The Space Congress® Proceedings 1966 (3rd) The Challenge of Space

Mar 7th, 8:00 AM

Apollo Spacecraft Integrated Checkout Planning

H. C. Goff Manned Spacecraft Center Support Operation, Apollo Support Department, General Electric Company

J. M. Schabacker Manned Spacecraft Center Support Operation, Apollo Support Department, General Electric Company

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Scholarly Commons Citation Goff, H. C. and Schabacker, J. M., "Apollo Spacecraft Integrated Checkout Planning" (1966). The Space Congress® Proceedings. 2. https://commons.erau.edu/space-congress-proceedings/proceedings-1966-3rd/session-5/2

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]. APOLLO SPACECRAFT INTEGRATED CHECKOUT PLANNING By H. C. Goff and J. M. Schabacker Manned Spacecraft Center Support Operation Apollo Support Department General Electric Company Houston, Texas

Summary Need for Integrated Checkout Planning

The Apollo pa^loads, Command Module, Service Many Organizations Participate in the Checkout Module, and Lunar Excursion Module require long range integrated checkout planning to assure mutual The need for integrated checkout planning checkout compatibility and launch vehicle/spacecraft within the Apollo spacecraft program stems from checkout compatibility. This function, performed the multiplicity of payload modules, participating in support of NASA's Checkout and Test Division prime contractors, and the NASA centers involved. of the Manned Spacecraft Center, provides integrated The total spacecraft consists of five structures checkout planning on an inter-center and inter- produced by two prime-contractors, as summarized contractor level. The end product results in NASA below: approved checkout flows and activities, in con­ junction with their related ground support equip­ North American Aviation (NAA) Spacecraft Modules. ment, which delineate optimized prelaunch checkout operations and requirements. This presentation o Command Module (CM) describes some of the aspects of the integrated checkout planning activity and gives examples of o Service Module (SM) benefits derived from this task. . o S-IVB/LEM Adapter (SLA) Definition of Integrated Checkout Grumman Aircraft Engineering Corporation (GAEC) Spacecraft checkout as the word applies in Spacecraft Modules. the Apollo Program can be simply defined as the testing carried out on a space vehicle to assure o Lunar Excursion Module Ascent Stage that the equipment is built correctly and operates (LEM-A/S) properly to meet the requirements of its planned space mission. Although some checkout is neces­ o Lunar Excursion Module Descent Stage sarily performed by the astronauts during the (LEM-D/S) spacecraft flight mission to assure certain operations or experiments are ready for perform­ Figure 1 illustrates how the five above modules ance, the checkout discussed in this paper is the comprise the total spacecraft payload. preflight testing performed on the spacecraft by engineers and technicians prior to the spacecraft's The NASA Centers. Two NASA Centers, Manned launch. Spacecraft Center (MSC) Houston, Texas, and John F. Kennedy Space Center (KSC) Florida are involved The prelaunch checkout starts when the space­ in the spacecraft preflight planning required for craft manufacture is completed at the contractor's the checkout. While both MSC and KSC jointly plan factory and is not completed until the end of the and coordinate the spacecraft checkout flow sequences. launch vehicle countdown and the space vehicle's KSC concentrates its efforts on the checkout taking liftoff from the launch pad. This prelaunch place at its own location - the field checkout and checkout, which involves both contractor & NASA launch site. personnel has the objective of assuring the National Aeronautics and Space Administration The Checkout Locations. The three major check­ (NASA) that the space vehicle is ready for launch out locations include the North American Aviation and that it will meet mission and crew safety factory at Downey, California, the Grumman Aircraft requirements. Engineering Corporation factory at Bethpage, New York, and the field checkout launch site at Kennedy Integrated checkout refers to that testing Space Center, Florida. performed on many systems of a spacecraft taken together or that testing of 1 more than one module Coordination Required for Efficient Operations joined at one time. For example the integrated checkout of the total Command Module/Service Integrated checkout planning is necessary to Module (when the Command Module is mated to the assure a fully checked out, completely assembled Service Module) is important because the two space vehicle which is ready for launch. This modules must not only fit mechanically but requires not only integrated systems checkout at operate together electrically. the KSC field site, but coordinated and efficiently scheduled checkout plans at the NAA and GAEC factories, Figure 2 shows the location of organizations associated with the checkout.

