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Phase 111A Crew Interface Specifications Development for Inflight Maintenance and Stowage Functions

This report presents the findings and data products developed during the Phase IIIA Crew Interface Specification Study for Inflight Maintenance and Stowage Functions, performed by General Electric for the NASA, Johnson Space Center with a set of documentation that can be used as definitive guidelines to improve the present process of defining, controlling and managing flight crew interface requirements that are related to inflight maintenance (including assembly and servicing) and stowage functions. During the Phase IIIA contract period, the following data products were developed: 1) Projected NASA Crew Procedures/Flight Data File Development Process. 2) Inflight Maintenance Management Process Description. 3) Preliminary Draft, General Specification, Inflight Maintenance Management Requirements. 4) Inflight Maintenance Operational Process Description. 5) Preliminary Draft, General Specification, Inflight Maintenance Task and Support Requirements Analysis. 6) Suggested IFM Data Processing Reports for Logistics Management The above Inflight Maintenance data products have been developed during the Phase IIIA study after review of Space Shuttle Program Documentation, including the Level II Integrated Logistics Requirements and other DOD and NASA data relative to Payloads Accommodations and Satellite On-Orbit Servicing. These Inflight Maintenance data products were developed to be in consonance with Space Shuttle Program technical and management requirements.

Carl, John G.↗

Space Shuttle Orbiter Reaction Jet Driver (RJD): Independent Technical Assessment/Inspection (ITA/I) Report, Version 1.0

The Space Shuttle Program (SSP) has a zero-fault-tolerant design related to an inadvertent firing of the primary reaction control jets on the Orbiter during mated operations with the International Space Station (ISS). Failure modes identified by the program as a wire-to-wire "smart" short or a Darlington transistor short resulting in a failed-on primary thruster during mated operations with ISS can drive forces that exceed the structural capabilities of the docked Shuttle/ISS structure. The assessment team delivered 17 observations, 6 findings and 15 recommendations to the Space Shuttle Program.

Gilbrech, Richard J.↗

Launch and Landing Effects Ground Operations (LLEGO) Model

LLEGO is a model for understanding recurring launch and landing operations costs at Kennedy Space Center for human space flight. Launch and landing operations are often referred to as ground processing, or ground operations. Currently, this function is specific to the ground operations for the Space Shuttle Space Transportation System within the Space Shuttle Program. The Constellation system to follow the Space Shuttle consists of the crewed Orion spacecraft atop an Ares I launch vehicle and the uncrewed Ares V cargo launch vehicle. The Constellation flight and ground systems build upon many elements of the existing Shuttle flight and ground hardware, as well as upon existing organizations and processes. In turn, the LLEGO model builds upon past ground operations research, modeling, data, and experience in estimating for future programs. Rather than to simply provide estimates, the LLEGO model s main purpose is to improve expenses by relating complex relationships among functions (ground operations contractor, subcontractors, civil service technical, center management, operations, etc.) to tangible drivers. Drivers include flight system complexity and reliability, as well as operations and supply chain management processes and technology. Together these factors define the operability and potential improvements for any future system, from the most direct to the least direct expenses.

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Introduction of the Space Shuttle Columbia Accident, Investigation Details, Findings and Crew Survival Investigation Report

