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Space Shuttle Propulsion Safety Upgrades

This document is a viewgraph presentation which reviews the proposed upgrades to the Space Shuttle Propulsion system, to improve safety, and reduce significant hazards. The goals of the program are to reduce the risk of a catastrophe in ascent, to achieve significant reduction in orbital and entry systems, and to improve the crew cockpit situational awareness for managing the critical operational situations. The document reviews the upgrades to the propulsion system which are planned to improve the safety. These include modifications to the Advanced Thrust Vector Control, modifications to the Space Shuttle Main Engine Block III, improvement in the Advanced Health Management System, the use of Friction Stir welding on the external tank, which is expected to improve mechanical properties, and reduce defect rate, and the modification of the propellant grains geometry.

Humphries, William Randy, Jr.↗

Automation and Upgrade of Thermal System for Large 38-Year-Young Test Facility

The Goddard Space Flight Center's Space Environment Simulator (SES) facility has been improved by the upgrade of its thermal control hardware and software. This paper describes the preliminary design process, funding constraints, and the proposed enhancements as well as the installation details, the testing difficulties, and the overall benefits realized from this upgrade. The preliminary design process was discussed in a paper presented in October 1996 and will be recapped in this paper to provide background and comparison to actual product. Structuring the procurement process to match the funding constraints allowed Goddard to enhance its capabilities in an environment of reduced budgets. The installation of the new system into a location that has been occupied for over 38 years was one of the driving design factors for the size of the equipment. The installation was completed on time and under budget. The tuning of the automatic sequences for the new thermal system to the existing shroud system required more time and ultimately presented some setbacks to the vendor and the final completion of the system. However, the end product and its benefits to Goddard's thermal vacuum test portfolio will carry the usefulness of this facility well into the next century.

Webb, Andrew T.↗

Automation and Upgrade of Thermal System for Large 38-Year Young Test Facility

The Goddard Space Flight Center's Space Environment Simulator (SES) facility has been improved by the upgrade of its thermal control hardware and software. This paper describes the preliminary design process, funding constraints, and the proposed enhancements as well as the installation details, the testing difficulties, and the overall benefits realized from this upgrade. The preliminary design process was discussed in a paper presented in October 1996 and will be recapped in this paper to provide background and comparison to actual product. Structuring the procurement process to match the funding constraints allowed Goddard to enhance its capabilities in an environment of reduced budgets. The installation of the new system into a location that has been occupied for over 38-years was one of the driving design factors for the size of the equipment. The installation was completed on-time and under budget. The tuning of the automatic sequences for the new thermal system to the existing shroud system required more time and ultimately presented some setbacks to the vendor and the final completion of the system. However, the end product and its benefits to Goddard's thermal vacuum test portfolio will carry the usefulness of this facility well into the next century.

Webb, Andrew↗

Shuttle Upgrade Plan

This viewgraph presentation gives an overview of the Space Shuttle upgrade plan, including details on safety enhancements, reliability and maintainability improvements, investment protection (mission life remaining), Next Generation Reusable Launch Vehicle technologies, HEDS exploration strategic goals, and upgrades for safety and supportability.

Source record↗

Flow Quality Measurements in the NASA Ames Upgraded 11-by 11-Foot Transonic Wind Tunnel

Among the many upgrades designed and implemented in the NASA Ames 11-by 11-Foot Transonic Wind Tunnel over the past few years, several directly affect flow quality in the test section: a turbulence reduction system with a honeycomb and two screens, a flow smoothing system in the back leg diffusers, an improved drive motor control system, and a full replacement set of composite blades for the compressor. Prior to the shut-down of the tunnel for construction activities, an 8-foot span rake populated with flow instrumentation was traversed in the test section to fully document the flow quality and establish a baseline against which the upgrades could be characterized. A similar set of measurements was performed during the recent integrated system test trials, but the scope was somewhat limited in accordance with the primary objective of such tests, namely to return the tunnel to a fully operational status. These measurements clearly revealed substantial improvements in flow angularity and significant reductions in turbulence level for both full-span and semi-span testing configurations, thus making the flow quality of the tunnel one of the best among existing transonic facilities.

