2003 ANNUAL REPORT TABLE OF CONTENTS

Center Director’s Message ...... 1

NASA Vision and Mission ...... 3

The President’s Management Agenda ...... 4

Significant Events ...... 6

Safety and Health First ...... 9

Build Reliance and Teamwork Everywhere ...... 11

Satisfy Our Customers’ Needs Anytime, Anywhere ...... 13

Environmental Leadership ...... 16

Space Shuttle Program ...... 18

International Space Station and Payload Processing ...... 22

Future Launch Operations ...... 25

Payload Carriers...... 28

Launch Services Program...... 29

Spaceport and Range Technologies ...... 32

Partnerships...... 37

KSC Reservists Called to Serve ...... 39

Columbia Recovery and Reconstruction ...... 40

Education ...... 43

Outreach to the World ...... 45

KSC Business Report ...... 50 Economic Impact ...... 51 Workforce Diversity ...... 53 Procurement Report ...... 54

KSC 2003 ANNUAL REPORT event or routine task, safety is always the unifying factor in everything we do. While the Center prompts many special professional and personal bonds, I realize our families are what are most A MESSAGE FROM important in life and I never forget that. THE CENTER DIRECTOR We remain good stewards of the environment by protecting the serene National Wildlife Refuge. KSC is living With the loss of STS-107 and the Space proof our world can continue Shuttle Columbia in February 2003, the progressing while responsibly caring for public may have expected NASA and our resources. the Agency’s John F. Kennedy Space Center to stop meeting the challenges None of these principles are successful of space exploration. However, the without serving our customers with challenge of restoring the Space Shuttle excellence at all times and relying on program to safe flight serves as the teamwork to accomplish this important perfect platform for KSC to flourish. task. Our truly collaborative approach creates a productive stability. As a Center built upon inspirational visions, dedicated workers and an When my leadership journey with KSC unquenchable thirst for exploration, we began this fiscal year, I joined a accept unexpected diversions as tremendous heritage. I intend to opportunities to test our strength. With continue this legacy by expecting much our mettle now forged by fire, we’ll from the workforce, thus ensuring we succeed in the future by overcoming meet the public’s expectations of challenges and leading the world in continuing our space exploration space exploration. journey for the benefit of humankind.

Fiscal Year (FY) 2003 was marked by Through remarkable teamwork in FY amazing milestones, especially our 2003, KSC supported eight Expendable workforce’s dedication to our Core Launch Vehicle missions, three Space Values and acceptance of our Guiding Shuttle launches and two landings, Principles. This approach is a passion of International Space Station processing, mine because a shared vision provides our reservists fighting the war on terror a foundation for future success. and much more. Our future comprises ambitious goals as well, including We excel because our inclusive setting returning our Space Shuttle fleet to safe not only respects differences, but flight and developing new technologies treasures everyone’s unique qualities. and future vehicles supporting the Vision We recognize the importance of each for Space Exploration. person’s contribution to the Center and how their perspective only makes our As KSC continues tirelessly inspiring results richer. By avoiding stagnant future generations and exploring the management, the Center’s leadership universe, we should all look forward to is fluid, serving as a catalyst for endless KSC’s future impact on our world. new ideas.

The safety of our workforce, astronauts and public remains our top priority, serving as the Center’s backbone. Whether supporting an awe-inspiring James W. Kennedy

1 KSC 2003 ANNUAL REPORT KSC 2003 ANNUAL REPORT 2 NASA VISION & MISSION

The NASA Vision To improve life here, To extend life to there, To find life beyond.

The NASA Mission To understand and protect our home planet, To explore the universe and search for life, To inspire the next generation of explorers ...as only NASA can.

A spiral galaxy as seen from the Hubble Space Telescope.

3 KSC 2003 ANNUAL REPORT THE PRESIDENT’S MANAGEMENT AGENDA

KSC fully embraces the President’s Space Plane, the NASA Engineering Management Agenda (PMA) to Safety Center and other Agency achieve NASA’s Mission as safely and priorities. efficiently as possible. Within the PMA framework are five initiatives used to Competitive Sourcing improve government performance. KSC In the framework of the NASA continues to fully support the Agency’s Competitive Sourcing initiative, KSC is implementation of these initiatives. working to achieve efficient and effective competition between public Strategic Management of and private sources, and is meeting Human Capitol competitive sourcing goals defined by NASA strives to attract and retain the the Office of Management and Budget best and brightest scientists and (OMB). The Center completed its engineers. KSC is enhancing recruitment Competitive Sourcing Plan and efforts, increasing technology-based exceeded the 15 percent OMB training opportunities and establishing requirement for FY 2003. Future plans for and aligning student programs to assure KSC include providing specific support a future “pipeline” of employees. In FY for the upcoming competition for the 2003, KSC rolled out the Agency’s NASA Shared Services Center, an Strategic Human Capital Plan and approach for consolidating specific hosted expos to discuss new initiatives NASA business and technical support and demonstrate new human capital services. tools to employees. KSC actively participates in the NASA Corporate Financial Management Recruiting Program, including leading Significant achievements included the recruiting trip to the University of implementation of the Integrated Puerto Rico, and spearheading Financial Management Program’s additional KSC-specific recruiting trips. (IFMP) Core Financial and Travel Using competency management and Manager modules in February 2003; training and development strategies, supporting the audit of NASA’s FY 2003 KSC is aggressively seeking ways to financial statements by providing optimize its workforce to facilitate financial data and analysis to staffing for Return to Flight, Orbital independent auditors and NASA

KSC 2003 ANNUAL REPORT 4 Headquarters; and working with the innovative spacecraft and range Competency Center to support full technologies for safe space operations cost configuration in Core Financial for and exploration missions; and provide FY 2004 operations. Progress continued and assure safe, world-class services. in addressing Core Financial stabilization and data issues.

e-Government KSC continued implementation of a common network infrastructure for NASA e-Gov activities, as well as participating in federal e-Gov initiatives. This year, KSC completed its network infrastructure upgrade plan, designed systems to support the One NASA portal, and led an Agency-wide pilot at seven NASA Centers for the Agency Security Update System. KSC also leads the One NASA ePresence pilot, and implemented Phase 1 of the NASA Management Information System. In addition, KSC manages the Agency’s Cyber Identity Management System Project, and leads the Office of Space Flight ODIN WebEx pilot.

Integrated Budget and Performance KSC prepared for implementation of full cost accounting procedures in FY 2004. These included establishing a Full Cost Team to implement full cost practices at KSC; delivering a training program for approximately 200 end- users; and updating and developing a full cost budget submission for FY 2004 thru FY 2009. KSC also worked with NASA Headquarters and the IFMP program to standardize structures; reconfigure the accounting system and resolve operational issues; as well as develop and deploy a program of Change Management for the Center, which included a “Full Cost 101 Road Show” offered to all Center employees.

Through this framework, KSC realizes its strategic goals to assure and advance access to space for exploration, development and use; provide

5 KSC 2003 ANNUAL REPORT SIGNIFICANT EVENTS

10/7/02 –STS-112/Atlantis launches to 12/17/02 – Final pieces for the Station’s deliver the S1 Truss to the International football-field-long backbone arrives at Space Station, and attach it to the S0 KSC’s Shuttle Landing Facility. Truss. 1/12/03 – NASA’s Ice, Cloud and Land 10/17/02 – The Tracking and Data Relay Elevation satellite and Cosmic Hot Satellite-J (TDRS-J) arrives at KSC’s Interstellar Spectrometer satellite lift off Shuttle Landing Facility. The TDRS System from Vandenberg Air Force Base (VAFB), is the primary source of space-to- Calif., aboard a Delta II launch vehicle. ground voice, data and telemetry for the Space Shuttle. 1/16/03 – Launch of STS-107/Columbia, a microgravity research flight and an 10/18/02 –STS-112/Atlantis lands at KSC. Extended Duration Orbiter mission.

11/23/02 – STS-113/Endeavour launches 1/25/03 – NASA’s Solar Radiation and to transport the Expedition Six crew, and Climate Experiment successfully deliver and attach the Port 1 Integrated launches aboard a Pegasus XL rocket Truss Segment to the ISS. from CCAFS.

12/4/02 - NASA’s third TDRS, TDRS-J, lifts 2/1/03 – A Space Shuttle contingency is off from Cape Canaveral Air Force declared in Mission Control, Houston, as Station (CCAFS), Fla., aboard an Atlas a result of the loss of communication IIA rocket. with the Space Shuttle Columbia at approximately 9 a.m. EST as it 12/6/02 – NASA chooses the Delta II descended toward a KSC landing. No expendable launch vehicle, provided communication and tracking by Boeing Launch Services, Inc., to information are received in Mission launch 19 NASA and NASA-sponsored Control after this time. The STS-107 crew medium-class scientific payloads members and Columbia are lost between 2006 and early 2009. because of a breach in the left Reinforced Carbon Carbon wing 12/7/02 –STS-113/Endeavour lands at leading edge. KSC.

KSC 2003 ANNUAL REPORT 6 2/7/03 – Private KSC employee 6/1/03 – A major Station memorial service occurs honoring the component, NASA’s Node 2, arrives at departed STS-107 Columbia crew. the Center. The European Space Agency (ESA) in Italy built Node 2 for 2/12/03 – Columbia Accident Investiga- NASA. tion Board (CAIB) arrives at KSC. 6/4/03 – A major Station component, 2/24/03 – First of two Mars Exploration the Japanese Experiment Module (JEM), Rovers, MER-2, arrives at Center from the arrives at KSC. The pressurized module is Jet Propulsion Laboratory in Pasadena, Japan’s primary contribution to the Calif. The rovers serve as robotic Station. geologists to seek answers about the evolution of Mars. 6/5/03 – KSC’s Web site celebrates its first-time online coverage of an 2/25/03 – Groundbreaking for the expendable vehicle mission with the first second Operations Support Building MER mission and its associated events. (OSB II). The site of the new six-story, 189,000-square-foot building is in the 6/10/03 – MER-A launches aboard a Launch Complex 39 area near the Delta II launch vehicle from CCAFS. Vehicle Assembly Building. 6/18/03 – KSC ceremony highlights 3/6/03 – The Space Infrared Telescope arrival of Node 2 and JEM. The event Facility (SIRTF) arrives at KSC for launch includes official transfer of ownership of preparations. On Aug. 25, SIRTF is Node 2 between ESA and NASA. renamed the Spitzer Space Telescope in honor of the late Dr. Lyman Spitzer Jr. 7/7/03 – MER-B launches aboard a Delta II launch vehicle from CCAFS. 4/28/03 – NASA’s Galaxy Evolution Explorer spacecraft launches from a 7/7/03 – Several days of tours begin for Pegasus XL rocket from CCAFS. The the workforce and their guests to view mission features an orbiting telescope to Columbia debris. Experts are available observe millions of galaxies across 10- to provide information and answer billion years of cosmic history. questions.