284 Utilization of Related Experience. A major MSC's Checkout and Test Division within the objective of integrated checkout planning is the Apollo Spacecraft Program Office (ASPO), with the achievement of reductions in time consumed for technical support of General Electric ! s Apollo checkout activities without compromising confidence, Support Department, provides coordination and reliability or flight readiness. This can be integration of these checkout requirements of achieved, in part, by applying techniques developed the spacecraft modules, prime contractors, three in one area to problems encountered in other major checkout locations, and the two NASA Centers activities. An example of the benefits derived involved. from this approach can be seen when we contrast two checkout techniques. The first utilized Functional Categories of Checkout Planning individual LEM A/S and D/S module workstands (Figure 3) for performing factory checkout activities, with The required integrated checkout planning the resultant numerous moves, cable and de-cable can be divided into four functional categories: operation, and validation of GSE reconnections, With this concept, the factory flow seemed unneces­ 1. Correlation of contractors* checkout sarily complex. Studies conducted jointly by plans with the NASA checkout criteria. MSC/GAEC showed that improvement in checkout flow efficiency could be achieved by utilizing integrated 2. Correlation of the CSM factory checkout workstands. These workstands which concentrate plans versus the LEM factory checkout the LEM spacecraft testing at one location plans. result in a reduction in the number of spacecraft factory moves, cable and de-cable operations, and 3- Integration and correlation of individual GSE validations. Figure h depicts the simplified checkout activities of CSM and LEM at factory checkout flow resulting from this integrated the field site. checkout method. h. Planning for combined CSM/LEM checkout Joint Usage of Facilities and GSE. Contractor operations at the field site. joint usage of checkout facilities and sharing of common use ground support equipment (GSE) also Progression of Checkout requires an integrated approach to the planned activities. In a program of the magnitude of The four functional categories generally Apollo there are literally hundreds of models of follow the checkout flow progression of the GSE required. To achieve GSE economies, many spacecraft leading up to launch. First, the models have been designated as common usage. This contractors 1 overall concepts for the total checkout includes both shared GSE and that which is built operation must be formulated and approved. As by one contractor and provided to both. The com­ will be discussed later, the contractors utilize monality of CSM and LEM propellants makes this direction given them from various NASA documents approach particularly attractive for GSE used to as a basis for their checkout planning. Detailed service the spacecraft. Also, the extensive checkout plans can then be formulated for the usage of ACE (Acceptance Checkout Equipment) factory phase of checkout and for the field check­ facilitates this common use GSE approach. The out at the launch site. checkout plans for CSM and LEM are thus effected by the usage of identical GSE, in many cases, and For the factory phase of checkout the contractor futher substantiate the need for the integrated coordinates with its subcontractors and the MSC-ASPO checkout planning being performed. Checkout and Test Division. Kennedy Space Center personnel enter the checkout planning for the field Implementation of Integrated Checkout Planning site. It is apparent that all organizations must work together on the overall approach to the The Apollo Spacecraft Program Office at MSC spacecraft checkout flow because the checkout is the NASA customer for the CSM and LEM contractors. carried out at one location effects the extent of As such, this office, supported by its own and checkout required at the other. Hence, if it is other NASA divisions provides technical direction decided to do additional spacecraft checkout at the and performs the role of integrating and coordinating factory location, for instance, then the depth activities of many agencies to achieve Its respons­ of checkout at the KSC field location can be reduced. ibilities to NASA Headquarters of meeting spacecraft delivery and checkout schedules. This office must As was mentioned earlier, the spacecraft check­ set the basic checkout philosophy and provide out is initiated at the factory immediately after consistent technical direction to the contractors. the module is turned over to the test team from the Decisions involving shared facilities, ground manufacturing personnel. The Command Module and support equipment, delivery schedules, site Service Module are built and checked out at the activation dates, and many other complex activities North American Aviation, Downey, California, factory* requires integrated planning approaches to permit optimum technical decisions.

