ATK THIOKOL

KSC Motor Integration

Presented by:

Motor Integration Team

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Motor Integration at KSC and CCAFS

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Integration Leadership Team

Steve Schmieder Russ Bakes
Integration Program Manager Integration Sub-system Manager

Paul Teehan
MSFC Resident Office

Bruce Tams
Integration Design Engineering Manager

Ted Shaffner
KSC Operations Manager

Mike Evans
Quality Manager

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Interfaces

The integration teams function is to assure ATK and MSFC requirements are incorporated into the motor processing at KSC The hands on work, i.e., build up, stack, close out, integrate, launch and disassemble the boosters is done by USA Because we work with an integrated vehicle and operate in a multi contractor environment our communication is with multiple elements

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RSRM Processing

KSC Operations

CCAFS Operations

Recovery and Postflight Evaluation Launch

SRB Stacking

KSC Operations

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Jay Jay Siding Suspect Siding Pads

VAB/ RPSF/ OSB Area

LMF Segment Onload

Hangar AF and Hangar N

Port Canaveral

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Shuttle Vehicle Processing Operations

Design Centers Element Refurbishment and Manufacturing Logistics and Shipping

RPSF

Recovery Disassembly and Assessment

Delivery Offload and Inspect

SHUTTLE LANDING

SRB RETRIEVAL SHIP

HANGAR AF

ORBITER PROCESSING FACILITY

SRB STACKING

Aft Booster Build Field Joint Mate Leak Test

Offload Buildup ET/SRB OPERATIONS

INTEGRATED VEHICLE OPS/VAB

ET STANDALONE

LCC HORIZONTAL PAYLOAD INT

Field Joint Protection System S&A SRB Integration

HYPERGOLIC FACILITY

PAYLOAD FACILITIES VERTICAL PAYLOAD INSTALLATION Pad Ops

Launch

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Delivery

Segments arrive at Jay Jay siding via railcar Cars are 200-ton railcars with fiberglass covers

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Offload and Inspect

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

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Aft Booster Build-up

Aft skirt mate Exit cone mate

Leak test Backfill

Nozzle severance connection, checkout, and close out GEI and heater power cable installation and test Stiffener ring installation and close out Froth-Pak Application Systems tunnel installation and close out Storage until ready to stack

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Aft Skirt Mate

The aft skirt (USA supplied) is placed in the build up stand and the segment is mated

177 pins are installed and secured with a steel retainer strap
The joint is closed out with a pin band and cork

Pin Retainer Strap

Cork

Aft skit clevis

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Exit Cone Mate

Aft exit cone is assembled to the forward exit cone at KSC (Joint No.1)

Phenolic mating surfaces are primed with DC1220 primer prior to assembly Primary and secondary O-rings are installed Exit cone is raised on an elevator and floated on an air bearing for mating The joint is bolted with 96 fasteners Leak test is performed at 83 and 30 psig with the Mass Flow Meter prior to joint backfill

Backfill

O-rings

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Exit Cone Backfill

Joint gap is backfilled (injected) with RTV sealant Spatulas are used to support the tape and aid in a deep fill of the joint Backfill is part of thermal barrier system Joint 1 is a static joint (opens less than 0.0005 in.)

Joint Interface

Backfill Nozzle

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Stiffener Ring Installation and Close-out

The function of the stiffener rings is to prevent case damage from splashdown due to cavity collapse

RT-455 Ablative

Stiffener rings have no flight function

Stiffener Ring

Three sections are bolted to the integral stub and joined together by splice plates RT-455 is used to protect fasteners and the painted hardware from heat loads The foam ramp helps deflect the water geyser at splashdown

3 Stiffener Rings

Foam

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Systems Tunnel

The aft segment systems tunnel is completed at the RPSF up to the ETA ring prior to transfer to storage
Cables are run and secured

Connections are checked

Covers are installed and closed out
Stiffener Ring

Systems Tunnel

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Segment Storage

All segments remain vertical on their pallets until they are transferred to the VAB for stack A KAMAG is used to pick up and transport the pallet Surges protect the hardware from rain, wind, etc.

Not climate controlled. Segments have weather proof covers on top

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Shuttle Vehicle Processing Operations

Design Centers Element Refurbishment and Manufacturing Logistics and Shipping

RPSF

Recovery Disassembly and Assessment

Delivery Offload and Inspect

SHUTTLE LANDING

SRB RETRIEVAL SHIP

HANGAR AF

ORBITER PROCESSING FACILITY

SRB STACKING

Aft Booster Build Field Joint Mate Leak Test

Offload Buildup ET/SRB OPERATIONS

INTEGRATED VEHICLE OPS/VAB

ET STANDALONE

LCC HORIZONTAL PAYLOAD INT

Field Joint Protection System S&A SRB Integration

HYPERGOLIC FACILITY

PAYLOAD FACILITIES VERTICAL PAYLOAD INSTALLATION Pad Ops

Launch

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RSRM Field Joint Mate

Current joint mate process was developed through testing during the RSRM redesign program Joint assembly objective is to prevent tang/clevis flat-on-flat and protect the o-rings from being cut or damaged: capture feature O-ring is most susceptible Calculations are performed based on case diameter data to determine proper Field Joint Assembly Fixture (FJAF) configuration for each joint mate

