in th icknes s reduced .Spider bea m shor tene d , and bea ms and sp l ice p la tes reduced inthickne s s .Re t rom otor s re located f r om S-IB s tage to S-IBIS-IVB in te r s tage.Eli mi na tion of COX check valves.Subst i tut ion of a comp uter-c ontrol led switch selec tor f l ight con trolsys t em fo r the f ligh t sequencer sys t e m p rev iously u sed .

Other changes ef fective on the S-IB s tage a r e a reduct ion in e lec t r ic al com -ponents and the use of hel ium in stead of GN2 for fuel tank pre ssu riza t ion .Addit ional data on the S-IB s tage a r e presen ted in tab le 4 .

The ba se of the S - IB s t age i s t he t a i l sec t ion th rus t s t ruc tu re a ssembly .The eight engines at tac h to the thru st s t ru ct ur e aft of the f i rewa ll . The en-g ines a r e par t ia l ly enclosed by the ta i l shrouds and heat sh ie ld , and only theengine th rus t cha mbe rs and hea t exchangers a r e v i s ib l e . Engine th rus t i st r ansm i t t ed f r om the th rus t s t ruc tu re th rough the LOX con ta iner s to thesp ider beam un i t a ssembly .

The container sect io n cons is t s of a 105-inch-diam eter ce nte r LOX con-ta i ne r , four 70- inch-d iam eter LOX container s , and four 70- inch-diameterfuel containers . The e igh t 70- inch conta iners a r e c lus tered around the 105-inch container . The com bined LOX capa city of the 105-inch LOX conta inerand the four 70-inch LOX conta iners i s approximately 622,000 pounds. Thecombined fuel capaci ty provided by the four 70-inch fuel contain ers i s ap-pro xim ate ly 260, 000 pounds. The fuel cont ainer s a r e mounted to the s piderbe am uni t asse mb ly wi th f loat ing a t tachments to a llow for LOX container


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TABLE 4. S-IB STAGE STATISTICAL DATA

shrinkage when the boo ster i s loaded with l iquid oxygen. Two 20-cubic-footcapac i ty , h igh-p ressu re he l ium (H e) sphere s a r e m ounted in the fo rw a rdsect ion s of fuel conta iner s F - 3 and F-4. I n s t ru m e n t c o m p a r t m e n ts a r e l o -ca ted in the forward sec t ion s of fue l conta iners F -1 and F-2 .

Gr os s Weight a t LiftoffPro pel l ant WeightEngines (8)Thru s t pe r EngineTota l Th rus t (Sea Level )Valves and Contro l DevicesM easurem en t s dur ing F l igh tE le c t r i c a l and E lec t ron ic C om ponen tsEle c t r ic a l Network Connect ions

(Excluding Inte rna l) of AboveComponents

Wiring UsedSt ruc tu ra l Fabr i ca t ionFina l A ssem blyNote : Al l f igures a r e approximate .

The sp ide r beam fo r m s the fo rw ard s t ru c tu re of the s t age and s e rv es toanch or the forwa rd end of the prope llant co ntainer s . Seal p la tes cover theforw ard sid e of the sp ide r beam .

971, 700 l b s.882,400 lbs .H- 1 Rocketdyne200, 000 lb s.1. 6 mil l ion lbs .3103001, 708

73,00053 miles27 weeks17 weeks

1. Tai l Area . Ins ta l la t ion of the water quench and b ar re l hea ter sy s-t e m , engine purge sys t em , LOX and fue l wraparound suct ion l ine s , lowerLOX rep len ish ing l ine , and f i r e de tec tion sys t em t r ans fo rm the s t ruc tu ra lta i l sec t ion asse mb ly in to the ta i l unit assem bly . To ut i l ize opt imum ac -cess ib i l it y , t hese ins t a l la t ions (F ig . 12 ) a r e norm al ly pe r fo rm ed be fo re thec lus ter in g opera t ion .

The boat ta i l condi tioning and water quench sy s te ms a r e per fora ted p ipesrouted fr o m a quick disconnect coupling a t the heat shield up the shrou d andalong the thrus t out r igg ers a t f ins I, 11, 111, and IV to the c enter b ar re l .Th i s i s a th reefo ld sys tem : f i r s t , it prov ides the necessa ry w a te r quenchcapabi li ty for f i r ings ; second, i t provides a me ans to purge the ta i l a r e a byground sou rce ; and th i rd , i t provides the nec ess ary duct ing for ground heat -ing of the tai l ar ea .


