B-Test Complex Overview_Attachment A for RFI_final Version from SSC SBDO_10_20_23.pdf

National Aeronautics and Space Administration John C. Stennis Space Center Stennis Space Center, MS 39529-6000

B-Test Complex Overview

Supplemental information to support Request for Information on Concepts for Operation and

Utilization of the NASA SSC B-Test Complex via an Enhanced Use Lease (EUL) Agreement

Provided by:

Stennis Space Center (SSC)

Strategic Business Development Office Bldg. 1111 Room 377

Stennis Space Center, MS 39529 October 2023

Contents B-Test Complex

B-Test Stand

Liquid Oxygen Propellant Systems

B-1 LOX Propellant Subsystem

B-2 LOX Propellant Subsystem

Liquid Hydrogen Propellant Systems

LH Propellant Subsystem Capabilities

GHe Spin Start System

Gas Supply Systems

Air Supply System

Helium Supply System

Nitrogen Supply System

Hydrogen Supply System

Master Facility Panel

Water Supply System

Electrical Power Distribution

Data Acquisition

Test Control Center

Appendices

Appendix A: Publicly available photo showing dual position capability of the B-1 Test Stand during the RS-68 Engine Test Program

Appendix B: Photo of North explosive storage building (B-4500) in B-Test Complex

Appendix C: Photo of South explosive storage building (B-4235) in B-Test Complex

Appendix D: Photo of B-Test Complex Test Control Center (Building B-4210)

Appendix E: Photo of High Pressure Inert-Gas Battery in the B-Test Complex

Appendix F: Photo of High Pressure GH storage area at the B-Test Complex

Appendix G: Photo of B-1 Observation Bunker (Building B-4225)

Appendix G: Photo of B-2 Observation Bunker (Building B-4226)

Appendix H: Photo of North Facing Side of B-Stand

B-Test Complex NASA SSC’s B-Test Complex is located within the secured and restricted-access test complex area of SSC that is surrounded by a 125,000-acre acoustical buffer zone. The B-Test Complex consists of approximately 150 acres and is accessible only through secured gates leading into SSC’s buffer zone and test complex.

The B-Test Complex contains multiple assets and buildings in addition to the B-1/B-2 Test Stand. The main buildings and assets in the B-Test Complex are annotated in Figure 1 below.

Figure 1: Annotated B-Test Complex Layout

Figure 2: B-Test Complex Looking Southwest

B-Test Stand The B-Test Stand consists of a dual-position, vertical, static-firing test stand designated the B-1/B-2 Test Stand. Each test position is capable of static-firing test articles up to 33 ft. in diameter. Each position can support a maximum dynamic load of 11.0 M-lbf. vertical (up), 8.5 M-lbf vertical (rebound), and 6.0 M-lbf (horizontal) [Note: Current configuration does not support maximum design limits]. The B-1 test position was configured for single engine testing for the Space Shuttle Main Engine (SSME) program in the late 1980s. It was last in operation with dual firing positions (B-1A and B-1B) for RS-68 testing in 2021; thus, the capabilities described at the subsystem level reflect configurations specific to that test program. The B-2 test position tested the first stage of the Saturn V Rocket, Main Propulsion Test Article (MPTA) for the Space Shuttle Program, Delta IV Common Booster Core, as well as the Core Stage of the Space Launch System (SLS) for the Artemis Program. The B-2 test position is currently being retrofitted to test the SLS Exploration Upper Stage (EUS) for the Artemis Program. The capabilities described at the subsystem level reflect configurations specific to that test program. Both positions are equipped with water cooled flame deflectors capable of flowing upwards of 150,000 gpm. The B-2 position has an acoustical aspirator that can flow more than 90,000 gpm.

The B-1/B-2 Test Stand is currently configured to be supplied with Liquid Oxygen (LOX) and Liquid Hydrogen (LH) cryogenic fluids, Gaseous Hydrogen (GH), inert gases, industrial water, and the electrical power necessary for test operations. LOX and LH are supplied to the stands from cryogenic transportation barges and supplied to the B-1 test position from on-stand run tanks (resupply from barge to run tank is possible during test operations for extended duration testing). Additionally, there is a ground based Vacuum Jacketed (VJ) storage vessel used to supply topping and replenish operations for the B-2 position. GH is provided as a pressurant for the LH run tank system. Gaseous Nitrogen (GN) is provided as a pressurant for the LOX run tank system. In addition to GN pressurant, the B-2 VJ LOX storage vessel (V-266-LO) has a vaporizer configuration that allows for pressurization with cold Gaseous Oxygen (GOX).

