msfc skylab orbital workshop, volume 5

8/8/2019 MSFC Skylab Orbital Workshop, Volume 5

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"

NASA TECHNICAL M.y i_74

MEMORANDUM" .-t

NASAT MX-(:_,81

A L_.,

GeorgeC . Marshall S pace Fli Tht Center

Marshall Space Fliqht Center, Alabama( NASA-T M- X -648 1 3 - V ol - 5 ) MSFC SK YLA_ . h ? _ - 2 U332

ORBI TAL WORKSHC_ , VOLUME 5 ( NASA) 450 pHC $9 .C 0 CSCt 22B

Un clasG3 31 _125 . 5

MSFC - Fo r m 31gO ( Rev June IgTl)

!) ,-+ ,.,_,, ,,,-,, ,4. ,_ ..... ,- -, _+ + .,


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pRPFTDING PAG_ BLANK NOT FII,MFTD

TABLE OF CONTENTS

Section Title PageVolume I

1 INTRODUCTION ........................ i-i

i.i PURPOSE AND (,-,COPE.................. i-i

1.2 S_M A_RY ....................... 1-3

1.2.1 Design Goals ................. 1-3

1.2.2 Mission Results ............... 1-9

2 SYSTEM DESIGN AND PERFORMANCE ............... 2.1-i

2.1 GENER AL ....................... ?.i-i

2.1.1 Design Philosophy .............. 2.1-1

2.1.2 Wet to Dry Evolution ............. 2,1-4

2.1.3 Overall Test Program ............. 2.1-9

2. 1 .4 Final Configuration Discussion ........ 2.1-16

2.1.5 Mission Performance ............. 2.1-51

2.2 qYSTEMS ....................... 2.2.1-1

2.2.1 Structu r al System .............. 2.2.1-1

2.2.2 Meteoroid Shield System ........... 2.2.2-1

2.2.3 Environ mental / Thermal ControlSubsystem (E / TCS) .............. 2.2.3-1

V lu e I2.2.4 Thruster Attitu_ g_n@rol System (TACS ) . 2.2._-1

2.2.5 Solar Array System .............. 2.2.5-1

2.2.6 Electrical Power Distribution System ..... 2.2.6-1

2.2.7 Illumination System ............. 2.2.7-1

2.2.8 Commanication and Data Acquisition System . . 2.2.8-1

2.2.9 Caution and Warning System ......... 2.2.9-1

2.2.10 Experiment Accammodations Systems ...... 2.2.10-1Volume III

2.2.11 Habitability Support Systems ......... 2.2.11-_Vpl_me ][V .2.2.12 Press_[re ua r men_ uonc a _1on_ System ..... 2.2.12-i

2.2.13 Stowage System ................ 2.2.13-1

2.2.14 Ground Support Equipment System ....... 2.2.14-1

2.2.15 Markings System ............... 2.2.15-1

2.3 MATERIAL U_AGE AND CONTROL .............. 2.3-I

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TABLE OF CONTENTS (Continued)

Section Title Page

6 ENGINEERING PROGRAM MANAGEMENT ............... 6-1

6.i PLANNING AND SCHEDULING ............... 6-1

6.1.1 Design and Development ............ 6-1

6.1.2 Design Changes ............... 6-3

6. i.3 Recommendations for Future Programs ..... 6-8

6.2 CONFIGURATION MANAGEMENT ............... 6-9

6.2.1 Configuration identification ....... 6-9

6-136.2.2 Configuration Control ............

6.2.3 Configuration Acco u nting ........... 6-21

6.2.4 Change Traffic ................ 6-2 26-24

6.2.5 Conclusions and Recommendations .......

7 MISSION OPERATIONS SUPPORT ................. 7-1

7 1 GENER AL ....................... 7-1

7. 2 MDAC-W SUPPO RT AT MSF C ................ 7-3

7. 2 .1 Overview of MDAC-W's Role at MSFC ...... 7-3

7.2.2 MDAC - W/ MSFC M'_ ss io n S u pp o rt I n terf ac e .... 7-47.2.3 Facility Definition ............ 7-6

7.2.4 MSF C Skyl a b D a ta System ........... 7-9

7.2.5 MDAC-W Suppor t Str uc tu r e a nd M s .nni n gSche d ules .................. 7-14

7.2.6 Action Request Flow ............. 7-15

7.3 : _' DAC-WSUPPORT AT hUNTINGTON BEA CH .......... 7-18

7.3.1 Overview ................... 7-18

7.3.2 Mission Support Te a m Definition / Org s _,ization . 7-18

7. 3 . 3 Summ ar y o f H un tingt on Be s ch Pre lau nchOp e r a tio ns Support .............. 7- 1 9

7.3.4 I den tification an d Man a g eme nt of OWSProblems / Action Requests ........... 7-23

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TABLE OF CONTk_TS (Continued)

Section Title Page

7 .3. 5 Su._ary of Mission Support Action Items . . 7-25

7.3.6 Facility Description / Evaluation ....... 7-31

7.3.7 Miss_ _ Support Manning Schedules(Mauned / Unmanned) .............. 7-37

7 h CONCLUSIONS AND RE COMMENDATIONS ........... 7- 43

7.4.1 General ........... _ ..... 7-43

7.4.2 Pre!aunch Support .............. 7-h 3

7.4.3 Mission Simulations ............. 7-437.h.4 Mission Support Organization and Manning . . . 7-44

7.4.5 Mission Support Facilities .......... 7-44

7.4.6 Action Item Assignment, Tracking and Response 7-45

7.4.7 Hardware and Test Support .......... 7-46

7.h.8 MDAC-W On-Site Support at MSFC ........ 7-47

8 NEW TECHNOLOGY ....................... 8-1

8.1 AEROSPACE APPLICATIONS ................ 8-I

8.1.1 New Technology Fatent Disclosures ...... 8-18.1.2 Applicable Hardware and Design Approaches . . 8-1

8.2 OTHER APPLICATIONS .................. 8-22

8.2.1 Electro n ic / Electrical ............ 8-24

8.2.2 Fireproof Materials ............. 8-25

8.2.3 Zero Gravity Restraint Equipment ....... 8-26

8.2. h Structural Technology ............ 8-26

8.2.5 Fire Det e ction, Prevention and Suppression . . 8-27

8.2.6 Biocide Wipes ................ 8-27

8.2.7 Therm_ Mechanical .............. 8-28

8.2.8 Potable Water Sterilizatio n ......... 8-28

8.2.9 Noise Control ................ 8-28

8.2.10 P n eum a tic Valve Desig n ............ 8 - 29

8.2.11 Product Saf e ty Evaluation .......... 8-29

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TABLE OF CONTENTS (C o ntinued)

Se c t ion Title Page

9 C ONCLUS IONS AND R ECOMM3_DATIO NS .............. 9 - I

9 . 1 MISSION PERFORMANCE ................. 9 -1

9 .1.i Str u ctu r a l System . ...... ..... .. 9 -I

9 . 1 . 2 Meteo r oid Shie ld (MS) ............ 9 -5

9 . 1 .3 T h e rmal Cont r o l Sy s tem (TCS) ......... 9 - 5

9 . l .h T h r u ste r Attit u de Cont r o l Sy s tem (TACS) 9-7

9.1.5 S o l a z A r ray Syst e m (SAS) ........... 9 - 8

9.1.6 Electrical Power Distribution System (PDS) . 9-10

9.1.7 Ill u mination System ............. 9-11

9.1.8 C o mmmlication an d Data Acquisition Systems(DAS) .................... 9-11

9.1.9 Caution and War n ing (C&W) System ....... 9-13

9.1.10 Ex p er iment Accommodations System s ...... 9 -13

9.1.11 Habitability Support Systems (HSS's) ..... 9-15

9.1.12 Pressure Garment Conditioning System ..... 9-_

9.1.13 Stowage System ................ 9-23

9.1.1h M a rking System ................ 9-25

9.2 PROG RAM PLANNING ................... 9-26

9.2.1 Orga n ization ................. 9-26

9.2.2 Establishing Requirements .......... 9-28

9 .2.3 Controlling to Requirements ......... 9- 2 9

9 2. h Improveme n ts for Future Progr a ms ....... 9-31

9 3 TESTING 9-36 . .

9,3.1 Deve lopment and Qualification ........ 9-36

9 .3. 2 S pa cec ra ft Sy st ems Te s ti n g .......... 9 -3 9

9. 3 . 3 Co n clu s i o n s and Rec o mmen d a tions ....... 9-h2

45. PRELAUNCH AND MISSION SUPPORT ............ 9-

i0 BIBLIOGRAPHY i0-i

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FIGURES

Nu mber Page

1.2.1-1 Skylab Orbiting Assembly 1-4

1.2.1-2 Skylab - F un ction of Modules 1-5

i. 2.1-3 Orbital Workshop 1-7

1.2.1-4 Mission Design Profile 1-8

I. 2.2.5-1 Miss ion Actual Profile 1-13

2. i. i-i S-IV-Gemini Space Laboratory Concept 2.1-2

2. i. 2-1 N ASA Saturn S-IVB Orbital Workshop 2.1-5

2. i. 2-2 Wet Workshop Launch Configuration 2 .1-7

2.1.4.1-1 Orbi t al Workshop Tank Assembly, Ski r ts and 2 .1-17

Inte r st age

2. i.h.2-1 Meteoroid Shield 2 .1-19

2. i. h. 3-1 Active Thermal Control System 2.1- 2 1

2.1.4.4-1 Th r uster Attitude Control System 2 .1- 2 3

2.1.4.5-1 Solar Arra_ Sys t em 2.1- 2 5

2. i. 4.6-1 Electrical Power Distribution System 2 .1- 2 7

2.1.4.7-i Illumination System 2 .1- 2 9

2.1.4.8-1 Comm,Anications Sys t em 2 .1-30

2.1.4.8-2 Data Acquisition System 2.1-32

2. i. h. 8-3 Electrical Command System 2 .1-33

2.1.4.9-1 Caution and Wa r ning System 2 .1-34

2. i.h.10-1 Waste Management Syste m 2.1-36

2.1. h.10-2 Waste Manage ment System Trash Disposal 2 .1-37

2. i, 4,10-3 Water System 2.1-39

2.1.4.10-h Personal Hygiene and Body Cleansing System 2 .l-hl

2.1.4.10-5 Food Management System 2 .1-h 2

2. i. h. i0-6 Sleep Support System 2.1-44

2. i, 4,10 - 7 Re f r ige r ation System 2.1-45

2. I. h. ll-1 Stowage System 2 .1-47

2.1. h.12-1 Waste Management Vacuum Provisions 2 . l-h9


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2 . i.4.1 2 - 2 Experiment Vacuum P r ovisions 2 .1-50

: 2 .2. i.i-i B a sic Shell Structu r e Forw ar d Ski rt 2 . 2 .1-3

2.2.1.1-2 Basic Shell Struc t u r e Fo rw ar d Ski r t - P a nel 2 . 2 .1-6

t I n st a l l ati o n

2 .2.1.1-3 B a sic Shell S t r uctu r e Af t Ski r t - P a nel 2 .2.1-7Install a tion

2 . 2 .1.1-4 Basic Shell St r u c tu r e Aft Skir t 2 . 2 .1-10

2.2.1. 1 -5 Basi c S h ell Structure Typi c al Aft Ski r t Se c ti o n 2 .2.1- 1 1

2.2.1.1-6 Basic Shell Structure Aft Skirt - Umbilical 2. 2 .1-1 3Installation

2.2 . 1.1-7 Basic Shell Structure Aft Skirt Thermal Shield 2 .2.1-ihf Static Pressure Distribution

2.2.1.1-8 TACS Nozzles Panel Installation 2.2.1-16

2.2.1.1-9 Basic Shell Structure Aft Skirt - TACS Nozzle, 2 .2.1-17Mount ing Provis ions