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The engine purge sy ste m provide s for the routing of engine pur ge l in esf r o m the two umb il ical s erv ice plates on the shroud to the purge manifold i nthe cen te r ba r re l a s sem bly . Lines extend fro m the manifold through thefir ew all to each of the engines. Eac h engine purge sy ste m co ns ists of: LOXpump seal purge and gearbo x pres suriz at ion , LOX dome purge, gas gene ra-to r LOX injector manifold purge, and thr us t cha mber fuel inje ctor manifoldpurge . The LOX pump se al purge and gearbox p re ss ur iz at io n obtains GN2f ro m the con t ro l p re s su re spheres . The rem ain ing purge sys t em s obta inGN2 f r o m the ground co ntrol so urce.

The 1. 5-in ch- diam eter GOX lin es fr o m the GOX manifold to the outbo ardengines a r e pref i tted for ins ta l la t ion af ter the engines a r e ins ta l led . Themech anical components of the f i re detect ion syste m a r e instal led, and theinfl ight hea t sh ield panels and s t ar a ssem bly a re pref i t ted . Te s t conf igura-t ion panels a r e used for s ta t ic tes t . The infl ight panels a r e re ins ta l led dur -ing pos ts ta t ic and prepara t ion for sh ipment opera t ions .

The component instal lat ions i n the af t s ki r ts of a l l the LOX c ontainerunit asse mbl ies ar e a lm ost the same for each conta iner (Fig . 13). Twosuction l ine bal l roto r LOX shutoff valves (pre valv es) a r e instal led alongwith the actuat ing pr es su re tubing and various tubing as sem bli es used f orp re s su re pickup, control , e tc . The LOX fi l l and dr ain valve i s instal led onthe su mp of con tain er L-3.

The aft sk ir t of fuel container F- 3 contains the con trol pr es su re GN2storage sphere with the associa ted regula to rs , cont ro l va lves , and connect ingtubing. The cont ro l pr es su re sy s tem suppl ies GN2 pr es su re to opera te thee lec t r ica l ly cont ro l led pressur e-op era te d fue l vent va lves , LOX vent va lves ,the LOX and fuel pr ev alv es , and the LOX and fuel f i l l and d ra i n va lves. Thefuel f i l l and drai n valve i s located in the af t s ki r t of fuel container F- 1. Thesys te m suppl ies pr es su re for pressu r iz in g the turbopump gearbox es , purgingthe LOX seal s , and purging the calo rim ete rs .

Measu rement rac ks and d is t r ibutors a r e loca ted in the af t sk i r t s of thefuel containers . Some of the measu r ing rac ks and e lec t r ica l d is t r ibu tors a r eshown in f igure 13. F o r addit ional informa tion ref er to the Satur n IB Fl ightMeasu remen ts Manual .

F i g u r e 13 shows the LOX and fuel interconnect lines and suction lines.Eac h outer container supplies one inboard and one outboard engine. The LOXcon tain ers a r e interconnected throu gh the sump of the 105-inch LOX con-tainer unit . The LOX replenishing s ys tem i s routed fr om the heat shield tothe sump of LOX container L-4.


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The four inboard engines ar e r igidly mounted to the thr ust s t r uct ureasse mbly i n a squ are pa t te rn around the centerl ine of the vehicle. The en-g ines a r e canted ou tward a t a th ree-d egre e angle . A flame shield and ac -ces s chute fo rm s a heat ba rr ie r between each of the inboard engines. Addi-t ional engine co mpa rtme nt tempe rat ure control is provided by the heat sh ieldand the f lexible f lam e curtains. The inboard engine gas gener ators a r eexhausted through the inboard turbine exhaust s yst em and heat exchange r.GOX for p re ss ur iz in g the LOX tanks i s obtained by routing LOX through theheat exch ange r and converting it to gaseous oxygen. The gaseous oxygen i srouted thr oug h a 3-in ch GOX manifold to a GOX flow-control valve and thenthrough the ce nte r LOX tank to the LOX pr es su riz at io n manifold (GOX di st ri -but ion system).

The outboard engines (Fig. 14) a r e gimbal mounted to provide a move-ment of plus o r m inu s 8 deg ree s by any one actuator . Engine gimbaling i saccomp lished through two actu ato rs operat ing in a closed hydraulic syste m.Gimbaling act io n i s ini t iated by e lec tr ic al s ignal fro m the guidance sys temthrough an e lect ro-hydrau l ic servo valve on each actuator .

Flex ible purge and propel lant bubbling l ines to the engine fro m the f i r e-wall permit engine gimbaling. The final length of the 1.5 -in ch GOX line tothe outboard engine is flexible. The turbine exhaust sys tem i s a componentpa rt of the outboard engine, and as pir at es through a port on the periphery ofthe engine nozzle. This type of setup for the exhaust s yst em con serv esspace and perm its engine gimbaling. The f lexible f lame curta ins around theengines, while preventing exce s sive engine compa rtment t em per atu re s ,al low free dom of movement for the engines.