The B-1/B-2 Test Stand is supplied with GH and inert gases from B-Test Complex gas storage batteries. The test stand's two positions can be operated from a common Test Control Center (TCC) configured with separate B-1 and B-2 control rooms. Both positions have separate dedicated Data Acquisition and Control Systems (DACS). The B-1/B-2 Test Stand is equipped with a 200-ton, main derrick lifting crane, and a 175 ton auxiliary derrick lifting crane (currently inactive).

Figure 3: B Test Stand with the SLS Core Stage being installed on the B-2

Liquid Oxygen Propellant Systems Before, during, and after testing, the LOX dock and transfer systems at the B-Test Complex provide LOX storage and transfer for both the B-1 and B-2 test positions. The B-1 test position is equipped with a VJ LOX run tank. B-2 is also equipped with a VJ LOX storage/transfer tank. Relevant data for the existing pressure vessels is presented in Table 1.

Table 1: B-Test Complex LOX Propellant Subsystem

Vessel Locator Number Vessel Description Certified Pressure (psig)

Water Volume (gal)

V-150-LO B-1 Run Tank 110 (ullage) 49,550 V-266-LO B-2 Storage/Topping 135 (ullage) 28,000

B-1 LOX Propellant Subsystem

• Dock facilities for three (3) LOX barges and all shore-to-barge interface accessories, including flexible hoses at the main fill manifolds. Two additional barge positions are available but have no piping or mooring devices.

• A LOX transfer line from the barge docks to the test stand. The line is comprised of 14 in. foam glass insulated piping from the dock to level, then transitions to 10 in. near level 5. A tee and manual shutoff valves are incorporated to configure the line for use at B-1 or B-2. The 10 in. line that feeds the B-1 run tank has a Y pattern 40 µ filter. The design pressure of the LOX transfer line is 275 psig.

• Each barge has a usable capacity of 95,000 gallons and is equipped with two pumps capable of transferring approximately 700 lbm/s (350 lbm/s per pump) at maximum efficiency to the test stand.

• A LOX run line from the bottom of the run tank to the test positions. The line is 12 in. diameter from the tank and transitions to 16 in. diameter on another level. A Y with separate manually operated isolation valves is employed to feed each test position (B-1A and B-1B). Separate remotely operated pre-valves and 800 micron strainers are include on each leg. The design pressure of the run line is 275 psig.

• A minimum 18 in. diameter LOX dump line to deliver LOX to LOX dump pit during chill down bleeds and emergency situations.

• A dockside, deluge-water piping system, supplying industrial water at 70,000 gals/min and 225 psig.

• GN purges are provided for throughout the LOX transfer systems via hand valves and remotely controlled solenoid valves.

B-2 LOX Propellant Subsystem

• It should be noted that the first two bullets from the “B-1 LOX Propellant Subsystem” are also the same for the

B-2 side.

• A 28,000-gallon storage tank for transfer of LOX for various test article flow operations. The storage tank has provisions for filling directly from propellant trailers and barges. The storage vessel can be simultaneously backfilled while transferring LOX to a test article. The vessel contains a vaporizer for additional pressurization capability.

• A 4 in. vacuum jacketed line from V-266-LO to the primary LOX transfer line. Connection points with manual shutoff valves are present at docks 1 and 2. Small centrifugal pumps are mounted on the LOX barges for various low flow rate operations. The design pressure of the topping line is 310 psig; some of the older line segments were originally designed for higher pressure. The system is capable of transferring LOX at a maximum flow rate of approximately 70 lbm/s to the test stand.

• Main transfer line piping terminates near the location of the test article and incorporates a tee type filter.

Liquid Hydrogen Propellant Systems Before, during, and after testing, the LH dock and transfer systems at the B-Test Complex provide LH storage and transfer for both the B-1 and B-2 test positions. The B-1 test position is equipped with a VJ LH run tank. Relevant data for the existing pressure vessel is presented in Table 2.

