METTS III Industry Day Scripts (site tour_12-19-19).pdf

METTS III Industry Day Bus Tour Scripts

Thursday, December 19, 2019

Please Note: The Stops listed below represent the route order for Bus 1. The route order for Bus 2 is the reverse of the route order for Bus 1.

Stop 1, Script 1: BLDG 4705, Mechanical Fabrication and Facility Operations

Summary

The machine shop is approximately 35,000 sq-ft. It contains machinery such as conventional lathes and mills, vertical turning lathes (VTL), 3-, 4-, and 5-axis horizontal and vertical computer numerical control (CNC) machines, and wire and plunge electrostatic discharge machines (EDM).

Stop 1, Script 2: BLDG 4705, 7-Axis Machining Center

The 7-axis machine is one of only three in the United States. It has previously machined the Multipurpose Crew Vehicle (MPCV) Stage Adaptor (MSA) and the

Orion Exploration Flight Test (EFT-1) Heat Shield. It has the range of X travel:

32.8 ft, Y travel: 13.1 ft and Z travel: 11.48 ft with an accuracy of less than +/-

0.001”.

Stop 1, Script 3: BLDG 4705, Mechanical Inspection

This environmentally controlled facility provides the capability for precision dimensional development and inspection of aerospace test and flight hardware. Precision measurements requiring linear, radial, parallelism, concentricity, and angularity with an accuracy of 0.0001 inch and 2 arc/second are possible. Equipment includes a Supermicrometer that has a range of 0.0001-9 inch with a 0.00001 inch accuracy. Leica Laser tracking/scanning equipment and expertise provides the ability to achieve high accuracy with unusual geometrics and a variety of sizes. The facility also includes a Space Electronics Mass

Properties Instrument with 350 lb capacity, Schenck Dynamic Balancing Machine, Indicorder and Proficorder profile and surface finish instrument, and various hand

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METTS III Industry Day Bus Tour Scripts ~ December 19, 2019 and bench tools that include multiple types of threads and special features. We have capability to inspect to drawings and/or CAD models.

Stop 1, Script 4: BLDG 4705, Precision Assembly

The precision assembly shop is housed in a 2,800 sq-ft, 100K clean room environment used for assembling mechanical parts into completed mechanical units and components. The technicians receive precision cleaned and sealed bagged parts. The hardware is assembled per detailed drawings and specifications using calibrated tools and fixtures as required. The shop also includes LN2 for chilling parts for press fits and ovens for critical bonding processes. This assembly operation supports many NASA enterprises, the most recent of which has been the

Environmental Control and Life Support System (ECLSS), and g-LIMIT projects.

Stop 1, Script 5: BLDG 4705, Precision Cleaning Facility

The Precision Cleaning Facility is used for processing hardware that requires a high degree of cleanliness such as the strenuous requirements of MSFC-SPEC-

164B, Class I, II, and III, Level A, B, or C, GSDO-RQMT-1080, VC sensitive and

MIL-STD-1246C, Level 250 to 1,000 parts per million (ppm). This facility contains three consoles capable of cleaning stainless steel and aluminum tubing up to 1.5 inch in diameter, an ultrasonic cleaner, three parts washers, one jet washer, one vapor degreaser, and one vacuum drying oven. This facility is classified as a

30K clean facility.

Stop 2, Script 1: BLDG 4619, Test Laboratory – Environmental Test Facilities

(ETF)

The ETF is used to try to simulate the extreme environments that hardware is expected to withstand during operations. The ETF provides these environments using a total of 17 chambers. Thirteen chambers capable of high vacuums, of which seven have LN2/coolant shrouds which allow extreme temperature to be achieved. In addition, four chambers are used for testing a combination of temperature, humidity, and high altitude conditions. The ETF can perform vacuum bakeout, simulated launch, and re-entry testing. Feed-throughs in chamber walls provide electrical, mechanical, and fluid connections to the test article as required.

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Stop 2, Script 2: BLDG 4619, Test Laboratory – Structural Dynamics

Structural Dynamics Testing comprises a wide range of testing techniques, which include vibration, vibro-acoustic, pyrotechnic shock, fluid slosh, and modal testing to characterize the dynamic behavior of a variety of structures. Dynamic testing may be required for a number of reasons. Testing may simulate the expected launch environment to ensure the successful performance of the flight article, it may be required for troubleshooting, or it may be conducted to validate structural models used in a variety of analyses.

Additional Comments during Walk-Through:

Vibration Testing:

Vibration testing is conducted utilizing two separate test cells located on the east and west ends of Building 4619 adjacent to high-bay structures. A total of six electrodynamic exciters are dedicated to development and certification vibration testing of flight and ground support hardware.

Acoustic Testing:

Vibro-acoustic development and certification testing is conducted utilizing a 5K ft3 concrete reverberation chamber. An adjacent 3K ft3 anechoic chamber provides the capability for transmissibility and absorption studies, as well as acoustic emission measurements.

