NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond A periodically updated document demonstrating our progress toward safe return to flight and implementation of the Columbia Accident Investigation Board recommendations June 20, 2006 Volume 1, Twelfth Edition An electronic version of this implementation plan is available at www.nasa.gov NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond June 20, 2006 Twelfth Edition Change June 20, 2006 This 12th revision to NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond provides updates to three Columbia Accident Investigation Board Recommendations that were not fully closed by the Return to Flight Task Group, R3.2-1 External Tank (ET), R6.4-1 Thermal Protection System (TPS) On-Orbit Inspection and Repair, and R3.3-2 Orbiter Hardening and TPS Impact Tolerance. These updates reflect the latest status of work being done in preparation for the STS-121 mission. Following is a list of sections updated by this revision: Message from Dr. Michael Griffin Message from Mr. William Gerstenmaier Part 1 – NASA’s Response to the Columbia Accident Investigation Board’s Recommendations 3.2-1 External Tank Thermal Protection System Modifications (RTF) 3.3-2 Orbiter Hardening (RTF) 6.4-1 Thermal Protection System On-Orbit Inspect and Repair (RTF) Remove Pages Replace with Pages Cover (Feb 17, 2006) Cover (Jun. 20, 2006 ) Title page (Feb 17, 2006) Title page (Jun. 20, 2006) Message From Michael D. Griffin Message From Michael D. Griffin (Feb 17, 2006) (Jun 20, 2006) Return to Flight Update From the Return to Flight Update From the Associate Administrator for Space Associate Administrator for Space Operations (Feb 17, 2006) Operations (Jun 20, 2006) 1-1 (Feb 17, 2006) – 1-18 (Feb 17, 2006) 1-1 (Feb 17, 2006) – 1-18b (Jun 20, 2006) 1-19 (Feb 17, 2006) – 1-24 (Feb 17, 2006) 1-19 (Feb 17, 2006) – 1-24 (Feb 17, 2006) 1-29 (Feb 17, 2006) – 1-40 (Feb 17, 2006) 1-29 (Feb 17, 2006) – 1-40 (Jun 20, 2006) NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond June 20, 2006 NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond June 20, 2006 Message from Michael D. Griffin Twenty-five years after John Young and Bob Crippen so capably flew the Space Shuttle’s maiden voyage, the Shuttle vehicles remain an important asset for our nation’s space program. Because of the Shuttle, the Galileo probe found the first evidence of a liquid water ocean on the large Jovian moon Europa, we have the International Space Station as a permanent out- post in Earth orbit, and the Hubble Space Telescope has fundamentally altered our understanding of the universe. Looking forward, NASA’s Shuttle and Space Station teams are embarking on some of the most difficult and challenging missions ever attempted in space. Next up is STS-121, the thirty-second flight of the Space Shuttle Discovery. This mission will return the International Space Station to a crew complement of three and test concepts needed to prepare for the challenges ahead. This 12th revision of NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond updates what we learned from the STS-114 mission and illustrates how NASA is using this knowledge to plan for the remaining Shuttle flights. These flights will result in the completion of the International Space Station and, possibly, a servicing mission to the Hubble Space Tel- escope. We also will use this knowledge to plan for an orderly transition to America’s next generation of spacecraft, launch, and cargo vehicles as we extend our scientific, economic, and exploration reach through the Vision for Space Exploration. I thank the members of the Shuttle team for their diligence and devotion to this important national program. Michael D. Griffin NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond June 20, 2006 NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond June 20, 2006 Return to Flight Update from the Associate Administrator for Space Operations When the first edition of NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond was released nearly three years ago, its purpose was to provide a clear path for returning the Space Shuttle to flight and to ensure full transparency and accountability during that process. But through diligence, hard work, and a reinvigorated programmatic and safety review process, the Space Shuttle team made enormous progress towards the ultimate goal of improving the Space Shuttle system. The results of that effort were seen on STS-114. The systems and procedures developed during Return to Flight worked. Mission managers knew, to an un- precedented degree, exactly what the condition of Discovery was before the return home. The Space Shuttle and the International Space