MONTHLY LITTLE JOE

PROGRESS II TEST

REPORT VEHICLE

LAUNCH

Report

No.

21

10 December

1964

Reference:

Par.

3.4.1

of NASA Revised

Statement

of Work 1964

GDC-62-361

21 September

NASA

CONTRACT

NAS 9-492

CONTENTS

Calendar SECTION A. B. SECTION

of Events I Contract Systems H Engineering 1. 2. 3. 4. Vehicle Launcher Technical Reliability

...................................

Status Integration

.............................. Interface .....................

................................. .................................. & GSE Support ............................ ........................... Control ..................

3 3 4 4 5

and Quality

SE CTION

HI Manufacturing 1. 2. 3. Material Tooling Fabrication ................................ ................................. ................................. and Assembly ..................... 8 8 8 9

SECTION A.

IV Launch 1. 2. Operations Site ............................ Operations Procedures ................................... ....................... and Support .............. 13 13 14 15

Launch Operations

B. SECTION A.

Logistics V Documentation 1. 2. 3. 4. 5. Periodic Other

............................... Reports ........................... Documents .................... ...................... ........................ .......................... iii

16 16 16 16 23 23

Scheduled

Unscheduled Approved December

Documents Documents Activity

CONTENTS(Continued) SECTIONVI A. Program Planning and Control 1.

2. 3. 4.

....................

28 28 28 28 28

PERT
Schedules WSMR Change

.................................
................................ Operations Control .......................... ............................

iv

CALENDAR

OF EVENTS

November

Convair

personnel

attended status for

meeting Mission

at WSMR A-002

with

NASAJoe II

MSC on schedule 12-51-1/BP-23}. November 5 - 6 Messrs. NASA-MSC, November 11 - 12 Mr. M. A. P.

(Little

S. Jaschke, visited Silveira, purposes.

O.

P. for

Littleton coordination visited

and M.

A.

Silveira,

Convair

purposes. Convair for

NASA-MSC,

coordination November 13 Messrs. NAA-S&ID, November 16 Messrs. visited report November 16 Mr. visited primacord November 19 Convair planning for George G. T.

W.

Batson,

J.

F. for

Proctor interface and L.

and

M.

P.

Ragusa,

visited Hyman,

Convair L. A-002

coordination. T. status Morris, and the GE-ASD, FRR

Riekert (LJII

Convair

to review

qualification

Mission Ratkovic, for mockup.

12-51-1/BP-23}. Corp./Downey, Little Joe H 12-51-2

Aeroject-General coordination of the

Convair

personnel meeting

visited concerning

NASA-MSC Mission

to attend A-004

preliminary Joe 1I

(Little

12 -51-3/AFRM-002}. November 23 Convair view personnel attended a preliminary for Mission readiness A-002 (Little reJoe II

{PRR}

at NASA-MSC

12 -51-1/BP-23}. November 23 - 30 Mr. nation BP-22}. COMING December Convair changes. December 2 - 3 Messrs. visit December December 4 8 Convair Launch M. Convair will E. for attend Dell the and P. S. Jaschke, of program at WSMR. Joe II 12-51-1/BP-23}. NASA-MSC, review. will personnel EVENTS to visit NASA-MSC to negotiate contract E. H. Jones, NASA-WSMR, on Mission A-003 visited (Little Convair Joe for coordi-

purposes

II 12-51-2/

purpose the FRR

of Mission

A-002

(Little

SECTION A.

I STATUS No. price 13 dated of $868,443, estimated price 14 is being 27 October a fixed fee 163 and 9 November 161 and including costs of $13,536,853. processed 1964 the and by NASA will contract as a result of negoin progam 1964 a fixed incorporated contract plus fee CCP No. This fee of 138,

CONTRACT 1.