As the Space Shuttle Program comes to an end, it is important that the lessons learned from the Columbia accident be captured and understood by those who will be developing future aerospace programs and supporting current programs. Aeromedical lessons learned from the Accident were presented at AsMA in 2005. This Panel will update that information, closeout the lessons learned, provide additional information on the accident and provide suggestions for the future. To set the stage, an overview of the accident is required. The Space Shuttle Columbia was returning to Earth with a crew of seven astronauts on 1Feb, 2003. It disintegrated along a track extending from California to Louisiana and observers along part of the track filmed the breakup of Columbia. Debris was recovered from Littlefield, Texas to Fort Polk, Louisiana, along a 567 statute mile track; the largest ever recorded debris field. The Columbia Accident Investigation Board (CAIB) concluded its investigation in August 2003, and released their findings in a report published in February 2004. NASA recognized the importance of capturing the lessons learned from the loss of Columbia and her crew and the Space Shuttle Program managers commissioned the Spacecraft Crew Survival Integrated Investigation Team (SCSIIT) to accomplish this. Their task was to perform a comprehensive analysis of the accident, focusing on factors and events affecting crew survival, and to develop recommendations for improving crew survival, including the design features, equipment, training and procedures intended to protect the crew. NASA released the Columbia Crew Survival Investigation Report in December 2008. Key personnel have been assembled to give you an overview of the Space Shuttle Columbia accident, the medical response, the medico-legal issues, the SCSIIT findings and recommendations and future NASA flight surgeon spacecraft accident response training. Educational Objectives: Set the stage for the Panel to address the investigation, medico-legal issues, the Spacecraft Crew Survival Integrated Investigation Team report and training for accident response.

Chandler, Michael↗

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the NASA Space Launch System (SLS) program. Testing was needed because SLS ascent loads are 35% higher than Space Shuttle loads. Objectives of testing were to determine margins of safety, demonstrate reliability, and validate analytical models. Testing combined with analysis was able to show heritage forward skirts were acceptable to use on the SLS program.

Lohrer, J. D.↗

Return to Flight Task Group

It has been 29 months since Columbia was lost over East Texas in February 2003. Seven months after the accident, the Columbia Accident Investigation Board (CAIB) released the first volume of its final report, citing a variety of technical, managerial, and cultural issues within NASA and the Space Shuttle Program. To their credit, NASA offered few excuses, embraced the report, and set about correcting the deficiencies noted by the accident board. Of the 29 recommendations issued by the CAIB, 15 were deemed critical enough that the accident board believed they should be implemented prior to returning the Space Shuttle to flight. Some of these recommendations were relatively easy, most were straightforward, a few bordered on the impossible, and others were largely overcome by events, particularly the decision by the President to retire the Space Shuttle by 2010. The Return to Flight Task Group (RTF TG, or simply, the Task Group) was chartered by the NASA Administrator in July 2003 to provide an independent assessment of the implementation of the 15 CAIB return-to-flight recommendations. An important observation must be stated up-front: neither the CAIB nor the RTF TG believes that all risk can be eliminated from Space Shuttle operations; nor do we believe that the Space Shuttle is inherently unsafe. What the CAIB and RTF TG do believe, however, is that NASA and the American public need to understand the risks associated with space travel, and that NASA must make every reasonable effort to minimize such risk. Since the release of the CAIB report, NASA and the Space Shuttle Program expended enormous effort and resources toward correcting the causes of the accident and preparing to fly again. Relative to the 15 specific recommendations that the CAIB indicated should be implemented prior to returning to flight, NASA has met or exceeded most of them the Task Group believes that NASA met the intent of the CAIB for 12 of these recommendations. The remaining three recommendations were so challenging that NASA could not comply completely with the intent of the CAIB.

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The Space Launch System -The Biggest, Most Capable Rocket Ever Built, for Entirely New Human Exploration Missions Beyond Earth's Orbit

NASA is developing the Space Launch System -- an advanced heavy-lift launch vehicle that will provide an entirely new capability for human exploration beyond Earth's orbit. The Space Launch System will provide a safe, affordable and sustainable means of reaching beyond our current limits and opening up new discoveries from the unique vantage point of space. The first developmental flight, or mission, is targeted for the end of 2017. The Space Launch System, or SLS, will be designed to carry the Orion Multi-Purpose Crew Vehicle, as well as important cargo, equipment and science experiments to Earth's orbit and destinations beyond. Additionally, the SLS will serve as a backup for commercial and international partner transportation services to the International Space Station. The SLS rocket will incorporate technological investments from the Space Shuttle Program and the Constellation Program in order to take advantage of proven hardware and cutting-edge tooling and manufacturing technology that will significantly reduce development and operations costs. The rocket will use a liquid hydrogen and liquid oxygen propulsion system, which will include the RS-25D/E from the Space Shuttle Program for the core stage and the J-2X engine for the upper stage. SLS will also use solid rocket boosters for the initial development flights, while follow-on boosters will be competed based on performance requirements and affordability considerations.