2.2.1.1-10 Orbital Workshop Separation Joint 2.2.1-19

2.2.1.2-1 Orbital Workshop Internal Color Requirements 2 . 2 .1-28

2.2.1. 2 -2 Basic Habitation Area Tank Structure 2.2.1-30

2.2.1.2-3 Cylinder Rib Intersection Attach 2.2. l- 3 2

2.2.1.2-h Bonded Experiment Dis c Installation 2.2.1-33

2.2.1.2-5 High Performance Insulation 2.2.1-35

2.2.1.2-6 High Performance Insulation Purge System 2.2.1-37

2.2.1.2-7 Side Acress P_nel Habitation Area 2 _. 2 .1-38

2.2.1.2-8 Aft Dome Port Closures 2 .2.1-hl

2.2.1.2-9 Habitation Area Tank Forward Entry Hatch 2.2.1-4 2

2.2.i. 2-1 0 Vi e wing Wi n dow A_s emb l y In s tallation 2.2. I - 4_

2.2.i. 2-1 1 Scientific Airlock 2.2.1-46

2.2.1.2-12 Water St o rage Container Installation 2.2.1-49

2.2.1,2-1 3 1 / 10 Se g ment of Water C o ntainer Supp o rt 2.2.1-51I nstallation

2.2. i.2-1h W a ter Container Typical Cross-section 2.2 . 1-54

2,2. I.2-1 5 Crew Quarters I nstallations 2.2.1-56

2.2.i.2- 1 6 Cre w Quarters Structural Arrange ment 2. 2 .1-58

2.2.1.2-17 Floor Grid Pattern 2.2.1-59

2.2. i . 2 -1 8 Fl oor Str u c t ure 2.2 . !-62

2.2.1.2-19 Orbita l Workshop Waste Tank 2.2.1-6h

2 . 2 . i . 2 - 20 Pene tr a tio n De t ail s - Co mmon Bu l k head 2 . 2 . 1- 67

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Number J _e

2.2.1.2-21 WMC Closeout at Floo r 2.2,1-71

2.2.1.2-22 Closeouts Between Floor and Ceiling 2.2.1-72

2.2.1.2-23 Closeouts on Aft Floor 2.2.1-7h

2.2. i. 2-2h Fo r ward Floor Colseouts 2.2.1-75

2.2. i. 2-25 Water Tank Closeouts 2.2.1-76

2.2. i . 2 -26 Wa r droom Ent r y Curtain 2.2.1-77

2.2.1. 2 -2y Crewman Rest r aints - Internal 2.2. i- 79

2 . 2 .1. 2 -28 Astronaut Aids (Pla t form Foot Restraints) 2.2.1-81

2.2.1.2-29 Ast r onaut Aids (Light Duty Foot Restraints) 2.2.1-82

2.2.1. 2 -30 Footwell Restraints 2.2. l-Sh

2.2. i . 2 -31 Triangle Shoe 2.2.1-86

2.2.1.2-3 2 Cr ewman Fixed Hs / _d Rest r aints (Inte r nal) 2.2.1-88

2.2.1.2-33 Dome Ring Locker Lower Leg Restraint 2,2.1-92

2.2.1.2-3h Table Restraints (T r ian&2e Shoe) Test 2.2.1-110

Configuration

2.2.1.2-35 Table Rest r ain t s (Fixed Foot Restraint) Test 2.2.1-111

Configuration

2.2.1.2-36 Triangle Shoe Test Configu r ation 2 .2.1-112

2.2. i. 2-37 Pelvic _est r aint Test Configuration 2 2. l-llh ,

2.2.1.3-i Aft Structure 2 2.1-138

2.2.1.3-2 TACS Gas Storage Sphere Installation Subsystem 2 2.1-139

2.2.1.3-3 TACS Ga s Sto r age Sphere Installation Subsystem 2 2.l-lh0

2.2.1.3-h T C-9 Test 3pecimen 2 2.1-1hl

2.2.1.3-5 TACS Sphere Meteo r oid Shield Installation 2 2.1-1hh

2.2.1.3-6 TACS Sphere Meteo r oid Shield and Skirt 2 2.1-ih5

2.2.1.3-7 Aft Structure - Radiator Support Structure 2.2. l-lh6

2.2.1.3-8 Radiator Sandwich Construction 2.2.1-1h8

2.2.1.3-9 Radiator - Thrust Casting Connection 2.2.1-1h9

2.2.1.3-10 Thermal Control Unit Ins tallation 2.2.1-150

2.2.1.3-11 Thermal Control Unit Installation 2.2.1-151

2.2.1.3-12 Radiator Impingement Shield 2.2.1-153

2.2.1.3-13 Radiator Shield Jettison Mechs mism 2.2.1-155

2.2.1.3-1h Plume Impingement Curtain 2.2.1-156

2.2.1. h-1 Aft Interstage Basic Structure 2.2.1-169

2.2. i. h-2 Ring Frames and Int e rcostals 2 . 2.1-170

2.2.1.h-3 Basic Shell Structure - Aft Interstage 2.2.1-172

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Number Page

2.2.1.4-4 Basic Shell Structure - Aft Interstage - Vent 2.2.!-173Openings

2.2.1.4-5 Basic Shell Structure Aft Interstage 2.2.1-174

2.2.1.4-6 Aft Interstage / GSE Interfaces 2.2. l-_ ' 6

2.2.1.4-7 Basic Shell Structure Aft Interstage J ....-1, _ "

2.2.2. i-i Meteoroid Shield 2.2. _

2.2.2.1-2 Meteoroid Shield Panel Joint 2.2.2-6

2.2.2.1-3 Meteoroid Shield Boot 2 . P . 2-7

2.2.2.1-4 Meteoroid Shield Auxili a ry T_u_nel Frame and 2.2.2-9Beaded Panel Cover

2.2.2.1-5 Meteoroid Shield Deployment Ordnance and Foldout 2.2.2-0Panels

' 2.2.2.1-6 Meteoroid Shield 2.2.2-]::

2.2.2.1-7 Deployable Meteoroid Shield 2 . 2.2-i_

: 2.2.2.1-8 Meteoroid Shield Rigging Device 2.2.2 -Jh

2.2.2.1-9 Meteoroid Shield Relea s e System 2 .2.2-17

2.2.2.1-10 Shield Release Device 2.2.2-18

2.2.2.1-11 Meteoroid Shield Release Mechanism 2 .2.2-19

2.2.2.2-1 Workshop Flight Systems 2.2.2-39

2.2.2.2-2 Forward Dome Structural Configurations 2.2.2-41

2.2.2.2-3 Airlock Cutout Impact Angles 2.2.2-42

2.2 . 2.2-4 End Cl o sure Configuration 2 . 2.2-43

2.2.2.2-5 Aft Dome / Skirt Configurations 2.2.2-44

2.2.2.2-6 Skylab Configuration 2.2.2-45

_ 2.2.2.2-7 Meteoroid Dam a ge Probabilities 2.2. _-49

2.2.2.2-8 Meteo r oid Shield Paint Pattern 2.2.2-52

2.2.3-1 Crew Comfort Criteria 2.2 . 3-4

2.2.3-2 Maximum Dynamic Input to PLV Fan / Shroud Assembly 2.2.3-11, (In all Three Axes)

2.2.3-3 VCS Schematic 2.2.3-20

2.2.3-4 Airlock to Workshop Interface and Mixing Chamber 2.2.3-22

2.2.3-5 Ventilation 2.2.3-232.2.3-6 Fan Inlet Duct 2.2.3-24 '"_

2.2.3-7 Duct DiffuSer 2.2.3-26

2.2.3-8 Fan Cluster and Muffler Assembly 2.2.3-27

2.2.3-9 OWS Ventilation System F a n Cluster Assembly 2.2.3-28

2 . 2 .3-10 Du c t Fan 2.2 .3 -2_

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Nu mber Page

2.2 . 3-11 Fl o or / Air Diffuser A r rangement 2.2 .3- 31

2.2.3-12 Sleep A r ea Ai r Outlet 2.2.3-3 2

2.2.3-13 Ventilation Control System Diffuser Locations 2.2.3-33

2.2.3-14 Portable Fan with Sound Suppression 2.2.3-34

2.2.3-15 Ci r cuit Breaker P a nel 614 2. 2 .3-36

2.2.3-16 Fan Control 2.2.3-37

2.2.3-.17 Fa n Bus Selection 2.2.3-38

2 .2.3-.18 Convec t ive Heate r 2.2.3-40

2.2.3-19 Contr o l a nd Displa y Panel 617 Thermal Control 2.2.3-42System

2.2.3- 2 0 Heater Cent r e3 2.2.3-44

2.2.3-21 Heater Control Duct 3 2.2.3-45

2.2.3-22 Radi a n t Heate r s 2. 2 .3-47

2.2.3-23 R_diant Heater - IB81046 2.2.3-48

2.2.3-24 Radiant Heater Components 2. 2 .3-49

2.2.3- 2 5 E CS Cont r ol Ps_el 2 03 2.2.3-51

2.2.3-26 Radiant Heater Control 2.2.3-52

2.2.3-27 0WS View Window Design Criteria 2.2.3-53

2.2.3-28 Wa r droo m Window 2.2.3-54

2.2.3-2 9 Wardroom Window 2.2.3-55

2.2.3-30 Wardroom Control and Display Panel 700 (IB84376-I) 2.2.3-57

2.2. 3 - 31 Wardr oo m Wi n d o w He a ter El e ctri cal Sche ma ti c 2.2. 3 -58

2 . 2 .3-3 2 Th e rm a l Con t rol S y s te m Sc h e ma t ic 2 . 2 .3-60

2.2. 3 - 33 Prei n stalled High Perf o rma n ce I n sulati o n 2.2, 3 -6 3

2.2.3-3h Forward Dome High Pe r forma n ce In s u l ation 2.2.3-64

2.2. 3-3 5 Hig h Performa n c e In s ul atio n Purge Syst em 2.2. 3 -66

2 . 2 .3-3 6 Ex ter nal Pai n t Patter n 2 . 2 .3- 7 0

2.2.3- 3 7 E x ternal White Pa int P a ttern 2. 2 . 3 -71

2. 2 . 3 -38 Therma l Ra d i ation Co a t i ng 2. 2 . 3 -7 3

2.2. 3- 3 9 Meteoroid Shield Boot 2 . 2 . 3 -7h

2.2. 3 -h0 Forward Thermal Shield 2. 2 . 3 -75

2.2.3-41 Aft Thermal Shield 2, 2 . 3 -76

2.2. 3 -h2 JSC Paras el Configuration 2. 2 .3-7 9

2.2. 3- h 3 MSFC So l ar Sai l C o n figua-atio n 2.2. 3 -8 0

2 .2. 3- _ 0 WS He a t Pipe Wic k Conf i guration 2.2. 3- 8 3

2.2. 3- h 5 Heat P i p e Location s 2.2. 3 -84

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[_u mber Page

2.2.3-46 Heat Pipe Installation at Water Bottle / Balsa Wood 2.2.3-85

2.2.3-47 Heat Pipe I n stallation at F!o o _'s 2.2.3-87

2 .2.3-48 Heat Pipe Sapport kssembly 2.2.3-88

2.2.3-49 Heat Pipe installation 2.2.3-91

2.2.3-50 OWS Viewing Window Cold Coating Test Results 2.2.3-101

2.2.3-51 SL-A Forward Compartment Wall Boost Temperature 2.2.3-106

Histor_j, Sensor C7034

2.2.3-52 SL-1 Forward Compartment Wall Boost Temperature 2.2.3-107

History, Sensor C7045

2.2. _-53 GL-I .o r ward Compartment Wall Roost Temperature 2.2.3-108

History, Sensor C7047

2 .2.3-54 SL-I Aft Compa r t ment Wall Boost Te mperature 2 .2.3-109History, Sensor C7053

2.2.3-55 SL-I Fo r wa r d Skirt Therma: Shield Boost Temperature 2.2.3-110History, Sensor C7185

2.2.3-56 SL-I Aft Skirt Ther mal Shield B o ost Tempe r ature 2.2.3-111History, Senso r C 7177

2 .2.3-57 Wardroom Window Daily Te mperature Extre mes 2.2.3-115

2.2.3-58 OWS Af t Ski r t Transduce r C 7189 Locati o n 2.2.3-127

2.2.3-59 Estimated Retro-Rocket Flu me Conta mi, ation 2.2.3-131

2 .2.3-60 Co rr elation of Tempe r a t u r e Data fo r S-13G Pain t ed 2.2.3-133Aft Skirt

2 .2.3-61 Af t Ski r t Maxim um Orbital Temperatures at Beta = 0 2 .2.3-134Dec. Sensor C7189

2.2.3-62 S-13G White Paint Degradation 2.2.3-136

2.2.3-63 Te mperatu r e Response of Gold Taped Sidewall to 2.2.3-141Direct Solar Exposure