7 KSC 2003 ANNUAL REPORT 7/11/03 – NASA spacecraft, designed to 8/20/03 – The Center inaugurates the test two of Albert Einstein’s Theory of Agency’s One NASA leader-led General Relativity predictions, travels to workshops, helping employees better the VAFB launch site for the Gravity understand the Agency’s overall Probe B mission. strategy and direction. One NASA is a cultural change emphasizing a strong 7/15/03 – Flight demonstration tests KSC- commitment to teamwork, accessible managed Space-based Telemetry And tools and a greater collaboration across Range Safety (STARS) at NASA’s Dryden the Agency. Flight Research Center demonstrating a more effective, economical tracking 8/25/03 – The Spitzer launches aboard a and communication technology. Delta II launch vehicle from CCAFS.

7/28/03 – Two new security gates 8/26/03 – CAIB releases its report on the complete the opening of Space Columbia investigation. NASA Commerce Park and a new roadway. Administrator Sean O’Keefe accepts This provides an alternate route for the CAIB Report recommendations and general public between Titusville and findings. Merritt Island, Fla. 9/17/03 – The Multi-Element Integrated 8/10/03 – James W. Kennedy becomes Test between the JEM and NASA’s 8th KSC Director after serving as Deputy Node-2 is successfully completed inside Director since Nov. 2002. Gen. Roy D. the Space Station Processing Facility. Bridges, former KSC Director, becomes Director of the Agency’s Langley 9/23/03 – Atlantis continues Research Center, Hampton, Va. preparations for Return to Flight. Some of the work includes reinstallation of the 8/12/03 – The Canadian Space Reinforced Carbon-Carbon panels on Agency’s Scientific Satellite Atmospheric the Shuttle’s wing leading edge, wiring Chemistry Experiment launches aboard inspections, and checks of the Shuttle’s an Orbital Sciences Pegasus XL at VAFB. engines in the Orbital Maneuvering System.

KSC 2003 ANNUAL REPORT 8 SAFETY AND HEALTH FIRST

Top: Promoting wellness, the annual Spaceport Super Safety and Health Day included a blood pressure check station. Right: Spaceport Super Safety and Health Day offers the workforce informative presentations and exhibits to reinforce safe and healthful behaviors.

Addressing safety and health concerns KSC not only complied with approxi- and continuously improving employee mately 500 OSHA requirements, but wellness, the Center tirelessly supports its several areas were also recognized as top priority and one of KSC’s four best industry practices. These included Guiding Principles — Safety and Health the Center Director’s use of electronic First. communications to the entire workforce highlighting safety and health aspects, After a two-year endeavor, KSC such as employee and management’s became Voluntary Protection Program safety and health roles and responsibili- (VPP) qualified by the Occupational ties, employee rights such as “stop work Safety and Health Administration authority,” incident and close call (OSHA). The Center selected VPP to reporting, and unannounced monthly ensure continuous safety and health workplace inspection results. program enhancements, and certification as a “Star” site constitutes OSHA also noted the establishment of recognition as an exemplary safety and “RehabWorks” (an on-site occupational health program. At least 78 percent of health rehabilitation center), employee KSC’s workforce, including two major awareness and knowledge of VPP, the contractors, are VPP Star certified. The Center’s Employee Safety and Health Center is currently the only federal site in Pocket Guide, and KSC’s Business World the region (Florida, Georgia, Mississippi Web site with safety and health links. and Alabama) VPP Qualified. The annual Spaceport Super Safety and During the VPP certification audit, OSHA Health Day increased awareness for representatives conducted formal and practicing “Safety and Health First” both informal interviews with civil servants, in professional and personal activities. gauging employee awareness and More than 120 exhibitors, located at involvement in KSC’s safety and health various Spaceport locations, offered program. OSHA representatives also safety and health related information, reviewed safety and health training sessions and demonstrations. documentation, and inspected work Activities also included astronaut sites verifying consistency and appearances, award presentations, a compliance. health fair and KSC Fitness Centers’ open houses.

9 KSC 2003 ANNUAL REPORT KSC’s Occupational Health Program Screening programs include continuously promoted employee cardiovascular disease risk reduction wellness throughout the year with and breast and colorectal cancer activities such as Fitness Center events, screenings. An employee health and physical exams, inoculation programs, fitness day taught employees about health education and screening community health and wellness programs and the Employee Assistance programs and provided health Program (EAP). During the fiscal year, screenings, as well as nutrition and employees made more than 3,000 exercise counseling. Additionally, the RehabWorks visits and 88,741 KSC Fitness workforce can receive free flu shots as Center visits. The Fitness Centers offered well as counseling services through the motivational programs such as the EAP. President’s Adult Active Lifestyle award, which promoted physical fitness.

KSC 2003 ANNUAL REPORT 10 BUILD RELIANCE AND TEAMWORK EVERYWHERE

NASA worker Joy Huff (right) shows Stafford-Covey Return to Flight Task Group members a wing leading edge subsystem bonded to tile.

As we strive for mission success in all our making changes to make reliance and endeavors, our dependence on one teamwork a way of life at the Center. another to provide services is critical. Therefore, KSC builds upon its strengths In addition to One KSC, the Agency in reliance and teamwork and commits initiated One NASA, a cultural change to completing opportunities for emphasizing a strong commitment to improvement consistent with the teamwork, accessible tools and a Center’s Guiding Principle to Build greater collaboration across NASA. Reliance and Teamwork Everywhere. Selected by NASA Headquarters, KSC These efforts assure future strategic hosted the first One NASA leader-led goals of KSC and the Agency are workshop Aug. 20, a direct response to realized. workforce feedback. One NASA also introduced key leaders from other Perhaps the most poignant display of enterprises participating in Center the Center coming together in the workshops. KSC Director James fiscal year was the STS-107 Space Kennedy visited the Jet Propulsion Shuttle Columbia recovery project. To Laboratory Oct. 16-17 to participate in collect debris, 870 KSC civil servants its One NASA activities, including a town and contractors helped with the tasks hall meeting. in East Texas. Workers searched a ground area corridor 250-miles-long by 10-miles-wide. About 38 percent of Columbia’s dry weight was recovered. Additional in-depth information about the loss of Columbia and its crew can be found throughout this document.

Last year, the Senior Management Team reviewed the Center-wide KSC Reliance and Teamwork Survey; subsequently, a One KSC Team formed to address feedback results. This team initially focused on a targeted approach to achieving One KSC and

11 KSC 2003 ANNUAL REPORT U.S. Forest Service members walk a grid during a Columbia Recovery search near the Nacogdoches, Texas site. A space program worker able to identify potential hazards of Shuttle parts accompanies the group.

KSC 2003 ANNUAL REPORT SATISFY OUR CUSTOMERS’ NEEDS ANYTIME, ANYWHERE

Integral to KSC’s strategic planning is facilitate additional communication, building and maintaining customer thus educating customers on financial satisfaction through relationship regulations, launch services, outreach management. Satisfying Our Customers’ materials and more. Needs Anytime, Anywhere is one of KSC’s four Guiding Principles. The The Shuttle Processing Directorate Customer Assurance and Analysis Office prepares the Space Shuttle for safe and serves as an independent advocate for successful missions. The ISS/Payload systematically managing customer Processing Directorate identifies and knowledge and feedback to develop satisfies ground processing and support, strategies for improvement and new as well as test and integration opportunities. requirements, ensuring a successful mission. Shuttle/ISS Improvements The ultimate goal is to ensure a include updating the Directorate customer focused culture with Information Technology Policy, customers consistently choosing KSC as publishing a Payload Processing Guide, their launch site. To achieve this, our and documenting standard/ core customers use customer nonstandard international customer satisfaction data to drive change and services. There is an ongoing effort to lead continuous improvement. KSC’s update customer orientation packages core customers are Launch Services and establish a single point of contact Program (LSP), Shuttle/International for communicating capabilities and Space Station (ISS) and Spaceport requirements. Engineering and Technology. The Spaceport Engineering and The LSP acquires commercially Technology Directorate provides available ELV launch services for NASA innovative and integrated solutions to and its customers. LSP ensures mission complex technical problems with success, provides low cost services on customer satisfaction as a priority. New time and maximizes customer to this effort, the directorate established satisfaction. LSP improvements include its customer base. The directorate will a Launch Services Connections use both internal and external customer newsletter and a new launch services feedback to improve processes and mission budget policy. Responding to customer support. customers’ requests, these additions

13 KSC 2003 ANNUAL REPORT With cables released, the first of two Mars Exploration Rovers sits on the floor of the Payload Hazardous Servicing Facility.

KSC 2003 ANNUAL REPORT An owl is held just before its release.

KSC 2003 ANNUAL REPORT ENVIRONMENTAL LEADERSHIP

Launch Complex-34 areas were polluted during the space program’s early history when DNAPLs cleaned Apollo rocket parts. Because DNAPLs tend to sink to the bottom of the water table and collect in pools, these solvents Nature thrives with technology as seen in this photo can contaminate fresh water sources of the Vehicle Assembly Building and surrounding when left untreated in the ground. grounds and water. In the foreground, perched on a plant, is an anhinga—a common Center inhabitant. Methods to clear up this potential problem are bio-augmentation, which Situated on 140,000 acres, that include degrades some environmental a wildlife refuge, the Center continues contaminants through the addition of to operate in the ultimate marriage of nutrients, and Emulsified Zero-Valent Iron. nature and technology. KSC spent the This approach uses environmentally fiscal year preserving and improving friendly oil and water to neutralize that union. DNAPLs. Micro-organisms are also added, rendering contaminating The Merritt Island Spaceflight Tracking chemicals harmless. and Data Network won the Federal Energy and Water Management Award. A Florida Power and Light (FPL) It was chosen by the Department of alternatively financed project remedied Energy for its long-term efforts to some of the Center’s inefficient energy improve energy efficiency at the operations. FPL provided a loan for up- tracking and data relay station. This front project costs and KSC uses energy group saved KSC approximately bill savings generated by the project for $100,000 annually in energy bills. financing.

Thousands of sites across the world are Projects in the high bays of the Space contaminated with dense, non-aqueous Station Processing and Operations and phase liquids (DNAPLs). DNAPLs Checkout facilities produced significant commonly come in the form of cleaning energy savings of about $500,000 solvents. KSC implemented new clean- annually. A Payloads/Station Team up technologies to help fight this battle. reduced heating, ventilation and air

KSC 2003 ANNUAL REPORT 16 New methods of environmental cleanup are explained at Launch Complex 34A.

conditioning system energy costs to one- importance of discovering and tenth the previous levels while improving protecting Florida’s environmental temperature and humidity conditions. diversity. The team received a 2002 KSC Environmental & Energy Bi-Annual Award Supporting environmentally friendly for their success. transportation, employees inspected an Alternative Fueled Vehicle and Global Similarly proactive, KSC’s Energy Working Electric Motorcar (GEM). The workforce Group provided educational also test-drove a Segway Human opportunities, making the workforce Transporter, and discovered using the knowledgeable about energy device is as natural as walking. efficiency. Included were tours of KSC’s largest mechanical equipment room Providing an opportunity to put and the Central Heat Plant, covering knowledge to use, Amnesty Days topics such as resourcefully maintaining allowed KSC workers to dispose of critical work conditions. unwanted government chemicals excluding biohazardous, radioactive or Learning about Earth-friendly personal explosive materials. In all, 20,166 pounds and professional practices was of excess materials were collected. stimulated by Environmental and Energy Awareness Week (EEAW) traveling Furthermore, KSC is home to some 25 presentations, tours, seminars and threatened and endangered species, exhibits. both permanent residents and annual migratory types. The U.S. Fish and Dr. Stuart D. Strahl, President/CEO of Wildlife Service manages the Center’s Audubon of Florida, spoke at the EEAW land. Efforts to increase population and Opening Ceremony. Audubon works to habitat usage included controlled ensure that conservation becomes a burning, wetlands enhancement and common interest in Florida rather than exotic, invasive plant removals. These being relegated to a special interest species continue to use KSC lands for group. Audience members learned the wintering, spawning and thriving.