Amaya, Max A.↗

Upgrades to the TPSX Material Properties Database

The TPSX Material Properties Database is a web-based tool that serves as a database for properties of advanced thermal protection materials. TPSX provides an easy user interface for retrieving material property information in a variety of forms, both graphical and text. The primary purpose and advantage of TPSX is to maintain a high quality source of often used thermal protection material properties in a convenient, easily accessible form, for distribution to government and aerospace industry communities. Last year a major upgrade to the TPSX web site was completed. This year, through the efforts of researchers at several NASA centers, the Office of the Chief Engineer awarded funds to update and expand the databases in TPSX. The FY01 effort focuses on updating correcting the Ames and Johnson thermal protection materials databases. In this session we will summarize the improvements made to the web site last year, report on the status of the on-going database updates, describe the planned upgrades for FY02 and FY03, and provide a demonstration of TPSX.

Squire, T. H.↗

Upgrade of the Goddard Space Flight Center's Mass Properties Measuring Facility

Goddard Space Flight Center has a Mass Properties Measuring Facility (MPMF), which is used to measure weight, center of gravity, moment of inertia, and product of inertia of satellites and space flight hardware. The system was originally purchased more than 30 years ago. While the MPMF was still in good mechanical condition, the measurement and control subsystem had begun to experience more frequent component failures. Many of the outdated, discrete components in the system are no longer available for replacement. A decision was made to upgrade the measurement and control subsystem of the MPMF to improve its reliability and reduce the chance of component failures leading to extended facility outages. This paper will describe details of the upgraded subsystems and summarize the new performance capabilities of the system.

Ross, Brian P.↗

Upgrades at the Propulsion Systems Lab (PSL)

The Propulsion Systems Lab (PSL) does ground testing on full size air breathing engines. These engines range from those on commercial airplanes to fighter jets. At the PSL, engineers receive test requirements from customers and put together the necessary instrumentation, data systems, power requirements, electrical control valves, and engine controls. The engineers are also responsible for facility maintenance, repairs and upgrades. There are four major sections at the PSL; the Test floor, the Data room, the Control room and, the WDPF room. On the test floor are two test cells, cell #3 and cell #4. It is within these cells that the actual engine resides for ground testing. The cells, once sealed and taken up to altitude, are capable of reaching engine inlet temperatures of 1000 F to -90 F, and various atmospheric pressures. The engine, when operational, takes in air and gives out exhaust of up to 2000 F. The exhaust is led to another section of the cell where it is cooled to 150 F before finally redirected to the appropriate disposer. Temperature and pressure transducers detect the conditions within the cell and transmit them to the data room where the results are captured, processed, analyzed, and translated to a more comprehensive language. This is made possible with the aid of several programmable logic controllers (PLCs) and instrumentation and control systems. The translated data is then sent, via the LAN, to the control room where the results can be viewed on monitors by the engineers and customers. From the control room, the test cell conditions can be changed whenever desired. During tests, a lot takes place in the facility. The WDPF control system monitors and controls all facility parameters. This summer, I will assist the engineers; on an upgrade to the facility's distributed control and dynamic data system, in preparation for an engine test that will begin in September, the installation of control systems and various miscellaneous projects around the PSL.

Audu, Abdullahi M.↗

Upgrade of the Goddard Space Flight Center's Mass Properties Measuring Facility

Goddard Space Flight Center has a Mass Properties Measuring Facility (MPMF), which is used to measure weight, center of gravity, moment of inertia, and product of inertia of satellites and space flight hardware. The system was originally purchased more than 30 years ago. While the MPMF was still in good mechanical condition, the measurement and control subsystem had begun to experience more frequent component failures. Many of the outdated, discrete components in the system are no longer available for replacement. A decision was made to upgrade the measurement and control subsystem of the MPMF to improve its reliability and reduce the chance of component failures leading to extended facility outages. This paper will describe details of the upgraded subsystems and summarize the new performance capabilities of the system.