Amendment 148, 150, in program increased for a total

139, crease

143,

152 through total program No. on 26 and 160, including

159,

162 into the

at an ina fixed

of $52,400.

amendment $815,174, 2. tiations portions price

to $12,721,679,

Amendment conducted of CCP No.

incorporate

specified

168 into

at an increase

of $436,040, 3. During

of $22,959. 1964, Contract Change Authorization

the

month

of November, by NASA. made

No.

67 through 4.

70 were plans the

initiated were

Tentative 171 during

in October 1964.

1964 to negotiate Negotiations were rescheduled

CCP not for

No. the

164A week

through

month

of November now been

accom-

plished during of 14 December B. SYSTEMS 1. continued BP-22. connect 2. components the associated 3. continued. North Design set

November 1964.

and have

tentatively

INTEGRATION/INTERFACE American of spacecraft is proceeding General program - Routine Aviation - Space and Information electrical changes test and starting configuration charge installation Systems interface BP-22 Division for type dis-

coordination testing Aerojet test

of spacecraft/launch umbilical, on schedule,

vehicle launcher with

in December. of nozzle with

Corporation and in support coordination

- Coordinated reviewed shaped of BP-22. in support

in support

of BP-23

Thiokol

of the

Little

Joe

II program

SECTIONH A. ENGINEERING 1. Vehicle a. Structural Design A center Algol manhole cover was designedto permit access into the vehicle for 12-51-2 configuration. Factory and field liaison continued on an as-neededbasis. b. Vehicle Control and Instrumentation Vehicle 12-51-1 field checkout has been completed, along with interface and integrated tests with the payload. A spin motor rate detection circuit was addedfor the roll rate gyro. Qualification testing has been completed on all componentsand subsystems, including the range safety subsystem battery and safe/arm units. Detail design for vehicle 12-51-2 is nearing completion. Checkout procedures are being prepared. c. Reaction Control andAerodynamic Control Systems Activity in these areas was confined to preparation of 12-51-1 vehicle for launch. Activity for December Support of launch operations at WSMRwill continue. Subsystem design for vehicle 12-51-2 will be completed and along with procedures will be reviewed with the NASA. Subsystemcheckout on vehicle 12-51-2 will be started at SanDiego.

2.

Launcher and GSE a.

Launcher Design for of the and upper and mast modification has been maintenance and umbilical completed. continued installation on the on an as-

BP-22

AFRM-002

Liaison

mast fabrication needed basis. b. GSE Design has been stallation Activity for of the

drawing

umbilical

rigging

fixture

for

BP-22

and

AFRM-002 in-

completed platform

and design for the range safety for BP-22 has been started.

system

December of the in January. Support Dynamics dispersion A-002), factors time as thrust, constant, control 30 November studies the drag, and were effects wind, completed hinge timing. development Attitude tests Control have Sysfor Mission performance pitch J umbilical will retract mechanism in mid-December using actual and discon-

Testing nect early 3. Technical a. Control Trajectory (Apollo of such command The been tem

equipment

be started

completed

delineating

on mission

moment,

pitch-up

integrated reported Tests,

system-vehicle Integrated 1964. digital the range control limits

by GDC-64-332,

A special to explore attack The found

five-degree-of-freedom the pitch-up were maneuver beyond acceptable

program

was

formulated of and simulation. mission.

cross-coupling of the gains for were

at angles explored

which effects

MSC analog

of unsymmetrical

to be within

a satisfactory

b.

Weight Analysis Monthly Weight and Balance Report No. 30 was published. Report No. 31, incorporating the final weight statement for vehicle 12-51-1 and addingvehicle 12-51-3, has been prepared.