Eight swept fin s, four inboard engine turbine exhaus t fai ring s, e igh t a i r -scoop skins, and four engine s kir ts a r e instal led on the tai l of the S-IB stage.The tu rb ine exhaust fa i r ings asp i ra te the exhaust ga ses f r om the inboard en-gines. The airsc oop s and engine s kir ts di rec t the flow of a ir around the tai lsect i on to control tai l heat ing and aerodyna mic loading on the engines.

At the forw ard end of the tai l unit , 60-degree fairin g as se mb lie s providea n aerodynam ic se al between the propel lan t container asse mbly and the ta i luni t assembly.

2. Propel lan t Containers . The container ar ea (F ig . 15) encomp assesthe four fuel tanks , the five LOX tanks , and pertin ent auxilia ry components.The re a r e m ore s imi la r i t ies than d i f ferences between the individual con-t a iner s . F o r a summa tion of sim ila r and different cha rac ter ist i cs, ref er totable 5 and figure 15.


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ANTISLOSHBAFFLES-

F I G U RE 15. PRO PEL LAN T CONTAINERSC-H


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TABLE 5. MAJOR S IMILARITIES AND DIFF ERE NC ES OF CONTAINERS

a. The center LOX conta iner unit ass em bly in ternal a r ran gem ent60C10130 is 105 inc hes i n diam ete r and 749.679 inche s long. In addit ion tothe components l i s ted in table 5 , the cente r tank has a sump and fue l in ter -connect manifo ld loca ted i n the af t sk i r t .

Aft er the auxil iary components ( including connecting hardw are ,tubing, and wir ing) ar e ins ta l led in the fo rward and af t s k i r t s and on the skin ,

1

ContainerAll LOXAll fuelAll LOXAll fuel

LOX, 105"

LOX, L -2 andL-4, fue l , F-2and F- 4

F - 2 a nd F-4

All fuelAll LOXF u e l , F - 3and F-4All fuel

F u e l , F - 1and F-2

ComponentAnti- Slosh Baffles

Continuous and Dis-c r e t e L iqu id Leve lSensor Sys tem sGOX Line

LOX and Fu el Lev elSensor Sys tem

Purpose and UseTo help mainta in stable load

To indicate c oa rs e and f ineliquid quantity

To d i rec t ly p ressu r i ze 105"conta iner , and manifoldpr es su r iz e the 70" conta inersT o a r m s e p a r a t i o n a nd r e t r o -rocke t E B W f i r ing uni t s .To give t ime ba se changecommand to IU

IFu e l D ep le t ion IS e n s o r sSumps

20- Cub ic-Fo ot High-P r e s s u r e He S p h e r e sEle c t r i ca l C ableIns ta l la t ionsIns t rumenta t ionC om par tm en t

To initiate outboard enginecutoffTo improve propellantt r a n s f e r c h a r a c t e r i s t i c sTo supply hel ium for fuelt ank p ressu r i z ingRoute cables f ro m af t sk i r t sto ins t rum enta t ion a s se m bl i e sHouse s ins t rumenta t ion ,t e l em e t ry and e l ec t r i ca lcomponents


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t h e c e n t e r L OX c o n t ain e r u n it a s s e m b ly b e c o m e s t h e 1 0 5 - in c h - d i a m e te r L OXconta in er , un it a sse mb ly 60C10014.

b. The 70- inch LOX con ta iners a r e 747 .43 inches long and 70 inchesin d i a m e te r . A f t e r in s t a l l a t i o n of th e a u x i l i a r y c o m p o ne n t s , e a c h c o n t a in e rweighs approximately 3700 to 4100 pounds.

A f t e r c o m p on e n ts a r e i n s t al l e d o n t h e e x t e r n a l s k i n an d i n th e s k i r t s ,t h e c o n t a in e r s b e c o m e 7 0 -in ch L O X c o n ta in e r u n it a s s e m b l i e s . Tab le 6 i s aq u ic k r e f e r e n c e t o t h i s t r a n s f o r m a t io n .