2.2.3-64 OWS External Wall Te mpe r ature Simulation for EREPS 2.2.3-14631 and 3 2

2.2.3-65 OWS External Wall Temperature Simulation for EREP 24 2.2.3-147

2.2.3-66 Tank Wall Optical Properties 2.2.3-14 9

2.2.3-6 ' [ OWS Mean Internal and Floor-Stowed Food Tempera- 2.2.3-157tare History, DOY's 135 - 147

2.2.3-68 0WS Rack-Stowed Food Temperat u re Histo_;, DOY' s 2.2.3-158' 135 - 147

2.2.3-69 0WS Film Vault Te mperature History, DOY's 135 - 147 2. 2 .3-159

I_ 2.2,3-70 OWS Mean Internal Temperature History, DOY's 2.2.3-161

i 147 - 154

2.2.3-71 OWS Rack-Stowed Food Te mperature History, 2.2.3-162

DOY's 147 - 154


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Nu mber Page

2.2.3-72 OWS Fil m Va ult Tempe ra tur e H i s tory, DOY's 147 - 155 2.2.3-163

2.2.3-73 SL-2 Cr ew Comfort Condi t ions 2.2.3-164

2.2.3-74 OWS Cooldown After Parasol Deployment 2. 2 .3-165

2.2.3-7 5 S L- 2 Ext e rna I S ur fac e Te mper at u r e Dis t ributi o n 2.2.3 - 167

2.2.3-76 OWS Mean I n ternal Tempe rat ure History, DOY ' s 2.2.1-16 9148- 17_

2.2 , 3-77 OWS Temperature Duri n g t h e F i r st Storage Period, 2.2. 3 -171DOY's 17 3 - 209

2.2.3-78 OWS Maxim um and Miniml,m I ntern a l Temperat,,re s , 2. 2 . 3 - 1 72DOY's 210 - 268

2.2.3-79 SL-3 Crew Comfor Conditions 2.2.3-174

2.2.3-80 OWS Surf a ce Temper a tures for a Single EREP Ma ne uv e r 2. 2 .3-177

2.2.3-81 OWS Surf a ce Tempe ra tures for B a ck-to-Ba c k EREP 2. 2 .3-178Maneuvers

2 .2.3-82 OWS Temper a tures During the Secon d Sto r age Period 2.2.3-180DOY's 268 - 3 2 0

2.2.3-83 SL-h Maximum and Minimu m Mean Internal Temper a t u r es 2.2.3-182

2.2.3-84 SL-4 Crew C o mf o rt Conditi o n s 2.2 . 3-184

2.2.3-85 OWS Tank Wall Temperatuze Response During EREP's 2.2.3-18729 and 30 (DOY 014)

2.2.3-86 OWS Structural Temperature Transducer Locations 2.2.3-193

2.2.4.1-1 TACS Minimum Thrust Versus Total Impulse Consumed 2.2.4-3

2.2.4.2- 1 TACS Schematic 2.2. h-h

2.2. _.2-2 TACS - Component Locations 2.2.4-5

2.2.4.2-3 TACS installation 2.2.4-6

2.2,4.2-4 TACS Control Valve 2.2.4-7

2.2.4.2-5 Typical Detail of Brazed Joint 2.2.4-9

2.2.4.2-6 TACS Bimetallic Joint 2.2.4-10

2.2. h.h-1 Skylab TACS Usage 2.2.4-16

2. 2 .5.2 -1 So l ar Array Wi n g Ass e mbly 2. 2 .5 - h

2.2. 5 .2-2 Solar Cell Module 2.2.5- 5

2.2.5.2- 3 Orbital Wor k shop SAS - Electrical Power 2.2.5-7

_.2. 5 .2-h SAS Bea m/ Fairi n g Skirt Atta c h Point 2.2. 5 -8

2.2.5.2-5 Wi n g Section Retention and Release Syste m 2.2. 5 -10

2.2.5.4 -1 O WS S olar Arra y Pe rfor ma n ce 2.2.5 -3 7

2.2. 5 .4-2 SAG Pe rf o rma n ce - SAG i _.-.dAG 2 2.2. 5 - 39( DOY's 1 59 , 8 = l O )

2 . 2 .5. 4 -3 SAG P e rfor mance - S AG' s 3 an d h (DOY 159 , 8 = i0 ) 2 . 2 .5- 4 0


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_: Number Page

I 2 .2.5.4-h SAG P e rfor ma n ce - SAG's 5 a nd 6 (DOY 15 9 , 8 = I 0 ) 2.2.5-hi

i 2.2.5.4-5 SAG Perf o rma n c e - SAG's 7 an d 8 (DOY 15 9 , 6 = i 0 ) 2.2.5-42.2.5.4-6 SAG Performan ce - SAG i (DOY 175, 8 = + 73.5 ) 2.2.5-43

I 2.2.5.4-7 SAO i Voltage, DOY 339, Beta -- -9 2.2.5-442.2.5.4 - 8 SAG i Curr en t, DOY 33 9 , B e ta = - 9 2.2.5-_5

2.2.5.4- 9 SA G's i and 2 Volta g e, DOY 034, Beta = 0 2.2.5-46

2.2.5._-i0 SAG's 3 and h Voltage, DOY 034, Be ta = 0 2.2.5-47

2 . 2 .5.4- 11 S AG' s 5 an d 6 Vol t a ge, DOY 03 4, Be t a = 0 2 . _.5-482 . 2 . 5 . 4 - 12 SA G's 7 an d 8 Voltage, DOY 03 b , Bet a = 0 2 . 2 . 5 - 4 9

2. 2 . 5 . h -13 S AG's i a nd 20_rre n t DOY 03 4, Bet a = 0 2 .2. 5 - 5 0

2 . 2 . 5 . 4-14 SAG's 3 an d 4 Curren t DOY 03 4, Be ta = 0 2. 2 . 5 - 5 1

2 .2. 5 . 4 -1 5 S AG's 5 and 6 Cu rre n t, DOY 03 4, Beat = 0 2 . 2 .5- 5 2

2 . 2 . 5 . 4-1 6 S AG's 7 an d 8 C urr en t, DOY 03 4, Be ta = 0 2 . 2 . 5 - 5 3

2 . 2 . 5 . 4-17 S o l a r Ar r s _ / Temp er atur e Tr an s du c e r T e mperat u r e 2.2.5 - 5 6Di ffe r e nt i al (B e ta = 0 )

2.2.5.4- 18 S olar Arrs_ / Tempe ratu re Trans du c e r Te mpe rat ure 2.2. 5-5 7Diffe ren tial ( Be t a = 73 .5 )

2.2.5.4-1 9 SAG Chara c teristics -15 Mo d ules DOY 15 9 ; SAG's 2.2.5- 5 8I, 2, 3, 4, an d 7

2.2.5.4 - 2 0 S AG Char a cteristics - 1 4 Mo dule s DOY 159; SAG' s 2.2.5-5 95 a n d8

2.2.5.4-21 SAG Characteristics - 13 Modules D0Y 159; SAG 6 2.2.5-60

2.2.5._-22 SAS Transducer Thermal Profile (DOY i59, Beta = 2.2.5-6 3l 0 )

2 . 2 . 5 . 4 - 2 3 SAS T ra ns d uc er The rmal Profile (DOY 175, Be ta = 2 . 2 . 5 -6 5+7 3 .5 )

2 . 2 . 5 . 4 - 24 SAS T r ans d u c er The rm al P r ofi le (DO Y 339 , Bet a = 2 . 2 . 5 -6 6- 9)

2.2.5.4 - 25 SAS Transducer Thermal P rofi l e (DO Y 0 3 4, Beta = 2.2.5 - 670)

2.2.5.4'26 T y p ical SAS Thermal Profile (Actual vs Pr e dicted) 2.2 . 5-6 8

2.2.5.4 - 27 SAS Te mper a ture Tramsducer Meas u re me n t Hist o r y 2.2.5 - 7 02.2.6. i -I Zero G Co nn ector - Di s e n gaged 2.2.6-10

2.2.6. i-2 Zero G Co nn ector - E ng aged 2.2.6-11

2.2. 6 . 2 -i Rigi d Trou 6h 2.2 , 6-17

2.2. 6 .2-2 Flex Tr ou g h Usage (Ge n eral Co n ce p t) 2.2 . 6-18

2.2.6.2- 3 Closed Trough Syste m ( Ge ne ral Co n cept) 2.2. 6 -1 9

2.2.7.2-1 0W S Floodlight Lo c atio n s a n d Ma r k i n g 2.2.7-7

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2.2.7.2-2 Re mote Lighting Swit c h Pane l 616 2.2.7-8

2.2.7.2-3 Rem o te Ligh t ing Switch P a nel 630 2 . 2.7-9

2.2.7.2-4 Circuit Bre ak er Panel - 613 Lighting 2.2.7-10

2.2.7.2-5 Floo d light Assembly Det a il 2.2.7-16

2.2.7.2-6 Exploded Floodlight Assembly 2.2.7-17

2.2.7.2-7 Floodlight Cross Section 2.2.7-18 _

2.2.7.2-8 Portable Lighting 2.2.7-20

2.2.7.6-1 Flo o dlight a s Origina l ly Pr o p o s e d - In F o rc e 2.2.7.- 3 7Until December 12, 1969

2.2.7.6-2 Pictori a l Histo r y of IB6936h Flood l ight Design 2.2.7-38

2.2.7.6-3 Floodlight Design in Force From Janu a ry 15, 1970 2.2.7-h0Until Febru a ry 13, 1970

2.2.7.6-4 Floodlight Design in Force Since Feb r uary 13, 1970 2.2.7-42

2.2.8.1-1 "Ring" Bus Ci r cuit Concept 2.2.8-5

2.2.8.1-2 Communication Box 2.2.8-7 i

2.2.8. !-3 Communi cations System _i r ing Concepts 2.2.8-16

2.2.8.2-1 OWS Signal Conditioning Power 2.2,8- 2 7

2.2.8.2-2 OWS DAS Heater Power 2.2,8-28

2.2.8. 2 - 3 Telemet r y System S chematic 2.2.8-29

2.2.8.4-1 Sequence No, C6 2.2,8-75

2.2. 9 . 2-I Fire Sensor Co n tr o l Sc h em a tic 2 . 2 . 9 -8

2.2.9.2-2 Cont r ol an d D i sp lay P a nel 61 6 - C a ution / War ning 2 .2. 9 -11System

2.2. i 0. i-I OWS Experiment Acco mmodation s - Ex per i ment 2 . 2.10 - 9

Loca tion

9.2. i 0. i-2 OWS Expe r iment Accom mod a tion s - Experiment 2.2.10-10Loc a tion

2.2. 1 0.1-3 Experiment. A cc ommo dati o n s Typ lca l F lo or Mo u nti n g 2.2.10-11Pr o vis io ns

2.2. i 0. i- 4 SA L Trip o d 2.2. 1 0 -12

2.2. i0. i-5 Water Pres s uriz a tion Network 2 .2.10-15

2.2. I 0.1-6 W a ter Pressuri z a tion Panel 2.2.10-16

2. 2 . lO.1-7 W a ter Pressurl z a tion Network 2.2.10-17

2.2. 1 0.1-8 ES S N2 Supply P a ne l 2.2. 10 - 1 8

2.2. i0 . 1 -9 OWS E xp eriment Ac c ommod at io n s Vacu um Syste m - 2.2.10 - 19Experiments

2,2, 10 , i- i 0 Rede si g n ed L BNPD Va cuum Sy s t e m 2.2, 10 -2 1

2.2. i0.2-1 Film V a ult 2.2.10- 3 5

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8 0 6 3 M0 93 S195T_I3 N_ 7 1 M1 3 3 M509801 9 M07 3 MI51

o R e frigeration System T e st Pro ced ure s

TAB LE h.2. 3 .i - i ( Continued)

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o OWS Tr an s port, Tow er 6 to T o wer 2

o Final Pr e parati on s f o r Shi p men t

o OWS Rem oval from T o wer 2 an d T r ans p o rt Loading

o We ight a n d Balance

o TACS System Proof Test at Seal B e ach

o HF MU Ha nd ling a n d Shippi n g Op e rations

o Han d ling Equi p me n t Operations Insi d e th e Spacecraft (Re a sses_me n tfor 0 WS Ba ck up)

o SAS Loading on Guppy

o OWS Ba c kup H an dling and S hippi n g Op e r a ti o ns

TABLE 4 . 2 .3. 1 - 1 (Con ti nu e d)

_ - 2 3


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SAFkTY AND SAFETY RELATED AUD I TS

o Not-F o r-Productio n -Us e ( NFPU) System

o I n sp e ction Guag e Productio n

o I ns pection Preplanning.

o Testing

o Surveillance Inspection

o Re p e titive Nonc o nf o rma n c e C ontrol

o Proc e ss Co n trol

o Processing Operations / Planning Call-(_ts

o Heat Treating

o Shipping Inspection

o Intercomponent Work OrCers (ICWO's)

o Skylab Workshop (SWS) Program - Florida Test Center (FTC)

o Controlled Material / Bulk Material Stockroom

o Control of Mercury

- o KSC Orbital Workshop / Airlock Modul_ Programs

o No nd e structive Testing

o Shipping I nspection

o Acceptance Testing

o Application of Standard Fasteners

o Reliability Critical Items (R CI)

o - Recurrence Control

o Surveillance Inspection

o Training and Certification

o Process Control - Cleaning

o Co n trol of Detail e d Proc e ss Material (DPM:s)

o Sampling Plans

CUSTOMEP

o OWS Quality, Reliability a n d System Saf e ty Survey

o An nu al Syst e ms Safety Sur vey of OWS Op e rations

o Pr e -Delivery Tu r n o v e r Review

o R e view of No n co n forming S u pp l y and Corr e ctive Action Syst e m

o Quality Syst e m Survey

o H_rdware Integrity Review

TABLE 4.2.3.2- I

4 - 25


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by the s e audits we r e a cc o mplished. TL_e Cust o mer audits, with min o r

exceptions, found the system and / or opera tions unu_r _,udit completely

satisfactory.

