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A list is presented of the facilities and environmental measurements to be monitored in support of the Apollo/Saturn vehicle AS-511. The measurement identification number, description, transducer operating range, recorder type and drawings illustrating measurement location are included. The following launch complex 39 facilities will be used on this vehicle: launch complex 39 pad A, and launcher umbilical tower number 3.
The launch complexes at NASA's John F. Kennedy Space Center (KSC) are critical support facilities for the successful launch of space-based vehicles. These facilities include a flame trench that bisects the pad at ground level. This trench includes a flame deflector system that consists of an inverted, V-shaped steel structure covered with a high temperature concrete material five inches thick that extends across the center of the flame trench. One side of the "V11 receives and deflects the flames from the orbiter main engines; the opposite side deflects the flames from the solid rocket boosters. There are also two movable deflectors at the top of the trench to provide additional protection to shuttle hardware from the solid rocket booster flames. These facilities are over 40 years old and are experiencing constant deterioration from launch heat/blast effects and environmental exposure. The refractory material currently used in launch pad flame deflectors has become susceptible to failure, resulting in large sections of the material breaking away from the steel base structure and creating high-speed projectiles during launch. These projectiles jeopardize the safety of the launch complex, crew, and vehicle. Post launch inspections have revealed that the number and frequency of repairs, as well as the area and size of the damage, is increasing with the number of launches. The Space Shuttle Program has accepted the extensive ground processing costs for post launch repair of damaged areas and investigations of future launch related failures for the remainder of the program. There currently are no long term solutions available for Constellation Program ground operations to address the poor performance and subsequent failures of the refractory materials. Over the last three years, significant liberation of refractory material in the flame trench and fire bricks along the adjacent trench walls following Space Shuttle launches have resulted in extensive investigations of failure mechanisms, load response, ejected material impact evaluation, and repair design analysis (environmental and structural assessment, induced environment from solid rocket booster plume, loads summary, and repair integrity), assessment of risk posture for flame trench debris, and justification of flight readiness rationale. Although the configuration of the launch pad, water and exhaust direction, and location of the Mobile Launcher Platform between the flame trench and the flight hardware should protect the Space Vehicle from debris exposure, loss of material could cause damage to a major element of the ground facility (resulting in temporary usage loss); and damage to other facility elements is possible. These are all significant risks that will impact ground operations for Constellation and development of new refractory material systems is necessary to reduce the likelihood of the foreign object debris hazard during launch. KSC is developing an alternate refractory material for the launch pad flame trench protection system, including flame deflector and flame trench walls, that will withstand launch conditions without the need for repair after every launch, as is currently the case. This paper will present a summary of the results from industry surveys, trade studies, life cycle cost analysis, and preliminary testing that have been performed to support and validate the development, testing, and qualification of new refractory materials.
The lifecycle cost analysis was based on corrosion costs for the Kennedy Space Center's Launch Complexes and Mobile Launch Platforms. The first step in the study involved identifying the relevant assets that would be included. Secondly, the identification and collection of the corrosion control cost data for the selected assets was completed. Corrosion control costs were separated into four categories. The sources of cost included the NASA labor for civil servant personnel directly involved in overseeing and managing corrosion control of the assets, United Space Alliance (USA) contractual requirements for performing planned corrosion control tasks, USA performance of unplanned corrosion control tasks, and Testing and Development. Corrosion control operations performed under USA contractual requirements were the most significant contributors to the total cost of corrosion. The operations include the inspection of the pad, routine maintenance of the pad, medium and large scale blasting and repainting activities, and the repair and replacement of structural metal elements. Cost data was collected from the years between 2001 and 2007. These costs were then extrapolated to future years to calculate the 20 year lifecycle costs.