Activity for December A memo report on Mission J (A-002} trajectory dispersion studies will be published. Results of the interaxis coupling studies (five-degree-of-freedom) for Mission J will be reported. Analog anddigital simulations of Mission N (A-003) and P (A-004) will be conductedto establish ballast requirements, RCSrequirements (or not), andpreliminary gains for autopilot control and pitch command. 4. Reliability andQuality Control a. Design Review and Monitoring Convair andvendor drawings and functional test and operation checkout procedures are continually reviewed for adequacyof quality control and reliability assurance provisions. A total of 39 Convair andvendor drawings or drawing changeswere reviewed during the month. Data documents from 27 vendors were reviewed. Data requirements include drawings; specification, reliability failure mode analysis, reliability predictions; service experience data; qualifications test reports; status, operating, and checkoutdata; and quality-control program data. b. ComponentSelection andVendor Monitoring Program During the month, emphasis continued on selection of reliable components. A total of 67 advancebills of material (ABMs) were reviewed to ensure that vendors would be required to comply with adequatereliability and quality control provisions. A total of 46 purchase orders were reviewed. Only vendors with demonstrated ability to produce reliable componentsof the type desired were awardedpurchase orders.

c.

Failure Analysis Status of all failure analyses reports (FARs) is summarized as follows: Total FARs initiated during reporting period Total FARs initiated to date FARs closed to date FARs remaining open 16 164 132 32

All inspection reports requiring material review and action are summarized each month in the Monthly Quality Report. d. Reliability Analysis and Measurement Program Updatedfailure analysis and reliability estimates are included in the Quarterly Reliability Status Report. e. Test Activities (1) The Repco command receiver has successfully completed qualification testing at Convair. (2) The Gulton battery to be usedwith the WSMRcommand destruct system is continuing in qualification testing. (3) The hydraulic actuator assembly qualification testing has been successfully completed. (4) Partial re-qualification testing of the American Wiancko rate gyro packagehas been initiated. This testing is the result of packageredesign by American Wianeko.
(5)
Qualification has and been dusts exhibited testing completed. failures tests, and of the Both during humidity after the Beckman high energy and Whitely and A high destructors units sand unit during tests, energy burn-out

low energy

high temperature tests. bridgewire

failed to ignite the primer the locked rotor test.

f.

Training Convair Training Section conducted108hours of instruction for NASA soldering certificates during the month.

g.

First-Article

Inspection inspection was conductedthis month.

One first-article h.

Quality Performance Audits Quality program procedures, test instructions, process specifications and certifications are being audited, and corrective and preventive action is initiated as required. These audits ensure that procedures are being followed.

i.

Vendor Quality Control A total of 8 supplier facility evaluation surveys were conducted and approvedto ensure that suppliers are meeting Convair quality assurance requirements.

j.

Process Control A total of 256 solution control analyses were performed on 59 tanks that are available for all production programs. A calibration survey of 5 ovens andfurnaces was conducted. A total of 25 incoming material evaluation tests were performed.

k.

Fabrication Inspection Detailed inspection results are being submitted as a part of the Monthly Quality Report.

1.

Surveillance A weekly surveillance of all inspection and factory areas, including segregatedstockrooms for Little Joe II material, for conformance to Inspection Check Lists is continuing. Corrective and preventive action is being initiated as required.

SECTIONIII A. MANUFACTURING 1. Material

An all-out effort is continuing in support of Vehicle 12-51-1 at WSMR. As of this date, all production material/parts have been shipped and are available at the base. There are a few spare items still duebut they are expected to be shippedby 4 December 1964. The majority of items required for Vehicle 12-51-2 have been released and purchase orders placed. Substantial quantities of parts havebeen received and are being received daily. All material is being handledon an expedite basis. A complete report of all items released hasbeen prepared by Engineering Work Order packagefor follow-up and scheduling purposes. It is anticipated that the shortage count will be high for a time, but will decrease rapidly to a point where a small number of items will fall in the problem category. Generally, parts released for 12-51-2 are electrical hardware type with short lead times. There still are some problems on delivery of certain hydraulic componentssuch as the Randall actuator and the Markite potentiometer but sufficient quantities of these items are expected by 9 December 1964. 2. Tooling

The planning required to rebuild "Little WSMR"has been released. Provisions have also been made in the system to maintain "Little WSMR" compatible with "Big WSMR". Planning for the 12-51-2 vehicle, the launcher andthe GSEis being processed in accordancewith program schedules. Premium time is being required in both the mechanical and the electrical planning sections to maintain schedule requirements. December Activity Planning will continue to support the schedule requirements for 12-51-1 and 12-51-2 firings. It is expected that premium time will be required for both the processing of the engineering releases and in support of the factory liaison.

