1974020215 MSFC SKYLABORBITALWORKSHOP Vol.I Skytab Program Office NASA GeorgeC. Marshall Space Hight Center Marshall SpaceFlight Center, Alabama (NASA-_M-I- 64813-Vol- I) MSFC SKYLAB N7U-28328 CRBI_AL IOBKS_O_, VOLUM£ I (NASA) 564 [: HC $10.75 CSCi 22_ Unclas G3/3_ 425_1 MSFC - Form 3190 (Rev Jua_e 1971) 1974020215-002 PRDCEDINGPAGE BI.ANK NOT _IL_IED TABLE OF CONTENTS Section Title Page Volume I 1 INTRODUCTION ........................ i-i i.i PURPOSE AND SCOPE .................. i-_ 1.2 SUMMARY ....................... 1-3 1.2.1 Design Goals ................. 1-3 1.2.2 Mission Results ............... l-y 2 SYSTEM DESIGN AND PERFORMANCE ............... 2.1-1 2.1 GENERAL ....................... 2. l-1 2.1.1 Design Philosophy .............. 2.1-1 2.1.2 Wet to Dry Evolution ............. 2.l-h 2.1.3 Overall Test Program ............. 2.1-9 2.l.h Final Configuration Discussion ........ 2.1-16 2.1.5 Mission Performance ............. 2.1-51 2.2 SYSTEMS ....................... 2.2.1-1 2.2.1 Structural System ............ 2.2.1-1 2.2.2 Meteoroid Shield System .......... 2.2.2-1 2.2.3 Environmental/Thermal Control Subsystem (E/TCS) .............. 2.2.3-1 Volume II 2.2.4 Thruster Attitude-C_n_ro_ System (TACS) . 2.2.h-i 2.2._ Solar Array System .............. 2.2.5-1 2.2.6 Electrical Power Distribution System ..... 2.2.6-1 2.2.7 I ll,_ninati on System ............. 2.2.7-1 2.2.8 Communication and Data Acquisition System . 2.2.8-1 2.2.9 Caution and Warning System .......... 2.2.9-i 2.2,10 Experiment Accommodations Systems ...... 2.2.10-1 Volume III 2.2.11 Habitability Support Systems ......... 2.2.11-1 V Imeu IV 2.2.12 Pressure Garmen_ Conditioning System 2.2.12-1 2.2.13 Stowage System ............... 2.2.15-1 2.2.1_ Ground Support Equipment System ....... 2.2.1h-i 2.2.15 M_-kings System ............... 2.2.15-1 2.3 MATERIAL USAGE AND CONTROL .............. 2.3- i in 1974020215-003 TABLE OF CONTENTS (Continued) Section Title Page Volume V 3 RELIABILITY PROGRAM .................... 3-i 3.1 OBJECTIVE AND METHODOLOGY .............. 3-i 3.2 RELIABILITY .................... 3-2 3.2.1 System Reliability Analysis ........ 3-2 3.2.2 Design Support ............... 3-12 3.2.3 Production and Test Support ......... 3-21 3.3 CONCLUSIONS AND RECOMMENDATIONS ........... 3-31 SYSTEM SAFETY PROGRAM ................... h-i 4.1 GENEmtL....................... _-i 4.2 CREW SAFETY..................... _-4 4.2.1 Concept Phase ................ 4-h 4.2.2 Design Phase ................ 4-4 4.2.3 Test and Operations Phase .......... 4-18 4.3 TRAINING ...................... 4-28 4.3.1 Skills Training ............... 4-28 4.3.2 Operational Training ............ 4-29 4.3.3 Employe Motivation/Awareness ........ 4-29 h.4 CONCLUSIONS AND RECOMMENDATIONS ........... 4-33 5 TESTING PROGRAM ...................... 5-1 5.0 INTRODUCTION .................... 5-1 5.1 TEST REQUIREMENTS .................. 5-5 5.1.1 General Requirements and Guidelines ..... 5-5 5.1.2 Documentation and Coutrol Requirements of Component and Subsystem Testing ....... 5-7 5.1.3 Documentation and Control Requirements - •.... Spacecraft Systems and Integrated Vehicle Testing ............... 