17 KSC 2003 ANNUAL REPORT SPACE SHUTTLE PROGRAM

The afternoon sun casts a shadow on Space Shuttle Atlantis as it launches on its journey to the International Space Station (STS-112).

Although STS-112 (launched 10/07/02) and upgrades were implemented at and STS-113 (launched 11/23/02) were KSC to support future Space Shuttle processed and launched during FY 03, missions. the tragic loss of Columbia and her seven-member crew prior to landing Shuttle Processing and Return to Feb. 1, 2003, brought Space Shuttle Flight Activities launch activities at KSC to a halt. The As part of Return to Flight activities and loss changed the focus of processing in consideration of CAIB recommenda- activities to support the investigation. tions, Non-Destructive Evaluation (NDE) For the next several months, KSC and testing was performed on all orbiter contractor workers were involved in vehicle Atlantis (OV-104) wing leading Columbia debris recovery and edge Reinforced Carbon Carbon (RCC) reconstruction efforts and Columbia panels. Insulator hardware was disas- processing reviews, and they assisted sembled, and Atlantis’ wing leading the Columbia Accident Investigation edge RCC panels were shipped to Board in determining the root cause of Lockheed Martin Missiles and Fire Con- the accident. trol Division to re-perform the original NDE testing and visual inspections. KSC NASA and contractor workers Logistics packed and shipped the concentrated on implementing process panels, and developed and coordi- improvements, performing upgrades to nated turnaround schedules to support the remaining fleet of orbiter vehicles the upcoming launch schedule. Attach- and developing new processes, ment hardware for wing leading edge hardware and tools to comply with CAIB reinstallation and panel reassembly recommendations to prepare the were identified and procured. orbiters for Return to Flight. Spaceflight Operations Contractor With a renewed emphasis on safety and United Space Alliance (USA) and NASA reliability, a number of new processes

KSC 2003 ANNUAL REPORT 18 continuously improve risk-management temporarily moored at the facility, is decisions regarding ground operations. transported up the Banana River to the The latest improvement uses the Process newly developed temporary mooring Failure Modes and Effects Analysis site at the Vehicle Assembly Building (PFMEA) tool to analyze a process. The basin, allowing for easy ET offload. objective of PFMEA is to document During launches, the barge is moved to potential failures that could occur the VAB turn basin, eliminating the need during a particular process and to for towing back to Port Canaveral and recommend actions to eliminate the returning after launch. The combined failure mode or control the hazard. The use of the Boeing Delta Mariner facility analysis quantifies risks to personnel and the temporary VAB mooring site safety, flight hardware and schedule resulted in savings of more than $40,000 delays. The PFMEA tool was used to on each delivery. complete more than 13 assessments this year. A team of KSC engineers and technicians and the Cryogenics Test KSC Shuttle Processing implemented an Laboratory developed a safe and updated electronic logbook (ELOG) to reliable technique to isolate a column of disseminate information between liquid oxygen behind a plug of frozen Shuttle Processing engineering, quality liquid precision-cleaning agent (Freon). and operations personnel and other The technique permitted successful Space Shuttle program projects on a replacement of a cracked gasket in a daily basis. liquid oxygen block valve at Shuttle Launch Pad 39A without draining (and ELOG’s future uses include surveillance potentially wasting) thousands of gallons database modules for Shuttle Processing of liquid oxygen. The technique will Engineering and Safety & Mission undergo further development for use on Assurance, closed-loop accounting of larger line sizes with different fluids. A U.S. surveillance plans and generating patent is pending. surveillance metric reports. Upgrades In conjunction with Agency experts, KSC A new Space Shuttle Main Engine Shuttle Processing successfully (SSME) horizontal handling truck arrived completed the inspection of Main to supplement the single truck in service Propulsion System Propellant Feed Line since the beginning of the program. The Ball Strut Tie Rod Assembly (BSTRA) new truck features an updated design, components following the observation increased capabilities and improved of a cracked BSTRA ball in Discovery portability for support of SSME removal in (OV-103). The inspection required the event of a Trans-Atlantic Landing. development of new tools and techniques at KSC and a multi-Center During performance of normal failure analysis investigation. KSC refurbishment programs on Crawler developed new procedures resulting in Transporters 1 and 2, failed bearings the execution of the first-ever removal of were found on the jacking and leveling a 17-inch (diameter) liquid oxygen cylinder bearings. USA ground propellant feed line from Discovery in operations engineering removed and order to return it to the vendor for repair. replaced 64 bearings on each of 32 cylinders, which weighed 10,000 pounds USA accomplished a substantial each. Extensive modifications to the procedural improvement by utilizing the Crawler Transporter 2 cab and exhaust Boeing Delta Mariner facility at Port system were also completed during the Canaveral. Starting with the delivery of window provided by Return to Flight External Tank (ET)-119, the ET Barge, activities.

19 KSC 2003 ANNUAL REPORT Workers in the Orbiter Processing Facility remove one of two Orbiter Maneuvering System pods from Endeavour.

KSC 2003 ANNUAL REPORT Infrastructure Improvements • Corrosion Control and Pneumatic and Modifications Tubing Replacement, • Slidewire System Cable FPL and the Shuttle Program completed Replacement, and Rotating Service the largest energy conservation project Structure Elevator Control System in KSC history with no up-front cost to Upgrade, the taxpayer. The project, which in total • Payload Ground Handling addresses $3.2 million worth of energy Mechanism Enhancement efficient upgrades and revitalization, Modification including Stem Strain was financed by FPL with loan Modification, and payments repaid completely from the • Engine Service Platforms “Frog” Rails accrued savings. The project earned repair. KSC the Department of Energy’s “Energy Champion” award as NASA’s Pad B modifications included: most outstanding initiative for the year. • Corrosion Control of the Rotating Service Structure, For the first time in KSC history, a • Payload Change-Out Room Door detailed account of energy transferred Repair, and in the form of chilled and hot water is on • New Hydraulic Power Unit fuel the horizon. A Center-wide project, servicing carts fabrication testing begun this year, will provide instrument and validation. readings (in BTUs) from KSC’s north and south ends. Installation of ultrasonic flow measurements at key locations will tie them into the Kennedy Complex Control System (KCCS) through the Ethernet. Completion of this measurement project, in conjunction with ongoing KCCS installations, will place KSC at the forefront of all NASA Centers in network-based facility management.

KSC recruited nationally recognized technical experts from the Department of Energy to develop projects for energy savings opportunities. These audits, as well as those performed in-house by the Shuttle Program and FPL, form the basis for future energy reduction initiatives. Future projects may include additional Launch Complex 39-area generation capability and software-based load control.

Following the loss of Columbia, infrastructure modifications continued at Launch Pads 39A and 39B. Pad A projects included upgrades to the following: • Orbiter Mid-body Umbilical Unit Support System,

21 KSC 2003 ANNUAL REPORT INTERNATIONAL SPACE STATION AND PAYLOAD PROCESSING

Astronaut Soichi Noguchi (left), with the Japanese Aerospace Exploration Agency, examines data during a Multi-Element Integrated Test of the U.S. Node 2 and the Japanese Experiment Module in the Space Station Processing Facility.

KSC’s Space Station Processing Facility relationships of these elements met (SSPF) is one of the world’s most unique requirements. processing resources. It is home to all Station elements prior to launch from To accomplish the test, multiple cables KSC on their journey to the International were connected between the two Space Station (ISS). It is inside this facility modules and the on-orbit Station that Station assembly components from emulator, providing electrical power, U.S. and international partners are data, command, and cooling to received, tested, integrated and validate the compatibility of the systems. validated, in preparation for their final Test results confirmed that both modules destination. Reflight carrier elements, would interact properly when delivered which are required for logistics and and attached to the Station. On future science resupply and return-to-earth, ISS missions, Node 2 will be attached to are processed here. In addition, the the U.S. Lab Destiny and the JEM “Kibo” SSPF supports the final integration and module will be attached to Node 2. checkout of ISS science prior to flight. Following delivery of Node 2 from Italy, KSC currently houses 10 Station an integration systems test was elements, in various processing and completed successfully. This included testing stages. As NASA looks forward to emulating the Space Station on-orbit Return to Flight in 2004, planning and configuration, testing the command and processing for the third phase of Station tracking systems that support the audio assembly has begun. and video systems on-orbit, and the caution and warning systems that During the fiscal year, the Center monitor life support systems in the completed its third Multi-Element module. Integration Test (MEIT 3), which included the European-built Node 2 module, the Additional significant ISS elements Japanese Experiment Module (JEM) processed for ISS missions included: Kibo Pressurized Module and an ISS simulator. MEIT 3 required assembly of an • Starboard 1 Integrated Truss segment integrated international and multi- for Mission STS-112 Center/contractors team at KSC, and • Port 1 Integrated Truss segment for proved the hardware/software Mission STS-113

KSC 2003 ANNUAL REPORT 22 STS-113 astronauts Michael Lopez (red stripe) and John Herrington service the newly installed International Space Station Port One truss

KSC 2003 ANNUAL REPORT Technicians supervise the transfer of the Integrated Equipment Assembly, a major component of the International Space Station’s Starboard 6 truss segment.

