1971 (8th) Vol. 1 Technology Today And The Space Congress® Proceedings Tomorrow

Apr 1st, 8:00 AM

Skylab Facilities and Operations

Robert B. Krause Chief, Skylab Ground Systems Branch, Apollo- Skylab Programs Office, John. F Kennedy Space Center, NASA

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Scholarly Commons Citation Krause, Robert B., "Skylab Facilities and Operations" (1971). The Space Congress® Proceedings. 1. https://commons.erau.edu/space-congress-proceedings/proceedings-1971-8th/session-11/1

This Event is brought to you for free and open access by the Conferences at Scholarly Commons. It has been accepted for inclusion in The Space Congress® Proceedings by an authorized administrator of Scholarly Commons. For more information, please contact [email protected]. SKYLAB FACILITIES AND OPERATIONS

Robert B. Krause Chief, Skylab Ground Systems Branch Apollo- Skylab Programs Office John F, Kennedy Space Center, NASA Kennedy Space Center, Florida

ABSTRACT

The purpose of this paper is to outline the essen­ demonstrated by previous manned missions and tial objectives and elements of the Skylab Pro­ we expect to capitalize on this prior experience gram and to describe the impact of the Program during the Skylab Program. Infra-red photo­ on the Kennedy Space Center. The operational graphs taken by the Apollo 9 astronauts were test flows and the required facility modifications used by scientists at the U. S. Geological Center to support Skylab checkout and launch require­ at Menlo Park, California, to observe the St. ments will be highlighted. Andreas Fault. These observations indicated a pressure buildup which forecast the imminence of a major earthquake in this area. This earth­ INTRODUCTION quake activity occured during the Apollo 14 mission in the California Imperial Valley. The Skylab Program, using basic hardware de­ veloped to support the Apollo manned lunar Further, Skylab represents an effective and landing, supplemented by several new flight economical approach to the development of a hardware modules, represents the next major basis for potential future space programs. These step in the orderly progression of manned space include a long duration earth orbital space station, flight. The Program has a number of basic ob­ with the capability of operation of up to two years jectives. or longer, and manned planetary exploration. The information we gather in Skylab will serve First is the conduct of long duration space flights as a firm base upon which the future space sys­ of man and systems. These flights will demon­ tems can be developed. strate the unique capabilities of man to both function in a space environment for extended The Kennedy Space Center is cast in its tradi­ periods of up to 56 days and to contribute mater­ tional role - being charged with the responsibility ially to mission success. Further, it will allow to conduct prelaunch checkout and launch opera­ us to establish a habitable space workshop and tions for the Skylab missions. Accomplishment verify our ability to conduct experiments within of this task also requires modification of KSC that structure. We plan to conduct a number of checkout and launch facilities previously utilized biomedical and behavioral experiments to deter­ to support Apollo manned launches. The design, mine the effects of long duration space flight on development and incorporation of the required the crew so that a logical basis can be established modifications to meet the peculiar Skylab Pro­ for increasing crew orbital stay time. gram requirements is also a KSC responsibility. Secondly, we will conduct scientific investigations The remainder of this paper will briefly outline in earth orbit using the Apollo Telescope Mount the essential elements of the unique Skylab flight to observe the sun. Such observations can be hardware and will highlight the KSC operational much more accurately obtained outside the re­ test flows, describing the processing of each strictive atmosphere of the earth, module through the checkout areas of the Opera­ tions and Checkout Building and Launch Complex Thirdly, a number of specific applications in 39. Particular emphasis will be placed on the earth orbit will be explored. Meteorlogical and * major modifications required which include the earth resources experiments will be conducted ATM clean room, the pedestal on the Launch and communications methods and equipment will Umbilical Tower to enable the Saturn IB/CSM be exercised and evaluated. The value of earth vehicle to be launched from LC-39, and new ac­ observation from space has already been partially cess and service arms to meet peculiar program

11-41 requirements. Of particular note is the fact that intervals from the SL-2 launch. These missions the inherent capabilities of Launch Complex 39 are open ended and planned to last 56 days. These to absorb new program requirements are being missions will reactive the workshop and reper- fully exploited at minimum cost in support of form medical, technical, scientific, earth re­ Skylab Program needs. This theme will be sources, and solar astronomy experiments. A stressed throughout this paper. mission profile of the entire sequence of Skylab missions is shown in Figure 1.