285 The S-IVB/LEM Adapter is built and checked out at Pressure Cell Testing. Propulsion system the North American Aviation, Tulsa, Oklahoma factory. and ECS pressure testing is performed on each The Lunar Excursion Module is built and checked out module "before certain of the electrical systems at the Grumman Aircraft Engineering Corporation, and black boxes are installed to facilitate Bethpage, New York factory. accessibility to the fluids piping systems. This high pressure testing is done in a protective The field site checkout follows a progression pressure cell for safety purposes. Pressure tests of spacecraft buildup, starting with the individual are performed to validate proof pressure capability, checkout of each module (CM, SM, LEM A/S, and LEM proper operation and regulation at normal D/S), followed by mated checkout of the CSM and LEM operating pressures, and acceptable leakage rates. and finally into the combined checkout of the mated Typical pressures used are 5500 psia for the proof CSM/LEM and launch vehicle. Figure 5 summarizes pressure tests, ^-000 psia operating pressure, this progression of checkout. and 185 psia downstream of the regulators. Leakage rates can be determined by use of a First Apollo with Full Payload halogen leak detector or by a bubble count versus time measurement. Nitrogen with freon added is The first few Apollo missions include only the commonly employed, although many tests are per- . flight of the CSM payload. However, the first Apollo formed with helium. with a full payload will contain the LEM as well as the CSM. For this mission the CM and SM will be QWT. The Quality Verification Vibration Test first checked out individually, mated and then given (QWT) is accomplished after all electrical systems an integrated spacecraft checkout at the NAA factory. are installed but prior to the integrated systems The LEM Ascent Stage and Descent Stage will be checked testing. This low level vibration test is performed out in like manner at the GAEC factory. After this to discover any loose electrical connections so checkout, the modules will be shipped to the KSC that they may be corrected prior to spacecraft field site for the final checkout and launch. shipment. For the QWT, the Command Module and Service Module are individually vibrated by electromechanical thrusters at a level well below Factory Operations the flight vibration level. The two modules are electrically mated and operating during this test, The checkout operations at the factory are although they are mechanically unmated, being intermixed with certain black box installation mounted on adjacent workstands. Figure 6 into the spaceraft. In applying the building depicts this test set up, showing the arrangement block approach to checkout, the systems of of the modules and the thrusters which provide components are individually tested after their the driving force. installation into the spacecraft, the systems are tested along with other interfacing systems and Weight & CG Determination. The Service finally all systems are tested together in the Module weight and center of gravity (CG) is spacecraft's integrated systems checkout. For determined after the integrated systems test and example, the CSM Stabilization and Control System prior to the service module's preparation for (SCS) would go through the following progression shipment to KSC. This test need not be repeated of test: at KSC. The Command Module, however, is given its one and only center of gravity determination 1. SCS installed system test (test of at KSC. This is a necessary part of the CM/Launch system after installation in spacecraft). Escape System (LES) alignment procedure which can be done only at KSC for safety reasons. The 2. Combined SCS/Guidance and Navigation solid propellant launch escape system motors are (G&N) System/Reaction Control System (RCS)/Service shipped directly from the vendor to the KSC Propulsion System (SPS) testing. field site because of their high TNT explosive equivalent. 3. Integrated System Test using all systems. Summarized Factory Flow. While the Command/ In addition to the buildup of the electrical Service Module factory checkout is specifically systems such as those above, three major mechanical covered in the explanation above, the LEM is tests phases are a part of the spacecraft factory given essentially the same type of factory test checkout sequence. These are Propulsion System sequence at GAEC's Bethpage location. The general and Environmental Control System (ECS) pressure factory checkout sequence may be summarized by the testing, Quality Verification Vibration Test (QWT) following flow sequence: and spacecraft module weight and center of gravity (CG) determination. 1. Individual spacecraft module proof, leak and functional pressure tests.