Shivers, C. Herb↗

Shuttle Program Loads Integration: Going From Concept to Operations and Staying Successful

From the beginning of the Shuttle Program to its end, integrated loads and dynamics analyses and tests have been critical in shaping the vehicle design and operational decisions for NASA and its customers. Starting with scaled models and simple mathematical simulations of the structural dynamics, engineers defined the required structural stiffness and predicted the limit loads for each element of the system. Early structural tests provided reasonable confidence that the models and predictions were good. The first launch of the Space Shuttle brought surprises, though, when the ignition overpressure event caused a forward fuel tank support strut to buckle, among several unexpected effects. The launch pad and other ground equipment became an integral part of the system integration, especially where the acoustic and pressure environments of ignition and lift-off were concerned. Following the Challenger accident, operating limits were changed in response to new understandings of how the integrated system performed. Controlling loads while maximizing performance was a key tenet of the Performance Enhancement design process, which enabled construction of the International Space Station. During the return to flight after the Columbia accident, engineers grew to understand that loads during the roll maneuver were also important to the vehicle s structural margin and life. At this point the crawler transport from the Vehicle Assembly Building to the launch pad also became a part of the integrated loads analysis. Even in the last years of the Space Shuttle Program, new data still provided interesting insights into this complicated and fascinating spaceship. This paper will present some examples of the important findings by the team of specialists that supported the Integrated Loads and Dynamics Panel for the Space Shuttle Program.

Bernstein, Karen↗

Space Shuttle orbiter modifications to support Space Station Freedom

The Space Shuttle will be the primary vehicle to support the launch, assembly, and maintenance of the Space Station Freedom (SSF). In order to accommodate this function, the Space Shuttle orbiter will require significant modifications. These modifications are currently in development in the Space Shuttle Program. The requirements for the planned modifications to the Space Shuttle orbiter are dependent on the design of the SSF. Therefore, extensive coordination is required with the Space Station Freedom Program (SSFP) in order to identify requirements and resolve integration issues. This paper describes the modifications to the Space Shuttle orbiter required to support SSF assembly and operations.

Segert, Randall↗

Space Shuttle Crawler Transporter Sound Attenuation Study

The crawler transporter (CT) is the world's largest tracked vehicle known, weighing 6 million pounds with a length of 131 feet and a width of 113 feet. The Kennedy Space Center (KSC) has two CTs that were designed and built for the Apollo program in the 1960's, maintained and retrofitted for use in the Space Shuttle program. As a key element of the Space Shuttle ground systems, the crawler transports the entire 12-million-pound stack comprising the orbiter, the mobile launch platform (MLP), the external tank (ET), and the solid rocket boosters (SRB) from the Vehicle Assembly Building (VAB) to the launch pad. This rollout, constituting a 3.5-5.0-mile journey at a top speed of 0.9 miles-per-hour, requires over 8 hours to reach either Launch Complex 39A or B. This activity is only a prelude to the spectacle of sound and fury of the Space Shuttle launch to orbit in less than 10 minutes and traveling at orbital velocities of Mach 24. This paper summarizes preliminary results from the Crawler Transporter Sound Attenuation Study, encompassing test and engineering analysis of significant sound sources to measure and record full frequency spectrum and intensity of the various noise sources and to analyze the conditions of vibration. Additionally, data such as ventilation criteria, plus operational procedures were considered to provide a comprehensive noise suppression design for implementation. To date, sound attenuation study and results on Crawler 2 have shown significant noise reductions ranging from 5 to 24 dBA.

Margasahayam, Ravi N.↗

The Shuttle Era

An overview of the Space Shuttle Program is presented. The missions of the space shuttle orbiters, the boosters and main engine, and experimental equipment are described. Crew and passenger accommodations are discussed as well as the shuttle management teams.