Tang

Clevis

Interference Fit Maintains O-ring Squeeze and Restricts Joint Rotation

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Joint Mate Preparations

Pressure Sensitive Adhesive (PSA) is applied to the insulation interfaces Metal parts are inspected and greased O-rings are installed FJAF configured and installed

Tang

Cases are measured to determine the relative shapes

J-Joint

Requirement is for shapes to be within +/-0.210 in. for nominal mate Shape can be improved by adjusting the 4 point beam load distribution
Clevis
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RSRM Field Joint Mate

Crane lowering rate is controlled to 0.060 in./minute maximum Levelness and rate of engagement are continually monitored during segment lowering FJAF contact with the case is monitored during maximum engagement Leak test of the joint and the vent port plug are the final acceptance of a successful joint mate

Field Joint Assembly Fixture Acts to Shoehorn the Segments Together

Temposonics to Measure Rate of Engagement, Parallelism, and Distance From Mate

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Field Joint Protection System (FJPS)

The purposes of the FJPS are:

Maintain an optimal temperature for O-ring tracking Prevent environmental contaminants such as rainwater from entering the joint area

Cork Joint Temperature Sensor Heater Retainer Strap and Thermal Barrier Joint Heater RT-455 Ablative

Final product is painted with white Acrymax paint

Cork

Pin Retainer Band RT-455 Ablative 306

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Skirt Joint Protection System (JPS)

Forward and aft skirt JPS is primarily to provide thermal protection, weather protection and to retain the pins A flat steel strap is installed over the pin heads Cork is bonded with EA934 and painted with Acrymax paint A grease bead is applied to the clevis/tang exterior interface of the joint
Cork

Steel Retainer Strap

Grease Bead

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S&A Installation

The ignition Safe and Arm (S&A) devices are installed after the RSRM is stacked and the forward skirt is installed

S&A Gasket

Fluorocarbon seals contained within a steel retainer gasket are placed between the S&A and the igniter adapter surface Crushable preload measuring washers are used to control bolt preload Leak test is performed with the bolts partially torqued to prevent false positive due to a metal to metal seal Final torque and cable connections are then performed

S&A

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Vehicle Integration

SRB integration

Joint heater and temperature sensor connections Thrust Vector Control (TVC) actuator to nozzle connections

Chamber pressure and ignition S&A connections

Systems tunnel cable runs Systems tunnel cove close outs Extensive checkouts of ground and flight electrical systems

The tank is mated to the SRB The orbiter is mated to the tank The assembled vehicle is rolled to the pad

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Shuttle Vehicle Processing Operations

Design Centers Element Refurbishment and Manufacturing Logistics and Shipping

RPSF

Recovery Disassembly and Assessment

Delivery Offload and Inspect

SHUTTLE LANDING

SRB RETRIEVAL SHIP

HANGAR AF

ORBITER PROCESSING FACILITY

SRB STACKING

Aft Booster Build Field Joint Mate Leak Test

Offload Buildup ET/SRB OPERATIONS

INTEGRATED VEHICLE OPS/VAB

ET STANDALONE

LCC HORIZONTAL PAYLOAD INT

Field Joint Protection System S&A SRB Integration

HYPERGOLIC FACILITY

PAYLOAD FACILITIES VERTICAL PAYLOAD INSTALLATION Pad Ops

Launch

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Launch

Launch countdown begins about 3 days prior to launch RSRM systems begin to activate approximately 18 hours prior to launch

S&A rotation test at Launch (L)-60 hours The igniter heater is activated at L-18 hours Operational Pressure Transducers (OPTs) are powered up at L-9 hours Joint heaters are powered up at L-8 hours OPTs are checked out at L-1.5 hours The igniter heater is deactiviated and the S&A armed at L-5 minutes Main engine start is at L-6 sec SRB ignition and hold-down post-firing at L-0
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Shuttle Vehicle Processing Operations

Design Centers Element Refurbishment and Manufacturing Logistics and Shipping

RPSF

Recovery Disassembly and Assessment

Delivery Offload and Inspect

SHUTTLE LANDING

SRB RETRIEVAL SHIP

HANGAR AF

ORBITER PROCESSING FACILITY

SRB STACKING

Aft Booster Build Field Joint Mate Leak Test

Offload Buildup ET/SRB OPERATIONS

INTEGRATED VEHICLE OPS/VAB

ET STANDALONE

LCC HORIZONTAL PAYLOAD INT

Field Joint Protection System S&A SRB Integration

HYPERGOLIC FACILITY

PAYLOAD FACILITIES VERTICAL PAYLOAD INSTALLATION Pad Ops

Launch

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Recovery

Ships crew gather parachutes and the frustum Divers install the Diver Operated Plug into the nozzle

The DOP system pumps water from the interior to get the booster into log mode

Recovery ships tow the SRBs back to Hangar AF

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Post Flight Disassembly and Assessment

SRBs are floated into a wharf and lifted onto the disassembly dolly with a straddle lift SRB and RSRM components are disassembled by USA Assessments of the flown hardware are performed by ATK, USA SRB and MSFC representatives

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RSRM Postfire Evaluation Process

Purpose of RSRM Postfire Evaluation

The objective of postfire evaluation (disassembly and assessment) is to verify integrity of recovered RSRM hardware and identify any anomalous conditions in a timely manner

Did the hardware perform as expected? What is it telling us? Were engineering requirements violated, and if so how does this effect performance? Is the condition in family with past observations? Does the condition affect subsequent launches or tests?