286 2. Final systems installation, installed 7- LEM Descent Stage - Main propulsion systems individual checkout and combined systems system functional checkout. testing. Integrated Checkout at Industrial Area. After 3. Quality Verification Vibration Test the individaul tests are accomplished the Command/ (QWT). For this test the LEM Descent Stage and Service modules are mated and the LEM Ascent/ Ascent Stage are both mechanically and electrically Descent stages are mated for their separate mated while the CM and SM are electrically mated integrated systems testing in the KSC Industrial only. This is possible, in part, because of the Area. Each contractor, NAA and GAEC, have separate LEM's lighter weight. facilities in the KSC Manned Spacecraft Operations Building for these specific integrated tests so k. Spacecraft integrated systems checkout operations may continue in parallel. The following and mission profiles with modules mechanically two tests are the primary checkout activities of and electrically mated. both the CSM and the LEM in this series:

5. Final mechanical system fit checks, weight 1. The Spacecraft Combined Systems Test is and CG determination, and spacecraft preparation performed to verify the spacecraft's systems for delivery to KSC. end-to-end compatibility during a flight simulation and to verify normal spacecraft KSC Field Site Operations systems operation during testing of the various abort modes. When the individual modules comprising the CSM and LEM arrive at KSC, the progressive buildup 2. The Spacecraft Altitude Chamber Test is previously mentioned takes place until the CSM/LEM performed to verify normal spacecraft systems are mated. Then, after a compatibility check operation in a near flight environment and during the CSM/LEM spacecraft is transported to the launch the simulation of a descent profile. complex for mating with the launch vehicle. The spacecraft and launch vehicle combined comprise The spacecraft modules are then ready for the space vehicle (S/V). mating in preparation for transportation to the launch complex. The LEM is mated to the SLA Initial Checkout at Industrial Area. The first which is followed by the mating of the CSM to main activity at KSC after each module's receiving the SLA.- After a CSM/LEM interface check the inspection are those unmated tests pertinent to combined payload is transported by flat-bed each module's particular on-board systems. The trailer to the launch complex for combination following testing is carried on in parallel: with the launch vehicle.

1. Command Module - Reaction control system Integrated Checkout at Launch Complex. After (RCS) functional checkout. the mechanical mating of the spacecraft (CSM/LEM ) to the launch vehicle a final series of integrated 2. Service Module - Service propulsion system tests are performed to insure that the total (SPS) functional checkout (at Launch Complex 16) space vehicle is ready for launch. The following and fuel cell functional checkout (at Cryogenic seven tests are the primary spacecraft oriented Facility). checkout activities carried out at the launch complex: 3. Service Module Reaction Control System Quadrangles (RCS Quads) - SM reaction control 1. The Integrated Test with Launch Vehicle system functional checkout (The SM RCS Quads may Simulator is performed to verify the functional be removed from the Service Module. This feature compatibility of the spacecraft electrical and adds the capability of performing this additional mechanical systems as well as to verify the checkout in parallel with all other systems.) launch complex compatibility of the spacecraft electrical systems. k. Launch Escape System (LES) - Buildup of solid propulsion motors. 2. The Spacecraft (S/C) - Launch Vehicle (L/V) Electrical Mate and Interface Test is 5. S-IVB/LEM Adapter (SIA) - Installation performed to demonstrate the integrity of the and checkout of pyrotechnic initiators wiring and S/C-L/V electrical interface. repair of any minor surface defects. 3. The Space Vehicle (S/V) Plugs-In Integrated 6. LEM Ascent Stage - Reaction control and Test is performed to demonstrate the compatibility main propulsion systems functional checkout. of the S/V electrical systems with the launch complex GSE and the range.