Stop 2, Script 3: BLDG 4619, Test Laboratory – Structural Strength Test

Laboratory (SSTL)

The SSTL has unique capabilities and experience to apply and react millions of pounds of mechanical loads in compression, tension, and laterally on various size structural test articles. Environmental profiles such as heat, cryogenic, vacuum, and humidity can be simulated during load testing. The facilities include test cells, machine shop, fabrication and assembly areas, material handling systems, load control systems, data acquisition systems, test structures/stands, and other associated areas/systems. Building 4619 is a high bay test facility that provides

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Static and Dynamic testing are conducted in the central and east high bays.

Additional Comments during Walk-Through:

Load Test Annex (LTA)

Specifications for this facility are as follows:

169 × 161 × 155 ft with a 60-ft × 75-ft door and a 55-ft × 55-ft concrete reaction floor 11-ft thick.

Load Reaction Crosshead is adjustable from 40-ft to 115-ft elevation with two 30-ton bridge cranes.

Crosshead is rated up to 30 Mlbf vertically and 2.4 Mlbf laterally.

3 Mlbf Gilmore Tensile Test Machine

Tensile Test Lab:

120 klbf Satec Tensile Test Machine

260 klbf Instron Tensile Test Machine

2 Mlbf Tensile Test Machine

Load Test Annex Extension (LTAE):

95 × 203 × 97 ft with a 40-ft × 40-ft door and a 70-ft × 160-ft concrete reaction floor 10-ft thick.

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DRIVE BY 1: To be read on BUS

Stop 3, Script 1: BLDG 4653, Valve and Component Servicing

This facility services components from fluid systems throughout the Center. This includes components used for hazardous fluids such as oxygen and hydrogen.

Typically, components are removed from systems by others and delivered to the

V&CS for servicing. Servicing involves disassembling the component, having the component parts properly cleaned by the Government, replacing the damaged parts and soft goods, reassembling the component, pressure testing for structural integrity and leaks, and packaging for pickup by the customer.

DRIVE BY 2: To be read on BUS

Stop 4, Script 1: BLDG 4634, Valve Lab Storage House

Building 4634 houses Agency Rocket Propulsion Test (RPT) valves and components as well as MSFC-owned valves, components, and spare parts. The

Contractor provides inventory control of all items housed within Building 4634.

Inventory of this facility consists of approximately 4,300 line items consisting of approximately 7,000 piece parts.

Stop 5, Script 1: Pressurants and Propellants (P&P) Delivery Systems (PPDS)

Summary (To be read on BUS)

Marshall has a partnership to support the Redstone Test Center (RTC) (a United

States Army Test and Evaluation Command (ATEC) tenant activity on Redstone

Arsenal, Alabama) with pressurant and propellant services for liquid nitrogen

(LN2) and gaseous nitrogen (GN2) and missile grade air (MGA). Marshall procures an average of 650 tons of LN2 each year through the NASA contract at

KSC and has the vendor deliver to eight RTC locations across RSA. Marshall provides GN2 and MGA to the RTC 4500 complex at the intersection of Martin

Road and Dodd Road through Marshall’s underground cross-country piping system. Marshall also provides GN2 in Government-owned tube trailers to RTC

Test Area 1 and Test Area 5 on an as needed basis. Benefits By leveraging

Marshall’s existing infrastructure, RTC is able to receive mission-critical LN2, GN2, and MGA more affordably and efficiently than if they developed the capabilities in-house.

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The Contractor provides all engineering services required to maintain and sustain operations of the PPDS in a safe and efficient manner. The Contractor also maintains control of peripheral subsystems and documentation such as instrumentation, non-pressure carrying elements, and electronics to an extent deemed necessary by the Government to ensure proper function of the propellant and pressurant systems. The Contractor operates and maintains Government-owned distribution plants providing propellants (e.g., Air, GN2, LN2, LOX, GOX, GH2, GHe, LH2, GCH4, LCH4)) by mobile equipment, pipelines, or other means to use points across the Center.

DRIVE BY 3: To be read on BUS

Stop 5, Script 2: BLDG 4659, HP GN2 and LN2 (P&P Nitrogen)

The Nitrogen Generation Facility, Building 4659, receives liquefied nitrogen and produces gaseous nitrogen at two pressures; 4,330 PSIG & 10,000 PSIG. This facility receives approximately 4-5 liquid vendor deliveries per day for a total of approximately 20 deliveries per week. This facility is capable of storing approximately 128,000 gallons of liquid nitrogen. Operation of the facility is as follows: Technicians operate cryogenic liquid pumps that push product through ambient air vaporizers to flash the cryogenic nitrogen liquid to gaseous nitrogen.

The duration of pumping operations determines cross-country pipeline pressure.

The cross-country pipeline consists of approximately 11 miles of underground high pressure piping. This facility also maintains, fills, and delivers three liquid mobile trailers and six gaseous mobile trailers that are used throughout MSFC.

