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Msfc Skylab Lessons Learned

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Msfc Skylab Lessons Learned U NASA TECHNICAL July 1974 MEMORANDUM NASA TM X-64860 / / / / MSFC SKYLAB LESSONS LEARNED Skyiab Program Office NASA George C. k4arshal! Space Marshall Space Flight Center, (NASA-TM-X-64860) MSFC SKYLAB LESSONS N74-30300 IEABNED (NASA) _ p HC $3.75 CSCL 22C 7/ Unclas 63/31 44768 MSFC - Form 3190 (Rev June 1971) TECHNICAL REPORT STANDARD TITLE PAGE 1. REPORT NO. 12. GOVERNMENT ACCESSION NO. 3. RECIPIENT_S CATALOG NO. NASA TM X-64860 I 4 TITLE AND SUBTITLE 5. REPORT DATE July 1974 MSFC SKYLAB LESSONS LEARNED 6. PERFORMING ORGANIZATION COOE 7. AUTHOR(S) 8. PERFORMING ORGANIZATION REPORr _t 9. PERFORMINGORGANIZATIONNAMEANDADDRESS 10. WORK UNIT NO, George C. Marshall Space Flight Center 1. CONTRACT OR GRANT NO. Marshall Space Flight Center, Alabama 35812 Is. tYPE OF REPORTa PERIODCOVERED ,2 SPONSORINGAGENCYNAMEANDADDRESS Technical Me morandum National Aeronautic s and Sp ace Administration Washington, D.C. 20546 14. SPONSORING AGENCY CODE 15. SUPPLEMENTARY NOTES 16. ABSTRACT Key lessons learned during the Skylab Program that could have impact on on-going and future programs are presented. They present early and sometimes subjective opinions; however, they give insights into key areas of concern. These experiences from a complex space program management and space flight serve as an early assessment to provide the most advantage to programs underway. References to other more detailed reports are provided for the individual's specific area of interest. 17. KE_' WORDS 18. DISTRIBUTION STATEMENT Unclassified-unLimited 19. SECURITY CLASSIF. (d tbAa repm't'l ]20. SECURITY CLASSIF. (of tide pe|e) 21. NO. OF PAGES ]22. PRICE / Unclassified ] Unclassified 72 _|t_l (Roy December ll?l) For sale by National Technical Information Service, Springfield, Virginia 221 S 1 / TABLE OF CONTENTS Paragraph Page l.O Foreword ....................... l.l MSFC Introduction .................. 1.2 Figure l, Skylab Orbital Assembly .......... 1.3 Glossary ....................... l .3.1 List of Acronyms ................... 2.0 Systems Engineering ................. 7 2.1 Systems Engineering and Integration ......... 7 2.1 l Cluster Requirements ................. 7 2.12 Interface Requirements ................ 8 2.13 Configuration Control ................ 8 2.14 Reviews ....................... II 2.1 4.1 Key Milestone Reviews ................ II 2.1 4.2 Skylab Systems/Operations Compatibility Assessment Review (SOCAR) ............ II 2.1 4.3 Special Reviews ............ 12 2.1 5 Test Requirements "and'Speci fi cations ......... 12 2.16 Special Topics .................... 13 2.1 6.1 Sneak Circuit Analysis ................ 13 2.1 6.2 Corona ........................ 13 2.1 6.3 Electromagnetic Compatibility (EMC) ......... 14 2.1 6.4 Skylab Mission Contingency Analysis ......... 14 2.2 Contamination .................... 16 2.2.1 Contamination Control As A System .......... 16 2.2.2 Contamination Control Working Group (CCWG) ...... 16 2.2.3 Contamination Modeling ................ 17 2.2.4 Contamination Monitors ............... 17 2.2.5 Material Source Properties .............. 17 2.2.6 Overboard Venting .................. 18 2.2.7 Experiment Exposure ................. 18 2.2.8 Waste Tank ...................... 18 2.2.9 Significant Contamination Sources .......... 18 2.2.10 Contamination Control During Ground Handling ..... 19 2.2.11 On-Board Cleaning and Storage of Optics ....... 19 2.3 Man-Machine Interfaces ................ 19 2.3.1 Interior Layout ................... 19 2.3.2 Translation and Stability Aids for Extrayehicular Activity (EVA) ................... 19 2.3.3 Container Latching Techniques ............ 20 2.3.4 On-Orbit Temporary Stowage Provisions ........ 20 2.3.5 Lighting ....................... 20 2.3.6 Airflow Retrieves Loose Objects ........... 20 2.3.7 Switch Guarding ................... 20 2.3.8 High Fidelity Mockup (Contractor) .......... 21 iii Precedingpageblank TABLE OF CONTENTS (Continued) Paragraph Page 2.4 Mission Operations .................. 21 2.4.1 Skylab Mission Simulations .............. 2] 2,4.2 Data Management ................... 21 2.4.3 Console Displays ................... 23 2.5 Experiment Integration and Compatibility ....... 23 25.1 Experiment Integration Engineer (EIE) ........ 23 25.2 Experiment Compatibility Engineer (ECE) ....... 24 25.3 Design Reviews .................... 24 25.4 Ground Support Equipment ............... 24 25.5 On-Site Support of Integrated Testing ........ 25 25.6 Mission Support ................... 25 2.6 In-Flight Maintenance ................ 25 2.6.1 Criteria for Design ................. 25 2.6.2 Selection of Tools .................. 26 2.6.3 Selection of Spares ................. 26 2.7 Thermal Control • • • • • • • • • . • • • • • • 6 • • 27 2.7.1 Integrated Thermal Analysis ............. 