A vital element to NASA's manned space flight launch operations is the Kennedy Space Center Launch Complex 39's launch pads A and B. Originally designed and constructed In the 1960s for the Saturn V rockets used for the Apollo missions, these pads were modified above grade to support Space Shuttle missions. But below grade, each of the pad's original walls (including a 42 feet deep, 58 feet wide, and 450 feet long tunnel designed to deflect flames and exhaust gases, the flame trench) remained unchanged. On May 31, 2008 during the launch of STS-124, over 3500 of the. 22000 interlocking refractory bricks that lined east wall of the flame trench, protecting the pad structure were liberated from pad 39A. The STS-124 launch anomaly spawned an agency-wide initiative to determine the failure root cause, to assess the impact of debris on vehicle and ground support equipment safety, and to prescribe corrective action. The investigation encompassed radar imaging, infrared video review, debris transport mechanism analysis using computational fluid dynamics, destructive testing, and non-destructive evaluation, including vibroacoustic analysis, in order to validate the corrective action. The primary focus of this paper is on the analytic approach, including static, modal, and vibro-acoustic analysis, required to certify the corrective action, and ensure Integrity and operational reliability for future launches. Due to the absence of instrumentation (including pressure transducers, acoustic pressure sensors, and accelerometers) in the flame trench, defining an accurate acoustic signature of the launch environment during shuttle main engine/solid rocket booster Ignition and vehicle ascent posed a significant challenge. Details of the analysis, including the derivation of launch environments, the finite element approach taken, and analysistest/ launch data correlation are discussed. Data obtained from the recent launch of STS-126 from Pad 39A was instrumental in validating the design analysis philosophies outlined in this paper.
An accurate database of meteorological data is essential for designing any aerospace vehicle and for preparing launch commit criteria. Meteorological instrumentation were recently placed on the three Lightning Protection System (LPS) towers at Kennedy Space Center (KSC) launch complex 39B (LC-39B), which provide a unique meteorological dataset existing at the launch complex over an extensive altitude range. Data records of temperature, dew point, relative humidity, wind speed, and wind direction are produced at 40, 78, 116, and 139 m at each tower. The Marshall Space Flight Center Natural Environments Branch (EV44) received an archive that consists of one-minute averaged measurements for the period of record of January 2011 - April 2015. However, before the received database could be used EV44 needed to remove any erroneous data from within the database through a comprehensive quality control (QC) process. The QC process applied to the LPS towers' meteorological data is similar to other QC processes developed by EV44, which were used in the creation of meteorological databases for other towers at KSC. The QC process utilized in this study has been modified specifically for use with the LPS tower database. The QC process first includes a check of each individual sensor. This check includes removing any unrealistic data and checking the temporal consistency of each variable. Next, data from all three sensors at each height are checked against each other, checked against climatology, and checked for sensors that erroneously report a constant value. Then, a vertical consistency check of each variable at each tower is completed. Last, the upwind sensor at each level is selected to minimize the influence of the towers and other structures at LC-39B on the measurements. The selection process for the upwind sensor implemented a study of tower-induced turbulence. This paper describes in detail the QC process, QC results, and the attributes of the LPS towers meteorological database.
The Ares I-X flight test is the first development flight of the Ares I crew launch vehicle. This mission, first conceived in 2006, will be launching later in 2009. Its primary mission objectives will be to demonstrate flight and roll control of a dynamically similar vehicle, perform a separation event and measure its shock effects, stack and recover a first stage booster, and demonstrate ground operations. All of the primary flight test vehicle s hardware is at Kennedy Space Center, and is being stacked in the Vehicle Assembly Building for a liftoff at Launch Complex 39B. Mission hardware specific to Ares I-X also is being installed at Launch Complex 39, which has been supporting Space Shuttle operations. This presentation will provide a status and preview of the upcoming mission.
Space shuttle launches produce environmental impacts resulting from the formation of an exhaust cloud containing hydrogen chloride aerosols and aluminum oxide particulates. Studies have shown that most impacts occur near-field (within 1.5 km) of the launch site while deposition from launches occurs far-field (as distant as 22 km). In order to establish baseline conditions of vegetation and soils in the areas likely to be impacted by shuttle launches from Vandenberg Air Force Base (VAFB), vegetation and soils in the vicinity of Space Launch Complex-6 (SLC-6) were sampled and a vegetation map prepared. The areas likely to be impacted by launches were determined considering the structure of the launch complex, the prevailing winds, the terrain, and predictions of the Rocket Exhaust Effluent Diffusion Model (REEDM). Fifty vegetation transects were established and sampled in March 1986 and resampled in September 1986. A vegetation map was prepared for six Master Planning maps surrounding SLC-6 using LANDSAT Thematic Mapper imagery as well as color and color infrared aerial photography. Soil samples were collected form the 0 to 7.5 cm layer at all transects in the wet season and at a subsample of the transects in the dry season and analyzed for pH, organic matter, conductivity, cation exchange capacity, exchangeable Ca, Mg, Na, K, and Al, available NH3-N, PO4-P, Cu, Fe, Mn, Zn, and TKN.