• Starboard 6 Truss segment, final cycle, it was determined they were sections of the Station’s truss system, fourth or fifth generation descendants of arrived at the SSPF for testing and the worms launched on STS-107. validation for a future Station mission. Second, researchers found moss intact with growth patterns that will enable Columbia Recovery Support researchers to learn how gravity and The ISS and Payloads Processing team light affect cell organization. BRIC was supported the recovery and able to download temperature data reconstruction of Columbia. At the KSC recorded on three data loggers, Columbia debris hangar, experienced including temperatures recorded while payload engineers combed through on the ground in Texas. debris to separate and identify payload and experiment hardware. Amidst the Liquid was extracted from the ZCG payload debris, the team found intact Furnace autoclaves thought to still experiment samples that contained contain Zeolite crystals flown in zero valuable science. gravity that could be recovered later in the lab. The durable and complex The Biological Research in Canisters crystals are known for their high (BRIC) experiments still contained living adsorption properties and are often worms and moss growth. The Zeolite used as catalysts in petroleum and Crystal Growth Furnace (ZCG) pharmaceutical industries. contained crystal samples, and the Commercial ITA, Inc. Biomedical Samples recovered from the CIBX-2, Experiment (CIBX) still held samples of that studied developing technology for an experiment that might yield new drug delivery systems to combat anti-cancer drug delivery systems. cancerous tumors and cancer metastasis, revealed The BRIC experiment yielded two microencapsulation. The drug delivery surviving types of samples. First, living C. technology uses co-encapsulation of Elegan worms were recovered from antibodies and immune stimulants into canisters on April 28, 2003. Since the micron microcapsules. worms have only a seven to ten day life

KSC 2003 ANNUAL REPORT 24 FUTURE LAUNCH OPERATION

The Center workforce looked forward this Advanced Checkout, Control and year and positioned KSC for future Maintenance System (ACCMS) launch operations. optimizes ground resources and processes needed to meet possible The Space-Based Telemetry And Range Reusable Launch Vehicle (RLV) Safety (STARS) project demonstrated a turnaround goals, safety standards and space-based platform’s Range Safety efficiency objectives. and Range User capabilities for various launch vehicles. Range Safety includes This technology will help alleviate the flight-termination processing from both complexity of many time-consuming space and ground resources and personnel tasks, automate routine tasks vehicle tracking using the Global and reduce organization support Positioning System satellites. Range User requirements. Most significant for RLV includes high-return link data rates for operations, ACCMS will reduce risk and voice, video and vehicle data. The brain time associated with unplanned of STARS, is known as the Command and maintenance activities. Data Handler. Estimates show that these new methods could reduce costs by up Additionally, Sierra Lobo, Inc., a to $40 million per year. contractor supporting KSC’s efforts, won NASA’s Small Disadvantaged Business Much of the STARS hardware was put to Prime Contractor Award. The Ohio- the test during the fiscal year. The trials based company was recognized for its exercised the equipment as it will be Densified Propellant Management used during flights. These tests prepared System contract work. The densified for Flight Demonstration 1, which propellants project is considered an analyzed different functions, capabilities “enabling technology” for some RLVs and environments. This was a “high because it can decrease vehicle mass. dynamics” flight with STARS hardware and antennas located in an F-15B Another KSC effort is the Operations aircraft. At NASA’s Dryden Flight Concept Development (OCD). The OCD Research Center in California, the turns operational concepts into aircraft performed the dynamic transportation elements. It clarifies maneuvers to determine antenna system operations, requirements, ideas coverage. and boundaries. KSC’s significant OCD expertise included pre-launch The latest in ground-based operations, processing, launch operations, landing launch and payload check-out operations and system design. automation systems were demonstrated as well, using a combination of flight KSC also supported the Lessons Learned qualification and ground hardware. The Database. This key development

25 KSCKSC 2003 2003 ANNUAL ANNUAL REPORT REPORT Members of the Space-based Telemetry and Range Safety project support a flight demonstration, which tested hardware on an F-15B aircraft. captures knowledge from previous and KSC also supported a Marshall Space existing human space flight programs Flight Center acquisition project by and dozens of space flight experts. contributing Ground Operations, Ground Processing Systems, Integrated To maximize industry’s creativity and Logistics Support, and Ground technical proficiency, NASA defined Operations Training sections for the necessary capabilities for a potential, Alabama-based Center’s drafting new transportation system. KSC also process. provided technical leadership. The Center assessed these requirements that The Launch Services Program (LSP) is will ensure final contractor products integrally involved in these efforts, as have the integrity needed to progress. well. LSP workers, including contractors, provided and analyzed ELV data KSC completed seven trade studies to supporting concept development determine feasibility of future operation efforts. The LSP also evaluated requirements, supported a Systems modifications required for existing ELV Requirements Review milestone, designs and launch complexes. compared various spacecraft Additionally, the LSP is participating in concepts, and provided data for the human and risk analyses and continuing future evaluation of contractor development of independent and proposals. The Center also began two reliable ELV modeling capabilities. trade studies analyzing facility, launch site and control center requirements.

KSC 2003 ANNUAL REPORT 26 International Space Station elements are processed for future Space Shuttle flights. The JEM pressurized module and the U.S. Node 2 are a few of the elements that line the SSPF’s high bay walls.

29 KSC 2003 ANNUAL REPORT PAYLOAD CARRIERS

The U.S. Node 2 moves toward a workstand in the Space Station Processing Facility. The Italian-built component is the second of three ISS connecting modules.

Program Improvements incorporates precise 3-D modeling and The Payload Carriers Program continued real-time simulation. efforts to improve carrier support for International Space Station payloads KSC’s LSSAT was recently recognized by and initiated structural rework of the the National Systems Training Lightweight Multi-Purpose Experiment Association as the best application in Support Structure to provide required 2002 for Modeling and Simulation support for Return to Flight activities. Analysis. The tool has the potential for future applications in other programs A study by Kansas State University to including ELVs. determine the useful life of payload carriers was expanded to document all Mission Support payload carriers throughout NASA. The Payload processing support was database expansion provides corporate provided for mission STS-107. Experiments memory to future generations of the supported by payload carriers in the science community for delivery systems. Shuttle’s payload bay included the Fast It also provides life expectancy analysis Reaction Experiments Enabling Science, capability for each individual carrier, as Technology, Applications and Research well as the fleet. These analyses allow (FREESTAR) Hitchhiker, which comprised informed carrier selection and cost six experiments. estimation decisions. The program supported the CAIB by The NASA/Boeing Launch Services providing flight hardware identification, Simulation and Analysis Laboratory flight documentation support and (LSSAT) team developed an innovative personnel interviews during debris strategy and integration tool used to recovery and reconstruction efforts. analyze payloads and achieve the best use of carrier space for payloads to be installed in the Shuttle. The tool

KSC 2003 ANNUAL REPORT 28 LAUNCH SERVICES PROGRAM

During the year, LSP managed the The first time a spacecraft was mated at launch of eight missions, including two KSC to an ELV occurred inside the Multi- powerful new Mars Exploration Rovers Payload Processing Facility Jan. 15, (MER) that traveled to the red planet 2003. The Solar Radiation and Climate aboard Delta II launch vehicles. MER-A Experiment (SORCE) vehicle was mated “Spirit” launched June 10, 2003, and to the Pegasus XL during pre-launch MER-B “Opportunity” launched July 7, processing. A successful launch aboard 2003. The identical rovers reached Mars Pegasus Jan. 25 sent SORCE to orbit the in January 2004 and are exploring Earth and provide accurate different areas of the planet’s surface in measurements of solar energy. search of evidence of water that may have been present in the planet’s past. NASA’s Galaxy Evolution Explorer (GALEX) launched April 28, 2003, from a TDRS-J, the second TDRS of three, Pegasus XL vehicle. GALEX, an launched aboard an Atlas IIA launch ultraviolet imaging and spectroscopic vehicle Dec. 4, 2002. TDRS-J will provide surveyor, will map the global history and improved communications to the Space probe the causes of star formations and Shuttle, ISS, Hubble Space Telescope their evolution. and other Earth-orbiting satellites well into the 21st century. Scientific Satellite Atmospheric Chemistry Experiment (SCISAT-1/ACE), NASA’s Ice, Cloud and land Elevation the first Canadian scientific small Satellite (ICESat) and Cosmic Hot Inter- satellite in more than 30 years, launched stellar Plasma Spectrometer (CHIPSat) aboard a Pegasus XL vehicle Aug. 12, launched Jan. 12, 2003, aboard a Delta 2003, from VAFB. SCISAT’s two-year II. ICESat is the benchmark Earth Observ- mission will monitor and collect ing System mission for measuring ice information about Earth’s ozone sheet mass balance, cloud and aerosol providing improved measurements and heights, as well as land topography and understanding of the chemical vegetation characteristics. CHIPSat, a processes that control the distribution of University-Class Explorer mission funded ozone in the Earth’s atmosphere, by NASA, will use spectroscopy to study particularly at high altitudes. very hot plasma believed to fill the local interstellar bubble.

29 KSC 2003 ANNUAL REPORT The Mobile Service Tower begins to roll back at Cape Canaveral Air Force Station’s Launch Complex 17B, revealing the Delta II Heavy launch vehicle carrying the rover “Opportunity” on the second Mars Exploration Rover mission.

KSC 2003 ANNUAL REPORT Another milestone was reached when will launch aboard NASA’s first flight of the Spitzer Space Telescope (formerly Boeing’s Delta IV launch vehicle. SIRTF) launched on a Delta II ELV Aug. 25, 2003. Spitzer, named for Dr. Lyman Future planetary missions include the Spitzer Jr., one of the 20th century’s most MErcury Surface Space ENvironment distinguished scientists, is the largest GEochemistry Ranging (MESSENGER) infrared telescope ever launched into spacecraft that will fly by and then orbit space and the last of four missions in the planet Mercury to conduct the first NASA’s Great Observatories Program. study of the planet; and Deep Impact, Previous missions included the Hubble a mission that will use an infrared Space Telescope, the Compton spectrometer to study a comet. Gamma-Ray Observatory and the Chandra X-Ray Observatory.

At any given time, KSC’s LSP manages 30 to 40 current and future ELV missions. The LSP team works with other NASA Centers—Jet Propulsion Laboratory: Marshall Space Flight Center in Huntsville, Ala.; and Goddard Space Flight Center in Greenbelt, Md.—to plan and process NASA’s scientific, research and communications spacecraft for launch on ELVs.

Missions involve multi-year planning and development between KSC’s program office and NASA Centers. Ground Operations, Payload Safety and Mission Integration Working Groups are involved in planning and processing for all launches. Facilities at KSC and VAFB in Calif. are used to process payloads and launch vehicles. Facilities outside NASA, such as Astrotech in Titusville, Fla. and Spaceport System International in Lompoc, Calif. are sometimes used to process payloads.

As the year winds down, the Launch Services team prepares for future Eastern and Western Range launches. Mission Integration and Ground Operations Working Groups continue to monitor planning and processing of vehicles and spacecraft. Among future scientific missions are Aura, NASA’s follow-up mission to Aqua and a key part of the Earth Observing System; SWIFT, a mission that will study the “afterglow” of gamma ray bursts; and the Geostationary Operational Environmental Satellite (GOES-N) that

31 KSC 2003 ANNUAL REPORT SPACEPORT AND RANGE TECHNOLOGIES

Dr. Richard Arkin records data as the hazardous gas detection system Aircraft-based Volcanic Emission Mass Spectrometer analyzes the toxic gases produced by Costa Rica’s Turrialba volcano. The system detects toxic gas leaks and emissions in the Shuttle.

Continuously electrifying NASA’s analysis, metallurgical and chemical technology efforts, KSC made several support. Activities included developing contributions this year in areas of an X-ray dot map of slag harvested applied research & development, from Reinforced Carbon Carbon engineering development and leading edge wing debris using a laboratory services. scanning electron microscope and energy dispersive X-ray spectrometer, as R&D Magazine selected a KSC well as development of lexan wing researcher as the recipient of the models for display of the RCC debris. prestigious “R&D 100 Award” for the product, “Flexible Aerogel A KSC research and development Superinsulation.” R&D considered the team used a new hazardous gas creation to be one of the most detection system to study Costa Rican technologically significant products of volcanic emissions. The new prototype the year. This is the first such award won system, Aircraft-based Volcanic Emission by KSC. Mass Spectrometer (AVEMS), also applies to the Space Shuttle program. It Water intrusion into Space Shuttle is a step toward an advanced system Thermal Protection System tile is an old that detects toxic gas leaks and problem. During ascent, water can flash emissions in Space Shuttle engine and off, potentially causing tile damage. crew compartments, providing an Due to this concern, for many years added level of protection. From air and heat lamps were used for hours on end the volcano’s crater, the team analyzed to dry out tiles in case an orbiter was gases vented from Costa Rica’s exposed to rain. Rectifying this tedious Turrialba volcano. The study was the first task, KSC developed a method to to sample and quantitatively analyze detect water intrusion in tile, as well as a fresh volcanic gases in their natural method for water removal using a small state. The new system shows vacuum system attached to existing commercial promise and could be used waterproofing holes. for breath, blood and workplace air quality analyses. KSC laboratories provided critical support to the CAIB. This included NASA, the National Oceanic and working in both the hangar and the Atmospheric Administration (NOAA) laboratories providing real-time failure

KSC 2003 ANNUAL REPORT 32 Dr. Grant Gilmore sits alongside undersea expedition Asideequipment from used recognizing to characterize and the condition granting of the monetarydeep-sea coral awards reefs and for reef inventions fish populations and in the otherOculina scientific Banks, a marine and protectedtechnical area, 20 miles offshore of the east coast of Florida. contributions that support NASA’s aeronautical and space goals, the Space Act Awards program stimulates and encourages creation and reporting of similar contributions in the future.