The engineering releases for

The fabrication the task rigging is expected fixture and 12-50-3 12-51-1 and in mating 3. the new

the

rigging

fixture in time masts.

have

been

received. Dept. 131

to be completed launcher

to support

Fabrication Vehicles Vehicle

Assembly and 12-50-4 In storage In launch Factory expedited at San operations support basis in Final effort close Diego. at WSMR. available as required. Assembly. made This with and An to meet includes an on an

Vehicle

12-51-2

In work all-out the a very

is being schedule. liaison

present

Engineer-

ing and material groups, extended work week. Vehicle 12-51-3 In Final Assembly to latest

firing

configuration. Vehicle 12-51-4 Fore Held Final Launcher No. 2 Mast firing San Diego accurately GSE The work. 12-51-1 firing. manufacture of the of the consoles new dual and RF will Command Consoles after is in simulate operational the launch facilities operations are being and aft bodies in fixture Assembly. rework for NAA umbilical to 12-51-2 in work. and updated to and complete. mating and

pending

updating

of launcher configuration modified at WSMR.

facilities

Modification

at WSMR

be accomplished

LAUNCH ASSEMBLY

ESCAPE

N o'rE AIR

OUTLET ADAPTER

CONDITIONING IN DOOR

ATTACHES

i OPENING.

PAYLOAD UMBILICAL

_-_

COMMAND

MODULE

UMBILICAL ARM BP SERVICE MODULE

STATION

UIPMENT SUPPORT ARM (SEE NOTE)

AREA

ACCESS

DOOR(3)

FOREBODY

STATION

227.0

AIR

CONDITIONING

ADAPTER

DOOR

ALGOL NOZZLE. -VEHICLE ELEVATION SCREWJACK CONTROL FIN (4) SUPPORT

(6)

PAD

(6)

MAIN

JUNCTION ION POSITION TRANSMITTER

ELECTRICAL )N (4)

TO

CABLE

TRENCH

IDLER TRUCK(2) PLUG-IN REMOTE CONTROLLER AZIMUTH POSITION INNER RAIL OUTER RAIL DRIVE TRUCK (2)

TRANSMI

Figure

1.

Launch

Vehicle

12-51-1

Launcher

10

sTA

0,00

STA 15.50 STA 33.40 TIEDOWNS LAUNCH SUPPORT ACCESS DOOR FITTING

STA 84.34 STA 92.09

ANTENNA

AIR CONDITION

DOOR

344

/
Q ALGOL ID MOTORS

RECRUIT

BALLAST

Figure

2.

Vehicle

12-51-1

Attltude

Control

11

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SECTION

IV OPERATIONS Site Operations facility of vehicle were initiated. operation checkout. completed, The were was initiated During and following the on 2 November report were period, Spacecraft/ integrated OCI's and

Aa

LAUNCH 1. Launch

Two-shift continued Launch Launch during Vehicle Vehicle the

launch period

systems checkouts

checkouts

accomplished: Vehicle Ignition Ignition Autopilot TM Power System and TM Hardline - 12-86011

Resistance Firing Sensors

- 12-86206 - 12-86207

Current

- 12-83006 and Transmission Pressure - 12-81040 Instrumentation Installation - 12-81044

Conditioning

RCS Motor Aft Bulkhead Algol Motor

Chamber

Aceelerometer Chamber Pressure

- 12-81063 - 12-81064

Instrumentation

H20 2 and Logic Algol and

GN 2 Pressure Control Angle System Leak and

Instrumentation Fin Integration

- 12-81056 - 12-83008

Nozzle

Adjustments - 12-83224 Check

- 12-82021

RF Command Hydraulic Installation Installation Range Lanyard Installation after and completing support Control the rework pad. Systems launcher Safety Pull