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Orbital Fitness: An Overview of Space Shuttle Cardiopulmonary Exercise Physiology Findings

Limited observations regarding the cardiopulmonary responses to aerobic exercise had been conducted during short-duration spaceflight before the Space Shuttle program. This presentation focuses on the findings regarding changes observed in the cardiopulmonary exercise responses during and following Shuttle flights. During flight, maximum oxygen uptake (VO2max) remained unchanged as did the maximum work rate achievable during cycle exercise testing conducted during the last full flight day. Immediately following flight, the ubiquitous finding, confirmed by investigations conducted during the Spacelab Life Sciences missions 1 and 2 and by NASA Detailed Supplemental Objective studies, indicated that VO2max was reduced; however, the reduction in VO2max was transient and returned to preflight levels within 7 days following return. Studies regarding the influence of aerobic exercise countermeasures performed during flight on postflight performance were mostly limited to the examination of the heart rate (HR) response to submaximal exercise testing on landing day. These studies revealed that exercise HR was elevated in individuals who performed little to no exercise during their missions as compared to individuals who performed regular exercise. In addition, astronauts who performed little to no aerobic exercise during flight demonstrated an increased HR and lowered pulse pressure response to the standard stand test on landing day, indicating a decrease in orthostatic function in these individuals. With regard to exercise modality, four devices were examined during the Shuttle era: two treadmills, a cycle ergometer, and a rowing device. Although there were limited investigations regarding the use of these devices for exercise training aboard the Shuttle, there was no clear consensus reached regarding which proved to be a "superior" device. Each device had a unique operational or physiologic limitation associated with its use. In conclusion, exercise research conducted during the Shuttle Program demonstrated that attenuation of postflight deconditioning was possible through use of exercise countermeasures and the Shuttle served as a test bed for equipment destined for use on the International Space Station. Learning Objective: Overview of the Space Shuttle Program research results related to aerobic capacity and performance, including what was learned from research and effectiveness of exercise countermeasures.

Moore, Alan D.↗

HAL/S - The programming language for Shuttle

HAL/S is a higher order language and system, now operational, adopted by NASA for programming Space Shuttle on-board software. Program reliability is enhanced through language clarity and readability, modularity through program structure, and protection of code and data. Salient features of HAL/S include output orientation, automatic checking (with strictly enforced compiler rules), the availability of linear algebra, real-time control, a statement-level simulator, and compiler transferability (for applying HAL/S to additional object and host computers). The compiler is described briefly.

Martin, F. H.↗

A vehicle scheduling algorithm using non-serial discrete dynamic programming with space shuttle applications

Description of the development and operation of a vehicle-scheduling algorithm which has applications to the NASA problem of assigning payloads to space delivery vehicles. The algorithm is based on a discrete, integer-valued, nonserial, dynamic-programming solution to the classical problem of developing resource utilization plans with limited resources. The algorithm places special emphasis on incorporating interpayload (precedence) relationships; maintaining optimal alternate schedule definitions (a unique feature of dynamic programming) in the event of contingencies (namely, resource inventory changes) without problem resolution; and, by using a special information storage technique, reducing the computational complexity of solving realistic problems.

Dupnick, E.↗

An overview of Space Shuttle anthropometry and biomechanics research with emphasis on STS/Mir recumbent seat system design

The Anthropometry and Biomechanics Laboratory (ABL) at JSC conducts multi-disciplinary research focusing on maximizing astronaut intravehicular (IVA) and extravehicular (EVA) capabilities to provide the most effective work conditions for manned space flight and exploration missions. Biomechanics involves the measurement and modeling of the strength characteristics of the human body. Current research for the Space Shuttle Program includes the measurement of torque wrench capability during weightlessness, optimization of foot restraint, and hand hold placement, measurements of the strength and dexterity of the pressure gloved hand to improve glove design, quantification of the ability to move and manipulate heavy masses (6672 N or 1500 lb) in weightlessness, and verification of the capability of EVA crewmembers to perform Hubble Space Telescope repair tasks. Anthropometry is the measurement and modeling of the dimensions of the human body. Current research for the Space Shuttle Program includes the measurement of 14 anthropometric parameters of every astronaut candidate, identification of EVA finger entrapment hazards by measuring the dimensions of the gloved hand, definition of flight deck reach envelopes during launch and landing accelerations, and measurement of anthropometric design parameters for the recumbent seat system required for the Shuttle/Mir mission (STS-71, Spacelab M) scheduled for Jun. 1995.