5-11 5.1.4 Documentation and Control Requirements - Mission Support Testing ........... 5-18 - iv 1974020215-004 TABLE OF CONTENTS (Continued) Section Title Page 5.2 COMPONENT AND SUBSYST}_4 TESTING ............ 5-21 5.2.1 Development and Qualification Testing ..... 5-2 5.2.2 Production Acceptance Tests (PAT) ....... 5-45 5.3 STRUCTURES TESTING .................. 5-hb 5.h SPECIAL DESIGN SLTPORT AND VERIFICATION TESTS ..... 5-h9 5.5 SPACECRA/T SYSTE4S TESTING .............. 5-59 5.5.1 General .................. 5-59 5.5.2 Structures .................. 5-63 5.5.3 Environmental Control ............. 5-6h 5.5.h Electrical .................. 5-66 5.5.5 Instrt_enta*ion and Communications ...... 5-69 5.5.6 Waste Management ............... 5-73 5.5.7 Solar Array System .............. 5-7h 5.5,8 Refrigeration ................. 5-76 5.5.9 Ordnance Subsystem .............. 5-78 5.5.10 l_le_atic Subsystem ............. 5-79 5.5.11 Crew Systems ................ 5-81 5.5.12 Stowage .................... 5-82 5.5.13 Experiments Subsystem ............. 5-83 5.5.14 Water ..................... 5-86 5.6 INTEGRATED VEHICLE TESTING - KSC ........... 5-87 5.6.1 General ................... 5-87 5.6.2 _'ehiele Arrival, Inspection and Vertical Assembly ................... 5-87 5.6.3 Subsystem Verification ........... 5-89 5.6.4 System Verification .............. 5-125 5.6.5 Final System Tes.t and La_nch ......... 5-128 b.7 MISSION $UPPCRT TESTING ................ 5-130 5.7.1 0WS Backup .................. 5-130 5.7.2 Laboratory .................. 5-141 1974020215-005 TABLE OF CONTENT5 (Continued) Section Title Page 6 ENGINEERING PROGftM MANAGEMENT ............... 6-1 6.1 PLANNING AND SCHEDULING ............. 6-1 6.i. 1 Design and Development ............ 6-1 6-3 6.1.2 Design Changes ............... 6. i.3 Recommendations for Future Programs ..... 6-8 6.2 CONFIGURATION MANAGEMENT ............. 6-9 6.2.1 Configuration Identification ...... 6-9 6.2.2 Configuration Control ........... 6-13 6.2.3 Configuration Accounting ........ 6-21 6.2. h Change Traffic ................ 6-22 6.2.5 Conclusions and Recommendations ....... 6-2h 7 MISSION OPERATIOn,S SUPPORT ................. 7-1 7.i GENERAL ....................... 7-i _.2 MDAC-W SUPPORT AT MSFC ................ 7-3 7.2.1 Overview of MDAC-W's Role at MSFC ...... 7-3 7.2.2 MDAC-W/MSFC Mission Support Interface .... 7-h 7 •2.3 Facility Definition ............. 7-6 7.2.4 MSFC Skylab Data System ........... 7-9 7.2.5 MDAC-W Support Structure and Manning Schedules .................. ?-lh 7.2.6 Action Request Flow ............. 7-i_ 7.3 MDAC-W SUPPORT AT HUNTINGTON BEACH ......... 7-18 7.3.i Overview ................... 7-18 7.3.2 Mission Support Team Definition/Organization . 7-18 7.3.3 Summary of Huntington Beach Prelaunch Operations Support .............. 7-19 7.3._ Identification and Man_gem_:nt of OWS Problems/Action Requests ........... 7-23 F 1974020215-006 TABLE OF CONTENTS (Cont inue¢,) Sectxcn Title Page 7.3.5 Su_ of Mission Support Action Items • . • 7-25 7.3.6 Facility Description/Evaluatiou . • 7-31 7.3.7 Mission Support Manning Schedules (MannedlUnmsnned) .............. 7-37 7.4 CONCLUSIONS AND RECOMMENDATIONS ........... 