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PSR Section 15

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Thruster alignment maintained by control of manufacturing tolerances ... No Hysteresis. 2 Counts Maximum Error. 0.2% FS. NMP / EO-1. NMP EO-1 PRE-SHIP REVIEW. 15 - 13 ... – PowerPoint PPT presentation

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Title: PSR Section 15


1
Section 15 Reaction Control System
. . . Mike McCullough Swales Aerospace
2
Reaction Control System - Agenda
  • System Overview
  • Test Verification Matrix
  • Component and Subsystem Level Testing
  • System Level Testing
  • Thermal Balance
  • Internal Leak Checks
  • Status of Launch Site Procedures
  • Status of Launch Site GSE
  • System Readiness

3
Reaction Control System
4
RCS Verification Matrix Items
  • Alignment - by analysis
  • Thruster alignment maintained by control of
    manufacturing tolerances
  • Static Load - Qualification by similarity
  • Proof Pressure - Test
  • Proof Pressure Tests conducted at component and
    subsystem level
  • Mass Properties - Weighed
  • Weighed at the subsystem level including Zenith
    Deck
  • Interface Verification - Test
  • Interfaces tested during Spacecraft IT Process
  • Functional - Test
  • Tested at the component and subsystem level

5
RCS Component Verification
  • Latch Valve
  • Internal and External Leakage Test
  • Operating Cycles
  • Visual Inspection and Cleanliness
  • Vibration
  • Thrusters
  • Hot Fire Performance
  • Proof Pressure, Vibration
  • Internal and External Leakage
  • Pull-In and Drop-Out Voltage
  • Visual Inspection and Cleanliness
  • Pressure Transducer
  • Vibration and Proof Pressure Test
  • Calibration
  • Electrical Characteristics
  • Propellant Tank
  • Determination of Volume
  • Proof Pressure Test
  • Internal and External Leakage Test
  • Radiographic/Penetrant Inspection
  • Visual Inspection and Cleanliness
  • Fill/Drain Valves
  • Inspection and Cleanliness
  • Proof Pressure
  • Internal and External Leakage
  • Operational Cycles
  • Filter
  • Proof Pressure Test
  • External Leakage
  • Bubble Point and D-P
  • Visual Inspection and Cleanliness

6
RCS Verification at Primex
  • System Welds
  • Leak Checked, Dye Penetrant and Radiographic
    Inspection
  • Proof Pressure Checks
  • High Pressure Proof Pressure Test (820 psig)
    excluding Tank
  • Complete System Proof Pressure Test (480 psig)
  • Internal Valve Leak Checks
  • Thruster and Latch Valve Seats checked
    individually
  • Electrical Component Resistance and Isolation
    Checks
  • System Level Functional Checks
  • Thrusters, Latch Valve, Pressure Transducer and
    Thermostats

7
RCS Verification
8
RCS Checks at Swales
  • Electrical Component Resistance and Isolation
    Checks
  • System Integration with Spacecraft
  • System Level Functional Checks
  • Pre and Post Integration
  • Thrusters, Latch Valve, Pressure Transducer,
    Thermostats and Thermistors
  • Thruster Phasing with Gas Flow at 15 psig

9
RCS Environmental Test Program
  • The EO-1 RCS was fully integrated with the
    spacecraft for Shock, Vibration and Acoustic
    Testing
  • RCS Functionality verified during CPT 5
  • Exercised thruster valves
  • Powered catalyst bed heaters
  • Exercised the latch valve
  • RCS Integrity verified during Pressure Transducer
    Calibration and Valve Leak Checks
  • Thermal Vacuum / Thermal Balance Testing Verified
    Proper Operation of the RCS Thermal Control
    System.
  • Temperatures maintained between 18C - 24C
    during cold case tests
  • No heater activity during hot case testing

10
RCS Thermal Control (1)
11
RCS Thermal Control (2)
12
RCS Pressure Transducer Calibration
  • End-to-end Test Performed, Propellant Tank to
    Ground System Display
  • No Change in Scale Factor
  • 100 psi/volt
  • Offset Adjusted by 1.3 psi
  • No Hysteresis
  • 2 Counts Maximum Error
  • 0.2 FS

13
RCS Internal Leak Check
  • Performed Internal Leak Check on All RCS Valves
  • Series Redundant Valve Seats checked individually
  • Checked At MEOP (320 psig)
  • Total of 9 Valve Seats checked
  • One Failed to Meet ATP Level Performance
  • Leakage Rate of 13 scc/h GN2 will still not
    permit liquid to pass
  • System Level Leak Rate Criteria Developed - 100
    scc/h per valve seat, no more than 130 scc/h
    combined leakage per thruster
  • System Level Performance is Acceptable

All Thrusters Pass revised Leak rate criteria
14
RCS Pressure Cycle Log
15
RCS Launch Site Procedure Status
  • Two procedures considered hazardous by NASA/KSC
    and Air Force 30SW - Review and Approval Required
  • RCS Checkout and Leak Test Procedure SAI-PROC-309
  • Hazardous due to pressures involved
  • Submitted to Range for comment
  • Comments incorporated
  • Ready for Final Range Review Approval
  • EO-1/SAC-C Propellant Loading Procedure PAC
    IP-0645
  • Hazardous due to propellants and pressures
    involved
  • Submitted to Range for comment
  • Comments incorporated - TIM held to discuss
    details
  • Submitted to the Range for final approval

16
RCS Ground Support Equipment Status
  • Propellant Loading Cart has been demonstrated
    using PAC procedure IP-0645
  • Pressure Test Console and all associated
    equipment has been calibrated and / or proof
    tested and will remain valid throughout the
    launch campaign
  • Portable Pressure Monitor Unit (PPMU) has been
    functionally demonstrated
  • All Export / ITAR issues associated with SAC-C
    propellant loading have been resolved
  • SCAPE / PHE and Interscan Training will be
    accomplished shortly after arrival at the launch
    site
  • Range Safety has reviewed GSE Design documented
    in the EO-1 MSPSP SAI-SFTY-019 submitted to the
    Range 26 Oct 99
  • Previewed by Range Safety Prior to Official
    Submittal

17
RCS Statement of Readiness
  • The EO-1 Reaction Control System is Ready for
    Launch Site Processing
  • System Integrity, Performance and Functionality
    has been demonstrated
  • The EO-1 RCS Launch Site Procedures are Ready for
    Launch Site Operations
  • Procedures have been demonstrated using GSE
  • There are no obstacles to procedure approval by
    the Western Range
  • The EO-1 RCS GSE is Ready to Support Launch Site
    Processing
  • Primex is Ready to Support EO-1 / SAC-C
    Propellant Loading
  • No Residual Risk for RCS
  • No Red Book Items
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