Launching the Space Shuttle Bob Sieck October 2005Agenda Background Engineering Operations Human FactorsKSC Shuttle Infrastructure Equivalent to a Small City Facilities Support  Kennedy Space Center 140,000 Acres  300 Generators, 60 UPS Units, 156 Substations  Vehicle Assembly Building 8 Acre Footprint,  30,000 Tons of Air Conditioning  Over 52 Cranes, 217 Hoists, and 55 Elevators 525’ Tall  100 miles of Water Distribution Lines  Three Orbiter Processing Facilities 30,000 SF Each  441 Pieces of Heavy Equipment  Launch Pads A&B Fuel/Oxidizer Tank  270 Miles of Fiber Optic Cable Capacity of 1.8 M Gal  Over 900 Fiber Optic Transmitters and 900 Fiber Optic  Shuttle Landing Facility 15,000’ Runway, Receivers 300’ Wide  LC-39 TV System Includes 166 Cameras, 9 Video  Operations Support Building 200,000 SF Office Recorders, and Over 7770 Monitors Space  142,000 Line Items in Inventory  10,000 Issues Per MonthStandard Work Flow Shuttle Processing Team  Space Flight Operations Contractor – United Space Alliance  Responsible for processing Orbiter, External Tank (ET), Solid Rocket Boosters (SRB) and Re-usable Solid Rocket Motors (RSRM)  Responsible for facility and Ground Support Equipment (GSE) maintenance  Additional support provided by development and institutional contractors  NASA Shuttle Processing Director is the designated Technical Manager for:  Management of NASA shuttle support at KSC  Disposition of technical issues for KSC equipment  Validating contractor processes meet NASA requirements  NASA Launch Director is responsible for:  Management of launch count, landing and recovery operationsNASA Shuttle Processing Responsibilities Engineering  Approve  Requirements  New/Changed Requirements  Implementation Procedures  NASA Managed Activities  Analyze Test Data  / Tasks  Audit Requirements Implementation  Assess Contractor Metrics Operations Integration  Lead NASA Managed Activities /  Lead Vehicle Flow Planning  Approve Requirements  Observe Critical Integrated Procedures / Tasks  Observe Day-to-Day Operations  Assess Contractor Metrics  Manifest (Flight Schedule) Development Non conformance to Program Observe Critical Procedures Approve ProceduresOrbiter Processing Facility (OPF) OperationsOrbiter Processing Facility (OPF)  Operations  Initial access and safing  Post-flight hardware problem resolution  Thermal Protection System maintenance, replacement and repair  Space Shuttle Main Engine (SSME) removal and installation  Payload bay operations  Down mission payload removal  Mission kit reconfiguration  Up mission horizontal payload configuration and installation  Orbiter modifications  Orbiter sub-system design requirement re-verification  Orbiter preparation for roll over to VAB (Vertical Operations)Vehicle Assembly Building (VAB) OperationsVehicle Assembly Building (VAB)  Operations  Perform External Tank (ET) checkout  Solid Rocket Booster stacking requires approximately three weeks  ET mate and closeout requires approximately two weeks  Orbiter mate requires approximately one week  Test interfaces between Shuttle elements  Perform structural closeoutLaunch PadLaunch Pads 39A and 39B  Operations  Pad processing takes approximately 4 weeks  Payload transfer from payload canister to Payload Change-out Room (PCR) to Orbiter  Shuttle/Pad system validation  Simulated launch count with astronauts  Final preparations to vehicle for launch countdownLaunch Processing System (LPS) / Control RoomLaunch Processing System (LPS) / Control Room  Description  Automated and computer controlled Shuttle launch and checkout system  Customized hardware for Shuttle  Custom language used for application software  Linked to orbiter, External Tank, and Solid Rocket Booster, and Ground Support Equipment at all processing locations  Operations Support  Automated checkout of Shuttle and associated Ground Support Equipment during preparation for launch  Problem resolution and data reductionEngineering Approach  Engineering Requirements – Demonstrate the “as built ready to launch shuttle” is the same “as designed and certified”  Development / design organizations establish requirements implemented at KSC  Requirements dictate hardware / software performance and limitations in ground tests and inspections  Verified by review of documents used to assemble, inspect and test  Periodic management reviews certify readiness  Launch Count Requirements  Requirements documented in engineering drawings, NASA Program documents and Launch Commit Criteria  Acceptable limits for the system performance and the configuration of the hardware and software  System Engineers develop procedures and software to implement requirements  Approximately 500 requirements with approximately 2000 associated measurements  Launch count procedures: Approximately 20 documents totaling 5000 pages  Approximately 500 software programsLaunch Team StructureLaunch DirectorMission ManagementTeamEngineering SupportNASA & ContractorProject ManagersNASA JSC FlightNASA & ContractorSenior EngineersNASA KSCIntegrationEngineeringNASA Test DirectorContractor TestConductorsRangeSafetyPayloadNASA and ContractorSystem EngineersShuttle Launch Operations Summary Activate and test flight and ground systems (16 hrs) No work hold (4 hrs) Load fuel cell cryogenics (8 hrs) No work hold (4 hrs) Activate and test remaining shuttle systems (12 hrs) Time critical stowage and service structure disconnects (12 hrs) ET propellant load preps (5 hrs) No work hold (2 hrs) ET Load (3 hrs) No work hold (3 hrs) Terminal count (4 hrs) 72 hrs Operations Sequenced to: Provide orderly closeout of vehicle and launch accessories Activate and verify systems meet requirements Minimize hazards to personnel and equipment Scheduled hold time to allow work to catch upShuttle Launch – Terminal Count Phase  T-3 hrs  Crew ingress  Communications tests  Crew cabin closeout and integrity test  Guidance systems initialization  T-20 min  10 minute hold  Orbiter computers sequencing initialized  T-9 min  45 minute hold  Final poll of management, operations, engineering, weather, range safety and