KSC’s Technology Commercialization Office received 128 New Technology Reports for innovations developed at KSC. These include patent and NASA, the National Oceanic and copyright licenses, cooperative Atmospheric Administration (NOAA) agreements, and Space Act and other ocean scientists studied and Agreements. Some of KSC’s recent mapped deep-sea corals off Cape patent and license awards and license Canaveral’s shore. A multi-beam sonar offerings include the Advanced Self- system provided the first high-resolution, Calibrating, Self-Repairing Data 3-D map of the Oculina Banks. Formed Acquisition System, the Multipurpose by a single species of coral, Oculina Thermal Insulation Test Apparatus, and Banks’ deep coral reefs occur no where the Cable and Line Inspection else on Earth. Mechanism.

NASA, NOAA, the Navy, the Coast Technology Successes Guard, and the Florida Fish & Wildlife Commission performed underwater NASA-KSC’s Technology Transfer Office acoustic research involving sensor transfers developed technologies to technology demonstrations studying industry for commercial use as spinoffs fields ranging from marine biological and leverages industry partnerships to research to homeland security. The work create “spin-ins.” Spinoffs typically are also served as a pilot project assessing license agreements with companies, the agencies’ cooperation. while spin-ins are performed primarily through Space Act Agreements. The This is the fourth consecutive year KSC KSC Technology Transfer Office identifies earned more Space Act Award dollars partners for both and facilitates than any other NASA center. The fiscal agreement negotiations with industry year 2003 award amount of $195,700 is partners. Occasionally, a company proportionately divided among award licenses a NASA technology for areas. commercial use and that company partners with NASA to advance that More than 100 inventors received technology to better meet KSC’s needs recognition at the Sixth Annual KSC through a Space Act Agreement. In Space Act Awards Luncheon. The 2003, NASA-KSC signed seven winners individually collected $500 to technology license agreements and five $21,000. NASA retiree and exceptional technology Space Act Agreements, Space Act Award recipient, Adam listed below. Kissiah, not only received praise for inventing the cochlear implant 25 years KSC’s patent license with Toxicological ago, but also accepted $21,000—the and Environmental Associates, Inc., largest award to a single inventor in KSC Baton Rouge, La., prompts the use and history. sale of Emulsified Zero-Valent Iron.

33 KSC 2003 ANNUAL REPORT and other ocean scientists studied and Agreements. Some of KSC’s recent mapped deep-sea corals off Cape patent and license awards and license Canaveral’s shore. A multi-beam sonar offerings include the Advanced Self- system provided the first high-resolution, Calibrating, Self-Repairing Data 3-D map of the Oculina Banks. Formed Acquisition System, the Multipurpose by a single species of coral, Oculina Thermal Insulation Test Apparatus, and Banks’ deep coral reefs occur nowhere the Cable and Line Inspection else on Earth. Mechanism.

NASA, NOAA, the Navy, the Coast Technology Successes Guard and the Florida Fish & Wildlife KSC’s Technology Transfer Office Commission performed underwater transfers developed technologies to acoustic research involving sensor industry for commercial use as spinoffs technology demonstrations, studying and leverages industry partnerships to fields ranging from marine biological create “spin-ins.” Spinoffs typically are research to homeland security. The work license agreements with companies, also served as a pilot project assessing while spin-ins are performed primarily the agencies’ cooperation. through Space Act Agreements. The KSC Technology Transfer Office identifies This is the fourth consecutive year KSC partners for both and facilitates earned more Space Act Award dollars agreement negotiations with industry than any other NASA Center. The fiscal partners. Occasionally, a company year 2003 award amount of $195,700 is licenses a NASA technology for proportionately divided among award commercial use and that company areas. partners with NASA to advance that technology to better meet KSC’s needs More than 100 inventors received through a Space Act Agreement. In recognition at the Sixth Annual KSC 2003, KSC signed seven technology Space Act Awards Luncheon. The license agreements and five technology winners individually collected $500 to Space Act Agreements, listed below. $21,000. NASA retiree and exceptional Space Act Award recipient Adam KSC’s patent license with Toxicological Kissiah not only received praise for and Environmental Associates, Inc., in inventing the cochlear implant 25 years Baton Rouge, La., prompts the use and ago, but also accepted $21,000—the sale of Emulsified Zero-Valent Iron. largest award to a single inventor in KSC NASA, University of Central Florida, history. Department of Energy, Department of Defense, Environmental Protection Aside from recognizing and granting Agency, and GeoSyntec, Inc. created monetary awards for inventions and the innovative solution, which is other scientific and technical described further in the Environmental contributions that support NASA’s Leadership section. aeronautical and space goals, the Space Act Awards program stimulates Through a patent license, Pacific and encourages creation and reporting Instruments, Inc.’s (Concord, Calif.) of similar contributions in the future. Signal Conditioning Amplifier Recorder (SCAmpR) provides signal conditioning, KSC’s Technology Commercialization amplifying and recording capabilities in Office received 128 New Technology a single circuit board. SCAmpR Reports for innovations developed at significantly improves reliability, reduces KSC. These include patent and cost and provides more flexibility than copyright licenses, cooperative pre-existing systems used during Space agreements and Space Act

KSC 2003 ANNUAL REPORT 34 Shuttle launches. A Space Act Due to the Center’s proximity to the Agreement for co-development of Atlantic Ocean, KSC is a corrosive SCAmpR and KSC’s use of client-server environment. Cortec Corporation in St. software for SCAmpR supports the Paul, Minn., licensed a NASA-developed agreement. corrosion inhibiting technology—a Galvanic Liquid Applied Coating NASA provided TABER Industries in North System—for concrete structures. This Tonawanda, N.Y., with a patent license inorganic coating slows or stops to develop and commercialize the corrosion of reinforcing steel inside Multi-Sensor Array pressure transducer. concrete structures, thus protecting Working with sensors around Space launch support structures, highway Shuttle launch pads, it records physical bridges and KSC buildings. phenomena. The technology enables sensor clusters to uniquely monitor their Detcon, Inc. in The Woodlands, Texas, own health and estimate their own signed an Exclusive Patent License remaining lifespan. agreement for the UV/IR Hydrogen Flame Detector (U.S. Patent No. The patent license with Armor Holdings 5,625,342). The ultraviolet/infrared Forensics in Jacksonville, Fla., supports hydrogen flame detector reduces false the manufacturing and sale of a scaling alarms due to reflections from a known device and accompanying software. flame source or from non-flame sources KSC engineers developed the device to that emit UV, such as lightning or assess Space Shuttle external tank welding arcs. The company is tailoring damage following hailstorms. When a the technology to meet the needs of photograph is taken, a pattern, their commercial market through a non- projected by lasers, appears with the reimbursable Space Act Agreement investigated object’s image, allowing with KSC. the viewer to quantify the size of the object. Accompanying software A meeting with Circuit Avenue calibrates the pattern in the photo Netrepreneurs, in Camden N.J., at the image and computes the distance National Design Engineer Show (March scale for the entire image, saving 2002) led to a partially exclusive license valuable time in establishing and for the Advanced Data Acquisition documenting measurements. System (ADAS) in the fields of chemicals, pharmaceuticals and biotechnology. A A reimbursable Space Act Agreement minority owned business, it will use ADAS with Phoenix Systems International to develop their command, control and supports development of a Nitrogen monitoring system, which collects data Oxides (NOx) emissions reducer in fossil from telemetry-enabled instruments and fuel-burning power plants. This effort is a makes command decisions. continuation of previous KSC developments. Previously, Phoenix Via a Space Act Agreement, the Open obtained exclusive rights for all Channel Foundation and KSC offer the commercial applications of the KSC public software for researching NASA- NOx technologies, which reduced costs KSC technologies at http:// and elimination of hazardous waste www.openchannelfoundation.org/ streams. Additionally, this development cosmic/. The download is free for any could directly apply to the Space U.S. citizen or U.S.-owned company, and Shuttle launch pad NOx scrubbers and returns the taxpayer’s investment to the Center boiler plants. Participation under U.S. economy. Each technology’s this Agreement demonstrates NASA’s forum, providing outlets for user commitment to environmental comments, is monitored by the stewardship. innovators themselves, allowing users

35 KSC 2003 ANNUAL REPORT Researchers conduct underwater acoustic research in the Launch Complex 39 area turn basin.

direct contact with the NASA expert for Orbital Technologies Corporation that particular technology. A minimum (ORBITEC) in Madison, Wis., partnered of nine technologies totaling 64 with Utah State University to develop a transactions of KSC-developed software Temperature and Moisture Acquisition have been downloaded. System (TMAS) under the SBIR program. The TMAS measures moisture in small Also enhancing KSC’s technology base root modules used for plant research in through industry partnerships is the Small microgravity and can be used wherever Business Innovation Research (SBIR)/ pinpoint moisture readings are desired. Small Business Technology Transfer (STTR) TMAS is the moisture sensor chosen for program managed by KSC’s use in ORBITEC’s Plant Research Unit Technology Transfer Office. In 2003, the (PRU)—a plant growth facility under Office managed 50 SBIR/STTR contracts development by NASA’s Space Station valued at $18.1million. Biological Research Program for Space Station experiments. TMAS also SBIR/STTR funds early-stage research complements ORBITEC’s other biomass and technology development designed production systems, previously used by to address future mission needs. In 2003, NASA Ames Research Center. four SBIR/STTR funded projects were successfully implemented at KSC and A SBIR success model, NASA highlighted are described below. a unique software system, jointly developed with SENTEL Corp. in KSC engineers employed Optimal Alexandria, Va. The Electronic Portable Engineering Solution’s P.I. EXPERT, Information Collection system (EPIC) is ensuring Shuttle maintenance the first paperless procedure system operations run efficiently. Recognizing a used to launch rockets into space. EPIC need for versatile statistical software, recently supported two Atlas V three former university professors launches. SENTEL developed EPIC to developed a prototype integrating record and maintain hundreds of traditional statistical quality assurance mission-critical procedures that must be tools with robust optimization techniques completed before each launch. To in a user-friendly format that is also manage those resources, EPIC offers a visually compelling. With SBIR/STTR wireless network that communicates a funding, the company in Daytona series of work authorization procedures Beach, Fla., created the process almost in real time. improvement technology, which is critical to businesses looking to restructure or accelerate operations in order to gain a competitive edge.