Ross, Brian P.↗

NASA Glenn's Single-Stage Axial Compressor Facility Upgraded

NASA Glenn Research Center's Single-Stage Axial Compressor Facility was upgraded in fiscal year 2003 to expand and improve its research capabilities for testing high-speed fans and compressors. The old 3000-hp drive motor and gearbox were removed and replaced with a refurbished 7000-hp drive motor and gearbox, with a maximum output speed of 21,240 rpm. The higher horsepower rating permits testing of fans and compressors with higher pressure ratio or higher flow. A new inline torquemeter was installed to provide an alternate measurement of fan and compressor efficiency, along with the standard pressure and temperature measurements. A refurbished compressor bearing housing was also installed with bidirectional rotation capability, so that a variety of existing hardware could be tested. Four new lubrication modules with backup capability were installed for the motor, gearbox, torquemeter, and compressor bearing housing, so that in case the primary pump fails, the backup will prevent damage to the rotating hardware. The combustion air supply line for the facility inlet air system was activated to provide dry air for repeatable inlet conditions. New flow conditioning hardware was installed in the facility inlet plenum tank, which greatly reduced the inlet turbulence. The new inlet can also be easily modified to accommodate 20- or 22-in.-diameter fans and compressors, so a variety of existing hardware from other facilities (such as Glenn's 9- by 15-Foot Low-Speed Wind Tunnel) can be tested in the Single-Stage Axial Compressor Facility. An exhaust line was also installed to provide bleed capability to remove the inlet boundary layer. To improve the operation and control of the facility, a new programmable logic controller (PLC) was installed to upgrade from hardwired relay logic to software logic. The PLC also enabled the usage of human-machine interface software to allow for easier operation of the facility and easier reconfiguration of the facility controls when necessary. Finally, a new health-monitoring system was installed to measure shaft speed, shaft movement, and machine vibration on all of the rotating equipment. The system also provides automatic alarms and shutdown of the equipment when required. An integrated systems test for checkout of the facility was completed on June 17, 2003. Research testing resumed on June 30 with data obtained in support of the Ultra-Efficient Engine Technology Project's Compressor Casing Treatment Project.

Brokopp, Richard A.↗

Space Shuttle Upgrades: Long Life Alkaline Fuel Cell

NASA has utilized the alkaline fuel cell technology to provide electrical power for manned launch vehicles such as Gemini, Apollo, and the Space Shuttle. The current Shuttle alkaline fuel cells are procured from UTC Fuel Cells, a United Technologies Company. The alkaline fuel cells are very reliable but the operating life is limited to 2600 hours due to voltage degradation of the individual cells. The main limiting factor in the life of the cells is corrosion of the cell's fiberglass/epoxy frame by the aqueous potassium hydroxide electrolyte. To reduce operating costs, the orbiter program office approved the Long Life Alkaline Fuel Cell (LLAFC) program as a shuttle upgrade in 1999 to increase the operating life of the fuel cell powerplant to 5000 hours. The LLAFC program incorporates improving the cell by extending the length of the corrosion path, which reduces the cell frame corrosion. UTCFC performed analysis to understand the fundamental mechanisms that drive the cell frame corrosion. The analysis indicated that the corrosion path started along the bond line between the cathode and the cell frame. Analysis also showed that the oxygen available at the cathode, the catalyst on the electrode, and the electrode substrate all supported or intensified the corrosion. The new cell design essentially doubled the corrosion path to mitigate the problem. A 10-cell stack was tested for 5000 hours during the development phase of this program to verify improved cell performance. A complete 96-cell stack was then tested for 5000 hours during the full manned-space qualification phase of this program. Additional upgrades to the powerplant under this program are: replacing the aluminum body in the pressure regulator with stainless steel to reduce corrosion, improving stack insulator plate with improved resistance to stress failure and improved temperature capability, and replacing separator plate elastomer seals with a more durable material and improved seal retention.

Kerri McCurdy↗

Case Study of the Space Shuttle Cockpit Avionics Upgrade Software

The purpose of the Space Shuttle Cockpit Avionics Upgrade project was to reduce crew workload and improve situational awareness. The upgrade was to augment the Shuttle avionics system with new hardware and software. An early version of this system was used to gather human factor statistics in the Space Shuttle Motion Simulator of the Johnson Space Center for one month by multiple teams of astronauts. The results were compiled by NASA Ames Research Center and it was was determined that the system provided a better than expected increase in situational awareness and reduction in crew workload. Even with all of the benefits nf the system, NASA cancelled the project towards the end of the development cycle. A major success of this project was the validation of the hardware architecture and software design. This was significant because the project incorporated new technology and approaches for the development of human rated space software. This paper serves as a case study to document knowledge gained and techniques that can be applied for future space avionics development efforts. The major technological advances were the use of reflective memory concepts for data acquisition and the incorporation of Commercial off the Shelf (COTS) products in a human rated space avionics system. The infused COTS products included a real time operating system, a resident linker and loader, a display generation tool set, and a network data manager. Some of the successful design concepts were the engineering of identical outputs in multiple avionics boxes using an event driven approach and inter-computer communication, a reconfigurable data acquisition engine, the use of a dynamic bus bandwidth allocation algorithm. Other significant experiences captured were the use of prototyping to reduce risk, and the correct balance between Object Oriented and Functional based programming.