287 follow a buildup from k. The Space Vehicle (S/V) Plugs-Out 1. Checkout flow will to complete space vehicle. Integrated Test is performed to demonstrate the component level S/V - range compatibility in as near a the checkout operation shall configuration as possible. During this 2. Each succeeding flight growth pattern which test the GSE monitoring equipment is not connected be based upon a progressive all proven acceptable checkout and the spacecraft umbilicals are disconnected takes advantage of accomplished. in the normal time sequence of the countdown. data previously of the test and checkout 5- The Countdown Demonstration Test is 3- The sum total performed on a vehicle shall performed to demonstrate the time phasing of operational sequence through all operations of the normal sequences necessary to prepare the exercise the vehicle spacecraft for launch. a mission profile. and abort Vehicle Flight Readiness k. All operational, redundant, 6. The Space be operated to show a final systems modes of the spacecraft systems shall Test is performed and flight readiness. verification in all modes prior to the entering and tested for compatibility of the launch countdown. 5. No tests shall be performed without a and developmental 7. The Launch Countdown is performed to valid engineering requirement, be performed on qualified carry out the final activities to launch tests shall not vehicles. the space vehicle. man-rated flight phases of MSG ! s Role in Checkout Planning 6. During simulated flight-test the checkout program, each subsystem will be and operations simulating MSC T s modus operandi is to supply NAA and subjected to conditions and alternate modes of GAEC with management information necessary to normal flight profiles coordinate checkout plans between themselves operation. contractor working level meetings. For at then individually formulated instance, MSC supplies the contractor with The contractors and pursued joint coordination mission and schedule information, development their checkout plans such as the Apollo Mission philosphy, and general spacecraft checkout through meetings Force (AMPTF) and the Prelaunch criteria. Planning Task Operations Working Group (POWG). Mission Information Apollo Mission Planning Task Force of mission and schedule inform­ Two examples Force made Directives and the Master The Apollo Mission Planning Task ation are the Mission Institute Schedules. There is one mission up of NASA, NAA, GAEC, and Massachusetts Development the Guidance and each flight spacecraft. These of Technology (MIT is developing directive for contributed give the primary, secondary, and Navigation for the spacecraft) has directives by creating the tertiary mission objectives, a brief description to integrated checkout planning to describe a single of the spacecraft systems, and the flight plans. Design Reference Mission for project reporting The Master Development Schedule defines missions mission which can be a basis design and operational of each flight and the flight hardware that and continuing spacecraft the Design Reference comprise the space vehicle. Both the Mission studies. The report of three voliam.es. Directives and Master Development Schedules give Mission is presented in launch dates and are therefore classified as Description" contains the Confidential. Volume I - "Mission mission - related spacecraft design and trajectory assumed, and a description Apollo Checkout Criteria ground rules which were of the mission by phases. philosophy as well as general Developmental of Events" spacecraft checkout criteria was transmitted Volume II - "Preflight Sequence of the preflight contractors in part by the"Apollo Checkout contains a detailed description to the includes document issued by MSC and created sequence of events. This description Criteria" activities for a GE Apollo Support Department. The summary charts of the scheduled by the time of Vertical Checkout Criteria" written in 196U gave typical CSM and LEM from the "Apollo to liftoff and a to the contractors by establishing Assembly Building (VAB) roll-out guidance and comments. certain ground rules for checkout such as the list of pertinent assumptions following:

288 Volume III - n In-Flight and Recovery Sequence 3. After LES installation, atmospheric of Events" summarizes the sequence of events electrical activity within 5 miles of the space taking place for the typical mission from the SV vehicle requires a clearance of the pad area. liftoff through the post-flight recovery operations. k. During L/V L02 and LH2 loading the pad Preflight Sequence of Events. Volume II - area is cleared of non-essentail personnel. Pad "Preflight Sequence of Events" contributes to the in condition "RED." integrated checkout planning because it details those checkout and countdown operations at the 5. S/C hypergolics servicing will be scheduled time the most Integrated checkout planning is to serially load fuel (MMH & Aerozine 50) then required - when the full space vehicle is assembled. oxidizer (N201+). The launch vehicle as used in the Design Reference Mission consists of the S-IC, S-II, and S-IVB 6. CSM and LEM have individual fluid stages and the instrument unit (lU), and- the distribution systems but share the transfer, launch area is therefore Launch Complex 39- See storage and command transfer equipment. figure 7 for the Launch Complex 39 configuration. The spacecraft consists, as mentioned before, of 7. S/C will load L02 and LH2 serially; the Command Module, Service Module, Lunar however, G02 and GH2 will be transferred simultaneously Excursion Module, Launch Escape System, and the for fuel cell operations, S-IVB/LEM Adapter (SLA). 8. Helium servicing will be scheduled as Prelaunch Operations Working Groujo a serial operation between the CSM and LEM using concurrent equipment on a time shared basis. The Prelaunch Operations Working Group (POWG) principally consists of NAA and GAEC members 9. Prior to MSS removal, the LEM cabin is although NASA and MIT personnel attend the closed out, the SLA internal platforms completely meetings as visitors for coordination purposes removed, and the LES pyros connected. as required. The Prelaunch Operations Working Group reviews and discusses NAA/GAEC operational 10. The CSM and LEM umbilical will remain interface problems and prepares integrated checkout connected across the swing arm during transport flow plans for all missions which consist of to the pad. combined CM and LEM's. Test plans and facility/GSE requirements for common tests, such as the CM-LEM 11. MCC (Houston) will have the capability Ascent Stage docking test, are worked out at the of monitoring pad operations. Mission simulation POWG. The Prelaunch Operations Working Group will include S/V control switchover. and the Apollo Mission Planning Task Force work together on like tasks often because of the 12. All umbilical and service lines are similar objectives of the two organizations. For disconnected during plugs-out and, mission simulation instance the AMPTF Preflight Sequences Working tests. Group prepared a set of constraints and ground rules for Launch Complex 39 which was discussed at Launch Complex 39 Ground Rules. T*he following the-Prelaunch Operations Working Group meetings. are some examples of Launch Complex 39 ground rules As actual utilization of Complex 39 is approximately taken from the document: a year in the future these ground rules are subject to change as refinements are made in operational 1. A simulated flight at the pad will be plans. conducted after the Countdown Demonstration Test (CDDT)-with the MSS inplace, and the connections Launch Complex 39 Constraints. The following to the S/V may be broken. are some examples of Launch Complex 39 constraints taken from the document: 2. A spacecraft system verification test will be required late in the countdown. 1. The CSM live launch escape system (LES) shall be installed at the Launch Pad after the 3- Mission simulation will consist of a mobile service structure (MSS) moves into place. segmented mission encompassing all automatic sequential functions from liftoff to reentry 2. Radio frequency (RF) silence is required and recovery* during installation and connection of pyrotechnics. S/C power other than RF (less than 150 KC) may be k. Interface testing between the spacecraft turned on during the operation. and L/V are completed in the VAB. Requirements Plan 5« T-0 occurs at hold down release (first The Ground Operations top document defining the motion). is the contractor engineering requirements for checkout of the The preflight spacecraft operations 6. Final swing arm umbilical disconnect spacecraft. is broken down into numerous test tests will be performed in the VAB. and checkout data sheets giving the test objectives, spacecraft requirements, and 7. Countdown demonstration will be performed configuration, GSE/facility description. The test data sheets in on a real time basis simulating actual countdown the test Operations Requirements Plans are operations as far as practicable. the Ground sufficiently detailed such that process specifi­ and operational checkout procedures (OCP's) Apollo Checkout Management Board cations may be prepared from the document. Operational are the documents used by In addition to the contractor meetings, the checkout procedures in the actual implementation MSC-ASPO Checkout and Test Division convenes the test engineers North American Aviation prepares formal NASA/contractor coordination meetings of the checkout. Operations Requirements Plan for the such as the Apollo Checkout Management Board the Ground prepares the Plan for the LEM. meetings. The Apollo Checkout Management Board CSM while GAEC and 9 for typical test data sheets has the task of carrying out integrated See Figures 8 checkout planning and then of implementing these from these documents. Test Division., realizing plans. The Checkout and coordination the need for close coordination with each contractor The contractors pursue initial through the Prelaunch Operations as well as the integration of all Command/Service of their documents (POWG) as part of their integrated Module and LEM activities formated the meetings of Working Group In addition, MSC Checkout the Board to include NASA/NAA meetings (to discuss checkout planning. sponsors review meetings for Command/Service Module Checkout) and NASA/GAEC and Test Division Operations Requirements Plan published meetings (to discuss LEM checkout) as well as each Ground coordinate the information in the NASA/inter-contractor meetings (to discuss to completely as make the necessary changes integration of CSM and LEM checkout). The Board document as well KSC, NAA, GAEC, and MIT including checkout management representatives from when required. MSC, take part in these meetings to NASA-MBC, IASA-KSC, NAA, GAEC, MIT, AC Electronics representatives the interdependent features of the and General Electric T s Apollo Support Department insure that checkout are satisfactory to all discuss such varied topics as checkout flow spacecraft schedules, facility utilization to meet checkout participants. and the status of hardware and requirements, Use GSE software to meet schedules. Common and Concurrent aspects include sharing of individual NASA/NAA meetings CSM checkout Interdependent In support equipment as well discussed. As checkout experience facilities and ground is specifically of the CSM/LEM spacecraft. to the CSM flow are proposed as the combined checkout is gained changes planning allows the utili­ like manner, individual NASA/ The integrated checkout and discussed. In use GSE in which are held to specifically discuss zation of common arid concurrent GAEC meetings types of GSE for the Those changes in one contractor's NAA and GAEC share certain LEM checkout. LEM respectively. Through applicable to the other contractor's checkout of the CSM and checkout flow scheduled contractor passed on since the same NASA Board the utilization of regularly checkout are when each contractor both the CSM meetings and the LEM GSE requirements reviews, members attend an item of GSE only When inter-contractor problems arise had like requirements for meetings. and that model was requirement for additional operations one model was developed causing the design of the the complete Checkout Management designated as common use. The coordination, coordinated between to jointly solve problems under the model of GSE would then be Board meets Control Documents of NASA/MSC as the chairman of the the contractors by Interface leadership vendor would make Board. (lCD's) and the producing enough units for use at KSC, NAA/Downey, California, York, or wherever they were needed. Ground Operations Requirements Plan GAEC/Bethpage, New When actual units of common The information thus obtained by these Concurrent Use. by NAA and GAEC at the various meetings is used by the contractors use GSE could be shared were called concurrent for checkout planning purposes. One resulting KSC field site these units contractors using these units contractor document is the Apollo Spacecraft use GSE. By the two or in serial a savings in total Ground Operations Requirements Plan. either in parallel