4. 2 . 3 . 3 Accident / Incident Investigation Reporting and C o rrective A_-tion - The

contractor's Accident / Incident Investigation Reporting and Corrective

Action activities were in accordance with requirements of the O,_S

System Safety Program Plan, as implemented by MDAC Standard Prac+_ce

SP 1.004 - ACN.

There were only seven repor t able in_.f_?ats involving damage; two of

a serious natu r e, one of a significant _ature, two mip o r, and tw o

near misses. These incidents, all r. ported in Quarterlv OWS Sy u t_n

Safety Program Reports, are s_marized.

A. Meteorid Shield - Du r ing initial portion of Skylab I flight,

the OWS Meteoroid E;hield failed causlng the loss of one $AS,

high OWS internal temperatures, and conbiderab!e perturbation

to fllght operations. Failure was cont r ibuted to des_gr, defic-

iency by a formal NASA Re, ew Boa r d investigation &nd by parallel

invest iga tions conducted by the cont rac tor.

B, Dar&ge to GSE - Significant damage was _ncur-e4 by GSE Model

DSV7-31h (Vacuum Pumping Unit) during tran._orta_ion _t _AC.

Incident was the result of improper fork lift operation and

r e sulted in approp__,te changes to procedures and i n s tructions

regar,iing s uch operation.

t

C. L_ mage to GSE - Two items of unused GSE incurred minor damage

_, during _rans_ortat_ -:. _at MDAC. The damage was the result o f

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improp er tie-down during tru ck tran sl_r tation and resulted

i n c ha ng e s to i ns tru ct ions and pr o c e du r e s re lat e d to tie-down.

D. Damag e to Forward Dome - Ve ry mi n or d amage to t he O WS forw a r d

d ome o ccur re d d uring rem o va l of a bo nd ed s up port br a c ket whe n

t e c h n ician failed to follow a ppropri a te proc e dur e s. All a ff e ct-

e d t e chnicians w ere r e i n struc te d re gar d ing suc h ope ra tions .

E. Goug es i n Tank St ru c ture - Se v e r al goug e s w e r e f o un d in w as t e

tank do me st ructur e d uring ro u tin e i n sp e ctio n, l' ilo au s e was

i de ntifi ed . All t e ch n i c ians performing wo rk i n this ar ea we r e

w e r e rei n s t ru c t ed with re gar d t o ne ed for c a r e and surf a ce

protec t ion.

F. Cr an e Over l o ad - T h i s n ear miss i nc i de nt wa s pote n tially the

mo st ser ious han dl i n g occur r sn ce d uri n g th e e ntir e p r ogr a m an d

was th e r e sul t of improper use an d ov e rlo ad of a mobil e cran e

d uring shipping p repa r a tio n s of t he Dynamic T e s t Veh icl e . H ad

o ver l o ad b ee n gr eate r or t he d yna mics of th e two c ra n e o p er at ions

b een d _ff ere nt , significa n t da mag e to t he DTA woul d h a v e r e sul ted.

Th is i nc i de nt r es ult ed in major cha n g es t o proc ed ur e s i nv olvi n g

t he use of all c r ane s.

G. Wi n ch F a ilu r e - T h is ne ar miss inci dent inv o lv ed f a ilur e of a

ha nd op e r ated reduc ti on g e ar d rive f ac ility winch e qu ippe d with

a r at c he t t yp e s a f et y lo ck . Malfu n ctio n o f t he s a f e t y l o c k

combi ned with f a i l u re of the d riv e han d l e fr eed the wi n c h and

a l low ed a large c a twalk ac c ess asse mbly to f_ll fr ee. Fort u n-

ately, n o contact resu lted . All r edu ction g._r dr ive wi nches

: in c r l t ic a l appl i c a t i on s wer e rep l aced with _ el f- lo cking worm


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going programs for both tra i ning and c ertifi c ation relat e d to pro-

du c tion s kill s c ontinu e d. B a si c training and ce rtifi c ation of an

on-going natur e in c lud e d s old e ring, torqu e and tubing, p a st e adhesiv e s,

and many oth e rs. Addition a l training, re la t e d to OWS pe c uli a r skills,

wa s in c orporat e d i n th e ov e rall program. Th e s e a dditions provid e d

f or trai n ing and c erti f i c ation o f OWS Ma nu f a c turing a nd Quality

Ass ur.an ce p e rsonn e l in such skills a s tub e indu c tion brazing, r e frig-

e ration syst e m insulation, wir e harn es s fir e proofing, a n d ot he rs.

Th e r e lat i v e ab sen ce of pr o ble ms in t he s k i l ls ar ea pr ovi d e d co nfi-

d en c e t h at t he progr a m implemen t ed w a s a deq uat e.

4. 3 .2 Operational Training - Spe c ial tra i n ing of a n o pe r atio n a l natur e

was provided i n several areas: safety, access co n trol, contamin-

ation preventio n , a nd syst e m famili a rization. Approximately 1400

perso n nel completed the safety, access co n trol, a n d contami n ation

preve n tio n trai n ing. Over 30 0 person n el completed basic OWS famil-

i a rizatio n / orie n tation training, includin g 80 MDAC FTC personnel a n d

127 NA SA, NASA Co n tractor, and Air Force perso n nel. Most of these

perso n nel also c o mpleted basic OWS sy s tems trai n in g a n d one or more

specialize d c ourses in OWS subsystem s .

4. 3 . 3 Employe Moti v ation / Awa reness - The Sk y l ab Orbital Work sho p Mo tiv a-

tion / Awarene s s ( M/ A) Program was e s tablished i n July 1 9 70, as an

activity to motivate bo_ h MDAC an d s u pp l ier e mp l oyes to pro d u c e

d e f e ct-free ha rdw a r e for th e sa f e ty of t h e crew and t he succes s of

the S k y l ab mis s io n . Pri mary e mp h asis was d ir e c ted to wa r d ma i n t a in ....

i_ t h e h ig he st s tan d ar d s o f w o r k ma nsh ip and avo i dan c e o f hu ma n

error s i n the m an ufac tu r e , t e st and ha nd li ng of ml ss ion / s afe t y c ri-

_ tical hardware . The program w as a _gressively pu rsued a n_ is being

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" activel y s us tai n e d un til th e c us t o me r ac ce pts a nd ta k e s de liv e ry o f

i t he OWS Bac k up Spa c ecraft in A p ril 1 9 74.

The scope o f MDA C M/A progr am embraced a ll of the key element s of

the NASA Aerospace Awa reness Pro gram a s subsequent ly de linea ted in

NPD 1 7 00 .3A a nd as r e comm end e d by t he O ffice of Ma nn ed Spac e F li g ht.

It was f o rmally i mplem en t e d p er a u thori ty c o nt a i ned i n MDAC S tan d ar d

Pract ice IO.O07-A CL , and d irec ted by the OWS Program Mana ger for

Sy st em S af e ty an d Pro d u c t Assura nce .

To en sur e th a t MDA C empl o y es a nd cri t ical sup pli e r s were fully awar e

o f th e s ig n ifica n c e o f t h e OW$ pr o gram as w e ll as th e im po rtanc e o f

th e ir OWS e ff or ts t o mis s i on s u cc es s , an d ext end ed se ri e s o f pr e s en -

tatio n s w e r e co nd ucted. The pres ent atio n s co n sisted o f t he followi n g:

A. T o p ma n agem en t pr o gram o vervi e w.

g. Two films: Quality Cr a ftm an ship ( NASA film)

Th e Essen tial F a ct o r (MDAC film)

C. Detailed bri e fing i ns i de OWS full s cal e m ockup .

D. F a cility tour o f OWS man u facturing area, payl oad shroud

ass emb l y ar ea a nd space ch amb er si mul ator .

E . H a ndou t m ater ial ( c re w ph o t o s , NASA S k yl a b b ro chur e, de tals),

By the time the OWS ma nu factur ing phase had been co mpleted, a pprox-

imately 1300 p e r sonne l fr o m i n -h ouse a nd s e l e ct ed supp li ers ha d

at tended these p resen tations.

Tn Sept ember 1970, a Skylab OWS c onferen ce was condu cted _y MDAC at

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Hun ti n g t o n Be ach s o t hat th e co l l e ctiv e ma n ag e ments of MD AC a nd

suppliers of critical OWS hardware could Jointly review their mutual

o bligations to the man - i,, space. Primary emphasis was devoted to

the criticality of each invited supplier's hardware to crew safety

and mission succ e ss. Invitations w e re ext e nde d to the Chi e f Execu-

tive and Project Director of tw e nty-six companies who v erc under

contract to provide components for use in the OWS. The Vic e -Presi-

d ent-Ge n eral Manager, Program Director an d ot h er members of the MDAC

Skylab OWS manag e ment team a d dres sed t he supplier rep r e se nt a tives

a n d str e s se d th e urg e nt r e q u irement fo r o n -tim e d e liv e ry o f d efect-

fre e hardware. Th e suppli e r's e xecutiv e s w e r e also e njoined to

e stabl ish th e ir own awar e n es s programs and pass on the information

to their people.

I n order t o mai n tain the mo mentum established by the Skylab presen-

tations and supplier's confer e nce, maximum use was made of the NASA

and MDAC motivational material as it became available. Approximately

560 MDAC West Co as t a nd MDAC/ KSC personnel a tt e nded s howings of the

NASA film "Invit a tion to Overconfidence" and an additional 150 saw

the film "Anatomy of an Accident." NASA and MDAC Manned Flight

Awar en ess post e rs w e re co n spicuously displayed in all OWS work ar e as

continuously throughout th e life of the program. N e w po s t e r s were

d ispl a yed a n d / o r r o t a t ed e v e ry tw o - tba . ee week s a n d ma i n tained

c urre n t with the cha n gi n g ph ase s o f th e pr o gr a m. Th_ p rincipal

themes that were emphasized included quality craftmanship, safety,

c are in h a nd li n g, c leanl i n e ss , c o n ta mi n ation co n trol a n d hu ma n e rr o r

avoidance. Another impressive display wa s a MDAC built 1 / 40-scale

model of the Skylab Cluster in-orblt. This scale model was

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On e ach o cc a s i on t h e fl igh t cr e ws v i si te d hundr e ds o f e mpl g_e s i n

t h eir wor k statio n s an d 7 5 of t h e mos t d e s ervi n g OWS tea m me mber s

were invited to witness the spect_ l presentation to the crew in the

ex e c u tive confere n ce roo m. Subseq uen tly, a color repro d uctio n of

the aut ogr a p h e d Sk yl a b p h o t ograp h and f l ag , pr es e nted to the co m-

pa n y by t h e crew , was i n tur n pre s e nt e d to th e s e l ec t g ro u p of OWS

team members.