Ferguson, Roscoe C.↗

NIRSS Upgrades: Final Report

This year we were able to further the NIRSS program by re-writing the data ingest and display code from LabVIEW to C++ and Java. This was leveraged by a University of Colorado Computer Science Department Senior Project. The upgrade made the display more portable and upgradeable. Comparisons with research aircraft flights conducted during AIRS-2 were also done and demonstrate reasonable skill in determining cloud altitudes and liquid water distribution. Improvements can still be made to the cloud and liquid logic. The icing hazard index was not evaluated here since that represents work in progress and needs to be made compatible with the new CIP-Severity algorithm. CIP is the Current Icing Potential product that uses a combination decision tree/fuzzy logic algorithm to combine numerical weather model output with operational sensor data (NEXRAD, GOES, METARs and voice pilot reports) to produce an hourly icing diagnosis across the CONUS. The new severity algorithm seeks to diagnose liquid water production through rising, cooling air, and depletion by ice processes. The information used by CIP is very different from that ingested by NIRSS but some common ground does exist. Additionally, the role of NIRSS and the information it both needs and provides needs to be determined in context of the Next Generation Air Traffic System (NGATS). The Weather Integrated Products Team has a plan for an Initial Operating Capability (IOC) to take place in 2012. NIRSS is not explicitly a part of that IOC but should be considered as a follow-on as part of the development path to a 2025 full capability.

Politovich, Marcia K.↗

Simulating Avionics Upgrades to the Space Shuttles

Cockpit Avionics Prototyping Environment (CAPE) is a computer program that simulates the functions of proposed upgraded avionics for a space shuttle. In CAPE, pre-existing space-shuttle-simulation programs are merged with a commercial-off-the-shelf (COTS) display-development program, yielding a package of software that enables high-fi46 NASA Tech Briefs, September 2008 delity simulation while making it possible to rapidly change avionic displays and the underlying model algorithms. The pre-existing simulation programs are Shuttle Engineering Simulation, Shuttle Engineering Simulation II, Interactive Control and Docking Simulation, and Shuttle Mission Simulator playback. The COTS program Virtual Application Prototyping System (VAPS) not only enables the development of displays but also makes it possible to move data about, capture and process events, and connect to a simulation. VAPS also enables the user to write code in the C or C++ programming language and compile that code into the end-product simulation software. As many as ten different avionic-upgrade ideas can be incorporated in a single compilation and, thus, tested in a single simulation run. CAPE can be run in conjunction with any or all of four simulations, each representing a different phase of a space-shuttle flight.

Deger, Daniel↗

Honeycomb vs. Foam: Evaluating Potential Upgrades to ISS Module Shielding

The presence of honeycomb cells in a dual-wall structure is advantageous for mechanical performance and low weight in spacecraft primary structures but detrimental for shielding against impact of micrometeoroid and orbital debris particles (MMOD). The presence of honeycomb cell walls acts to restrict the expansion of projectile and bumper fragments, resulting in the impact of a more concentrated (and thus lethal) fragment cloud upon the shield rear wall. The Multipurpose Laboratory Module (MLM) is a Russian research module scheduled for launch and ISS assembly in 2011 (currently under review). Baseline shielding of the MLM is expected to be predominantly similar to that of the existing Functional Energy Block (FGB), utilizing a baseline triple wall configuration with honeycomb sandwich panels for the dual bumpers and a thick monolithic aluminum pressure wall. The MLM module is to be docked to the nadir port of the Zvezda service module and, as such, is subject to higher debris flux than the FGB module (which is aligned along the ISS flight vector). Without upgrades to inherited shielding, the MLM penetration risk is expected to be significantly higher than that of the FGB module. Open-cell foam represents a promising alternative to honeycomb as a sandwich panel core material in spacecraft primary structures as it provides comparable mechanical performance with a minimal increase in weight while avoiding structural features (i.e. channeling cells) detrimental to MMOD shielding performance. In this study, the effect of replacing honeycomb sandwich panel structures with metallic open-cell foam structures on MMOD shielding performance is assessed for an MLM-representative configuration. A number of hypervelocity impact tests have been performed on both the baseline honeycomb configuration and upgraded foam configuration, and differences in target damage, failure limits, and derived ballistic limit equations are discussed.