27 2.7.2 Fast Response Math Models .............. 27 2.7.3 Mission Support Hardware ............... 28 2.8 Attitude and Pointing Control System (APCS) ..... 29 2.8.1 APCS Integration ................... 29 2,8.2 APCS Verification .................. 29 2.8.3 ATM Error Analysis .................. 31 2.8.4 Crew Motion Disturbance ............... 31 2.8.5 Generation of APCS Functional Schematics ....... 32 2.8,6 APCS Control Law and Compensation Filters ...... 32 2.8,7 Contingency Operation ................ 33 2.9 Electrical Power System (EPS) ............. 34 2.9.1 General ....................... 34 2.9.2 Solar Array Systems ................. 34 2.9.3 PCGs and CBRMs .................... 35 2.9.4 Parallel Operation .................. 35 2.9.5 Special Documents .................. 36 2.9.6 Power Management ................... 37 2.10 Instrumentation and Communication (l&C) ....... 37 2.10.1 Skylab I&C Integration ................ 37 2.10.2 RF System Analysis and Verification ......... 39 2.10.3 Special I&C Documentation .............. 40 2.10.4 On-Board Displays .................. 41 iv TABLE OF CONTENTS (Continued) Paragraph Page 2.11 Structures ...................... 42 2.11.1 Dynamic Analysis Modeling .............. 42 2.11.2 Vibroacoustic Testing ................ 44 2.12 Integration Electrical Support Equipment ....... 44 2.12.1 Program Management .................. 44 2.12.2 Hardware Design .................. 45 2.12.3 Software Design ................... 45 2.12.4 Test and Checkout Procedures ............. 46 3.0 Other Experience ................... 47 3.1 Design ........................ 47 3.1 .l Contact Resistance .................. 47 3.1.2 304 CRES Corrosion .................. 47 3.1.3 Prevention of False Stars .............. 48 3.1.4 Pressure Switch Diaphragm .............. 48 3.1.5 Transducer Welds ................... 48 3.1.6 Liquid Dump Freezing ................. 49 3.1.7 Iodine Absorption From Water System ......... 49 3.1.8 Portable Fans .................... 49 3.1.9 Seals ........................ 49 3.1 .lO Urine Separator Check Valve Screens ......... 50 3.1 .ll Solar Cell Environments ............... 50 3.1.12 Rain Leak Control .................. 50 3.1 13 Welding Distortion .................. 50 3.1 14 Relocation of Components ............... 50 3.1 15 Paint ........................ 50 3.1 16 Flexible Metal Hoses ................. 50 3.1 17 Gas Storage Technology ................ 51 3.1 18 Regenerative C02 Removal System ........... 51 3.1 19 Fluid System Integrity ................ 51 3.1 20 Cabin Heat Exchanger Performance ........... 51 3.1.21 Optical Spaceship Windows .............. 52 3.1.22 Sensitive Expendables ................ 52 3.1.23 On-Board Calibration ................. 52 3.1.24 Off-The-Shelf Components ............... 52 3.1.25 Provisions for Handling ............... 52 3.1.26 Cross-Connection of GSE ............... 52 3.1.27 Jamming of Strip Recorders .............. 52 3.1.28 Conductive Adhesive ................. 52 3.1.29 Caution and Warning System .............. 53 3.1.30 Alarm Power Source .................. 53 3.1.31 Optical Grating Materials .............. 53 3.1.32 Contamination from Detonating Fuse .......... 53 3.1.33 Nickel-Cadmium Battery Short Circuits ........ 53 V TABLE OF CONTENTS (Continued) Paragraph Page 3.1.34 Electrical Brush Material .............. 54 3.1.35 Photo Tube ...................... 54 3.1.36 Film Storage ..................... 54 3.1.37 Draining Hollow Structural Members .......... 54 3.1.38 Thermal Uses for Portable Fans ............ 55 3.1.39 Reservicing Capability for Fluid Loops ........ 55 3.1.40 Tolerance for Particulate Contamination in Fluid Systems ................... 55 3.1.41 Moisture in Window Cavities ............. 55 3.1,42 Redundant Fluid Systems ............... 55 3.1.43 High Structural Safety Factors ............ 55 3.1.44 Valves Vs. Orifices ................. 55 3.1.45 Gas Purges ...................... 55 3.1.46 Ultrasonic Cleaning of Fluid Systems ......... 56 3.1.47 Component Thermal Data ................ 56 3.1.48 Corona From Multilayer Insulation Outgassing ..... 56 3.2 Manufacture ..................... 56 3.2.1 Urine Bag Fabrication ................ 56 3.2.2 Mercury Contamination ................ 56 3.2.3 Manufacture of Qualification Units .......... 56 3.2.4 Cables ........................ 57 3.2.5 Cleanliness ..................... 57 3.3 Test ......................... 57 3.3,1 Qualification Environments .............. 57 3.3.2 Water Tank Ground Handling .............. 57 3.3.3 Gas Leak Control ................... 58 3.3.4 Megger Test ..................... 58 3.3,5 Test Teams ...................... 58 3.3.6 Test Procedures ................... 58 3.3.7 Prototype Unit .................... 58 3.3.8 Problem Close-Out .................
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