SKYLAB MISSION PROFILE SKYLAB UNIQUE MISSION HARDWARE The Skylab Program consists of four launches, one unmanned and three manned, to conduct three To accomplish the Skylab Program objectives, a interrelated missions. The first mission, SL-1/ number of new hardware flight modules have been SL-2 will consist of two launches approximately developed. The essential elements of each are one day apart. The SL-1 vehicle configuration briefly described below. consists of a two stage Saturn V launch vehicle - the S-IC and S-II stages - and the Saturn Work­ shop (SWS) comprised of a modified S-IVB ORBITAL WORKSHOP (OWS) Orbital Workshop (OWS), Airlock Module (AM), Multiple Docking Adapter (MDA), Apollo Tele­ The OWS is a modified S-IVB stage that is ground scope Mount (ATM), and Instrument Unit (IU). outfitted to provide a habitable environment for After launch from LC-39 Pad A, the workshop extended crew operations. The LH2 tank is will be placed in a nominal 235 nautical mile al­ divided into two floors by open aluminum grid titude by the two launch vehicle, the ATM structures compartmented to provide space for deployed to its orbital configuration and the or- crew habitation and operational activities. See assembly stabilized in the proper attitude. Figure 2. The crew quarters are divided into four areas, as shown in Figure 3: sleep com­ The of the assembly will be verified by partment, waste management compartment, ground command telemetry data prior to the wardroom, and experiment compartment. A launch of the CSM mission, SL-2, from side hatch into the wardroom is provided for ac­ LC-39 Pad B, The launch vehicle is a standard cess into the OWS during ground checkout. Saturn IB, consisting of the S-IB and S-IVB stage and Instrument Unit, similar to that used Astronaut mobility/stability aids are required to on Apollo 7 to place the first manned Apollo assist the astronauts in performing tasks as­ spacecraft in earth orbit. The SL-2 vehicle sociated with activation, crew habitation, ex­ be launched approximately one day after the perimentation, and deactivation. These aids are SL-1 launch. The CSM will rendezvous and of two basic types: fixed and portable. Fixed the orbital assembly. Following astronaut aids include handrails, tether attach the crew will transfer into the OWS, devices, and the central handrail. They are per­ the OWS life support systems and place manently installed in locations throughout the the in a quiescent, minimum energy de- LH2 tank where it is expected that heavy traffic for the duration of this initial or task loading will occur. Portable astronaut operations period. aids include handholds, tether attach brackets and foot restraints. SL-1/SL-2 will be primarily directed toward the accomplishment of a series A meteoroid shield is designed as a structurally- of medical related to the extension integrated part of the OWS and protects the cylin­ of manned space!light. Secondary emphasis drical portion of the tank. After deployment, will be on. solar astronomy, earth resources, the shield does not extend more than 6 inches and technical experiments. This mission is radially from the outer surface of the LH2 tank. open but is to last 28 days begin- Deployment is accomplished during orbit by a with the launch of the SL-2 CSM. At the signal from the IU. of period, the will be pre­ pared for an during which it A Solar Array System (SAS) is provided as a will be in a semiactive condition. The crew source of power during orbital operations. will transfer to the CSM, from the or­ Routing of this power is accomplished via the bital assembly, deorbit return to earth. Airlock Module power distribution system. The SL-3 and SL-4 will perform at and six

11-42 AIRLOCK MODULE (AM) provides for the following:

The AM provides the major work area and sup­ a. Installation and removal of experiment film port equipment required to activate and operate cassettes during orbital operations (by of the OWS. The AM includes a fixed airlock shroud EVA); (FAS) and an ATM Deployment Assembly. In­ tegration of the AM structure within the cluster b. Remote-controlled protective covers for the provides for: a pressurized interconnecting experiments and for the pointing optics at the passageway between the MDA and the OWS; sup­ sun end of the experiment canister. These port for intervehicular activity (IVA) and extra­ covers can be controlled from the ATM control vehicular activity (EVA) via the AM airlock; and display panel located in the MDA; structural support for the MDA; the supply, dis­ tribution and control of the cluster atmosphere, c. Contamination protection and thermal con­ and thermal control of the SWS (excluding the trol for solar experiments and internally- ATM) before OWS SAS deployment and during mounted hardware; dark-side operations. d. Gimballed fine pointing and offset pointing The general arrangement of the AM and its com­ for solar experimentation. This experiment ponent systems are shown in Figure 4. package gimbal is locked in place during launch to provide a separate load path that prevents it from being damaged. MULTIPLE DOCKING ADAPTER (MDA) Control and display of the various ATM systems The MDA is that part of the SWS which provides is furnished at the ATM control and display con­ a permanent interface with the AM and a docking sole located in the MDA. interface with the CSM. The MDA permits the transfer of personnel, equipment, power, and electrical signals between the docked module, the COMMAND AND SERVICE MODULE (CSM) AM and the OWS. For Skylab missions, modifications to the Apollo Integration of the MDA structure within the clus­ Block n modules are required because of the dif­ ter provides for: a pressurized passageway be­ ferent operational and support requirements for tween the AM and the docked CSM; two docking Skylab which result from longer mission dura­ interfaces (one axial; and one radial) for the CSM. tion, new orbital rendezvous requirements, The radial port has a physical docking capability cluster support requirements, mission attitude only. Complete interfacing equipment and um- constraints, and increased return payload. The bilicals at the axial port are provided to allow Skylab CSM will operate essentially as does a integration of the docked CSM with the SWS; in­ Block II spacecraft during ascent, rendezvous ternal storage of hardware and experiments and docking to the cluster. When docked, much launched and operated in the hardware and ex­ of the equipment in the modules will be shut off periments launched and operated in the MDA; to conserve power. support for the conduct of experiments and crew operations; use of the ATM control and display console to control and monitor the attitude con­ PRELAUNCH CHECKOUT OPERATIONS AND trol system and the ATM. The general con­ RELATED FACILITY MODIFICATIONS figuration of the MDA is shown in Figure 5. A summary hardware checkout flow of the ac­ tivity within the Operations and Checkout (O&C) APOLLO TELESCOPE MOUNT (ATM) Building and Launch Complex 39 is shown in Figure 7. This section will describe the major The ATM consists of various solar-observatory elements of the flow and the attendant facility experiments and supporting equipment for ob­ modifications required to accommodate checkout serving, monitoring, and recording solar pheno­ operations. mena. Experimental data will be taken in the white-light, ultra-violet and x-ray regions of the spectrum. Observations will be conducted both O&C BUILDING within and near the solar disc. Figure 6 shows the ATM general arrangement. The AM/MDA, the and the simultaneous checkout in the and The cylindrical ATM experiment canister Checkout in the