In additio n to t h e for e going motivational activiti es, a c ons i de r a b le

amo un t of progra m l i ter a ture an d mis cell aneou s m otiv a tional material ,

receive d from NASA and generated in-house, was trans mitted and cir-

culate d r ou tl _e l y to all MDA C d epart me n t s a nd to critical su pp l ier s.

Mat e rial so d i s trib u t ed inclu d e d Sk y la b boo k lets, _ A broc h ures,

pocket ins er ts , c rew photo s, d ecals, b u mpe r sti c k e rs, l a p el b u tto ns

and Awaren ess Newsletters.

_.4 C ONCLUS I ONS & RECOMMENDAT IONS - In retr os p e ct, t h e S k yl a b OWS Syst e m

Safety Pr o gram is co n si de r ed to have attai ned its obj e ctiv e s by

p r ovi d i n g for th e wel fare of the crew an d t h e e v en t u al su cce s s o f th e

Sk y la b mis sio n. Sp e cific a r eas whe r e either ne w t e c h niq ue s wer e

devel op ed o r th e state-of-the-art w a s c h al l e n ged are h igh l ighted

b el ow wit h r es p e ct t o t he i r e ff e ctiv ene ss as w ell a s so me d o' s a nd

don 't s fo r fut u r e man ned s p a c e progra ms.

A. Ha zardo u s Mate r i a l s C _ n t ro l - M e t h o d s w ere acc e ptabl e s i n c e cr e w

t ox icity s y mpt o ms d u e to air b o rne che mical co n t a mi nan ts w ere

no t r e po r te d f o r a n y S k ylab m iss i on. The i n iti a l 0 WS ch emical

con taminan t load was greatly redu ced due to the high temperature

bakeou t and the mul tiple ven ting of the O W8 atmosphere p rior to

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SL-2 en try. Th is ove r h e at co n ti_ ? e n cy was a p os itive fact o r i n

mi n i mizing t h e offgassing of carbo n mo n oxid e a nd total orga n ics

from th e non -me tallic materials for th e life of th e S k ylah.

B. Flam mable Materia l Control - This progra m was highly successfu l

and resulted in maximum devel opment and usa ge of many new n on-

flammable non -metallic materials; e.g., fluorocarbon ru bber,

impreg n a t e d fib e rglass mat e rials o f d iff e r ent t yp e s , car d boar d,

e_c

Sky lah de sign objecti v e was to sel e ct t he b es t n o n -f l a mmab l e

mat e rial for t he inte nded p u r pos e . When s n on-f la mmab le mat e r -

ial c o u ld n ot b e fo und , th e r e c ommended ma t e ri al was d oc u men te d

a nd coor d i nated w it h th e c ust o me r fo r c o n c u rra n ce . Ra tio n al e

wa s su ppli ed to su pport t h i s tec hni cal J ud g eme n t . Pa r t of t he

ratio n al e i n c lud e d s howing t he p la cem en t Of t he mate rial on th e

non -f l am mabi l ity map ( MDAC dra wing I B77 015) f or a sse s s ment of

po ten tial f l a me prop a gation. So me mat e rials , t o mee t f l a nma-

bility r eq uire men t s, m ay co mpr omise f l ight cr e w c omfo r t a nd ther e -

fore ne c ess it ated e arly c oo rd i na tio n wit h t he c r e w.

C. Mi c robial Co n ta mi na ti o n Co n t r ol - M icr o bial s am p li n g of OWS

sur faces prior to shipment to KSC d smonstra ted that the manu -

facturing c l ea n l i n ess stan d a rds we r e very sati s f acto r y i n ma i n-

tai n ing a nor mal micr ob i a l flo r a populati on x n the OWS.


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SECTION 5 - TESTING PROGRAM

5. 0 INTR ODUCTION - This section defines the sc o pe o f the Orbital W o rksh o p

test program performed by MDAC-W. This reflects the baseline scope

of effort associated with the "Dry" launched Workshop concept and

also identifies that effort common to either the "Wet" or "Dry"

stage configurations.

The prime objective of the test program was to ensure that the

hardware and equipment furnished by MDAC-W fulfilled the objectives

stipulated in the NASA Mission Requirements Document I-MRD-0OIA and

the requirements of the OWS Contract End Item Detail Specification

CP2080JIC. The following testing was performed:

Component and subsystem testing

a. Development

b. Qualificat ion

c. Production acceptance

Structural testing

Special and module testing

Spacecraft system testing (post-manufacturing checkout)

Integrated vehicle testing

Mission support testing

The following rationale was used by MDAC-W in the formulation of the

Orbital Worksh o p Test Plan:

Orbital Work sh o p con s i de r ed o ne -of -a- ki nd ex p e ri men tal v e hicl e .


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@ :,_JAC-Wperformed development and qualification tests on selected

equipment and hardware to the extent necessary to provide or

._upport t he technical Justification for usage. Testing was

accomplished on specific flight hardware or equipment categorized

as follows :

Vehicle Mounted Equipment and Hardware

Category 1 - Equipment whose failure could adversely affect

crew safety.

C a tegory 2 - Equipment whose failure could result in not

achieving a primary mission objective but would

not adversely affect crew s a fety

Hardware and equipment evaluated at the Workshop system level

during vehicle or cluster checkout was considered ready for

flight where successful fulfillment of the design and mission

objectives and requirements were achieved. Where analytical

models could be developed and evaluated for parti_-ular items of

hardware and equipment, those items would not be subjected toI

component or subsystem level tests prior to vehicle installation.

0ff-the-shelf hardware or equipment was not requalified to the

Orbital Workshop levels where analysis was performed to Justify

their usage on the vehicle.

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Hardware or equipment qualified on the Saturn IVB environmental

leve-s was not retested to the Saturn V vehicle levels, if

a ssessment showed th a t pr e vious te s t lev e ls were s a ti s f a cto r y

The test program was based on fulfilling the total Skylab

mission llf e objectives; however, in int e r e st of cost effective-

nes s full mis s ion performance wa s v e rifi e d by a combin a tion of

both t e sting and a ssessment, except wher e aualy s ls s howed a

nece s sity for long llf e or full mission duration testing. Th e

rationale for selecting te s ting and / or a ss e ss ment to verify

e lements of mission p e rformance was documented in the Test and

Asses s ment Docum e nt (Refer e nc e MSFC-DRL-171A, Lin e It e m GO9).

Checkout and integrated testing followed a logical progres s ion

to preclude i . _validating tests or activities already accomplished,

and to f a cilitate f a ult isolation without intecfer e nce from

o t h er s y s tems. I n t e grated s y s t em testing wa s p e rform e d at the

high e st l e v e l of as s embly possible to ensure that all equipment,

systems, an d support equipment function e d properly in r e lation

to th e total mis s ion.

@ Verification of GSE d e si g n re q uirem e nt s was accomplishe d by

Pro d uction Acceptanc e Te s ting. No separat e d e v e lopm e nt or

qualification testing o f GS E was acc ompl ished.

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Test Program Objectives - Implementation of this Orbital Workshop

Test Plan fulfilled the following objectives:

Performed all tests necessary to verify flight readiness of the

Orbital Workshop hardware and equipment.

Demonstrated that the Orbital Workshop hardware / equipment ful-

filled the requirements of the Contract End Item Specification

CP2080JIC.

Test Categories - The categories of tests described in this report

are defined as: Development, Qualification, Production Acceptance,

Special, and Spacecraft Checkout and Integration Tests. A brief

description of each type is presented.

Dev e l o pment Te s ts - H a rdware utilized during these t es t prc-

grams was eith e r protolype or pre-producticn configurations

depending on the particular phase of design evaluation at the

time of program initiation. Development testing was performed

to optimize hardware configuration and identify potential areas

of marginal design or performance. These tests also served to

determin_ and evaluate design feasibility, functional parameters

and environmental limitations. Development Tests also demon-

strated fulfillment of design objectives and requirements and

identified areas where design improvements would be required

prior to finalization of the production configuration.

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Hardware and equipment provided was designed to fulfill the require-

ment of 8-months of orbital l i f e (Reference CEI Specification

CP208OJIC). Continuous operation environmental testing was

ge n eral l y de_ . onstrated o n l y f o r th e initial 28 -d ay habitation

period; however, full or compressed mission duration life cycle

testing was conducted when, the test assessment indicated further

testing was required.

Flammability testing at the components and subsystem levels were

ccaducted. Material evaluation tests were performed in accordance

_ith the requirements deiined in CEI CP2080JIC. Some of these

tests were performed in the MSFC facilities.

The general policy for conducting Electromagnetic Compatibility

(EMC) tests was to evaluate hardware and equipment at the highest

level of assembly wherever possible. EMC testing conformed to the

:equirements delineated in MIL-I-6181 and MDAC Specification

No. 7883817-501.

5.i.2 Documentation and Control Requirements of Component and Subsystem

Te stin g

@ Comp one nt Test Co n tr o l Au tho r i ty (CTCA) - The general testing

requirement for any MDAC-W or supplier tested item was denoted on

Form s 850-7 (CTCA) which were u s ed as the control document during

each specific test progr s m. A CTCA was prepared for each item of

hardware and equipment.


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Test Contr o l Drawing (TCD) - A TCD wa s prepared for each of the

items subjected to compo:Aent or subsystem testing at MDAC-W. The

TCD w_ the engineering requirements document used as the basis

_ for t h e prepar_ion o f a Test Pr o cedure Drawing (TPD), when

_ required.

T e st Proce d ur e Drawing (T PD) - T h e TPD, whe n r e q u ire d , w_ pr e -

p ar e d by e ither th e testing laboratory or d e sign secti o n. It

outlined the d e tail e d procedure for p e rformance of the test and

w_ prepare d in accord_ce with the auth o rizing TCD.

Specification Control Dra wing (SCD) - An MDAC-W Specific_ion

Control Drawing w_ prepared for each item supplied by suppliers

on deliverable items of equipment and hardware. -Section h of the

SCD d e fined those t e st requirements to be verified by the supplier

to support des i _ u sage i ncluding Development, Qualification and

Production Acceptance testing. For each test, a test procedure

document w_ r e quired to be submitted to NDAC-W for approval

prior to start of testing. MDAC-W Engineering and Quality ControlJ

monitored the testing at the suppliers facility to verify all test

_qu i rem e nt s we r e me t.

Qu a lific a ti on Test Co ntr o l s - The qu a lification tests were c on-

ducted by MDAC - W Devel o pment Engineering with optional surveill- i _

_ c e by NASA o r its represe n tative i n accord_ce with the

z' o llowing:

2

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The TCD was prepared for each of the items to be subjected to

testing. The TCD was the engineering requirements document

defining each test condition and environment per CTCA form and

used as the basis for preparing a TPD, as required. In certain

cases, it was necessary to make redline changes during the test

activity. These changes were reflected in a subsequent TCD

revi s i on . All redli n e c hanges wer e appr ov ed by a representative

o f the Contractor Design Tec h n o l o gy and co o rdinated with an

a ut h o r iz e d NASA RM0 Re p resentative.

NOTE: When supplier tests w e re conducted, the procurement

specif ication completely defined th e engineering test

requirements and provided for all anticipated environ-

ments to which the component may be e xposed during the

life of the component.

@ Test Failure / Anomaly Reporting - When a failure occurred during

d e velopment testin g , the resolution was the respon s ibility of

MDAC-W Development Engineering.

During the Qual ification Test Program, s hould a compon e nt / modul e

fall to perform in accordance with t es t requirem e nts of the TCD

or TPD_ the contractor would immediately instigate an investig a tion

o r diagn os tic test t o determine the cau s e o f the anomaly. I f it

was determined by the c o ntractor that a true failure existed,

i.e., t h e c omp on ent / module would n o t meet the te s t require ments

when subjected to proper test conditions, the NASA RMO was verbally

notified within one working day of the contractor's determination

of f a ilure. A Fa ilure R e p o rt (FR) w as g ene rat e d by MDAC-W

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Quality Assurance as requested by MDAC-W Development Engineering.

: Test anomalies other than failures were documented in the Test

Log Book. Adjustments or equipment replacement was permitted

during an operation only if they were part of the normal use

cycle.