Impact on future launches is addressed in flight/test readiness review (FRR/TRR) process

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RSRM Postfire Evaluation Process

Postfire Evaluation Requirements

Postfire Hardware Evaluation System Operating Plan

Defines system requirements for:

Disassembling, evaluating, documenting, reporting, and databasing the condition of postfired RSRM hardware Identifying, reviewing, tracking, and resolving observed abnormal/anomalous conditions or trends

Postfire Engineering Evaluation Plans

Defines requirements for:

Engineering evaluation, hardware observation limits (allowable and reportable), and photo/video documentation Approved by NASA MSFC

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RSRM Postfire Evaluation Process

Postflight Evaluation Process and Timeline

Launch + 2-21 days, CCAFS Hangar AF (Florida)

Recovered solid rocket boosters initially assessed, including assessment for missing external insulation

Forward and aft skirts, S&A devices, igniters, nozzles, and exit cones removed and assessed
Case field joints demated and internal insulation assessed S&As disassembled and assessed Arming-Monitor and Barrier-Booster disassembled and assessed Internal nozzle joints demated and assessed

Launch + 8-14 days, ATK Thiokol M-66A Facility (Utah)

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

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

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

Nozzle bondlines, nozzle liner char/erosion measurements, case and igniter insulation measurements, and factory joints demated and assessed

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RSRM Postfire Evaluation Process

SAFETY AND ARMING DEVICE

Barrier-Booster Housing

Throat Inlet Assembly

Booster Basket PLI Nested Washer Safing Pin Environm ental Seals Locking Shaft A-M Backfill Port Visual Indicator Window A-M Sw itch Deck Clutch Assembly Attach Bolt

Forward Exit Cone Assembly Vented Positive Stop Set Screw

Nose Inlet Assembly Flex Bearing Snubber Detail: Ring, Segment, Retainer Vented Positive Stop Set Screw Flex Bearing Protector Cowl Insulation Segment Fixed Housing Assembly Flexible Boot Assembly

B-KNO3 Pellets B-KNO3 Granules Foam Cushion Perforated Plate

Cowl Housing Cowl

Vented Positive Stop Set Screw

Rotor (m echanical barrier) SII Motor Armature Barrier-Booster Rotor Shaft Seals
A041627a1

Safing Arm Gear Reduction (625:1)

Motor Field Windings A-M Electrical Connector

Aft Exit Cone Assembly A038797aDDB

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RSRM Postfire Evaluation Process

Postfire Anomaly Record (PFAR) System

Any observation that falls outside of established limits or is unexpected is reported on a Squawk (Florida) or Preliminary PFAR (Utah, California) Each Squawk/Preliminary PFAR is presented to SRB/RSRM Postflight Assessment Team (SPAT Board) for review

SPAT Board consists of NASA, senior contractor management, and engineering

SPAT Board determines if violation should be elevated to PFAR which requires corrective actions and further reviews

PFAR corrective actions worked by component teams PFAR closure rationale approved by ATK Thiokol and MSFC All PFARs presented in FRR/TRR process including impact and rationale for upcoming flights/tests

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RSRM Postfire Evaluation Process

Postfire Hardware Evaluation System
TWR-16899

Observation checklist and recording form

Hardware Disassembly and Evaluation

Defines overall postfire system

RSRM-XX Special Issues

Postflight Postfire Observation Records (PFORS)

RSRM-XX RSRM-XX Postflight Postfire Report Report

Review, Cause, Corrective Action & Disposition

Postflight Postfire Engineering Engineering Evaluation Evaluation Plan Plans

PEEP limit violation or unexpected condition

(PEEP) (PEEPs)

Postflight Postfire Anomaly Record (PFAR)

TWR-50051/2
Defines standard hardware evaluation requirements, observation limits and photographic /video coverage requirements Defines motor-set unique evaluations based on specific changes & issues
Squawk (KSC) Preliminary Postflight Postfire Anomaly Record (Utah)

Disposition and Close

Elevate to PFAR

SRB/RSRM Postfire Assessment Team (SPAT) Board 320

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RSRM Postfire Evaluation Process

Postfire Database, Trending, and Documentation

RSRM postfire data is entered into historical database Data is trended with historical data to verify performance within approved limits

Violations of trending limits are reported and investigated as necessary

Closure of violations is approved by ATK Thiokol management (and MSFC for significant trends) Postfire observations and trend data included in final report(s)

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Return to Utah

Segments are loaded onto the same type railcars as they were delivered Nozzle components, igniters, stiffener rings and other smaller components are shipped by truck The joint pins remain at KSC and are refurbished by ATK personnel

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