Ryan, Shannon J.↗

A Cooling System for the EAPU Shuttle Upgrade

The Shuttle orbiter currently uses hydrazine-powered APU's for powering its hydraulic system pumps. To enhance vehicle safety and reliability, NASA is pursuing an APU upgrade where the hydrazine powered turbine is replaced by an electric motor pump and battery power supply. This EAPU (Electric APU) upgrade presents several thermal control challenges most notably the new requirement for moderate temperature control of high-power electron ics at 132 of (55.6 C). This paper describes how the existing Water Spray Boiler (WSB), which currently cools the hydraulic fluid and APU lubrication oil, is being modified to provide EAPU thermal management.

Tongue, Stephen↗

NASA Glenn PSL-3 and 4 Control System Upgrade

An overview of the PSL-3&4 Jet Engine Test Facility control system; including its history, a description of the present effort to upgrade from Emerson Ovation v2.2 to V3.3.1, and future upgrade plans is shown.

Lizanich, Paul J.↗

Recent Upgrades to NASA SPoRT Initialization Datasets for the Environmental Modeling System

The NASA Short-term Prediction Research and Transition (SPoRT) Center has developed several products for its National Weather Service (NWS) partners that can initialize specific fields for local model runs within the NOAA/NWS Science and Training Resource Center (STRC) Environmental Modeling System (EMS). In last year's NWA abstract on this topic, the suite of SPoRT products supported in the STRC EMS was presented, which includes a Sea Surface Temperature (SST) composite, a Great Lakes sea-ice extent, a Green Vegetation Fraction (GVF) composite, and NASA Land Information System (LIS) gridded output. This abstract and companion presentation describes recent upgrades made to the SST and GVF composites, as well as the real-time LIS runs. The Great Lakes sea-ice product is unchanged from 2011. The SPoRT SST composite product has been expanded geographically and as a result, the resolution has been coarsened from 1 km to 2 km to accommodate the larger domain. The expanded domain covers much of the northern hemisphere from eastern Asia to western Europe (0 N to 80 N latitude and 150 E to 10 E longitude). In addition, the NESDIS POES-GOES product was added to fill in gaps caused by the Moderate Resolution Imaging Spectroradiometer (MODIS) being unable to sense in cloudy regions, replacing the recently-lost Advanced Microwave Scanning Radiometer for EOS with negligible change to product fidelity. The SST product now runs twice per day for Terra and Aqua combined data collections from 0000 to 1200 UTC and from 1200 to 0000 UTC, with valid analysis times at 0600 and 1800 UTC. The twice-daily compositing technique reduces the overall latency of the previous version while still representing the diurnal cycle characteristics. The SST composites are available at approximately four hours after the end of each collection period (i.e. 1600 UTC for the nighttime analysis and 0400 UTC for the daytime analysis). The real-time MODIS GVF composite has only received minor updates in the past year. The domain was expanded slightly to extend further west, north, and east to improve coverage over parts of southern Canada. Minor adjustments were also made to the manner in which GVF is calculated from the distribution of maximum Normalized Difference Vegetation Index from MODIS. The presentation will highlight some examples of the substantial inter-annual change in GVF that occurred from 2010 to 2011 in the U.S. Southern Plains as a result of the summer 2011 drought, and the early vegetation green up across the eastern U.S. due to the very warm conditions in March 2012. Finally, the SPoRT LIS runs the operational Noah land surface model (LSM) in real time over much of the eastern half of the CONUS. The Noah LSM is continually cycled in real time, uncoupled to any model, and driven by operational atmospheric analyses over a long-term, multi-year integration. The LIS-Noah provides the STRC EMS with high-resolution (3 km) LSM initialization data that are in equilibrium with the operational analysis forcing. The Noah LSM within the SPoRT LIS has been upgraded from version 2.7.1 to version 3.2, which has improved look-up table attributes for several land surface quantities. The surface albedo field is now being adjusted based on the input real-time MODIS GVF, thereby improving the net radiation. Also, the LIS-Noah now uses the newer MODIS-based land use classification scheme (i.e. the International Biosphere-Geosphere Programme [IGBP]) that has a better depiction of urban corridors in areas where urban sprawl has occurred. STRC EMS users interested in initializing their LSM fields with high-resolution SPoRT LIS data should set up their model domain with the MODIS-IGBP 20-class land use database and select Noah as the LSM.

Case, Jonathan L.↗