Hazards monitoring data display and transmission system for launch complex
The Space Shuttle program has ended and elements of the Constellation Program have either been cancelled or transitioned to new NASA exploration endeavors. The National Aeronautics and Space Administration (NASA) has worked diligently to select an optimum configuration for the Space Launch System (SLS), a heavy lift vehicle that will provide the foundation for future beyond low earth orbit (LEO) large-scale missions for the next several decades. From Fall 2010 until Spring 2011, an SLS decision-making framework was formulated, tested, fully documented, and applied to multiple SLS vehicle concepts at NASA from previous exploration architecture studies. This was a multistep process that involved performing figure of merit (FOM)-based assessments, creating Pass/Fail gates based on draft threshold requirements, performing a margin-based assessment with supporting statistical analyses, and performing sensitivity analysis on each. This paper focuses on the various steps and methods of this process (rather than specific data) that allowed for competing concepts to be compared across a variety of launch vehicle metrics in support of the successful completion of the SLS Mission Concept Review (MCR) milestone.
Footage shows panoramic views of the Atlas launch vehicle on the launch complex. Also shown are ignition, liftoff, several different launch replays from different cameras, and views of the complex after launch.
A trade study and litera ture survey of refractory materials (fi rebrick. refractory concrete. and si licone and epoxy ablatives) were conducted to identify candidate replacement materials for Launch Complexes 39A and 398 at Kennedy Space Center (KSC). In addition, site vis its and in terviews with industry expens and vendors of refractory materials were conducted. As a result of the si te visits and interviews, several products were identified for launch applications. Firebrick is costly to procure and install and was not used in the si tes studied. Refractory concrete is gunnable. adheres well. and costs less 10 install. Martyte. a ceramic fi lled epoxy. can protect structural stccl but is costly. difficullto apply. and incompatible with silicone ablatives. Havanex, a phenolic ablative material, is easy to apply but is costly and requires frequent replacement. Silicone ablatives are ineJ[pensive, easy to apply. and perl'onn well outside of direct rocket impingement areas. but refractory concrete and epoxy ablatives provide better protection against direcl rocket exhaust. None of the prodUCIS in this trade study can be considered a panacea for these KSC launch complexes. but the refractory products. individually or in combination, may be considered for use provided the appropriate testing requirements and specifications are met.
The plume-induced environment created by the Ares 1 first stage, five-segment reusable solid rocket motor (RSRMV) will impose high heating rates and impact pressures on Launch Complex 39. The extremes of these environments pose a potential threat to weaken or even cause structural components to fail if insufficiently designed. Therefore the ability to accurately predict these environments is critical to assist in specifying structural design requirements to insure overall structural integrity and flight safety. This paper presents the predicted thermal and pressure environments induced by the launch of the Crew Launch Vehicle (CLV) from Launch Complex (LC) 39. Once the environments are predicted, a follow-on thermal analysis is required to determine the surface temperature response and the degradation rate of the materials. An example of structures responding to the plume-induced environment will be provided.
Ceramics can be defmed as a material consisting of hard brittle properties produced from inorganic and nonmetallic minerals made by firing at high temperatures. These materials are compounds between metallic and nonmetallic elements and are either totally ionic, or predominately ionic but having some covalent character. This definition allows for a large range of materials, not all applicable to refractory applications. As this report is focused on potential ceramic materials for high temperature, aggressive exposure applications, the ceramics reviewed as part of this report will focus on refractory ceramics specifically designed and used for these applications. Ceramic materials consist of a wide variety of products. Callister (2000) 1 characterized ceramic materials into six classifications: glasses, clay products, refractories, cements, abrasives, and advanced ceramics. Figure 1 shows this classification system. This review will focus mainly on refractory ceramics and cements as in general, the other classifications are neither applicable nor economical for use in large structures such as the flame trench. Although much work has been done in advanced ceramics over the past decade or so, these materials are likely cost prohibitive and would have to be fabricated off-site, transported to the NASA facilities, and installed, which make these even less feasible. Although the authors reviewed the literature on advanced ceramic refractories 2 center dot 3 center dot 4 center dot 5 center dot 6 center dot 7 center dot 8 center dot 9 center dot 10 center dot 11 center dot 12 after the review it was concluded that these materials should not be ' the focus of this report. A review is in progress on materials and systems for prefabricated refractory ceramic panels, but this review is focusing more on typical refractory materials for prefabricated systems, which could make the system more economically feasible. Refractory ceramics are used for a wide variety of applications. Figure 2 shows many ofthese applications, their life expectancy or requirement, and the exposure temperature for the refractory ceramic. Note that the exposure temperatures for