PSR Section 15

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Section 15 Reaction Control System
. . . Mike McCullough Swales Aerospace
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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

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Reaction Control System
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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

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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

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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

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RCS Verification
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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

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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

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RCS Thermal Control (1)
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RCS Thermal Control (2)
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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

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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
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RCS Pressure Cycle Log
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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

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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

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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