TA BL E 6. CONTAINER IDENTIF ICATION

c . T h e 7 0 - in ch - d i am e te r f u e l c o n t a in e r u n it a s s e m b l i e s a r e743. 804 inc he s long. T a b le 6 i d e n t if i e s t h e c o n t a in e r s , t h e i n t e r n a l a r r a n g e -m e n t d r a w in g s , a n d t h e c o n t a in e r s a f t e r c o m p on e n t i n s t al l a ti o n . T h e i n t e r n a la r r a n g e m e n t of t h e f u e l c o n t a in e r s i s s im i l a r f o r a l l c o n t a in e r s ( F ig . 1 5 ) ;h o w e v e r , t h e r e a r e s o m e d i f f er e n c es . S e e t a b l e 5. T h e m o s t o b viou s d if -f e r e n c e b e tw e e n t h e fu e l c o n t a in e r s i s th e f o r w a r d b u lk h ea d s of c o n t a in e r sF - 1 a n d F - 2 t h a t f o r m i n s t r u m e n ta t i on c o m p a r t m e n t s , u n i t s 1 3 a n d 1 2 r e -s pe ct iv e ly . F e e d - th r o u g h a d a p t e r s fo r th e f u el p r e s s u r i z a t i o n s y s t e m a r ea l s o i n s t a l l e d o n t h e f o r w a r d b u lk he a d s.

Conta inerNumber

LOXL-105L - 1L - 2L - 3L - 4F u e lF - 1F - 2F - 3F - 4

Conta iner Unit Ass emb ly( I n te r n a l A r r a n g e m e n t )

Drawing No.6OClO13O6OClO13160C1013260C1013360610134

60610135606101366061013760610138

Conta iner Uni tA s s e m b l y ( A f t erComponent In-s a l l a t i o n )

Draw ing No.60C1001460C1000560c100066OC1OOO760C10008

60Cl000960ClOOlO60ClOOll60C10012


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E. S-IVB STAGEThe S-IVB stage (Fig. 17), manufactured by Douglas A irc ra ft Company,

i s a se l f -suppor t ing s t ru ctu re des igned for u t il iza tion a s the th i rd s tage ofthe Sat urn V vehicle and adapted a s the second stage of the Satu rn IB vehicle.The s tage, including the forward sk i r t and af t in ter s tage assem bl ie s , i s 59 .1fee t long and 260 inches i n diame ter .

Bas ical ly , the s tage i s a two-sect ion tank s t ru ctu re to which the forw ards k i r t a s s em b l y , a f t s k i r t a s s em b l y, a ft i n t e r s t age assembly , t he a ft i n t e r -s tage fa i r ing , and the th rus t s t ruc tu re a r e a t tached . An insulated commonbulkhead divides the tank str uc tur e into a forw ard LH2 tank and an aft LOXtank. The inte rna l surf ace of the tank cyl inde rs fe atu re s a mil led wafflesurf ace pat t ern . Ac ces s to the interio r of the LH2 tank is provided througha m anhole i n the top. Ac ce ss to the int er io r of the LOX tank i s providedthrough a detachable sump. A ring-type baff le i s ins tal led in the LOX tankto minim ize sloshing. An ext erna l tunnel extending fro m the forwa rd sk ir tassem bly to the a f t sk i r t a s sem bly houses var ious in t ras t age tubing , cab les ,and l ine s fr om the cold hel ium sp he re s mounted inside the LH2 tank.

1 . Tai l Area. The engine th rus t s t ru ctu re (F ig . 17) i s a t runcated coneof reinfo rce d skin and str in ge r construct ion. The large end of the cone isatt ac he d to the aft dome of the LOX tank. The engine , engine hyd rau licactuat ing components, and a con tro l p re ss u re he lium sphere a r e mounted onthe th rus t s t ruc tu re . The cont ro l p r es su re sphere supplies ambien t hel iuma t 3 , 0 0 0 psig fo r pneuma tic ope ratio n of valves i n the LH2 and LOX sy st em s,and sup plies c onstan t purge fo r the engine gearbox. Two doors provide ac -ce ss to the th rus t s t ru ctur e th rough a t rapezoidal opening .

The aft in ters tage (F ig . 17) i s a cy l indr ical sk in and ex ternal s t r in gerst ru ct ur e located between the aft s ki r t f ield spl ice plane of the S-IVB andS-IB sta ge s and the inte rfac e of the S-IVB and S-IB sta ges . The int er sta gese rv es to t r a nsm i t s t ruc tu ra l l oads be tween the s t ages and a l so p rov ides a naerod ynam ic enclos ure between the s tages . There ar e provis ions for e igh tequal ly spaced mounting points on a 220-inch diam ete r c irc le for the int er -fa ce of the S-IB and S-IVB st ag es . Four r e t rom oto rs a r e mounted on theaft in ters tage aft of the s epa rat io n plane and at 90-degree inte rva ls aroundthe per iphery . The re t r om oto r s and suppor t b racke t ry a r e enclosed in ae r o -dynamic fa i r ings . The four so l id propellan t re t r om otor s produce a re tard ingfor ce on the S-IB s tage to prevent S-IBIS-IVB inte ract ion during separat ion .The re t r om oto rs ign i te , dur ing separat ion , 16 to 31 ~ni l l i se con ds f ter theshaped explos ive charg es a r e f i red that cu t the sk in a t the separa t ion p lanebetween the S-IVB and the S-IVB stage. A door located in the forwa rd port ionof the inte rsta ge provide s person nel ac ce ss for maintenance purpos es. Anaf t in ters tage fa i r ing i s a ttached to the r e ar of the aft in ters tage. The fa i r in g