KSC 2003 ANNUAL REPORT 36 academic and commercial tenants supporting NASA’s mission. The collaborative NASA and Florida Space Authority effort provides sites for commercially-developed research, technology and academic facilities. The year’s major focus was the PARTNERSHIPS Environmental Impact Statement and related analysis. This investigation helped NASA determine facility locations and provide Florida a long- term lease of the site. The park will accommodate up to 2 million square feet of development over a 20-year period.

The Center, Dynamac Corp., 45th Space Wing, Jet Propulsion Laboratory, The Center’s capabilities and research the National Oceanic and Atmospheric potential endlessly grows through its Administration, and National Marine relationships with pioneering Fisheries Service developed a passive organizations. acoustic monitoring systems prototype. These systems monitor vital fishery life KSC, the Air Force, the Secretary of history activities such as reproduction Defense office and the Federal Aviation and human activity. The Naval Administration addressed space launch Undersea Warfare Center and U.S. needs associated with low-cost, routine Coast Guard Research and and safe space access. As a result, the Development Center may deploy these Future Interagency Range and technologies for Cape Canaveral Spaceport Technology Program (FIRST) homeland security endeavors. emerged. FIRST develops key technologies to achieve global, The system can distinguish between interoperable spaceports and ranges. marine life and possible human and/or underwater craft movements. If marine Agency, Dynamac Corp., Bionetics and life is observed, it can tell the type of fish University of Florida researchers and and how many. It can even hear shrimp scientists moved to the 100,000 square- walking around and clicking their claws. foot Space Life Sciences (SLS) If human, it can tell if the noise is a diver, Laboratory located at the International a small submarine, etc. Space Research Park (ISRP). This facility serves as a research hub for plant KSC, GeoSyntec Environmental growth experiments, resource recovery Consultants, the DoD and U.S. Navy and microbiology/microbial ecology tested the NASA-developed Emulsified studies. Built by the state of Florida and Zero-Valent Iron environmental cleanup NASA, the laboratory also contains technique. This technology is described analytical chemistry labs, space flight further in the Environmental Leadership experiment facilities and a flight section. hardware development growth chamber. KSC and Phoenix Systems International, Inc. developed an application of the After SLS Lab completion, a developing Center’s oxidizer scrubber technology 320-acre tract outside the KSC security for use at coal- and oil-fired electric zone will expand the ISRP for access by power plants. The new system should be

37 KSC 2003 ANNUAL REPORT Hundreds of guests attend a ribbon cutting ceremony officially opening the U.S. Astronaut Hall of Fame as part of the KSC Visitor Complex. more cost effective, reduce nitrous adapted to the Return to Flight oxide emissions and extend the nation’s environment. coal reserves. Relying on the NASA/USAF Cape NASA’s Office of Space Science Canaveral Spaceport Planning and selected KSC, Cornell University, Florida Customer Service Office, some key Institute of Technology, University of developments progressed through the Arkansas at Little Rock, and Arctic Slope relationship. The Advanced Technology Regional Corp. to develop a Mars dust Development Center provides a particle analyzer for future landers or demonstration and testing environment rovers. Meeting stringent size, weight closely resembling a launch facility. The and power guidelines, this miniaturized Space Exploration Technologies instrument intends to perform real-time, (SpaceX) launch system is a privately simultaneous measurements of Mars funded commercial space launch dust particles. company. The Underwater Technology Development Program and its Passive Since the mid-1960s, the partnership Acoustical Monitoring System supports between KSC and the U.S. Air Force’s research. 45th Space Wing has highlighted the vast array of facilities, infrastructure, processes and intellectual talent both groups share. During the fiscal year, the partnership grew and evolved as KSC

KSC 2003 ANNUAL REPORT 38 KSC RESERVISTS CALLED TO SERVE

While orbiter processing and Columbia Though some have returned home, investigation work continued at KSC, many KSC reservists are still serving world events called many KSC civil today. servants and contractor workers away from families, friends and the Space KSC honors these brave men and Coast. Nearly 100 dedicated men and women as they continue to defend our women were called to serve and country and work to ensure liberty and defend our country as reservists in the justice for all, whether at home or on nation’s armed services. foreign soil.

As they serve in the Air Force, Army, Coast Guard or Navy, they carry with them the spirit, hope and determination of their “space” family at KSC.

KSC 2003 ANNUAL REPORT THE COLUMBIA RECOVERY AND RECONSTRUCTION

agencies, eventually encompassing 16,500 workers at all debris recovery sites. USA quickly pulled together the Workers place the final piece of the STS-107 mission necessary communications support patch on the outside of the hangar, where pieces of effort by Feb. 2 and provided computer Columbia debris were collected and identified. workstations and laptops with connectivity to the NASA sites at Barksdale AFB, and Texas locations in KSC Assists in Columbia Nacogdoches, Hemphill, San Augustine, Recovery Efforts Lufkin and Palestine. By the conclusion of debris recovery efforts, more than 800 KSC civil servants and contractor KSC employees were at 16 locations in workers went to Texas, Feb. 1, 2003, as six states. Search efforts were the result of the Columbia (OV-102/STS- conducted on land, by air and at sea. 107) tragedy. The first Rapid Response Team (RRT), comprising about 40 NASA and contractor personnel, traveled to Columbia Reconstruction Barksdale Air Force Base, La., within 10 at KSC hours of the accident. Within 72 hours, In the first days following the accident, a 120 USA managers and employees were team formed to plan Columbia’s deployed to Texas and Louisiana. reconstruction. The state’s Reusable Launch Vehicle hangar at the Shuttle Upon arrival at Barksdale AFB, the RRT Landing Facility was selected as the set up a command center to manage optimal reconstruction facility, based on resources and establish the its size, available technical workforce, infrastructure necessary to support such access to the vehicle ground- a large-scale effort. NASA coordinated processing infrastructure and its the overall effort, along with USA and proximity to materials science other contractors, the Federal laboratories. The facility became known Emergency Management Agency, as the Columbia Reconstruction Environmental Protection Agency, the Hangar. Texas Forestry Service and other assisting

KSC 2003 ANNUAL REPORT 40 The Reconstruction Team established During Columbia’s reconstruction, several critical processes for safe systems experts hosted more than 60 handling and management of the guided tours of the Columbia debris, which included receiving, Reconstruction Hangar and Launch handling, decontamination, tracking, Complex 39 Shuttle processing facilities, identification, cleaning and assessment provided presentations and led of the debris, with an emphasis on discussions for the CAIB, the media, evidence preservation. The team visiting Center personnel and other comprised engineers, technicians, interested officials. At the completion of inspectors and managers from NASA, the CAIB’s investigation, ground USA, Boeing and the National operations personnel supported a Transportation Safety Board. Columbia Reconstruction Hangar walk- through for more than 11,000 KSC The reconstruction effort spanned five workers and their families during six days months, during which 27 truckloads of in July 2003. Columbia debris arrived at the Columbia Reconstruction Hangar from Workers inventoried, packed and Barksdale AFB. The debris recovery moved Columbia debris to the Long- workers collected an estimated 38 Term Storage Facility in the Vehical percent of the orbiter’s dry weight, or Assembly Building. Parts of the vehicle approximately 84,900 pounds will be available to scientific, research, comprising 83,900 items. The majority of academic and governmental items were no larger than half a square organizations for hypersonic studies and foot. More than 40,000 items could not design of future aircraft and spacecraft. be positively identified. The remaining balance of debris was instrumental in steering the investigation toward a root cause—with 876 pieces associated with Columbia’s left wing as the most critical.

Initially, a two-dimensional reconstruction of the orbiter outer mold line was developed to facilitate assessment of the debris. As debris was positively identified, the left wing leading edge became the investigation’s main focus area. This initiated a three-dimensional reconstruction of panels one through 13 of the left wing leading edge.

Technicians used virtual reconstruction to create a replica of the orbiter left wing leading edge. A full-scale left wing was also built on tables to display lower surface thermal protection tiles and structure. These reconstruction techniques, used in conjunction with material sampling and failure analyses, allowed investigators to extract the greatest amount of information possible from the debris. Large items of Columbia debris seem to lay in an endless line.

41 KSC 2003 ANNUAL REPORT NASA Administrator Sean O’Keefe (left) looks over Columbia debris with Shuttle Test Director Steve Altemus, also a Columbia Reconstruction Project Team member.

KSC 2003 ANNUAL REPORT EDUCATION

Students place flowers at the Space Mirror Memorial to honor the fallen crew of Space Shuttle Columbia.

The Education Programs and University schools chosen from our regional service Research Division assists NASA in area. inspiring and motivating students to pursue careers in science, technology, Educators and students depend on the engineering and mathematics; and Center continuously for on- and off-site engaging the public in shaping and space-related workshops that provide sharing the experience of exploration curriculum material and classroom and discovery. Education Programs techniques. The office hosted 498 K-12 (EP) is one of 18 NASA Themes. schools, 46,004 K-12 students and 15,406 K-12 teachers. This year, the Division supported the development and implementation of This year, the Division strengthened its NASA’s Educator Astronaut Program. activity with the Workforce and Diversity Nearly 9,000 nominations generated Management Office to integrate efforts from the Center’s service area. KSC for the NASA Corporate Recruiting continues to follow the selection activity. This partnership strengthened process and interacts with many NASA’s recruiting and hiring of students applicants offering guidance and who competently fill gaps, and support. prepared for existing employee retirements. It also funneled EP KSC also helped implement a second participants into KSC vacancies. new Agency initiative—the NASA Explorer Schools Program. Five KSC In the research area, the Division regional service area schools are worked closely with the Spaceport participating to acquire new teaching Engineering and Technology directorate resources and technology tools for their to identify KSC’s top technology fifth to eighth grade classes. The Center requirements. With KSC’s Technology welcomed 22 Florida and Georgia Planning Team, Education identified educators for an intensive, hands-on potential technology research projects. summer workshop including a Station Adhering to the Team’s guidelines, link-up to interact with Expedition 7 participating faculty and students crew members. The KSC Education acquired projects supporting one of six office is in the process of strengthening Center Strategic Technology these relationships by visiting all five Development Initiatives.

43 KSC 2003 ANNUAL REPORT Students pause during work on their experiments that flew on Space Shuttle Columbia. STS-107 launched experiments designed and developed by students from six different countries.

Following the Columbia tragedy, collaborated with the Japanese countless students encouraged the Aerospace Exploration Association to Center and NASA family with letters, welcome a group of Japanese high pictures and other sympathetic school students whose experiments flew expressions. on STS-107. They honored the Columbia crew with a floral tribute at Spacehab’s Columbia Elementary School’s (Palm STS-107 memorial stone in Cape Bay) sixth graders greeted Kirstie Canaveral. McCool Chadwick, STS-107 Pilot William “Willie” McCool’s sister, attended By working with elementary and science demonstrations and placed secondary students and teachers, the carnations at the Space Mirror Division will keep improving the public’s Memorial. Gifted fourth and fifth graders understanding and appreciation of contributed a memorial quilt and wrote NASA’s missions, and promote letters to the Astronaut families, awareness of NASA EP’s vital role in President Bush, NASA employees and supporting the nation’s education Administrator Sean O’Keefe. A Sanford efforts. school created an STS-107 Memorial Garden. Education and KSC’s ISS and Payloads Processing Directorate

KSC 2003 ANNUAL REPORT 44 OUTREACH TO THE WORLD

This aerial view of the KSC Visitor Complex shows full-scale solid rocket boosters and external tank in the foreground, a full-scale model of a Space Shuttle orbiter behind them, the Launch Status Dome to the right, and the Astronauts Memorial Space Mirror next to the pond.