Table 2: B-Test Complex LH Propellant Subsystem

Vessel Locator Number Vessel Description Certified Pressure (psig)

Water Volume (gal)

V-151-LH B-1 LH Run Tank 66 (ullage) 90,000

LH Propellant Subsystem Capabilities

• Dock facilities for three LH barges and all shore-to-barge interface accessories, including flexible hoses at main fill and LH barge GH vent manifolds.

• Each barge has a usable capacity of approximately 240,000 gallons. The LH barges use a pressurization transfer design and can transfer more than 100 lbm/s to the test stand, depending on the downstream piping configuration.

• A 10 in. diameter, VJ LH transfer line from barge dock to dual-stand B1/B-2 positions. A tee with separate shutoff valves at the base of the test stand provides flow to the B-1 or B-2 (B-1 valve is currently removed) position. Piping for the B-1 side runs from the base of the stand to the bottom of the LH run tank and includes a shutoff valve and 200 µm filter. Piping for the B-2 side runs from the base of the stand and includes shutoff valves, bleed valves, a 50 µm filter, and multiple bypass legs with flow control valves to provide various flow configurations. The design pressure is 70 psig.

• An LH run line from the bottom of the B-1 run tank to the test positions. The line is 12 in. diameter from the tank and transitions to 16 in. diameter immediately below the LH tank valve. A Y with separate manually operated isolation valves is employed to feed each test position (B1A and B1B). Separate remotely operated pre-valves and 800 micron strainers are include on each leg. The design pressure of the run line is 275 psig.

• A 12 in. diameter GH vent system with a dedicated flare stack for venting boil off from the three LH barge positions and boil off/purge flow from the transfer line.

• A Hydrogen vent system with a dedicated flare stack for the B-1 position. Piping is 10 in. and 8 in. diameter on the stand and transitions to 18 in. diameter at the base of the stand. Boil off from the LH run tank and bleed flow through the test article at B-1A or B-1B is vented through this system. Run duct and transfer line bleed, drain, and relief valves discharge to this system also.

• A GH vent system with a dedicated flare stack for the B-2 position. Piping is 18 in. diameter. Boil off from the test article would be vented through this system. Transfer line bleed, drain, vehicle drain, and relief valves discharge to this system also.

• A dockside, deluge-water piping system supplying industrial water at 12,500 gals/min and 225 psig.

Figure 4: B-1 LOX (Left) and LH (Right) Run Tanks Looking Northeast

Figure 5: B-1 LOX (Left) and LH (Right) Run Tanks Looking Southeast

Figure 6: B-2 LOX Topping Tank V-266-LO

Figure 7: B-Test Complex LH Dock Area

Figure 8: B-Test Complex LOX Dock Area

GHe Spin Start System A Gaseous Helium (GHe) spin start Helium Spin Start (HeSS) system at B-1 provides a high flow rate of GHe for engine start. The system consists of two spherical vessels to provide a surge capacity of GHe at the Test Stand. Relevant data for the existing pressure vessels is presented in Table 3.

Table 3: GHe Spin Start System Storage Capabilities

Vessel Locator Number

Vessel Description MAWP (psig)

Certified Pressure (psig)

Water Volume (ft3)

V-257-HE South HeSS Sphere 3000 3000 80 V-272-HE North HESS Sphere 3000 3000 80

Design and operating characteristics of the GHe HeSS Systems are:

• B-1 o 3 in. diameter schedule 80S piping from the two spheres to the flow control valve with shutoff valves at each sphere and on the main line. A regulator in this line reduces the pressure to 1850 psig max.

o A hydraulically controlled flow control valve. Ancillary hydraulic system provides 2400 psig hydraulic for operation.

o 3 in. diameter schedule 80S piping with shutoff and check valves from the flow control valve to the two test positions B-1A and B-1B.

o 3 in. diameter schedule 80S piping from the spheres to the B-2 position (valves and regulators have been removed).

• B-2 o An HeSS system at B-2 provides a high flow rate of GHe for various vehicle operations. The system consists of a single cylindrical vessel to provide a surge capacity of GHe at the Test Article interface. V- 815-HE is a 25.5 cubic foot vessel with a Maximum Allowable Working Pressure (MAWP) of 8000 psia.

o 2.5 in. diameter schedule 160S piping from the single bottle to the pressure regulator with shutoff valves at the bottle and on the main line. The current regulator in this line reduces the pressure to 1500 psig max.