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H Y D R O G E N

'ORWARD SKIRT

A U X I L I A R Y PR(S Y S T E M M O D U L

- A F T S K I RT

7 ETROMO

A F T I N 1

ITORS (4 1

- E R S T A G E

FIGURE 17. S-IVB STAGE


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provide s a n aerody nam ic shea th over the S-IB s tage sp ider be am and theup pe rm ost port ion of the S-IB s tag e propel lant container .

The af t s ki r t (Fig . 17) i s con structed of a luminum with a skin and ex-t e rna l s t r i nge r des ign . The af t umb il ical plate , a hydrogen feed l ine fair in g,th re e u llage rocke t mot ors , and two auxi l ia ry propuls ion sys tem (APS)modules a r e mounted on the a f t sk i r t . U llage mo to r f i r i ng i s t he f i r s t s t epin t he s epa r a t ion sequence . The ul lage mo to r s impar t f o rward acce l e r a t i o nwhen f i red ; th i s fo rce se t t l e s the fue l to provide a posi tive turbopump headand aid s S-IBIS-IVB s tage separa t ion. The APS con sis ts of the two APSmodules mounted 180 deg rees ap ar t on the sk in. Each module contains th r eef ixed s torab le -prope l lan t- fue led engines a r ra nge d to cont ro l a t t itude in thepi tch, rol l , and yaw planes . The APS i s control led by the vehicle guidancecomputer i n the ins t rum ent un i t. The APS main ta ins ro l l cont ro l dur ingS-IVB powered f l ight , and provid es complete a t t i tude control dur ing ea r t ho rb i ti ng and maneuve r ing exe rc i s e s . The af t sk i r t s t ruc tu re i s unp re s su r i zedand house s var io us el ec tr i ca l components of the propel lant control sys tem ,engine cont ro l sy s tem , the auxi l ia ry hydrau l ic pump moto r , two ba t t e r ie s ,and por t ions of the ins t rum enta t ion and te lem et ry sys tem .

2. Prope l lan t Conta iners . The LH2 conta iner , fo rm ed by the forwardend of the tank s tru ct ur e and the forw ard s ide of the common bulkhead, ha sa cap acity of app rox im atel y 10, 377 cubic feet . Inside s ur fa ce s of the LH2contain er have 314-inch polyurethane foam bonded to the wal ls . Gla ss c lothcoa ted wi th po lyurethane sea lan t c ove rs the foam. Pipes and f it tings a r evacuum jacke ted . Mounted ins ide the tank a r e fue l m as s , t em pera ture , andl iquid leve l se ns or s for prope l lant ut i l izat ion operat ion, propel lant loading,and ground moni tor ing d isp lay . E ight co ld-hel ium sph eres a r e ins ta l led inthe contain er to supply hel ium for inf light LOX t ank pressur iza t ion . The coldhe l ium i s expanded by pass ing i t th rough a hea t exchanger in the J - 2 enginetu rb ine exhaust sy s t em. A sc re en a t t he LH2 tank out le t provides vo rtexsup pre ss io n and fue l f i l t e r ing . Vent and re l ie f va lves a r e ins ta l led in thefo rw ar d end of the contain er. LH2 f i l l , dra in , and replen ish ing a r e accom -pl ished throug h one f i l l and dr ain valve located in the bot tom of the c ontaine r .

The LOX contain er , forme d by the af t end of the tank s t ru ctu re and theaft sid e of the com mon bulkhead, ha s a capacity of approxim ately 2, 828cubic feet . The suc t ion l ine i s a t tached to the sump, and an an t ivor tex sc re eni s mounted in the sump. LOX f i l l , dra in , and rep len ish ing a r e accompl i shedthrough one f i l l and dr ai n valve located on the bottom of the contain er. Ventand rel ief valves a r e instal led in the forwa rd end of the container . T e m p e r a -tu r e , m as s , and li qu id l eve l s enso r s a r e mounted in t he con ta ine r fo r p ro -pe l lan t management .