@ Test Status - Test status of all component / module tests was pro-

vided to NASA on a monthly basis. The status was presented in

the form of MDAC-W work plans. These plans were the in-house

working plans utilized by the MDAC-W for program management s_d

assessment of performance.

Change Control - The test specimen quantity, configuration, and

testing environments for each component and subsystem test adhered

to the requirements defined in the appropriate CTCA form. MDAC-W

changes occurring during the Development Test Program as to con-

figuration, additions or deletions to test environments or speci-

men quantity were denoted in revision CTCA forms and submitted to

the NASA Resident Management Office as information. Changes to

Qu a lif: cation Test CTCA forms and the addition or deletion of

Development and Qualification Test line items were authorized by

mutual approval of a revised CTCA under cover of a T e st Plan Change

Form. If MDAC-W notified NASA that the revision was a major change

in scope, a change order was issued directing the change. Test

Plan changes resulting from Class I OWS flight hardware changes

were submitted to NASA by the ECP submitting the hardware change

(reference paragraph 6.2.2.2 for Class I change definition).


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Certificatioz of Component Acceptance - Certificates of Component

Qualificaticn were prepared f o r all items in criticality cate-

gories i and 2 prior to Pre-Flight Readiness Review.

Data Submittal Requirements - Data submittal t o the Co ntracting

.Agency during the MDAC-W period of performance was in accordance

with the Data Requirements List MSFC-DRL-171 (DRL).

5.1.3 Documentation a nd Control Requirements - Spacecraft Systems a nd

Integrated Vehicle Testing

D oc ume n tation - In o rder t o ensure a c o mplete an d a d equate c h eck-

out was performed, a series of support documentation was provided.

Documentation was as follows:

Checkout C o ntr o l Plan - T h e 1B79 32 1 Checkout C o ntr o l Plan, an

internal _S_AC-W Engineering document, provided advanced checkout

planning for both Huntington 2each (HB) and Kennedy Space Center

(KSC ).

The final r e leas e of this document wa s an "A" Revision, dated

h August 197 0 . Subs e quent planning was incorporated in Test

Outline Drawings (T OD' s ) and t h e IB8 3 42 9 Test and Ch e ck o ut

Re quir e ments, Sp e cifications and Crit e ri a Do cume n t (TCRSC).

T es t and Ch ec k o ut P lan (TCO P ) - Th e TCOP wa s a ma tr ix li s t in gwh ic h c o rrelated t h e HB t e st r e quirem en ts c o n tai n ed in th e TCRSC,

the TOD's a n d the Test and Checkout Procedures (TCP's). Each

requirement identified in the TCRSC Document as applicable for

HB chec k out was listed i n the TCOP. A matri x was completed

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were als o i ncluded . Auth o rization f o r usage of ACD's was by

Manufacturing Planning Assembly Outlines (AO's). ACD's were

submitted to the Resident NASA Management for approval prior

t o utilization.

Test Outline Drawings (TOD's) - TOD's were prepared in accord-

ance with Line Item J2h of DRL-171A.

A TOD was prepared for each TCP that was accomplished during

HB checkout. The TOD's were updated until the r elease of the

corresponding TCP after which time no additional releases were

required. These documents included the checkout flow stud

operations for each procedure to a depth necessary to specify

the basic operations for each procedure to a depth necessary

to specify the basic operations to be performed. Test pre-

requisites, facility support, ground support equipment (GSE)

support, and other significant support information were

included. Detail checkout operations (e.g., connect, dis-

connect) and GSE interface operations were included. The

information contained in the TOD's provided the information

from which the detailed TCP was prepared. In the case of

autcmatic tests, the T0D contained sufficient detail informa-

tion required to generate the automatic portion of the TCP.

The principal engineering design discipline responsible for

each _c , t was resp o nsibl e for c oo rdination o f inputs from all

o t h er discip l in e s, t h e c ol lation o f the input s , and the prep-

station of the respectiv e T0D and TCP. Each design discipline

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ensured that its individual requirements for each test was

recognized by the responsible discipline and incorporated into

the test sequence TOD's were submitted to the NASA for review.

TOD's were prepared and utilized at the KSC in the same manner

as noted.

Test and Ch e ckout Procedures (TCP's) - The TCP's were prepared

in acc o rdance with Line Ite m J 0 1 in DR L- 171A.

These procedures identified the step-by-step checkout to be

performed during the HB operations.

The TCP's were used to perform the tests and provide the buyout

documentation for acceptance of the OWS. TCP's were prepared

and utilized at the KSC in the same manner as noted.

GSE End Item Test Plan (EITP) - The GSE EITP was contractually

required by Line Item JOb of DRL-171A.

The GSE EITP contained a column listing of each item of GSE

used to support OWS checkout and handling operations at HB.

Included in the listing were the GSE model number and title

_ along with identification of the procedure used to verify proper

operation of the model.

@ Test Manage ment - The MDAC - W Development Engineering Vehicle 1

Checkout Laboratory (VCL) functional organization, was responsi-

ble for managing and performing Spacecraft checkout operations

at Huntington Beach (HB). This organization was responsible

for:


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@ Verifying _onfiguration before starting OWS checkout.

@ Assuming and retaining custody of the OWS from initiation

of checkout operations until turnover for shipment.

@ Spacecraft modifications required to meet mission peculiar

requi r e_ent s.

@ Planning, organizing, directing, and controlling assigned

checkout tasks.

Updating, modifying, maintaining, and testing test and

supp o rt equipm e nt, and a s suring necessary calibration was

accompli shed.

Ensuring safety of personnel and hardware.

Maintaining an effective training level of checkout

representatives.

Planning and controlling checkout area cost and budget

requirement s.

Maintaining liais o n with t he NASA Re sid e n t Manag emen t as

design a ted in program requirement s .

Ge ne rating and retaining o bjective evidence i n the f c _ ' m of

test records to verify or establish that the test require-

ments were met.


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The MDC G2427, Huntington Beach Vehicle Checkout Laboratory _

Operating Plan, identified: (i) applicable management

directives associ ated with directing the VCL oper ations,

(2) s upporting MDAC-W elem e nts wh o pr o vide d pers o nnel, skills

and serv ice s , (3) custody turnover requirements from manu-

facturing to the VCL, (4) applicable Test Plans / Specifications,

work scheduling requirements, (6) te st team structure,

{ (7) test conduct, (8) hardware configuration control, and

i (9) test problem reporting syst em, etc. This plan w as a more

comprehensive document than was normally required for a _ost-t

manufacturing checkout b e cause of the man_ - interfaces between

the various NASA centers and experiment developers.

Speciai Operating Instructions (SOI'_) were released to define

operating procedu r es for use by all personnel assigned to the

VCL SOI's were written to interpret and implement the in-

tent of MDAC-W Management Directives or to provide operating

instr uctions where existing directives did not apply.

Safety aspects of the VCL operations were specified in the

following:

The IB88179, B Revisi o n, OWS Saf e ty and Retreat Op e rating

Instruc tions , AS-VCL, specified redline monitor instructions

and retreat pr o cedure s t o b e fo llow ed in the event emergency

action was required during OWS operations.


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@ The MDC GC937, 0WS Safety Brochure of the Vehicle Checkout

Laboratory, Huntington Beach, dated November 1971, speci-

fied the safety rules and procedures to be observed by all

personnel engaged in checkout of the OWS in the VCL.

In order to ensure timely release of Test and Checkout Pro-

cedures (TCP's), verify all test requirements were included, 7

and to improve TCP coordination with the NASA, an OWS Review

and Pevision Plan was implemented. Initial release of TCP's

was scheduled no later than test minus four (4) weeks. TCP's

imple mented the r e quire ment s o f Test 0utline Drawings (TOD's),

satisfied test requirements previously approved by the NASA,

and were thoroughly reviewed by affected technologies. Test

time min u s three weeks a revie w meeting wa s held wit h repre-

sentatives from affected technologies and the NASA. NASA

approval letter was prepared and transmitted to MDAC-W

a ppr o ving TCP conti n gent o n inc o rporation of initial revieweeting agreements. Review comments were incorporated into

TCP by firm letter change release. A final review meeting i

was held at test minus one (i) week. Procedure changes re-

suiti n g fr om final re v iew meeting were i n c o rporated into all

test team copies by Procedure Change Instructions (PCI's).

Inspection and man / machine interface stamps (Snoopy)

MAN. (_IZACHII J[ _ we r e applied t o TCP In spection Mast e r.VERiFiCATION Ca iW_nz_

The Snoopy was a symbol us e d to indicate that a cr e w systems

e ngineer had a requirement to perform a functional test to

properly evaluate whether the action met the loads and hand-

; ling capabilities o f a flight cr e wman. Inspection master

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procedure vellum was then approved by the NASA and MDAC-W

personnel. Real t_me procedure changes were also incorporated

by the PCI method.

Overall responsibility for the Saturn Wo:,Kshop Skylab (SWS)

program at the KSC was the NASA Kennedy Space Center (KSC)

Spacecraft Operations (SO). Skylab Preflight Operations ?

Procedures (POP's) were established to define Contractor

Interface Guidelines for SWS Spacecraft Opera:ions at t4e KSC. _

5.1. k Documentation and Control Requirements - Mission Support Testing

_ @ Action Requests generated to solve Mission problems generally

flowed from Johnson Space Center (JSC) Flight Operations Manage-

ment Room (H)I_) to Huntsville Operations Support Center (HOSC);

however, requests were sometimes phoned directly to the MDAC-W

Mis s i o n Supp o rt (MS) R oom C aptain (RC). Each action was assign e d

a unique Action Item Number.

Action Requests requiring use of the OWS Backup or Component and

System Hardware to resolve a Mission problem resulted in prepara-

tion of a Mission Support Test Request (MSTR) by the RC A

responsible,engineer was assigned. The engineer was responsible

f o r preparation o f t h e MSTR Test Plan, coordinating test require-

me n t s , within MDAC - W and with MSF C, p a rticipatin_ i n t h e test wh e n

required, providing the solution to the Mission probl e m, and com-

pleting the action item form. Acti o n Requests and as s ociated

MSTR' s are pres e nted in Figure 5 .1-5. Th e MSTR, with Te s t Plan

included, wa s submitted to the VCL Progrsm Manag e r s n d the NASA

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Senior Vehicle Systems Checkout Rep r esentative for approval prior

to c::_aencing any hA'."dw are activities. The MSTR was then submitted

to t h e affected technology Task Leader. The T a sk Le a d e r imple-

mented the requirements of the MSTR on a Test Preparation qheet

(TPS) and ra n the test. All other agencies supported prepar ation

of the TPS and performance of the test as required. At the com-

pletion of the test, the T ask Leader was responsible for subm'.tting

the results of the test to the responsible engineer / Room Captain

and preparing a final report.

The documentation utilized during Mission Support special tests

vere :

Mission Support Area Control Drawing. MSACD's provided the

means to authorize, direct, control and document sp e cial tests

requested by a MSTR.

Test Preparation Sheets - TPS's wer e gener a ted by the Ergineering

Task Leader to implement the requirem e nts of the MSTR. TPS's

' included but were not limited to the following:

Pre-test s e tups

@ Re co rdi n g r e qu i re me n ts

T e st instructions

Temporary configuration chan qe s

Authorization for re mo va ls / d is conn ections

In sp e cti o n buy o ut for app 3 icable d e tails associated wit h

returning the Spacccraft back to original configuration, and _

r e t e st of invali d , ed s ubsystems.

I de ntifying Ma n uf a cturing Planning r_uirements

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N o n - Co nf o r ma nc es - Non-Confo r manc e s w e r e d o c u men te d i n acco r d an c e

with Qua l ity Ass u r a n ce Sta n d ar d Pr a ctice s .

O Docume n tation - Missi o n Support Test do-"u me n ts were mai n tained by

Quality Co n trol duri n g Mission Support (M S) . At th e co mpletion

o f MS, all special test docu men tation was transferred t o Qu a lity

Data R e cords File.

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5.2 COMPONEh T AND SUBSYST_4 TESTI NG

This section e nu me r ate s th e de v e lopment a n d q ua lificati o n t e sts

p erfo rme d o n t h e c omp o nent an d su bsy s tem s . P ro v ide d is a l isti n g

showing the quant ity and types of tests with th e corr esponding

report nu mber that cont ains a ll of the test dat a. A br ief is

provided that descr ibes the gener al pur pose of the tests. For

deta iled tes t descri ption and d iscuss ions on s ignificant anoma lies,

re ference is made to the Tests Sect ion with in each su bsystem in

Section 2.2 of th is re por t.