290 units required was affected which reduced costs appreciably in the program. As an example of concurrent use GSE, the following is a listing of typical concurrent use servicing GSE used by both NAA and GAEC at the KSC field site:

-- 002 Oxidizer Transfer and Conditioning Unit

SlH-008 Fuel Transfer and Conditioning Unit

Water Glycol Cooling Unit

-- 060 Fuel Toxic Vapor Disposal Unit

SlU-06l Oxidizer Toxic Vapor Disposal Unit

Sl^-108 Fluid Distribution System, Launch Complex 39 , Pad 39A : ' =

SlU-111 Battery Charger

Required Coordination. The required inter- contractor common use/concurrent use GSE coordination and utilization scheduling is performed by NAA and GAEC in the Prelaunch Operation Working Group. In addition, MSC-ASPO issues a monthly summary document giving the identification and utilization of all common use and concurrent use GSE.

Common Facilities

Joint usage of KSC facilities by both the LEM and CSM also requires an integrated approach. For example, the spacecraft T s checkout flow in the Manned Spacecraft Operations Building is inter­ dependent even though separate work areas are provided for LEM and CSM. Maximum operational interdependence for each is a NASA goal but the achievement of the goal requires an overall knowledge and integrated planning approach. The checkout activities of both vehicles must be planned and performed to permit the CSM/LEM mated tests to occur at the optimum point in time to support- the prelaunch operation.

Conclusion

The complexity of the checkout activities required to produce the completely checked out space vehicle demonstrates the need for the Apollo spacecraft integrated checkout planning. The planning techniques, successfully implemented can contribute to a well managed Apollo program and aid in achieving the lunar mission in a timely manner .

As the Apollo program progresses and accelerates to meet our goals, the benefits of this planning will become evident.

291 LAUNCH ESCAPE MOTOR

LAUNCH ESCAPE SYSTEM

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S/M ENGINE NOZZLE EXT.