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3 . Forw ard Skir t. The forw ard sk i r t i s a 260- inch-diameter , 122-inch-long cylinder of typical skin and ext ern al str in ge r construction. Thesk ir t incorp orates provisions fo r mounting the Instrume nt Unit . Cold pl ate sa r e mounted to the wal ls of the sk i r t . Ins t rumenta t ion , an tennas , ba t te r i es ,and other types of equipment a r e mounted to the plates . Env ironm ental con-ditioning for th e instru men tation i s accomplished by pumping liquid coolantthrough the cold plates f ro m the ground support instru men t unit ther ma l con-ditioning system . The forw ard sk ir t contains the umbil ical plate fo r thehydrogen vent line and elec tr ic al umbil icals. The te lemetry antennas a rea ls o mounted on the sk i r t . Provis ions for ins ta l ling two re t rom oto rs a r eincorporated i n the sk ir t , a l though such mo tors wil l only be instal led in con-junction with a th ree -s tag e configuration of the Saturn IB vehicle. Ac ce ss tothe forward sk i r t i s through the acces s door in the ins t rument unit . Mountingfor a remo vable work platform i s provided in the s kir t .I?. INSTRUMENT UNIT

The Sa turn IB ins t rument uni t (Fig. 18) i s an unpre ssur ized , cy l indr ica l,load- supporting st ru ctu re of sandwich- type bonded cons tructio n 260 inchesin d iameter and 36 inches long. The s t ru c ture i s const ruc ted in thr ee 120-degre e s egm ents, each having a forward and aft interstage connecting r ingsegment . These three segments a r e assembled a t the launch complex .Mounted on the in teri or skin a r e honeycomb panel cold plates to which ismounted the ele ctr i cal and elec tronic equipment. Environmental conditioningis provided by a ther ma l conditioning sys tem that pumps a w ater-methonalmixt ure through the cold plates. Prela unch cooling i s accomplished usingground sup port equipment. Jnflight conditioning i s accomp lished by the on-board closed-loop condit ioning sy ste m that incorpor ates a n ele ctr ic mo tor -dri ven pump and a heat exchanger to complete the refrig era t ion cycle ,

The ins t rument unit houses an e lec t r ica l system , ins t rumenta t ion sys-tem, rad io f requency system , environmental contro l syste m, the emergencydetection system, and the guidance and control system.

The guidance, control , and monitoring sy ste ms govern perfo rman ce ofthe vehicle throughout a maj or p ortion of i ts mi ssi on, Instru men t unit con-tr ol begins a t liftoff and includes injection of the combined S-IVB stage,instru ment unit , and Apollo space craft into eart h orbit , and extends throughpart ic ipat ion in ini t ia l orbi ta l maneuvers. This period includes the followingphas es of f l ight: f i rs t stage powered f l ight , f i r st stage separat io n, secondstage powered flight, in jec tion into ear th orb i t , ea r th orb i ta l coast s tab i l iza-t ion, space craft turn-around and docking maneuver, and through spa cec raf twithdrawal fr om the remai nder of the launch vehicle in ea rth orbit . Theins tru me nt unit c ea se s functioning when it i s jettisoned in conjunction withthe S-IVB stage a t the conclusion of the aforementioned maneu ver. The


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FIGU RE 18. INSTRUMENT UNIT

guidance and con tro l equipment includes an ST-124 (four g imbal gyro-s tab i l ized) ine r t ia l guidance p la t fo rm, the p la t fo rm e lec t ron ic box , a gu id -ance s igna l p r oc es so r , a d ig i ta l compu te r , and a p rogram ming dev ice . Agaseous n i t rogen a i r -bea r ing supp ly i s used in con junc tion wi th the ine r t ia lp l a t fo rm .G. PAYLOAD

Fi gu re 19 of the Apollo spac ecr af t i l lu s tr a te s in cutaway view the com -mand module (CM), se rv ic e module (SM) , lunar excurs io n module (LEM), andthe sp ace cra f t adapte r (SA), each of which is a m ajo r component of the Apollos p a c e c ra f t . Not shown in th i s v iew i s the launch escape sys t em , a l so a m ajo rcomponent of the spac ecra f t , which i s a t tached to the forw ard end of the com -mand module . The CM conta ins the thr ee as tr ona uts and a ma jor i ty of thesp ace cra f t contro l equipment . The SM provides propuls io n for the combinedCM and SM in s pace . In t he S a tu rn IB /Ap o llo e a r th o rb i t a l t e s t p ro g ra m , t h eSM ma in propuls ion engine wil l be tes ted and wil l be u t i l ized to prope l andma neu ver the CM/SM com binat ion in to the prop er posi t ion for ree ntr y of the