7-43 0 h . i General . • • • • • • • • • • • • • • • • • 7 -- 43 :.A. 7.4.2 Prelaunch Support .............. 7-43 . h • 3 Mission Simulations • . • • • • • v e • o • • 7 43 7.h._ Mission Support Organization and Manning . 7-44 7.h.5 Mission Support Facilities .......... 7-44 7._. 6 Action Item Assignment. Tracking and Re,,ponse 7-45 7._. 7 Hardware and Test Support .......... 7-46 7.h.8 MDAC-W On-Site Support at MSFC ........ 7-47 8 NEW TECHNOLOGY ....................... 8-1 8.1 AEROSPACE APPLICATIONS ................ 8-1 8.1.1 New Technology Patent Disclosures ...... 8-1 8.1.2 Applicable Hardware and Design Approaches . 8-1 8.2 OTHER APPLICATIONS .................. 8-22 8.2.1 Electronic/Electrical ............ 8-24 8.2.2 Fireproof Materials ............. 8-25 8.2.3 Zero Gravity Restraint Equipment ....... 8-26 8.2.h Structural Technology ............ 6-26 8.2.5 Fire Detection, Prevention and Suppression . 8-27 8.2.6 Bioe_de Wipes ................ 8-27 8.2.7 Thermal Mechanical .............. 8-28 8.2.8 Potable Water Sterilization ......... 8-28 _ ._ 8.2.9 Noise Control ................ 8-28 8.2.10 Pneumatic Valve Design ............ 8-29 8.2.11 Product Safety Evaluation .......... 8-29 :_ vii 1974020215-007 TA_L_ OF CONTENTS (Continued) Section Title Page 9 CONCLUSIONS AND RECOMMENDATIONS ............. 9-1 9.1 MISSION PERFORMANCE ................ 9-A 9.1.1 S+ructural System .............. 9-1 9.1.2 Meteoroid Shield (MS) ............ 9-5 9.1.3 Thermal Control System (TCS) ......... 9-5 9.l.h Thruster Attitude Control System (TACS) • • • 9-7 9.1.5 Solar Array System (SAS) ........... 9-8 9.1.6 Electrical Power Distribution System (PDS) . 9-10 9.1.7 Illumination System ............. 9-11 9.1.8 Communication and Data Acquisition Systems (DAS) .................... 9-11 9.1.9 Caution and Warning (C&W) System ....... 9-13 9.1.10 Experiment Accommodations Systems ...... 9-13 9.1.11 Habitability Support Systems (HSS's) ..... 9-15 9.1.12 Pressure Garment Conditioning System ..... 9 Z3 9.1.13 Stowage System ................ 9-23 9.1.14 Marking System ................ 9-25 9.2 PROGRAM PLANNING ................... 9-26 9.2.1 Organization ................. 9-26 9.2.2 Establishing Requirements .......... 9-28 9.2.3 Controlling to Requirements ......... 9-29 9.2.h Improvements for Future Programs ....... 9-31 9.3 TESTING ....................... 9-36 i 9.3.1 Development and Qualification ........ 9-36 9.3.2 Spacecraft Systems Testing .......... 9-39 9.3.3 Conclusions and Recommendations ....... 9-h2 9.4 PRELAUNCH AND MISSION SUPPORT ............ 9-45 i0 ]IBLIOGRAPHY I0-i / _ viii J 1974020215-008 FIGURES : N umber _ • 1.2. i-i Skylab Orbiting Assembly 1-4 1.2.1-2 Skylab - Function of Modules 1-5 :z i i.2.1-3 Orbital Workshop I-7 1.2.I-4 Mission Design Profile i-8 % 1.2.2.5-1 Mission Actual Profile 1-13 2.i. i-i S-IV-Gemini Space Laboratory Concept 2.1-2 2.i. 2-I NASA Saturn S-IVB Orbital Workshop 2.1-5 2.1.2-2 Wet Workshop Launch Configuration 2.1-7 2.1. h.1--1 Orbital Workshop Tank Assembly, Skirts and 2.1-17 Interst age ? 2.1.4.2-1 Meteoroid Shield 2.1-19 2.1.4.3-1 Active Thermal Control System 2.1-21 ! 2.1.4. h-1 Thruster Attitude Control System 2.1-23 2.1.4.5-i Solar Arr%y System 2.1-25 2.1.