refractory ceramics are very similar to the exposure conditions for specialty ceramics (rocket nozzles, space vehicle re-entry fields, etc.) and yet the life expectancy or requirement is relatively low. Currently NASA is repairing the refractory lining in the flame trench after every launch - although this is not a direct indication of low life expectancy, it does indicate that the current system may not be sufficiently durable to maximize economy. Better performing refractory ceramics are needed to improve the performance, economy, and safety during and after launches at the flame trenches at Kennedy Space Center (KSC). To achieve this goal a current study is underway to assess different refractory systems for possible use in the flame trenches at KSC. This report will target the potential applicability of refractory ceramics for use in the flame trenches. An overview of the different refractory ceramics will be provided (see Figure I). This will be followed with a brief description of the structure of refractory products, the properties and characteristics of different systems, the methodology for selecting refractories, and then a general design methodology. Based on these sections, future challenges and opportunities will be identified with the objective of improving the durability, performance, economy, and safety of the launch complex. Refractory ceramics are used for a wide variety of applications. Figure 2 shows many ofthese applications, their life expectancy or requirement, and the exposure temperature for the refractory ceramic. Note that the exposure temperatures for refractory ceramics are very similar to the exposure conditions for specialty ceramics (rocket nozzles, space vehicle re-entry fields, etc.) and yet the life expectancy or requirement is relatively low. Currently NASA is repairing the refractory lining in the flame trench after every launch - although this is not a direct indication of low life expectancy, it does indicate that the current system may not be sufficiently durable to maximize economy. Better performing refractory ceramics are needed to improve the performance, economy, and safety during and after launches at the flame trenches at Kennedy Space Center (KSC). To achieve this goal a current study is underway to assess different refractory systems for possible use in the flame trenches at KSC. This report will target the potential applicability of refractory ceramics for use in the flame trenches. An overview of the different refractory ceramics will be provided (see Figure I). This will be followed with a brief description of the structure of refractory products, the properties and characteristics of different systems, the methodology for selecting refractories, and then a general design methodology. Based on these sections, future challenges and opportunities will be identified with the objective of improving the durability, performance, economy, and safety of the launch complex.
Operational ground support equipment for Voyager project, including data handling system, launch complex equipment, system test complex, and mission dependent equipment
A brief description of Complex 39L as it is currently conceived is presented. A brief discussion of lunar thermal history is then presented. From this follows a discussion of the current lunar thermal environment which will impact the design of cryogenic storage and handling facilities on the moon. Some previous studies are discussed. A conceptual design of liquid oxygen and hydrogen storage facilities is presented. The essential feature of this facility is that cryogens are to be stored in a number of small tanks which can serve as lander propellant tanks rather than as one large storage vessel. These tanks will be placed under a Fuel Inventory Tent (FIT) for shadow shielding. Methods of dealing with propellant boil-off are discussed. A base case cascade refrigeration system for requirements are such that it seems very feasible to construct a prototype boil-off recovery system in a laboratory environment.
After a general, overall definition of Complex 39L during the previous two years, the 1988-89 projects were chosen to focus on more specific aspects, specifically, guidance systems and propellant systems. Six teams or subtasks were formulated: cascade refrigeration for boil-off recovery of cryogenic storage vessels; lunar ground-based radar system to track space vehicles; microwave altimeter for spacecraft; development of a computational model for the determination of lunar surface and sub-surface temperatures; lunar cryogenic facility for the storage of fuels; and lunar lander fuel inventory tent for the storage of cryogenic vessels. At the present time, a cascade refrigeration system for a cryogenic boil-off recovery system has been designed. This is to serve as a baseline system. The ground-based tracking system uses existing technology to implement a reliable tracking radar for use on the lunar surface. A prototype has been constructed. The microwave altimeter is for use on lunar landers. It makes use of the Doppler effect to measure both altitude and the vertical velocity component of the spacecraft. A prototype has been constructed. A computational model that predicts the spatial and temporal temperature profiles of the lunar subsurface was formulated. Propellant storage vessels have been designed. A support for these vessels which minimizes heat leaks was also designed. Further work on the details of the Fuel Inventory Tent (FIT) was performed. While much design work on the overall Complex 39L remains to be done, significant new work has been performed in the subject areas.
Qualification testing of pressure gauge used at Cape Kennedy in launch complex 34 pneumatic distribution portion of propellant consoles
History of Cape Kennedy launch complex noting origin, initial construction, organization, launching sites, ground support equipment, and significant accomplishments