System

- 12-83106 - 12-82029 on Algol - 12-83223 Motors - 12-82023

of PETN of Shaped Destruct Test of the

Primacord Charges System - 12-83218.

fourth

{final)

fin

on the were was

vehicle completed deactivated.

was

accomplished with spare the fin for the

of the Test

fin trailing checkouts Facility

face

to correct

interference

Operational

(CSTF)

13

Engineering design and installations were completed for incorporation of roll rate gyro rotational speedmonitoring capability. An additional Vidar voltmeter was installed in the dual console and facility circuitry was modified for this function. Tests were conductedto obtain RCSmotor control valve operating current signature for all installed valves. Modifications to provide an exponential pitch-over input signal to the inflight instrumentation system were completed. Installation of the RangeSafety Destruct System was completed and a lanyard pull test (OCI 12-83218)was accomplished. Functional testing of all flight componentswas completed with checkouts of the AN/DRW-ll receivers. Buildup of TM trailer No. 2 was completed with the installation of Sanbornrecording equipment anddiscriminators. NASA validation was completed and the trailer was placed in operation. Continued assistance was provided to NASAfor operation of both telemetry trailers on a two-shift basis, to support spacecraft and launch vehicle checkout operations. Coaxial connectors for telemetry transmitters A and B were reworked to correct antennaproblems. Functional testing and calibration of spare componentswas continued throughout the report period. 2. Operations Procedures and Support

Review, revision or rewrite of Operational CheckoutInstructions continued throughout the report period, as required to support program scheduling. The Launch Vehicle CountdownProcedure was completed and issued. The Test Director's countdown, which integrates the Spacecraft countdown OTP-010 and the LaunchVehicle Operations Manual OCI 12-08901, andthe integrating documentfor OTP-008 and OCI 12-86019, Integrated Checkouts, were approved. A Preliminary Flight Readiness Report was presented to the Flight Readiness Review Board at Houston, on 23 November.

14

December

Activity

Planned Vehicle and Integrated open item will operations review will will be completed

Spacecraft/Launch and a final inspection, The personnel will Flight cleanup Readiness

be conducted. and GD/Convair

Report Flight

be completed Review. final

participate

in the in simulated

Readiness and

Participate 12-51-1. Accomplish Participate Participate reports. Inspect secure B. launch

countdown

countdown

for

vehicle

launch

of vehicle

12-51-1. recovery operations. in preparation of post-launch

in post-launch at WSMR and

Houston,

launcher

and

pad,

accomplish

preventive

maintenance

and

facility.

LOGISTICS November activity Vehicle 1 and task 2. was consisted and of spare of; selection 12-51-3 parts (1) a reduction activity together from List of the GFP vendor. of shipment GSE being of remaining spares to the reworked spares BP22 to and the revision. Data Spares and in the with North to North Acceptance spares from changes American American (4) Package from to portion for for shipping design

backlog changes Launchers of the of the Vehicle WSMR purchase.

to seven affecting No. (3) 12-51-1. for repair launcher Hardware

items.

(2) Spares 12-51-2 A list compiled of the List

continued

and recommended Hardware returned or the as a part

Preparation Utilization (5)

Preparation

Processed

GSE items

by GD/Convair activity to the will

December support of design A FRM-002 Vehicle changes

consist and and

12-51-1

launch, Launchers

selection

of supporting

as a result

configurations.