Kennedy Space Center Visitor Astronauts Sally Ride, Dan Brandenstein, Complex Story Musgrave and Robert “Hoot” Kennedy Space Center Visitor Complex Gibson were inducted into the (KSCVC) helped spread NASA’s Astronaut Hall of Fame, June 21, 2003. message to more than 1.4 million guests The event garnered extensive media from all over the world in 2003. The coverage. ABC’s Good Morning number is expected to grow steadily America broadcasted live from the through the continuous additions of new Astronaut Hall of Fame and featured attractions, exhibits and tour stops. interviews with both the new inductees as well as those honored in prior years. The addition of the Astronaut Hall of CNN broadcast the ceremonies live Fame as part of the KSCVC experience nationally. perfectly compliments the existing exhibits and attractions. Balanced A new retail store opened mid-year at against the machines and hardware the Orlando International Airport. Its that make space exploration a reality, success provides daily evidence of the the Astronaut Hall of Fame tells the other public’s respect for NASA and reminds side of the story, the human side. It those visiting Central Florida how close focuses on the astronauts who took the Visitor Complex is to Orlando. The those first brave steps into space, store serves as a NASA icon to the more offering a glimpse at the formative years than 13.5 million visitors passing through of these pioneers, and a first-hand look the airport annually. at the NASA training that molded them into heroes. KSCVC education programs continued to expand in 2003. The summer day Space Camp facilities opened more camp program had a record year with opportunities for the public to more than 900 participants. An participate in learning about human extremely successful patch program space flight. New programs, such as day designed exclusively for home- Astronaut Training (ATX), allow visitors to schooled students attracted more than engage in a hands-on Shuttle launch 1,500 students and parents. In and mission. November, the Visitor Complex

45 KSC 2003 ANNUAL REPORT Employees produce a KSC Direct! Web broadcast.

partnered with NASA, the Brevard The Office provided input to the Web County School Board and the National site myregion.org project, which Space Club to host every Brevard promotes regional cooperation and County sixth grade student at KSCVC for development, and assisted KSC a day of hands-on learning. management with presentations to the Brevard County Commission. Government Relations KSC’s Government Relations Office KSC Web site and Webcasting arranged several significant meetings Expanded capabilities and new features and events, including Florida Space Day on both KSC’s Web site and KSC Direct! in Tallahassee, March 27. Former Center highlights the year. Several new Web site Director Roy Bridges and industry features were added, including the KSC partners met with Florida Gov. Jeb Bush, Hall of Honor Web site, which allows Lt. Gov. Toni Jennings, Secretary of State former and current employees to add Glenda Hood, Senate President Jim King career summary information, and a new and Speaker of the House Johnnie Byrd KSC 45th Anniversary site full of to reinforce NASA’s Vision and KSC’s informative text, photos and videos. mission. The NASA contingent emphasized the many economic, Earlier this year, KSC assumed Agency- research and technological benefits wide responsibility for the content and that the Space Program brings to management of the “Mission” section of Florida. the newly revised NASA Portal. Mission timeline information, feature articles and The Office hosted visits to KSC by U.S. NASA Direct! video features about Earth Sen. Bill Nelson, U.S. Reps. Dave Weldon Observation, Shuttle and ISS, Solar and Tom Feeney, and Congressmen System, Deep Space, Science and Tom Delay (Texas) and Mike Ross (Ark.). Technology, and Research Aircraft

KSC 2003 ANNUAL REPORT 46 Young women sign a Columbia tribute poster at the Sally Ride Science Festival. Held at the University of Central Florida, Orlando, Fla., the event encourages girls to pursue science, math and technology career paths.

missions are added regularly. Since format in English, as well as a new assuming this responsibility in June 2003, Spanish version. the Mission section has been the most frequented of the Portal’s four public Live Space Shuttle launch coverage feature sections. Web sites and Web broadcasts were also created for Missions STS-112 Multimedia Gallery search capabilities (October), STS-113 (November) and STS- were improved, and archived video 107 (February). on-demand capabilities now enhance the site. Development and launch of a Shuttle Columbia Tribute/Information site on New ELV mission Web sites, live launch Feb. 3 kept the public informed with the and NASA Direct! Web broadcasts latest information. Updated daily were introduced this year to provide throughout the CAIB efforts, the site up-to-the-minute launch countdown included press briefings, hearings, updates, extensive mission information, reports, memorials, transcripts and and interactive question and answer general information. sessions with program experts. This new programming began with the MER-A During the year, KSC’s Web site, live “Spirit” (June 10), followed by MER-B mission coverage and KSC Direct! “Opportunity” (July 7) and SIRTF (Aug. programming reached more than 10 25) launches. million people. U.S. visitors accounted for approximately 80 percent of those The first live launch Web coverage from accessing the site throughout the year. Vandenberg Air Force Base occurred An average of 859,000 visits were made during the SCISAT launch, Aug. 12. to the site per month.

A redesigned KSC Site Survey now Exhibits allows for better public feedback. To The exhibits team took the NASA keep the public informed and updated message on the road to 39 events and on important NASA news, our Weekly reached more than 509,000 people— News Briefs now feature a two-anchor double those reached last year—across

47 KSC 2003 ANNUAL REPORT Col. Everett Thomas (left), 45th Space Wing, presents a framed memento to astronaut John Herrington, the world’s first Native American astronaut. the country and beyond. From the Air Show at the request of the state of National Association for the Florida, and to a Lisbon, Portugal Advancement of Colored People workshop. (NAACP) Convention in Miami, Fla., to the Centennial of Flight in Dayton, Ohio, Speakers Bureau to the National Space Symposium in Over the years, the demand for Colorado Springs, Colo., KSC’s road speakers has grown and this year was show explained NASA’s exciting space no different. KSC sent speakers to 566 flight history, education programs, and events, reaching approximately 300,000 new science and technology programs. people throughout Florida and Georgia, other U.S. states, along with the Virgin Exhibits included graphic displays of Islands, England, Holland and Canada. NASA-wide programs (Space Shuttle, ISS The number of events represents and LSP), spaceport technology, the approximately a 20 percent increase benefits of space, spinoffs, NASA’s over last year. mission and vision statement, and focused on the One NASA theme KSC’s Speakers Bureau supported 12 throughout the year. international events and 40 national events. These included the Florida State KSC worked closely with the Jet Native American Youth Program Propulsion Laboratory to educate the sponsored by the Governor’s Office, public on the importance and safety National Space Day, and the concerns of the Mars missions. One of dedication of many Columbia KSC’s guiding principles, the Memorials throughout Florida, Georgia environment, was showcased at the and Puerto Rico. Environment Convention in San Diego, Calif. A group of 25 astronauts and many others brought the NASA message to a Other events included exhibits in broad base of diverse events and Georgia, New York, North Carolina, organizations, including the Women in Texas and Utah. Beyond our own shores, Law Enforcement Conference, the KSC also took the message to the Paris Florida Department of Transportation

KSC 2003 ANNUAL REPORT 48 Conference, aviation associations, The News Center also coordinated aerospace clubs, Boys Scouts, Girl requests from production and Scouts and Florida Library programs. documentary companies, television, radio and print news reporters from the Speakers also presented to the Hispanic U.S., Spain, Switzerland, Latin America, Heritage Celebration in Tampa, Fla., the England, Hungary, Italy, Japan, the Hispanic Conference in Puerto Rico; Netherlands, France, Russia and American Society of Engineers of Indian Belgium. During the year, the Press Site Origin; Youth Leadership Program for arranged access for and escorted 34 Hispanic Students in Orlando; Society of production companies and 20 television Women Engineers; Brevard County Parks news crews to various locations around and Recreation Summer Day Camps for the Center, provided support for 31 KSC disadvantaged youths; and the special events, and coordinated and Governor’s Council on Indian Affairs. accompanied 46 print journalists during assignments. Topics ranged from general to specific aspects of NASA’s space flight Among the many significant projects programs. supported were The History Channel/ Greystone filming of a one-hour Media Outreach documentary on lightning; NASA TV During a Space Shuttle launch and coverage for the ISS elements Node 2 landing, special event, or just the day- and JEM arrival ceremony; and Mars to-day business of doing what KSC does Rover viewing; also, the IMAX White best, the KSC News Center hosts Mountain Productions shoot for a movie hundreds of local, national and titled, “Mars”; interviews for The international media representatives, Discovery Channel; and a Kazakhstan, dignitaries, photographers and film Russia TV crew for a series of TV crews. Stories generated at the Press magazine programs. Site result in millions of people around the world learning more about America’s Space program.

The KSC News Center team produced a wealth of print, audio and video material, and photographic images ensuring requests were fulfilled with current information. During the year, the Press Site provided 134 news releases, 2,548 interviews, 492 audio tapes, 3,833 videotapes, 161,042 photographs, and bi-weekly issues of Spaceport News. Media support was provided during Missions STS-112, STS-113 and STS-107. Topics included Space Shuttle processing, rollout, crew pre-flight training and activities, and Space Shuttle launches and landings. The News Center also provided media support to the LSP for ELV launches, which included TDRS-J, ICESat/CHIPSat, SORCE, GALEX, At Launch Complex 39B, media representatives are SCISAT, SIRTF, and MER-A and MER-B. briefed on the improved tracking cameras that will capture ascent imagery during future Space Shuttle flights.

49 KSC 2003 ANNUAL REPORT KSC BUSINESS REPORT

principles will be used to formulate future annual budgets. Financial operations under this practice began in Financial Highlights October. Financially, FY 2003 included significant changes for the Agency and the Both the IFMP implementation and Full Center. The new IFMP replaced the Cost Initiative support the legacy financial systems used for more Administration’s “President’s than 20 years. In February 2003, KSC Management Agenda,” focusing on began recording transactions in the improving performance and new Agency-wide Core Finance system. demonstrating results. During that time, a new Travel Manager system was also initiated as part of the KSC successfully maintained and integrated system to manage all Center increased its share of the NASA budget travel-planning and expenses. (see accompanying chart). The FY 2003 KSC-managed budget totaled $1.760 Additional financial activities included billion, which including the JSC- preparation and planning for future managed Space Flight Operations modules of the integrated system, Contract, with 5,000 workers located at including Budget Formulation, Asset KSC. While this budget level essentially Management, E-Payroll and E-Travel. remained constant with FY 2002 levels, Another significant change was the the Center projects an increase to more implementation of the Full Cost Initiative than $2 billion for FY 2004. beginning in FY 2004. The Full Cost Initiative ties direct and indirect costs to This funding fuels the local economies of NASA’s major programs, projects and Brevard County and Central Florida, institutional activities. KSC’s institutional with the resulting economic impact and infrastructure costs, such as civil measured, analyzed and published service salaries and the use of facilities annually. While FY 2003 results are and support services, are now linked to incomplete to date, they are the Center’s programs and projects. summarized and projected in the next section. The work performed at KSC, whether it be an Agency program or external work FY 2003 was a productive year that will on a cost reimbursement basis, will pay significant future dividends for the include the full range of costs required Agency, the KSC workforce and the to perform the activity. Full Cost local economy.