5.2.1 Development and qualification Testing - For pur pose of clar ity, the

deve lopment and qu alific at ion test ing wh ich was per formed is grouped

in accordan ce with respect ive fun ctional OW S hardware bre akdo wn stru c-

ture. Test s wh ich were not co mpat ible with th is group ing because o f

scope and method o f accompl ishment are de fined a s specia l tests in

Par agra p h 5 .4 of th i s rep o rt. Maj or f Unct io n al gro upings ar e l i sted

be lo w:

o Crew A cco mmo dat i ons

o H ab i tab i l i t y Su p p o rt Sy ste ms

o El e ctrical Sys tems

o I llu mi n a t ion Syste m

o Co mmun ica t io n S ys t em

o Da t a Acqu isiti on System

o Th ermal C o nt ro l Systems

o _,ruster Att itude C ont rol System

o Corollary Exper iment Accommodat ions

5.2.1.1 Crew Accommodat ions - This portion o f the test progra m ver ified the

integr ity _ the cre w qu arter s, astronaut aids, cre w safety pro visions

and the orbita l maintenance _rovisions.


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|

Testing of items in this category were initiated ea r ly in the OWS

program an d many completed prior to the conversion from the "wet"

t o " d ry" c o ncept . Tw e lve of th es e t ests re ma ine_ a p plic ab le to the

" d r y" version .

o Cre w Quarter s - Tests app lic ab l e t o th is ar ea e n co mp as sed t h e

floo r, c e ili n g, c omp a r t ment i zat io n , vi e wing wi nd ow an d col_r

sch e me. Li s te d b elow are Tes t Line I t em s u se d to develop and

qualify the cr ew qua r ters.

L ine Repor t

Title I t em T_e S t art Comple t io n Numbe r

Floor Pan e l CA-I Dev 08 / I h / 6 ( 10 / 0 6 / 67 TM - II 5

Floor & Wall ( h.2 Grid) CA - 2 Dev 10 / 16 / 67 02 / 15 / 68 TM-1 2 3

Wall & Floor Grid Splice CA- 3 De v 12 / 1 8 / 67 1 2 / 27 / 67 TM- 12 h

Th e rmal Cur t ain & Ceiling CA-h Dev 12 / 1 5 / 67 12 / 31 / 68 MP- 5 16 9 h

Gre en Alodi ne Coatin g CA-5 De v 03 / 1 5 / 68 10 / 28 / 6 9 DAC-6211 5

Coa t ing A1 Foil MD- 1 9 CA-6 D ev 08 / 0h / 67 12 / 0 5 / 67 DA C- 62116

Color Anodic Films CA-7 De v 02 / 26 / 68 12 / 16 / 68 MP 5 1,386

Viewing Wi n dow & I ns t al CA-18 D ev 11 / 1 6 / 7 0 0 8 / 2 0 / 7 1 G3 86 5

Vi e wing Wi nd ow & I ns t al CA -19 Qual 08 / 1 8 / 7 1 12 / 0 7 / 7 1 G3 76 1

Vi e w Wi nd ow In t Sh ield CA - 27 D ev 09 / 27 / 7 1 0 h / 0 7 / 72 G337 2

o A str ona ut Ai ds - Ite ms _e sted in t hi s c a t egory in v o lv e d both fixed

an d po rt abl e aid s inc l uding han dr ails, t e t h e r at ta chme nt s and foot

r es traints. The tes ts noted below cover the d e vel o pmen t o f the s e

i t ems.

I ns ul at e d Pl u g Ass e mbly CA-8 De v 08 / Ih / 68 05 / 02 / 69 TM-131RI

Porta ble Foot Re straints CA- 9 Dev 0 9/ 0 3 / 68 07 / 1 1 / 69 TM - 1 90

Por t able Han d Hold CA-10 D ev 0 6 / 1 7 / 68 0 6 / 21 / 68 TM -1 88

Tether A tta c h Pin CA-II D e v 06 / 24 / 68 06 / 2 5 / 68 TM-184

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o Crew Safety Provisions - Testin g in s upport o f crew safety

p rovisio n s consiste d of d evelop me n t c ad qualific a tio n of th e fire

p r o t ec t ion and me te o r oi d s h iel d d e pl oy me n t syst e ms. Te st L ine

I t em s C A-5. CA -6 a nd CA-7 n o t e d und e r crew qua r te rs . _ = - . e l ope d

th e fire ret a r dant c o atin g uti li z e d. In add i t io n, t e st i n g wa s

accompli sh e d on t he fo a m i n s ulat io n a pp l i ed to th e c o ,,, o n bul kh ead

d ome u nd e r L ine It e m CA- 2 1Li n e R ep ort

Titl e Item T ype Start Completion Number

Foam In s u latio n CA-21 Dew 06 /11/7 0 09 /22 / 7 0 TM-1 3 8

Liste d b e low are those Tes t L i n e Items that d evelop e d a n d qu alified

the d eployme n t of th e me t eoroi d shiel d .

Met e oroid S h ield R e l Sy s CA-12 qual 0 4 / 21 / 7 1 0 5 / 19 / 71 R68 9 012

Exp Tu be / CDF & EBW CDF CA-1 3 De v 0 6 / 2 3 / 69 0 7 / 2 5 / 6 9 R65 7 3 A

Exp Tu be CA-lh Dew 0 1 / 17 / 68 0 9 / 12 / 6 9 R666h

Exp Tub e C A-1 5 Qual 02 / 1 9 / 71 0h / 2 9 / 71 R687 0 A

mExpand Tube & Str a p Assy CA-28 Dew 07 / 12 / 71 09 / 04 / 71 G h 022

Ex p Tube / St r a p Assy CA- 3 0 Qual 03 / 0 8 / 72 04 / 14 1 72 R7 0 h2A

Exp Tu be / Stra p F u ll S ca le CA- 3 1 Q u al 0 1 / 11 / 7 2 02 / I0 / 72 RTOh 3

Me teoroid Shie l d Po s t I nst CA-3 2 Dew 1 2 / 13 / 7 1 0 1 / 31 / 72 G33 7 3

Me teoroi d S h iel d Dep loyLatch CA- 3 h Dew 02 / 17 / 72 07 / 1 9 / 72 G33 7h

o Orbi t al Mai n tenance Provisio n s - Since most orbital maintenance

l ogis t ics sp a res w ere st ore d in st ors_e co n tai n e r s , it w as n e c e ssary

to d emonstrate that t h is e qu ip me n t coul d wit h st and l a un ch an d b oo s t

d y na mic l oa d env ir o nment s . The Tes t Line I tem note d be l o w wa s

uti l ized f o r t h is pur po se .

Sp nre Eq u ipme n t Stow CA-1 6 Q u al 09 / 2 0 / 7 1 05 / 13 / 72 Ch ll 2Co n ta i ner Vo l . I ,

II &II l

WTested a t suppl ier.

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5.2. 1 .2 H a bit abi li ty S uppor t S ys tem - T he habi t ability s y s t em co n sis t e d of

mmk7 m a jor s u b s y st e ms re qu iring e x t e ns i v e d e v e l opm e nt a n d qual ifi -

ca ti o n te sting prior to flig h t of the OWS. In a d d ition to these

tes t l ine i t ems, Ne utra l Buoyanc y a n d Ze r o- Gr a vi t y t es t ing , i d enti f ie d

i n P a r a gr ap h 5.h a s Lin e Ite ms S T-I an d ST -2, w e r e c ondu c t ed a t MSFC.

Som e de sign v e rifi ca tion w as acc omplis hed on t h e sp acec r a ft wi t h

c r e w p a rticip a ti on d uring p o s t-m a nu fac tu r ing c h ec ko ut .

For t he pru p o se of thi s r e por t , t h e Ha bit a bilit y Suppor t S ys te m wa s

c o mp o s e d of t h e fo l lowing su b syst ems : Crew Re s tr a i nt s, W as te Man a ge-

me rit , Wat er , Person al H ygi e n e , Food _a na g e me n t an d Ref r i g e r a t i on ,

Tr as h Dis p os al a nd V ac uum p rov i sions .

o Cr ew Re stra i nt s - Cr ew r est ra i nts ve _e e valua t ed a n d d e v e l o p e d b y

Tes t Lin e It em HS- l. T hes e i n c lu de d Foo d Ma n a gem e n t Com part ment,

Pre ss ure Su i t Foot, Port a ble a n d F i x e d Foo t , S leep an d Equ i p me n t

Restra i n t s. In a d d ition to t h e o n e " G" t es t s a t Hun tingto n B e ach,

t hese res tr a int s were t e st c d in n e utral buoy anc y a t MS}_ f ac iliti es .

Sl e e p r es tr a int s t owag e t es ti n g was initi a t ed un de r Line I t e m HS- 69

and sub sequ ent ly stopped du e to mater ial chan ge and testing

acc omp l i s he d at MS F C. B e l o w a re Te st L i n e i te ms i nv o lv e d .

Li n e Rep ortTitle Item T_e Start Completion Number

Cre w Rest ra in ts HS - I Dev 11 / 03 / 69 0 7 / 27 / 71 R6901

Sl eep Re str Ass y HS- 69 Dev 0 2 / 02 / 72 02 / 03 / 72 N/ A


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o Waste Mana gement Su bsystem - The subsystem provided t he hard ware

necess ary for safe. effect ive and hy gien ic collect ion , process ing.

stowag e and return or di sposal of all waste products for the t hree

Skylab missions. Belo w are l isted the develop men t and qu alificat ion

test line items ap plicable to this subsystem includin g some supplier

tests .

Line ReportTitle Item Ty pe Start Completion Number

Ws_ te Man ag e ment Su bsys H S- 2 Qua/ 07 / 15 / 7 1 11 / 21 / 72 Gh17 6

" Zer o -G Fecal C o llect o r HS-3 D e v 11 / 0 1 /6 9 Oh / lh / 7 0 TM-19 2

" Wa ste C ollec t o r & P r oc H S- h Dev 12 / 0 7 / 7 0 06 / 2 8 / 72 TM- 1 98

" Ur i n e Pr ocess o r & St o r H S -5 D e v 11 / 0 3 / 6 9 0 3 / 05 / 7 0 TM-1 99

Apol l o Blower HC-27 Qual 02 / 1 6 / 7 0 0 7 / 20 / 7 0 R669 0A

*Apono System Hs- 28 quaZ 0 7/08 /70 o8/17/7o TM- 195*Was te Man agem ent Odor Cc n t H S-3 h Dev 06 / 30 / 7 1 11 / 19 / 7 1 TM-2 0 3

mUCMSS - P r elim Spec T ests HS-39 Dev 0 7 / 28 / 7 0 1 0 / 06 / 7 0 TM- 1 93

Uri ne F r eez e r HS-h l Qu a l 11 / O8 / 71 0 3 / 2 8 / 7 2 R 7 03 8

Ur i ne Sa mp l e Return StorCo n tain er HS-42 qu a l 0 4 / 28 / 72 07 / 1 3 / 72 G3 9 7 3

" UCMSS - Two -B s_ U r ine HS- 51 D ev 1 0 / 2 7 / 7 0 1 1 / 13 / 7 0 TM-1 9 6" Ur i ne Ce nt r Sep Ass y H8-55 Dev 0 6 / 2 1 / 71 0 1 / 28 / ' ( 2 TM -20h

I Ce ntr S e p fPl ex ig la s s ) HS- 6 0 Dev 07 / 2 0 / 71 0 9 / 2 1 / 7 1 T M- 2 0 6

Two Ba6 Urine Tracer"Ver ificati on HS- 61 De v 11 / 2 9 / 71 0 2 / 2 5 / 71 TM-2 0 5

Centr Sep C oll e c t Su b sy s . HS-6 2 Dev 09 / 1 8 / 71 0 8 / 1 6 / 72 0 h1 3 2

Urine _ eezer / Tr _7 Fro st HS-6 h Dev 0 6 / 0 9 / 7 1 06 / 1 5 / 71 R68 8 8

Urine Freezer (Ur i ne &Bl o o d HS- 85 Qual 06 / 2 9 / 72 1 0 / 05 / 72 GhlS0

Ur l ne / Bl oo d Sa mp le Return

Storage Con taLner HS -8 6 Qual 10 / 1 6 / 72 10 / 27 / 72 Gh 15 2Urine S u b syste m- Redes lg ned H 8 - 8 9 Dev 1 0 / 2 5 / 72 12 / 1 5 / 72 Gh1 98

Ur i ne Su b syste m-R edes lg ned H8-90 Qual 1 2 / 0 8 / 72 0 h / 09 / 7 3 Gh I99

Ur in e B ag Asay HS- 9 1 Qual 0 1 / 17 / 7 3 0 2 / 1 2 / 7 3 3h1 9 6

iT, st a ucomplished a t Supplier.