Klute, Glenn K.↗

Spray-On Foam Insulations for Launch Vehicle Cryogenic Tanks

Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability with throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex of many variables starting with the large temperature difference of from 200 to 260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.

Fesmire, J. E.↗

Johnson Space Center's Risk and Reliability Analysis Group 2008 Annual Report

The Johnson Space Center (JSC) Safety & Mission Assurance (S&MA) Directorate s Risk and Reliability Analysis Group provides both mathematical and engineering analysis expertise in the areas of Probabilistic Risk Assessment (PRA), Reliability and Maintainability (R&M) analysis, and data collection and analysis. The fundamental goal of this group is to provide National Aeronautics and Space Administration (NASA) decisionmakers with the necessary information to make informed decisions when evaluating personnel, flight hardware, and public safety concerns associated with current operating systems as well as with any future systems. The Analysis Group includes a staff of statistical and reliability experts with valuable backgrounds in the statistical, reliability, and engineering fields. This group includes JSC S&MA Analysis Branch personnel as well as S&MA support services contractors, such as Science Applications International Corporation (SAIC) and SoHaR. The Analysis Group s experience base includes nuclear power (both commercial and navy), manufacturing, Department of Defense, chemical, and shipping industries, as well as significant aerospace experience specifically in the Shuttle, International Space Station (ISS), and Constellation Programs. The Analysis Group partners with project and program offices, other NASA centers, NASA contractors, and universities to provide additional resources or information to the group when performing various analysis tasks. The JSC S&MA Analysis Group is recognized as a leader in risk and reliability analysis within the NASA community. Therefore, the Analysis Group is in high demand to help the Space Shuttle Program (SSP) continue to fly safely, assist in designing the next generation spacecraft for the Constellation Program (CxP), and promote advanced analytical techniques. The Analysis Section s tasks include teaching classes and instituting personnel qualification processes to enhance the professional abilities of our analysts as well as performing major probabilistic assessments used to support flight rationale and help establish program requirements. During 2008, the Analysis Group performed more than 70 assessments. Although all these assessments were important, some were instrumental in the decisionmaking processes for the Shuttle and Constellation Programs. Two of the more significant tasks were the Space Transportation System (STS)-122 Low Level Cutoff PRA for the SSP and the Orion Pad Abort One (PA-1) PRA for the CxP. These two activities, along with the numerous other tasks the Analysis Group performed in 2008, are summarized in this report. This report also highlights several ongoing and upcoming efforts to provide crucial statistical and probabilistic assessments, such as the Extravehicular Activity (EVA) PRA for the Hubble Space Telescope service mission and the first fully integrated PRAs for the CxP's Lunar Sortie and ISS missions.

Valentine, Mark↗

Space shuttle configuration accounting functional design specification

An analysis is presented of the requirements for an on-line automated system which must be capable of tracking the status of requirements and engineering changes and of providing accurate and timely records. The functional design specification provides the definition, description, and character length of the required data elements and the interrelationship of data elements to adequately track, display, and report the status of active configuration changes. As changes to the space shuttle program levels II and III configuration are proposed, evaluated, and dispositioned, it is the function of the configuration management office to maintain records regarding changes to the baseline and to track and report the status of those changes. The configuration accounting system will consist of a combination of computers, computer terminals, software, and procedures, all of which are designed to store, retrieve, display, and process information required to track proposed and proved engineering changes to maintain baseline documentation of the space shuttle program levels II and III.

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