Stop 6, Script 1: BLDG 4607, P&P Air Station

The Central Air Station (Building 4607) is a 13,806 sq-ft facility housing three compressed air systems. Six compressors and a dryer skid comprised the 150 psig

“Shop Air System” supporting eight MSFC Facilities via 1.5 miles of underground piping. Five compressors and dryer skid comprise the 3275 psig “High Purity Air

System” supporting 43 MSFC facilities via approximately 14 miles of underground piping or mobile compressed gas trailers. Two compressors and a dryer skid comprise the 420 psig “Wind Tunnel System” supporting one MSFC facility via

0.5 mile of underground piping.

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Stop 7, Script 1: BLDG 4650-South, Test Laboratory - Metrology and

Calibration Laboratory Metrology and Calibration Lab Script

The Metrology and Calibration Laboratory (MCL) provides metrology and calibration services to all MSFC organizations, programs, and projects that utilize measurement and test equipment (MTE). Additionally, the MCL provides metrology and calibration services to other NASA Centers and support facilities, Department of Defense services branches, and commercial companies. The MSFC mission involves numerous disciplines and sub-disciplines that include a wide array of specialized and/or highly complex measurements and calibrations to support research, development, and testing. In some specialized areas, the MCL maintains the only capability in NASA, and in others, only a few laboratories nationwide can perform. Services include, but are not limited to, operation, maintenance, repair, functional checks, special tests, calibration, production control, and pickup/delivery. In addition, the MCL provides specialized metrology support and expertise to assist NASA and MSFC organizations and other customers with measurements and equipment.

Additional Comments during Walk-Through:

Room 116: Quality

Room 118: Electrical Standards

Room 127: Vibration/Microphones/Sound

Room 127A: Anechoic Chamber

Room 120: Production Control

Room 129: Metrology Library (Original Equipment Manufacturer manuals to the 1960s)

Room 122: Direct Current/Low Frequency

Room 131: Direct Current/ Low Frequency

Room 124: Time/Radio Frequency (RF) up to 26.5 GHz

Room 137: Thermodynamics

Room 104: High Bay – Force (Gilmore is up to 5M ft lbs, 500,000 deadweight below ground/hydraulic to 5M, 26 ft lb deadweight machine, 1000 ft lb deadweight machine, 5,000 ft lb machine, 55,000 ft lb machine in compression and tension) and Flow (pneumatic up to 200 cu ft and liquid up to 3,000 gpm)

Room 107: Vacuum and Gas Detectors

Room 105: Torque and Linear Variable Differential Transformers (LVDT)

Room 103: Pressure

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Rooms 100 A & B: Dimensional

Room 100C: Mass

Drive By 4: To be read on the Bus

Stop 8, Script 1: Propulsion Test Laboratory (PTL) Support (East and West

Test Area) Summary

The PTL conducts component, scale model, and system-level propulsion tests of hardware at any technology readiness level. Each test facility provides unique capabilities, allowing the flexibility to test a wide range of experimental, developmental, and flight-ready hardware with minimal buildup. The PTL consists of the Solid Propulsion Test, Advanced Engine Test, Cryo-structural Test, Hydrogen Cold Flow, Solar-Thermal Test, Environmental Test, Hot Gas Test, and

Hyper-thermal Test facilities, five test stands, five test cells, and their associated systems and equipment. High-pressure gas and liquid propellants and inerts are readily available and include, but are not limited to, hydrogen, methane, oxygen, nitrogen, helium, RP-1, De-Ionized water, and Trielhylaluminum/ Triethylborane

(TEA/TEB).

Drive By 4: To be read on the Bus

Stop 8, Script 2: (Use as applicable depending on which areas viewed)

East and West Test Areas:

Test Stand (TS) 115, TS116, and multiple Test Cells provide the ability to test injectors, preburners, turbopumps, combustion chambers, igniters, seals, bearings, valves, engine subsystems, and small solids with little facility modification.

The Solid Propulsion Test Facility (SPTF) was designed to support simulation of reuseable solid rocket motor (RSRM) combustion environments and provides the ability to test solids up to 100,000 lbf vertically and 172,000 lbf horizontally.

The Cryostructural Test Facility is ideal for evaluating the structural integrity of tanks and other propulsion components under a variety of conditions using compression, sheer, and tension loads.

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The Hydrogen Cold Flow Facility is ideal for low pressure (≤ 50 psig) flow tests of hydrogen engine and subsystem components.

The Solar-Thermal Test Facility is capable providing 1 MW/m2 solar power in a high vacuum environment.

The Hot Gas Test Facility is a hydrogen/air combustion-driven environmental test facility capable of generating flow speeds up to Mach 4, convective heating rates from 4 to 50 Btu/ft2-s, and radiant heating rates up to 30 Btu/ft2-s in a 16-in × 16-in × 40-in test section.

The Hyperthermal Test Facility is built around a high-powered gas discharge device that produces a steady high-enthalpy flow for use in a variety of R&D testing applications. The 1.5 MW input power and multiple test sections allow for heating rates of up to 15,000 Btu/ft2-s in a variety of flow environments.