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r

NOT E: Expendab le stor age and dispe nsing equipme nt wh ich

included co llection bag supply module , bag dispenser,

uti l it y wat er d is p e ns e r, a n d s t o r a g e c ont a i ne r s we r e

evaluated d uri ng th e qualifi c a t ion t e s t o f Waste

Mana g e me nt Subs ys t e m, Lin e Ite m HS-2 .

o Wate r Man a g e me n t S ubs y s te m - Two se p a r ate in s t allat ions of t h e

Wate r Sub s yst e m we r e ma d e in t he OWS - On e fo r personal hy gi e n e

a n d on e f or food ma nag e me n t. These provided capa bi l i t y fo r stor ag e,

s uppl y, co n d i t i on ing , dispe n si ng f o r food an d b evera g e prepa r at l c n ,

drinking a nd body c le a nsing d uring all mis s ions. Test Line Ite m

HS- 7 q ual ifi e d t he wa t e r m a nag e me nt s u b sys t e m. Li n e It e m HS- 94

was t h e q u alifi ca tion t es t ini t i a t e d on a r e de signed water he at e r

wit h C AL-R OD t y pe el emen t for u se in th e OWS Ba ckup sp a c e cr a ft.

Li s t ed below a re the t e s t s performed to d evelop and qu ali f y thi s

major sub s yste m,

Lin e Rep or tTit l e I t em TYp e Star t C o mp let io n Nu mber

Wa te r Su bsys t e m HS- 7 Qu a / i i / 0 2 / 71 06 / 1 5 1 7_ G_194

Wa ter S t orage A s s e mbly HS - 8 D e w 09 / 16 / 70 11 / 1 0 / 72 G417 5 VOLI & II

Food Re co n s t Di s p Unit H S- I O Dew 03 / 0 2 / 7 0 0 7 / 0 7 / 7 1 R6915

Drink W ate r Di s p enser H S- II Dev 02 / 1 0 / 7 008 / 1 6 / 7 1 R693 8

* Water Hea t e r HS- 1 2 D ev 09 / 2 9 / 71 0 6 / 0 h/ 71 G39 h 5

Micro b iol o gical E Rp HS - l h D e v 1 2 / 0 1 / 7 0 05 / 2h / 72 Gh1 56

Pe r Hyg Wat e r Disp H S - 16 Dev 0 7 / 22 / 7 0 09 / 1 6 / 7 0 _47 60

*Wa ter St or a ge Cont Bel HS - 3 2 Dev 1 2 / 1 7 / 7 0 0 3 / 1 2 / 71 03 6 11

He a te r Con tr oll er HS -4 6 Dew 0 3 / 2 9 / 71 06 / 1 1 / 71 R 6 87 5

Urin e S ep F lu s h Dis p Ass y HS -56 De w 09 / 27 / 71 01 / 31 / 72 R 69 8 9 A

I Water De ioni z ation A s sy H S - 59 De v 12 / 0 8 / 71 0 7 / 12 1 72 C_ 1 8 1

J Water Heate r H S - 9 _ Q u al 08 / 0 2 / 7 3 11 / 27 / 7 3 R 722 8_ *Te sted at S up p l ier .

i 5 26


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Li n e Rep o rtTitl e I tem T yp e Start Com ple tion N umbe r

Refrig Subsystem HS-19 Qu a / 92 / 05 / 71 01 / 1 2/ 73 04180

Rad iator & P l ume S h iel d HS- 31 D ev 0 5 / 2 5 / 71 0 4 1 20 / 72 R7060

P ump Logi c Co nt r o l H S -35 qual 11 / 17 / 71 0 3 / 2 0 / 72 R6 9 67

Rad i a tor By p a ss Val v eContr oller HS- 3 6 Qua/ 0 3 / 21 / 72 0 7 / 1 3 / 72 C_ 00 4

" Pr Rel V al v e , R TC HS -66 De v 08 / 11 / 71 0 9 / ih / 71 S tererD TR-2 9 4 50-S A

B y pa s s Co n trol Mo n it o r HS-76 q u al 0 5 / 03 / 73 06 / 06 / 72 RT073A

Radi a tor & P l ume Shiel d HS-77 Dev 03 / 11 / 7 2 01 / 2 3 / 7 3 0 42 3 4

: _ Po tabl e Wat er Chill er HS-78 Dev 0 2 / 28 / 72 05 / 0 9 / 72 Gh087

: Co ol a nt P u mp I n v er t e r HS-88 qua/ 0 1 / 0 2 / 7 3 02 / 08 / 7 3 C, 1 93

O Trash Dis po sal S u b s y s t e m - Th is su b s y st e m in clud ed the c o l le ct ion

a nd d i s po sal e quipment nec essar y to r emo ve trash and g a rb a g e f r om

the LH2 tank of the workshop a n d e xpe l it into t h e L0 X tank ar ea .

This w a s ac co mp l i s h e d b y means of an a i r lock l oc a te d in t h e c o mmon

bulkhead . Test i n g was per fo r me d o n the bags uti lize d t o c o nta in

l iq u id s and sol id s ex p ell e d thr ough th e alr l oc k (HS - 67) a s we ll a s

t he scr ee ns , b a ff l e s , g a g e an d th e t ras h a ir l o ck it sel f. B el ow ar e

l i s te d th e tes t l ine i tems u ti l iz ed in ver ifyi n g th e d e sign i n tegrity

o f this subsystem.Line Report

_ Title Item, Type Stsr t Completion Num ber

Trash Dis p Ai rl oc k HS- 2h D ev 09 / 28 / 7 0 1 1 / 0 8 / 7 1 033 64

i Tr a s h Ba gs HS-6? D e v 0 7 1 15 1 71 05 / 1 9 / 72 C,_09_

Waste T ank S creen HS -7 3 De v 10 / 15 / 71 01 / 14 / 72 R 7 0h0

Pre ssure Ga ge, TrashDi sp o se / Ai rl oc k HS -? 5 Dev 1 2 / 2 0 / 7 1 0 2 / 09 / 72 033 77

Was te Tank - Sc ree n Ba ffle HS-81 D e v 0 3 / 03 / 72 03 / 3 1 / 72 R7 039

_ Te sted at Supp lier .

5-28


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o Vac u u m Pro v isio ns - These p r o vis io n s w e r e p r ovi ded i n th e Wo rk sh o p

to p ro v i de v a c u um d i s c h arge a nd s h u toff c apa bility for vari ou s

i tems of equ i p ment an d e xp e ri men t su pp o rt. 1 -i nch a nd i / 2 - i n c h

bal i v al v e s we r e u ti l i z e d i n th e Was te Mana geme nt Co mpart ment t o

accommodate the urine and processor dump systems, waste management

and wardr oom wate r systems and the waste managemen t dum p system .

These valves were a lso ut ilized for shuto ff capability to t he

Low e r Bo d y Ne gative Pr ess _r e (L BNP ) expe r i me nt, an d ve nt re f r ig er a t ion

coolant l e a k age i nt o th e was te tan k. Tes ting of the co mpo nent s an d

su b s y stem s w e r e acco mp l is hed by t he fo l l o wi n g l i n e i tems.

Li ne Re por tTitle Item Type Start Coml_let!on Number

Vac Outlet Valves HS - 25 D-v 08 / 29 / 68 03 / 19 / 70 R6358

Va c u um Ou t l et Sy s tem HS -2 6 Qu a l 10 / 18 /7 1 05 / 2 0 / 72 G4 1 17

1 / 2 I nch Vacuum Vl v HS- 6 5 Qu al 01 1 17 1 72 Oh 1 26 / T2 R7065

Co ndens at e Dump Sy s t H S -8 0 De v 06 / 30 / 72 0 8 / 15 / 72 G42 03

Hea ter Pr obe/AM Co ndDu mp Sy s t em HS- 87 Qual 1 0 1 1 9 /72 01 1 2 6 / 7 3 G_20 k

Htr Prob e B ac k - u p BS - 9 2 Dev 01 / i _/7 3 0 1 / 31 / 7 3 G_2 05

5.2.1.3 E lectr ical Sy stems - The systems associated with the W or kshop electrical

power generat ion, distr ibution and control are con tained in th is section.

There are t hree ma jor d ivisional breakd owns involved: Launch Support

El e ctric a l Syst e m; El ec t r ical Dist r ibution a nd C o n trc l; a nd th e S o l ar

Array System.

o Lau n c h Supp or t El e ctrical Sy s t e m - Th is op e rat ed only d uri n g l a un ch

and a scent phases of the OW8 m ission and rema ined pas sive su bsequent

t o o r bital i ns erti on a nd Ins t r u men t Un it (IU ) p o wer d own . Har d wa r e

u ti l i zed was pr ev i ou sly qu alifie d f or the S - I VB _tag e ; ho we ver, th e

system _as ver ified dur ing clus ter t est ing at KSC.

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o Electrical Power Di s tribution an d Control - Electric a l energy i s

pr o vid e d by th e S o lar Array Sy s t e m _SA S) with p o wer co n ditioning

acc o mpli s h e d by eq uipment in s talled in th e Airl o ck M o dule (AM).

Single voltag e DC p o we r is then r e gulat e d and tra n sferr e d int o the

Wo r k shop ele ctric a l p o we r distribution and co n trol s yst em whe r e

final d i s trib u ti on to e nd it ems o f eq u ipment i s m a de .

Th e fo ll owi n g te sts w e re co ndu ct ed to en su re de si gn s u i t abi l ity

a nd verification of the electrical s y s tem which supplies _ o we r t o

e ach of t he Orbital Wor k shop c omp on e n t s.

L in e Rep o rt

Title It em T_e S tart Co mple tio n Nu mber

LH2 Wicking & I g n ES - I D ev 0 7 / 1 2 / 67 0 7 / 2 9 / 6 7 R 6 08 8

Cr y o Mat Eval ES- 2 Dev 11 / 06 / 67 03 / 11 / 6 9 R61 3 4Zero G Conn ES- 3 De v 0 2 / 06 / 6 9 0 7 / 50 / 7 1 R65h SA

Ze r o G Co nn E S-h Qua l 05 / 0 6 1 70 02 / 03 / 72 R6 9 7 0 A

For wa rd Do me ' _ e st E S-5 Dev Oh / Ol / 7 0 05 / 28 / 7 0 G2 0 71

Co n t & Disp l Pan e l ES-6 D e v 03 / 19 / 7 0 0 6 / 09 / 7 0 R66 9 6A

' Cont & Disp l Pa n e l E S-7 Qual 10 / 1 1 / 7 1 06 / 15 / 72 Gh 0 2 3

OWS Re lay Modules ES-II Qual 0 5 / 03 / 7 1 1 0 / 2 9 / 71 R6 9 h 3

! 30 Amp G. P . Re l ay ES -13 Qu al o 6 / I0 / 71 07 / o 8 / 71 R68 7 7

WMC C & D Pan e l ES- lh Qual 1 0 / 21 / 71 12 / 16 / 71 R6 939

Mod u l e , I so l . Di ode ES- 1 5 Qua l 05 / 09 / 72 0 6 / 09 / 7 2 RT O5 3 A

Ser i es Re g Mo du l e ES-16 Qual 0 5 1 15 / 72 0 6 / 06 / 7 2 RT 05 h

o S o la r Array Sy s t e m (S AS) - The S ola r Array was t he pr im ary so u rc e of

ele ctrical p ow e r fo r t he O rbital Wor ksh op. The tes t p ro gr a m co ndu ct ed

to d evel o p t h e SA_ a n d fi n ally qu alify it for f l ight c ons is ted of

development test ing and qua lification test ing of array panel asse mblies,

ar ray deploymen t mechanisms, and pass ive ven t module . This t esting w as

fo llo we d b y a qualificatio n t e

msfc skylab orbital workshop, volume 5

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