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CM and i t s as t ronau t c rew into the ea r th ' s a tmosphe re . The t e s t p r og ramwill evaluate the SM for future u se in the Sa turn V progra m. In the Sa tu rnV pro gram , the SM propuls ion syste m wi ll be used to make mid- course co r-rec t ions of the spa cecr af t enroute to the moon, to propel the s pace craf t in topro per launch orbi t upon ar r i va l a t the dest inat ion , and to r e t ur n the CM,containing the astr on au ts, toward the ea rt h in the f inal pha ses of the lun armiss ion . The LEM wil l be tes ted dur ing the S a turn IB /Apollo ea r t h orb i t te s tprogram . The tes t s wil l eva lua te the LEM for future use in the Sa turn Vprogram. During the lunar m issi ons of the S aturn V pro gra m, the LEM wil lbe ut i l ized in the following mann er. The LEM ( asc ent and descent sta ge s incombination) wil l land astro nau ts on the lunar sur face for explora t ion andaf te rwa rds wi ll r e tu rn them ( in the LEM ascent s tage) to the CM/SM com-bination orbiting overhe ad aroun d the moon. Upon completion of this re nd ez -vous and tr an sf er of the astr ona uts back into the CM, the LEM (asce nt stag e)wil l be je t tisoned to orb it around the moon. The CM/SM will pro pel theastr ona uts back toward the earth. Ea ch of the aforementioned Apollo sp ace-craf t mane uvers , required for the lunar mis s ion of the Sa turn V p r o g r a m ,wil l be executed during the ea rt h orbita l co ast period a s pa rt of the S atur n IBpro gra m. Thorough test ing of the Apollo spa cecr aft sy st em st capabil i t ieswi ll be perfo rmed dur ing the ear th orb i ta l coast per iod . The configurationof the L EM shown in this i l lus trat i on is a n ear ly design. Th i s LEM ea r ly de -s ign has a gene ra l t the l i cop te rbubble" forw ard face of the asc en t stage. Theascent s tage i s designed to ascend f ro m the moon af te r lunar explora t ion bythe as t ro nau ts ( in the Sa turn V program) . The LEM descent s tage i s designedto descend f ro m lunar orb i t and land upon the lunar surface dur ing the Sa turnV pro gram . The LEM descent stage wil l be left behind on the moon when theas t ronau t s r e tu rn to ea rth . Extensive development tests and redesign haveresu lted i n enlarge ment of the S-IVB stage propellant containe rs. This en-largement has necessi ta ted folding the LEM descent stage landing gear forcomp actness of s tora ge inside the spac ecra ft ada pter . The SM m ain propul-sion engine and the fuel and oxidizer propellant co ntainers a r e als o i l lustra ted.Two of the four re act io n control sy ste m (RCS) modules a r e shown. Each ofthese four modules con sist s of four reac t ion je ts which wil l be ut i l ized toprovide maneuvering capabili ty and at t i tude control in space. Expulsion ofgas through these RCS jets wil l provide the pulsed thru st vector control of theCM/SM combination which wil l be ne ces sa ry to effect pr eci se dire ct io n andstability.H. PROPELLANT DISPERSION SYSTEM (DESTRUCT SYSTEM)

The pr im ary purpose of the range safe ty command dest ruc t sys tem is toprovide a posi t ive me ans for term inating the vehicle f light upon comm andfr om the ground.


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'AGE

F I G U R E 19 . APO LL O PAY LOAD


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E.D.S. DISTRIBUTOR

Q - B A L L

I

2 O U T O F 3 VO T IN G F O R ABO R TAND CAPSULE COMMANDSR ED U N D AN C Y F O R V ISU AL

IN D IC AT IO N

COMMANDM O D U L E

2 O U T O F 3V O T I N G C I R C U I T

R AT E EXC ESSIVEAU T O M AT IC ABO R T

D E A C T I V A T E S W IT CHS- IB TWO ENGIN E

O U T A U T O M A T I C A B O R TD EAC T IVAT E SW IT C HH A N D C O N T R O L L E R

M A N U A L A B O R T

E N G 1 EN G 2 EN G 3 EN G 4 ENG 5 ENG 6 ENG 7 ENG 8C-H 8602-1

b

A P O L L O-.U.