LEM ASCENT STAGE

LEM ASCENT STAGE PROPULSION LEM DESCENT STAGE LEM DESCENT STAGE PROPULSION S-IV B/LEM ADAPTER

Figure 1 - Apollo Spacecraft Configuration

292

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Figure 3 - Original LEM Factory Checkout Flow

294 LEGEND: ROTATE _^_. MATED FLOW & CLEAN w^v^^- A/ S FLOW minium D/S FLOW

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295 CONTRACTOR'S FACTORY KSC INDUSTRIAL AREA LAUNCH COMPLEX

CM FACTORY C/0

CSM FACTORYC/0

SM FACTORY C/0 CM FIELD C/0 CSM FIELD C/0 SM FIELD C/0 DO to CD SC LAUNCH COMPLEX C/0 A/S FIELD C/0 LEM FIELD C/0 D/S FIELD C/0 CSM/LEM MATE A/S FACTORY C/0

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Figure5 - TotalProgression of SpacecraftCheckout COMMAND MODULE A14-220 Al4-186

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A14-063 QVVT THRUSTERS A14-Q26 9EH-0623 9EH-0624 9EH-0626 A14-044 9EH-0627 A14-056

Figure 6 - Test Setup for CSMQuality Verification Vibration Test

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7 7 -

FACILITY FACILITY

Figure Figure

ORDNANCE ORDNANCE

VAB

ANNEX

UTILITY UTILITY

00 to SC-384, SPACECRAFT MATE AND FORWARD DECK BUILDUP

LOCATION

MSOB

OBJECTIVES

1. Install LEM in SLA.

2. Build up forward deck and install ordnance devices and forward heat shield.

TEST SETUP

CSM, SLA and LEM

TEST IDENTIFICATION AND SEQUENCE

LEM/SLA/CSM Mate

The lower section of the SLA is in position in the SLA/SC integrated test stand. The mated LEM is lowered into the SLA lower section and secured, followed by the installation of the upper .section of the SLA and the internal access platform set. The LEM ACE carry-on equipment is moved from the ACE support platform to the internal access platform. The LEM carry-on cabling is not disconnected during this operation. The LEM/SLA umbilical is connected and verified and the LEM/SLA GSE tunnel is installed.

The CSM is then installed on the SLA and aligned using the optical alignment set. The SM/SLA electrical connectors are mated.

Forward Deck Buildup

The forward heat shield thruster rods are checked for length by placing a gaseous nitrogen pressure source at the gas generator source. The pyrotechnic gas generators are installed. The flotation bags, drogue, and pilot parachute systems are installed. The forward heat shield is lowered and attached to the command module.

SPECIAL CONSIDERATIONS

Only qualified parachute riggers are to perform parachute handling and packing procedures. Only personnel experienced with ordnance handling and special safety procedures are allowed to handle and install pyrotechnic devices.

Figure 8 - Typical Test Data Sheet from CSM Ground Operations Requirements Plan

299 Test No. 32202 Test Time h Hrs. Revision ____C ____ Location GAEC

Subsystems Structural & Mechanical

Title Demate - Ascent From Descent Stage

Gb jective To physically disconnect the ascent from, descent stage.

Prerequisites Test No.

60051 Manufacturing Vibration Test 1^2506 Location Change

Test Description area to The mated LEM is moved "by the facility crane from the vibration in the the D/S support stand at DG-lf. When the vehicle is secured all j/ater stage connections ("bolts, nuts, umbilicals, hardlines, stand clear are disconnected. The auxiliary crane then hoists the A/S etc.) stage and moves it to the ascent general install, area. The descent will "be remains on the D/S support stand vhere engine installation initiated.

GSE Required Part No* Nomenclature

1|.20-13650 D/S Workstand ^20-13700 D/S Support Stand 14-20-13060 Aux. Crane Control lj-20-13100 A/S Sling lj-20 -13l|00 A/S Support Stand

Vehicle Test Configuration

Mated LEM

Figure 9 - Typical Test Data Sheet from LEM Ground Operations Requirements Plan

300