Station teams worked together flawlessly and were able to complete not only the Space Shuttle test objectives but all tasks planned for the International Space Station. Nevertheless, STS-114 was a test flight, and as such the teams learned that there were some areas that needed more attention. Two areas in particular, the protuberance air load (PAL) ramps and gap fillers, required additional engineer- ing work. The data collected during preparations for and the flight of STS-114 were vital in pinpointing previously unimagined foam loss mechanisms. Given these data, engineers made the necessary hardware modifications, including the re- moval of the PAL ramps. With these changes, the Space Shuttle is once again ready to be tested in flight. While we expect to see some foam loss again on STS-121, the data from this second test flight will add to our knowledge of loss mechanisms and will allow additional modifications to be made to the foam on subsequent flights. This will be a process of continual learning and constant improvement. At the same time, the Space Shuttle Program decided not to remove foam from the External Tank’s ice/frost ramps prior to STS-121. This was a difficult decision, but the options for ice/frost foam removal left as much uncertainty as flying with the existing design. Wind tunnels and analysis cannot fully predict performance of these ramps. The decision was made to fly the existing design and monitor performance with our new camera systems, giving us additional data and confidence in the changes we will make to future External Tanks. This 12th Edition of the Implementation Plan details NASA’s work in these and other areas over the past year. Despite enormous challenges, especially the devastation wrought by Hurricane Katrina on the External Tank team, everyone involved has shown tremendous dedication and resolve in keeping this critical program on track. Their efforts are an inspiration to us all and show the bound- less tenacity and drive of this team. The challenges of space flight truly bring out the best in us all. We are ready for the challenge of resuming recurring Space Shuttle flights, and for setting course aboard new ships for new destinations. William H. Gerstenmaier Associate Administrator for Space Operations NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond June 20, 2006 NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond June 20, 2006 Contents Introduction ...................................................................... xiii Return to Flight Cost Summary....................................... xvii Part 1 – NASA’s Response to the Columbia Accident Investigation Board’s Recommendations 3.2-1 External Tank Thermal Protection System Modifications [RTF] .............................................. 1-1 3.3-2 Orbiter Hardening and Thermal Protection System Impact Tolerance [RTF]............................ 1-19 3.3-1 Reinforced Carbon-Carbon Nondestructive Inspection [RTF]................................................... 1-25 6.4-1 Thermal Protection System On-Orbit Inspect and Repair [RTF] ..................................... 1-29 3.3-3 Entry with Minor Damage ..................................... 1-41 3.3-4 Reinforced Carbon-Carbon Database.................. 1-43 3.3-5 Minimizing Zinc Primer Leaching.......................... 1-45 3.8-1 Reinforced Carbon-Carbon Spares...................... 1-47 3.8-2 Thermal Protection System Impact Damage Computer Modeling.............................................. 1-49 3.4-1 Ground-Based Imagery [RTF] .............................. 1-51 3.4-2 External Tank Separation Imagery [RTF] ............. 1-57 3.4-3 On-Vehicle Ascent Imagery [RTF]........................ 1-59 6.3-2 National Imagery and Mapping Agency Memorandum of Agreement [RTF]....................... 1-63 3.6-1 Update Modular Auxiliary Data Systems .............. 1-65 3.6-2 Modular Auxiliary Data System Redesign ............ 1-67 4.2-2 Enhance Wiring Inspection Capability.................. 1-69 4.2-1 Solid Rocket Booster Bolt Catcher [RTF] ............. 1-73 4.2-3 Closeout Inspection [RTF].................................... 1-77 4.2-4 Micrometeoroid and Orbital Debris Risk............... 1-79 ix NASA’s Implementation Plan for Space Shuttle Return to Flight and Beyond February 17, 2006 Contents 4.2-5 Foreign Object Debris Processes [RTF] ..................... 1-83 6.2-1 Scheduling [RTF]........................................................ 1-85 6.3-1 Mission Management Team Improvements [RTF]................................................... 1-91 9.1-1 Detailed Plan for Organizational Changes [RTF]........................................................... 1-95 7.5-1 Independent