I

T D K18

FIGURE 20 . BLOCK DIAGRAM SATURN IB EDS

R E D U N D A N TC IR C U IT F O R

V I S U A LIN D IC AT IO N

J

I

A N G L E O FA T T A C Ka

I T Y Y V Y I

AL A[

4 A

AL AA A A

T O2

T O K19

---

D A T AA D A P T E R

S- IVB- - --I B

-- -

---

R A T E G YR OSARMED FOR

A U T O A B O R T- - - - - - - - - - - - - - - - - -

20

--

S- IVB SEQUENCER

PR O PU L SIO N D IST R IBU T O R

T O K T O K21

D EST R U C T C O N T R O L L ER S

- -

L3& NGINES OUTPUTPIEN G IN E 1- - - - - - - - - -

D EST R U C TC O N T R O L L ER S

I I Y

4 1 + EN G IN E O U T PU T- M AINDISTRIBUTOR

--- - -


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of th is au tom atic abor t featu re i s possible afte r completion of the S-IB stagepowere d flight and co mm encem ent of the period of S-IVB sta ge powered flight.At th is t im e the Satu rn IB vehicle wil l have reached a n a l t i tude of approxi-ma te ly 42 naut ica l mi le s . At su ch a n a l t i tude the vehic le h as suffic ient spacein which to maneuver in the even t of e r ra t i c pe rformance . Also, f r om th i sa l t i tude the astr ona uts have adequate t im e to escape should the vehicle los epower and begin descent . The danger of f i re o r explosion wil l s t i l l be pr es -ent , but th i s danger wil l be g reatl y minim ized after successful completion ofthe f i r s t s t a ge se pa ra tion p roc e du re . The exac t t ime a t which the au tomat icabo rt featur e may be deactivated is determin ed by the requir eme nts of theindividual mi ss io n for each vehic le . A single ov err a te l ight will be energizedon the display panel before the a str on aut s in the CM whenever r at es of motiona r e exceeded i n any p lane. The l ight wil l be energize d by a dis cre te signalf r om the sen sor s in the ra te package . The l ight wi ll adv ise the as t ro nau t sof o ve rr a t e condit ions for use in making decisions reg ardin g manual abo rtaft er dea ctivation of the automatic abor t c ircuitr y . During S-IVB stagepowered f l ight , abo rt because of ove rra te condit ions wil l be in i t ia ted manually .The l im it s may be v aried to accommodate the conditions expected during eachpar t i cu la r f l igh t.

The lo s s of t hr us t fr om any two of the eight H-1 engines of the S-IB stagein i t ia tes au tomat ic abor t . Fo r spe cia l miss ion s the a s t rona u t s a r e p rov ide dwith the m ean s of bypassing this S-IB stage engine fa i lure autom atic abo rtfea tu re . Back-up capability fo r deactivation of the engine fai lur e autom aticab or t capabil i ty is provided i n the Satu rn IB launch vehic le sequencer.


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GLOSSARY

Definitiont e ma b o r t

AFRM

AMR

Apollo

att i tude

a z i m u t h

( 1 ) T o t e r m i n a t e , o r t o l i m i t t h e o b j ec t iv e s , a sa cons equence of a malfunction or ot he r un-sc he du le d c i rc ums ta nc e . (Re la te s to a fl ightmis s ion , a de velopme n t t e s t , e t c . )( 2 ) A m i s s i o n , t e s t , e t c . , t h at i s a b o rt e d ." A i r f r a m e . " Denotes a f l ight-weight moduleof the Apollo Spacec raft , man ufac ture d withha rd tool ing ( i . e . , nonimp rovised too l ing ; too l -ing in which m a j o r c ha nge s a r e no t a n t i c ipa te d ) ,a nd equipped with suc h spa c e c ra f t sy s te ms a sn e c e s s a r y t o a c co m p l i sh t he a s s i g n e d m i s s i o n .Antonym: boilerpla te .At lan t ic Miss i le Range . The Cape Kennedy,F l or i da , fac i l i t ie s of the At lan t ic Mi ss i l e Rangeincl.ude the lau nch com plex es fr om which theSa turn-Apollo spac e veh ic les a r e launched .The designation of the proj ect and the ass oc ia te dsp ace cra f t by me ans of which a manned lunarlanding i s to be accompl ish ed wi th in the p r es en tdecade . In Gr eek and Roman mytho logy , Apol loi s the god of p rophec y , a s we l l a s the god ofmu s ic , poe t ry a nd me d ic ine .

The angular p osi t ion of the spa ce vehic le withre sp ec t to a s e t of space-f ixed coord ina te axes .The a ngu la r d i s t a nc e , e xp r e sse d in de g r e e s ,m ea su re d c lockwise , be tween the d i rec t ion oft ru e Nor th ( in the Nor the rn H e misp he re ) o r Sou th( in the Southern Hemis pher e ) and the d i r ec t io n offl ight .


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Definitiont e mgimbals

GOX

GSEhypergol ic

IMCC

The mechanica l mount ing for a movable propu l -s ion engine in a S aturn l aunch vehic le s t age o rthe Apollo Serv ice Module. T he g i m b a ls p e r m i tthe engine to pivot about two mutual ly per pen -d i cu la r ax es t ha t l i e i n a pl ane t ha t i s e i t he r n o r -m al to o r near ly no rma l to the longi tudina l ax i sof the vehic le. So me or al l of the pro pul sio n en-g ines in each

Saturn IB Orientation

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