Figure 9: Spin Start Spheres V-257-HE and V-272-HE at B-1

Gas Supply Systems The High Pressure (HP) inert-gas battery in the B-Test Complex contains high pressure air (HPA), GHe, and GN gases. A separate gas battery is utilized for GH. The gas batteries serve the B-1 and B-2 test positions and function as accumulators that are resupplied by cross-country gas transfer from the High Pressure Gas Facility (HPGF).

Figure 10: HP Inert-Gas Battery in the B-Test Complex

Air Supply System The HP air storage at the B-Test Complex inert gas storage battery consists of one HP vessel containing missile-grade air.

Relevant data for the existing pressure vessel is presented in Table 4.

Table 4: B-Test Complex High Pressure Air Storage Capability

Vessel Locator Number Certified Pressure (psig)

Water Volume (ft3)

Storage at Certified Pressure

(70)°F (SCF)

V-146-HA 2,800 950 177,494

Design and operating characteristics of the HP Air transfer systems are:

• A 3 in. diameter transfer line from the HPGF to the B-Test Complex gas storage battery with an operating pressure of 3,700 psig.

• A 3 in. diameter transfer line from gas battery to the B-Stand regulators.

Helium Supply System The HP GHe storage at the B-Test Complex inert gas storage battery consists of three HP vessels. Relevant data for the existing pressure vessels is presented in Table 5.

Table 5: B-Test Complex GHe Capability

Vessel Locator Number Certified Pressure (psig)

Water Volume (ft3)

Storage at Certified Pressure

(70)°F (SCF)

V-141-HE 6,300 1,065 380,752

V-143-HE 6,300 1,500 536,270

V-144-HE 6,300 1,500 536,270

Design and operating characteristics of the HP GHe transfer systems are:

• A 2 in. diameter transfer line from the HPGF to B-Test Complex with an operating pressure of 6,000 psig.

• A 3 in. diameter transfer line from the B-Test Complex gas battery to B-Stand regulators.

• Dual regulators to reduce supply on the Test Stand to desired pressure. Regulators feed the master facility panel and other ancillary purge panels on the Test Stand.

• B-2 side has Pressure Reducing Area (PRA) bypass leg to allow for higher pressure purges.

• B-2 side has a small helium booster skid on level 9 supplying 6 on stand pressure vessels with 72 cubic feet of storage at 7,400 psig maximum for short duration higher pressure applications.

Nitrogen Supply System The HP GN storage at the B-Test Complex inert gas storage battery consists of four HP vessels. Relevant data for the existing pressure vessels is presented in Table 6.

Table 6: B-Test Complex GN Storage Capability

Vessel Locator Number Certified Pressure (psig)

Water Volume (ft3)

Storage at Certified Pressure

(70)°F (SCF)

V-225-GN 6,600 760.1 260,180

V-226-GN 6,600 762.6 261,036

V-231-GN 6,600 759.2 259,872

V-232-GN 6,600 757.3 259,222

Design and operating characteristics of the HP GN transfer systems are:

• A 4 in. diameter transfer line from the HPGF to B-Test Complex with an operating pressure of 4,500 psig.

• A 10 in. diameter transfer line from B-Test Complex GN storage battery to the B-Stand regulators.

• A PRA at the base of the Test Stand with four high flow pressure control valves (PCVs) to regulate the stand supply to a maximum of 3400 psig. Normal operating pressure is 2500 psig.

Hydrogen Supply System The HP GH storage area at the B-Test Complex consists of three HP vessels. Relevant data for the existing pressure vessels is presented in Table 7.

Table 7: B-Test Complex GH Storage Capability

Vessel Locator Number Certified Pressure (psig)

Water Volume (ft3)

Storage at Certified Pressure

(70)°F (SCF)

V-224-GH 5,000 600 167,795

V-227-GH 6,600 608.9 260,895

V-072-GH

(Not in service currently) 3,378 2,530 509,606

Design and operating characteristics of the HP GH transfer systems are:

• A 2 in. diameter transfer line from HPGF to Test Complex (tee joint to A and B-Test Complexes); with an operating pressure of 3,000 psig.

• 1½ in. diameter transfer line from Test Complex (tee joint B-Test Complexes) to B-Test Complex GH storage battery.

• A 2 in. diameter transfer line from B-Test Complex, GH storage battery to Test Stand.

• A shutoff valve and bypass regulator at the base of the Test Stand to maintain GH pressure at less than 400 psig when test operations are not in progress.