11-43 Industrial Area. e. Floor stability: less than 5 arc seconds in 24 hours. A layout of the O&C Building is shown in Figure 8. Early in this flow, a docking test between the The Clean Room will be constructed within the CSM and AM/MDA will be performed to verify O&C Building adjacent to the Apollo LM Ascent the docking interfaces. The CSM is placed in the and Decent Stage checkout stands. Because of West Integrated Test Stand. The AM/MDA is on-go ing Apollo LM operations for Apollo 17, removed from its mobile transporter and lowered, construction of the Clean Room will require extra­ MDA down, to mate with the CSM. The CSM has ordinary care and coordination between opera­ a probe identical to that used in Apollo and the tional, design, and fabrication elements to pre­ MDA docking port has a drogue similar to that clude interference with LM checkout operations. used in the Apollo LM for docking. A leak check The design of the Clean Room was planned to re­ is performed to verify the mechanical docking quire only a minimum amount of welding and interface. Electrical/communications tests are other contamination producing activities within accomplished to validate all electrical connect­ the O&C Building that might contaminate the sur­ ions. These tests are the only interface tests rounding areas and disrupt operations. involving the flight CSM and the AM/MDA prior to launch. The next time these modules inter­ A complete systems test of the ATM and its ex­ face is following rendezvous manuevers in earth periments will be conducted and the experiment orbit as earlier described. optics aligned and verified. Following installa­ tion of inflight film and the solar panels, the After the docking test is complete, the CSM will ATM will be prepared for its move to the VAB. be moved to the East Altitude Chamber where it will undergo a series of premate tests including manned altitude tests similar to those performed LC-39/SL-1 on the Apollo mission CSMs. No modifications are anticipated to the Altitude Chamber for Sky- In parallel with the activity in the O&C Building, lab. The West Integrated Test Stand will then be the S-IC and S-II launch vehicle stages, and the reconfigured to accept the AM/MDA (see Figure Orbital Workshop (OWS) will be undergoing check­ 9). Basic structural modifications will have been out in the Vehicle Assembly Building (VAB) at incorporated prior to the docking test. Minor Launch Complex 39. The launch vehicle stage modifications to the work platforms will be made checkout is virtually identical to that for the to accommodate the AM/MDA vehicle profile. Apollo Saturn V stages and no facility changes are The Fixed Airlock Shroud (FAS) will be installed required in these areas. The three upper exten­ in the test stand, the AM/MDA mated and aligned sible platforms in the VAB High Bay (Platforms with it and a leak check performed to verify the A, B and C) will require modifications because interfaces. This will be followed by installation the vehicle profile and protuberances on the SL-1 of the ATM deployment assembly, verification of vehicle payload are different than the Apollo Sat­ its operation and systems tests of the installed urn V configuration. The SL-1 space vehicle experiments. has a 22 foot diameter from the OWS to the nose cone covering the ATM. The Apollo vehicle has The third of the Skylab unique models, the ATM, a conical section between the Instrument Unit and will be undergoing its prelaunch tests in a the CSM which reduces the diameter of the upper specially designed clean room as seen in an portion of the vehicle to 13 feet. artist's concept in Figure 10. This facility is the only major modification required in the O&C In order to maintain a clean environment around Building. The environment around the ATM must the ATM following mate with the other modules be rigidly controlled in order to avoid contamin­ in the VAB, a clean room will be required on ation of the lenses and other critical components Platform A of the High Bay. This will allow for of the ATM experiments. The clean room has access to the optics during integrated checkout the following essential characteristics. operations. a. Cleanliness: class 10,000 as defined by In addition to the above changes in the VAB, a Federal Standard 209A. number of modifications to the Launch Umbilical Tower (LUT) will also be required. While the b. Temperature: 75° + 3° F space vehicle is on the pad, a membrane, in­ stalled between the AM/MDA and the ATM, will c. Moisture content: 54 grains/pound of dry air keep the clean environment around the ATM. In addition, there will be a number of work plat­ d. Size: approximately 36 f x 37 f x 38 f forms within the payload enclosure surrounding

11-44 the AM/MDA and ATM to provide access during vehicle to the Complex provided a much more checkout operations and for film loading prior to economical approach to the problem than would closeout of the payload prior to launch. These have resulted if all S-IVB stage, IU and CSM platforms and the membrane described earlier interfaces had been relocated lower on the tower will be removed prior to launch through the ATM and the S-IB stage erected on the existing laun­ Access Arm (Service Arm #8) modified from the cher deck. Apollo configuration. For Apollo, this Service Arm provided servicing to the Service Module. Some of the essential characteristics of the ped­ The basic Arm is being utilized for Skylab with estal include: changes to the extension and retract systems, addition of new payload services across the arm, a. A four-legged round section steel structure and modifications to the accessway from the tower. b. K-truss welded construction The Apollo missions required a white room for c. Floating connections between the tower astronaut and spacecraft checkout crew access to section and the pedestal (The pedestal will be the CSM. This was accomplished via Saturn V stiffer than the LUT Tower. The floating con­ Service Arm #9 (Apollo Access Arm) with an nection feature eliminates the transfer of environmental chamber attached to the end. stresses between the two structures.) Since the SL-1 vehicle has no requirement for this service at that location, the arm will be re­ d. A horizontal spring constant of 450 kips/ moved and relocated with a new environmental inch chamber to provide access to the OWS at the launch pad via the side hatch. The present arm e. A launcher ring - 28 f diameter inside - 44 T is made of two basic truss sections. A spacer diameter outside will be added between these sections to compen­ sate for the difference in location between the f. A combined SL-2 vehicle, LUT, and pedestal OWS hatch and the CSM hatch. weighs 13, 130 kips compared to 12, 740 kips for the Apollo Saturn Vehicle (Apollo 13) with its Service Arm #7, formerly used to provide ser­ LUT. vices to the Lunar Module and the Saturn V S-IVB third stage, will provide services instead to the Holddown arms, service masts and other select­ AM/MDA and ATM and OWS. A new umbilical ed items of ground support equipment which plate will provide the interface into these mod­ were used to launch Saturn IBs from LC-34 and ules. The arm and umbilical will be requalified LC-37 will be removed from those complexes for operational use via testing at the Marshall and installed on the pedestal. Existing Apollo Space Flight Center. These tests will include Saturn V Service Arms 1, 3, 4 and 5 (S-IC and umbilical withdrawal, liftoff simulation, and S-II stage servicing) will not be required for the vehicle motion simulation. Saturn IBs and will be removed and stored. Service Arm #2 will be modified from its Since there are only two propulsive stages in the present S-IC configuration to provide for S-IB SL-1 launch vehicle, minor modifications will stage servicing. This arm will not require any be required at the launch pad and in the firing modification but the umbilical plate will be room to remove S-IVB stage propellant control changed to the S-IB configuration and the arm and sensing circuits. Control and monitoring relocated to the old Service Arm #5 location on consoles for the OWS will replace S-IVB con­ the tower. soles in the firing room. Again, the launch pad and firing rooms will re­ quire changes 'in the propellant servicing, con­ LC-39/SL-2 trol and monitoring areas to be compatible with a two stage launch vehicle. Operations will be The most significant single modification required similar to a normal Apollo CSM checkout ex­ to support the Skylab missions at LC-39 is the cept that a launch vehicle tanking test will be construction of a 127 foot high pedestal on the run early in the test flow. This test is designed Launch Umbilical Tower to adapt the shorter to validate the new propellant loading system. Saturn IB vehicle to the tower* This pedestal Minor modifications to the Mobile Service allows the Saturn IB second stage, instrument Structure will also be needed to provide access unit, and spacecraft to interface with the LUT at to the smaller diameter S-IB stage on the the same vehicle stations as an Apollo Saturn V. manned launches* This method of adapting the smaller Saturn IB