15

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STATUS 8 VEHICLES 2 LAUNCHERS 1964

CUT-OFF

DATE: 1965

NOVEMBER

30,

1964

CCA NO. 18 T[ CONTRAScT GO-AHEAD/CONTRACT NAS 9-492

TO CONTRACTI

DELIVERIES LAUNCHER GROUND

ON SITE

SUPPORT

EQUIPMENT

FFVEHICLE INTO STORAGE - SAN DIEGO NO. 4 ACFVEHICLE GO-AHEAD ENGINEERING MATERIAL TOOLING SUBCONTRACT FACTORY NO. FABRICATION ASSEMBLY MAJOR ITEM ASSEMBLY CHECKOUT COMPLETE EQUIPMENT / _l_ I q I

/ /
I /

OPERATIONAL FACTORY GROUND SUPPORT

I I
I

DOCUMENTATION-GENERAL LAUNCH TEST OPERATIONS FACILITY (BY MISSION) OCCUPANCY

I
I
i IN i I (GFP)

LAUNCHER PROPULSION ALGOL RECRUIT ALL SYSTEMS

CHECKOUT SYSTEM

I i IN0

i e
TEST/EVALUATION | L

FLIGHT

REPORT

LEGEND

SCHEDULE ACTUAL

NOTE: WITH

ATTITUDE AN ASTERISK

CONTROL (*) ARE

VEHICLES THE DATES

2, 3,4, PRIOR

DESIGNATED TO THE

SCHEDULED

OPERATIONAL

O-----0

LATE AHEAD

TO OF

SCHEDULE SCHEDULE

CHECKOUT/FACTORY STORAGE PERIOD. SUBSEQUENT DESIGNATES AFTER THE

COMPLETE

SCHEDULED

DATE

FOR

THESE

VEHICLES COMPLETE

0----0 ACF FF RCS

RE-SCHEDULE ATTITUDE FIXED FIN CONTROL SYS CONTROL FIN

OPERATIONAL CHECKOUT/FACTORY STORAGE PERIOD. OF

LAUNCHER NO. 2 IS IN PROCESS AND UPDATING TO BE COMPATIBLE

MODIFICATION WITH VER 12-51-2.

REACTION

Figure

3.

Milestones

(Continued)

26

14,0001 13,800: 13,600 13,4001 13,200 1%000! 12,800; 12,6001 12,400 12,200 12,000 11,800 I

11,400 11,200 11,000

10,600

9,800 o i9,600 9,400 9,200 9

5 J o
8,400 8,200 8,000 7,800 7,600 7,400 7,200 7,000 6,800 6,600 6,400 6,200 6,000 5,800 5,600 5,400 5,200 5,000 5,800 4,600 FORECAST EXPENDITURES MEN 3OO 280 260 240 220 200 180 160 140 EXPENDITURE_ MANPOWER 120 100 8O 6O 40 2O 0 JULY AUG SEPT OCT 1963 NOV DEC FEB MAR APR MAY JUNEJULY 1964 AUG SEPT OCT NOV DEC FORECAST EXPENDITURES

Figure

4.

Expenditures

by Month

27

SECTION A.

VI PLANNING AND CONTROL

PROGRAM 1. PERT PERT

update reports, analysis reports, and current Network submitted as stated in Section V. 57C has been completed 1964. and will be implemented into the

masters

were

Network NASA PERT 2.

system on 11 December Schedules Affected Program

Schedules have been revised to reflect NASA per

directed changes for delivery of Vehicles 12-51-2 and 12-51-3 to WSMR, CCA

No. 49, and storage of Vehicle 12-50-4 at the Convair plant in San Diego, No. 57. WSMR Operations Status Reports are being received from the Convair Daily reporting Report to MSC, to support the bi-weekly PERT Vehicle.

per CCA 3.

Daily PERT Operation at WSMR Houston 4. until launch

relating progress on Vehicle 12-51-1. of the Control Change covered assigned GSE; and their checkout Proposals design current No. 172 through to vehicles and also and cover to vehicle

will continue, from WSMR,

Change Contract

176 were 12-51-2 related 12-51-1

submitted and 3 rechanges Range

to to Safety

NASA. quired the System, distribution.

These to perform

CCP's facility

changes changes

missions

launcher

vehicle

procedures

at WSMR;

reductions

in documentation

28

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I I

8
0 0 0 0 0 0
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