KSCKSC 2003 2003 ANNUAL ANNUAL REPORT REPORT 50 these economies and created a multiplied level of total economic activity that far exceeded NASA’s initial injection.

To conduct its exploration of space, NASA requires an extraordinary range of commodities including fuel, missile ECONOMIC IMPACT engines, computers and photographic equipment. The range of services it purchases is just as wide, including communications, laboratory testing, Space Shuttle processing, payload integration and testing, expendable launch services and university research. To meet NASA’s demand for these goods and services, local contractors employ workers, fund payrolls and Just as the sights and sounds of a rocket generate output. These workers and launch brings excitement to the lives of contractors generate additional many Central Floridians, the enormous impacts as they spend their incomes operation that is required to make the and place orders with other regional launches possible releases a powerful firms for materials and services. Each blast of economic activity that flows round of spending recirculates NASA’s through the businesses and households initial demand among Florida’s of Brevard County, the Central Florida businesses and households, multiplying region and other areas of the state. the direct impact on the economy. While the thrill of the launch is relatively short-lived, the economic effects of There are a number of other activities NASA operations in Florida are directly associated with NASA that also continuous and sustained. In FY 2003, of add to its total economic impact in the $15 billion NASA budget, NASA-KSC Florida. These include the local travel and other NASA centers injected over expenditures of out-of-state business $1.4 billion into Florida’s local and state and government personnel that travel economies. This spending prompted a to KSC to conduct business and the KSC cycle of economic transactions that Visitor Complex sales to out-of-state flowed throughout many sectors of visitors.

KSC BUDGET AUTHORITY SUMMARY FY 2002 THRU FY 2004 (DOLLARS IN MILLIONS)

51 KSC 2003 ANNUAL REPORT DIRECT PURCHASES FROM CONTRACTORS AND PAYMENTS TO HOUSEHOLDS BY KSC AND OTHER NASA CENTERS IN FLORIDA IN FY 2003 (Preliminary)

THE TOTAL ECONOMIC IMPACT OF ALL NASA ACTIVITIES AT KSC IN FLORIDA BY GEOGRAPHIC AREA FY 2003 (Preliminary)

KSC annually conducts an Economic report. The 2003 report is not yet Impact Analysis to measure NASA’s completed, but estimates for 2003 are effect on the economy at the local, provided. regional and state levels. The University of Central Florida conducted the 2002

KSCKSC 2003 2003 ANNUAL ANNUAL REPORT REPORT 52 WORKFORCE DIVERSITY

KSC is the most broadly based, complex To accomplish the various missions and successful launch center in the expected of the Space Center, world. Through NASA, KSC acts as a employees carry out a multitude of premier national landmark capable of tasks. At the end of each year, the showcasing the United States’ prowess Center takes a “snapshot” of its in science and technology. KSC is able workforce. This picture includes all to help the nation achieve its objectives federal and contract employees in Space due primarily in part to the chartered to work for KSC. Other dedication of its workforce, which not organizations, such as the European only includes civil service employees, Space Agency and Patrick Air Force but also a large number of contractor Base, have roles here, but are not employees. Together they are essential reflected in these numbers. As of Sept. in making KSC’s vision a success. 30, 2003, the KSC workforce was as follows:

Kennedy Space Center Workforce

On-Duty Full Time Civil Servants 1,748 On-Duty Other-than-Full Time Civil Servants 91 Total Civil Servants 1,839

Civil Servant Skill Mix Scientific & Engineering 59.2% Administrative 25.7% Technical 8.3% Clerical 6.9%

On-Site Contractor Employees 9,738 Off-Site Contractor Employees 753 Total Contractor Employees 10,491

Total Construction Employees 379

Total Tenants 1,303

TOTAL KSC POPULATION 14,012

53 KSC 2003 ANNUAL REPORT PROCUREMENT REPORT

Industry Partners at a Glance and worldwide Trans Atlantic Landing The companies listed below were KSC’s sites. The SFOC has a total award value top business contractors (in terms of of $12.7 billion. obligations) for FY 2003. The following briefly describes their work for the Boeing Space Operations Center: Company Boeing Space Operations Company is Space Gateway Support (SGS) the prime contractor for the Checkout, SGS, a joint venture (with Northrop Assembly and Payload Processing Grumman, Shaw and Wackenhut) Services (CAPPS) contract. Its primary provides base operations support for purpose is to support payload KSC, CCAFS and PAFB, including roads processing for the ISS, Space Shuttle, and grounds maintenance, facilities ELVs and other payload programs. maintenance, custodial, fire, security, Boeing performs all aspects of payload calibrations and propellants handling. processing, including the planning and They held one contract valued at $2.7 receiving of payloads, payload billion over the life of the contract. processing, maintenance of associated payload ground systems, integration of United Space Alliance (USA), payloads with the Space Shuttle, launch Limited Liability Corp. support and Space Shuttle post-landing payload activities. CAPPS is a cost-plus USA is the prime contractor for the performance/award fee contract with a Space Flight Operations Contract basic four-year period of (SFOC) whose primary purpose is to performance and options to extend the ensure mission success (including contract for an additional six years. The meeting the manifest) for the Space value of the contract for the initial four Shuttle Program. KSC is the primary point year period is $332 million. Work is of responsibility for launch and landing performed at the Center, CCAFS, VAFB, of the Space Shuttle, and supports Space Shuttle landing sites and at Ground Operations and Orbiter Logistics various payload associated work elements of the Space Shuttle Program. locations within and outside the U.S. KSC partnered $100 million in FY 2003 on the SFOC contract. USA performs at KSC, JSC, MSFC, SSC, DFRC, White Sands

KSC 2003 ANNUAL REPORT 54 Delta Launch Services Inc. to engineering and technical support of Delta Launch Services Inc., the Boeing various KSC laboratories and test beds. Company, is the prime contractor for ASRC Aerospace utilizes a consortium of one of two existing NASA Launch affiliated universities in performing Services (NLS) multiple award Indefinite applied research and technology Delivery Indefinite Quantity (IDIQ) task development efforts. ASRC Aerospace order contracts. Principal work location also provides technology outreach to for the Delta II vehicle assembly is foster awareness and utilization of KSC Decatur, Ala. Launches occur from unique capabilities. CCAFS and VAFB. Orbital Sciences Corp. Lockheed Martin Commercial Orbital Sciences provides small ELV Launch Services Inc. services for the Agency, using the Pegasus and Taurus small ELVs launched Lockheed Martin Commercial Launch from CCAFS, VAFB, Wallops Flight Services, Inc. is the prime contractor for Facility, Va., and equatorial launch one of two existing NLS multiple award ranges. IDIQ task order contracts. Principal work location for the Atlas vehicle assembly is Denver, Colo. Launches occur from Dynamac Corp. CCAFS and VAFB. The Life Sciences Services Contract provides a broad range of life sciences The Artic Slope Research Corp. services to NASA. These include medical operations for Shuttle and Station (ASRC) Aerospace programs, environmental compliance ASRC Aerospace provides research and and stewardship, life sciences payload engineering services and technical operations, support to the Agency support to the KSC Spaceport Occupational Health Program Office, Engineering and Technology biological science, life sciences payload organization and other Center development, workforce protection, operational customers. The support fitness and musculoskeletal ranges in scope from providing rehabilitation, and education outreach. research, engineering development, management of complex research and development and technology projects

55 KSC 2003 ANNUAL REPORT DISTRIBUTION OF FISCAL YEAR ‘03 OBLIGATIONS BY BUSINESS TYPE (IN MILLIONS)

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Analex Inc. Supporting Small Business Analex is the prime contractor on the Supporting small business is a NASA ELV Integrated Support contract. The priority. During the fiscal year, KSC contractor is responsible for performing obligated $127.2 million dollars to small and integrating the overall businesses, achieving 141.33 percent of programmatic ELV business and the small business goal of $90 million. This administrative functions, including was a significant increase from the program/project planning, risk $102.9 million dollars in small business management, evaluation and awards made in FY 2002. information technology. Services provided include the management, operation, maintenance and sustaining engineering of the NASA ELV telemetry stations located at CCAFS and VAFB; engineering services/studies and technical services for various ground/ flight ELV systems and payloads and; management, operation, maintenance and sustaining engineering of the assigned NASA facilities, systems and equipment at VAFB. Services are provided at KSC, CCAFS, VAFB and other launch sites and launch service provider facilities.

KSC 2003 ANNUAL REPORT 56 YOUR PROCUREMENT DOLLARS AT WORK

During the fiscal year, the Center obligated approximately $856 million within the U.S. in support of the NASA mission. As indicated by the chart below, 34 different states received procurement dollars from KSC.

GEOGRAPHICAL DISTRIBUTION BY STATE (FISCAL YEAR 2003 OBLIGATIONS)

State Total ($k)

Alabama 543 Arizona 11,741 California 81,737 Colorado 2,397 Connecticut 7,027 District of Columbia 99 Florida 720,020 Georgia 2,790 Hawaii 93 Illinois 411 Kansas 139 Kentucky 1,340 Louisiana 345 Massachusetts 3,554 Maryland 3,022 Michigan 241 Minnesota 825 Mississippi 99 North Carolina 382 North Dakota 27 New Hampshire 301 New Jersey 288 New Mexico 3,813 New York 2,509 Ohio 2,597 Oklahoma 362 Pennsylvania 661 Rhode Island 52 South Carolina 455 Texas 4,853 Virginia 2,907 Washington 131 Wisconsin 295 Wyoming 225

Total: * $856,281 * Includes Intragovernmental, Grants, Agreements and Bank Card Transactions.

57 KSC 2003 ANNUAL REPORT TOP 20 KSC BUSINESS CONTRACTORS FOR FISCAL YEAR 2003

Contractor Number of Dollars Obligated Contracts (in Thousands)

Space Gateway Support 1 297,222 The Boeing Company 8 162,728 Delta Launch Service Inc. 1 107,127 Lockheed Martin Integrated 3 33,878 Systems Inc. Boland David A Inc. 1 23,989 Analex Inc. 1 17,406 A S R C Aerospace Corp. 1 16,868 Dynamac Corp. 4 14,439 Orbital Sciences Corp. 1 11,422 O A O Corp. 1 10,711 Air Liquide America Corp. 2 9,592 Praxair Inc. 5 8,258 Dynacs Engineering Company 1 6,507 Inc. Air Products & Chemicals Inc. 2 5,213 Military Construction Corp. 9 4,843 Johnson Controls World Services 1 4,115 Advanced Electrical Installation 4 2,528 Telephonic Corp. 1 2,364 All Points Logistics Inc. 4 2,257 Jones Edmunds & Associates 17 2,209

TOTAL: 68 $741,467

* Note: The JSC managed Space Flight Operations Contract recorded $690 million managed by the KSC Procurement Workforce in FY 2003.

KSC 2003 ANNUAL REPORT KSC 2003 ANNUAL REPORT 58 Attached underneath the L-1011 aircraft is the Pegasus XL rocket, containing NASA’s Solar Radiation and Climate Experiment.

KSC 2003 ANNUAL REPORT