11-45 CONCLUSIONS REFERENCES In. summary, the es.senti.al elements of the facil­ (1) Skylab Program Sbunmfltary, June, 1970, ities designed and. developed to support the Apollo National. Aeronautics and Space Administration, lunar missions are being employed with only Office of Manned Space Flight, minor modifications required to support the Sky- lab- Program.. This inherent flexibility will (2) Skylab Operations Handbook, ATM - Volume I make it possible to adapt Launch Complex 39 to Systems and Experiments Description, Novem­ future program, requirements such as. the Space ber 16, 1970, National Aeronautics and Space Shuttle and Space Station. Operational modes for Administration, Maimed Spacecraft Center, Skylab again, are based, on precedence and. exper­ Houston, Texas. ience gained during the processing of Apolto CSMs and LMs through their phases of checkout. (3) Orbital Workshop Design Data Document, Thus the resources of the Kennedy Space Center August 1, 1970, Mcbonnell Douglas Astronautics ha¥e 'been, effectively focused on the accomplish­ Corporation. ment of Skylab with minimum, changes and. max­ imum effectiveness. We all look forward to the successful, completion of these missions as a ILLUSTRATIONS • prelude: to more' sophisticated and ambitious In. the years to come.. Figure 1. Skylab Mission. Profile Figure 2. Orbital Workshop Crew Quarters Figure 3. Orbital Workshop Crew Quarters Con­ figuration Figure 4. Airlock Module General. Arrangement - Airlock. Module Figure 5, MDA General Arragement ATM - Apollo Telescope Mount Figure 6.. ATM General Arrangement CSM - Command and Service Module • Figure 7. SL-l/SL-2 Hardware Checkout Flow EVA. - Extravehicular activity Figure 8. Assembly 6 Test Area, O&C Building - Fixed Airlock Figure 9, West Integrated Test Stand IB - Instrument Unit Figure 10. Artist Concept of Clean Room I\TA - Intravehicular activity KSC - Kennedy Space Center LC-39 - Launch Complex 39 LHg - Liquid Hydrogen LM - Lunar Module LUT - Launch Umbilical Tower - Multiple Stocking Adapter Building - Operations Checkout Building - Orbital Workshop S-IB - First, si age of Saturn. IB launch vehicle S-IVB - Second. of Saturn IB- launch vehicle S-1C - First of Saturn ¥ launch S-n - of Saturn. V launch vehicle - Solar 1 " Array System: SL-1 - launch SL-2 - SL-3 - Third launch SL-4 - -

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11-46 MISSION SL-1 MISSION SL-1 MISSION SL-1 SL-1 /SL-2 STORAGE SL-3 STORAGE SL-4 STORAGE (APPROX (APPROX. (UN- 80 DAYS) 30 DAYS) "DEFINED)

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11-48 WARDROOM POSITION EMERGENCY III EGRESS

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11-49

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11-52 Flow

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