Master Facility Panel The Master Facility Panel (MFP) consists of numerous regulator stations to provide gases at different pressures to meet the needs of various facility systems.

Water Supply System Water for the B-Test Complex is supplied from the High Pressure Industrial Water (HPIW) facility through a 96 in.

diameter water line at a pressure of 225 psig and an operating flow rate of 350,000 gals/min. The HPIW facility utilizes

(10) 33,000 gpm pumps and (1) jockey pump to supply HPIW to the B-Stand.

Electrical Power Distribution Electrical power is distributed to the Test Complex by two, 13.8 kV feeder circuits from the SSC Main Substation. At the B-Test Complex, circuits 11 and 21 source double-ended, 480 V substations at the B-1/B-2 dual Test Stand and at the B- Test Complex TCC. Both main feeder circuits (circuits 11 and 21) are electrically separated using a “bus” tie breaker.

This “bus” tie breaker is normally operated in the “open” position. Dedicated transformers for both circuits (circuits 11 and 21) are used to step the voltage down from 13.8 kV to 480 volts alternating current (VAC). Feeder circuit breakers then distribute the 480 V to lighting panels, Motor Control Centers (MCCs), transformers, 28 VDC rectifiers, etc., for utilization. Control power is provided by redundant 28 VDC rectifiers with battery backup should the 480 V fail. The batteries are sized to carry the control power load for approximately 20 minutes in the event of a power failure (loss of 480 V input power to the rectifier). All safety-critical control devices (PLCs, relays, solenoid valves, etc.) are powered with 28 VDC to ensure that a test can be terminated safely if there is a power failure. During engine testing, the test conductor may request that the emergency generators supply power to the Test Complex to avoid a test interruption should utility power fail. During the use of emergency generators, the commercial power system is electrically separated from the test complex. In addition, the stand has an Uninterruptible Power System (UPS) system capable of providing backup power for a limited number of minutes to the stand control system.

Data Acquisition The B-Test Complex Test Control Center (BTCC) is the central data collection and processing facility receiving pre- and post-test data from the test article and the B Test Stand. The B-TCC uses redundant loggers connected to an isolated network to acquire, store, and post-process test data. Test data is also recorded onto control computers that are located on the test stand near the data acquisition systems.

Real-time display of data is provided in both tabular form as well as graphical trend. Data can be displayed in engineering units and raw counts. The low speed data acquisition system (DAS) has the capability of acquiring up to 592 (B-1) and 592 (B-2) analog input channels at a rate of 250 SPS (samples per second) each. The B-1 RS68 program currently used a DAS sample rate of 200 SPS. The high speed data acquisition system in the B-1 Test Stand has the capability of acquiring up to 64 channels at a sample rate of 204.8K SPS. The B-2 high speed data acquisition system has 192 channels with a sample rate of 204.8K SPS. Transducers are interfaced to the facility data acquisition systems using electrical cables that are referred to as “drag on cables.” Patch panels are used to connect the current test stand to this low speed DAS. Front-end signal conditioning and amplifiers for resistance temperature detectors (RTD), thermocouples, strain gages, etc., are provided as required at the test stand. Redundant, non-filtered signal outputs are patched to a separate computer system to provide redline cutoffs for critical measurements. The B-1 Test Stand uses a programmable logic controller (PLC) system to provide facility redline protection. The PLC based system has a capacity of 128 channels.

A modernization project upgraded and increased the capacity of the B-2 DACS in 2007. As a result, B-1 and B-2 have separate, dedicated systems with the capabilities listed in Table 8. These systems have a low setup time, reconfiguration ability, and ability for pretest/post-test tasks.

Table 8: B-Test Complex Data Acquisition and Control System Capabilities

1. 592 Channels of Low Speed Analog Data with signal conditioning and 16 bit A/D Mux (B-1 and B-2)

2. 64 Channels of Digital High Speed Analog Data recorded direct to disk (B-1) 192 channels of Digital High Speed Analog Data recorded direct to disk (B-2)

3. High Speed Fiber optic data network between test stands and Test Control Centers (TCC)

4. Automated system configuration, calibration, setup, and checkout procedures (B-1 and B-2)

5. Computer based Control System with Graphical User Interface for facility functions (B-1 and B-2)

6. NTSC Video in color and B/W/IR for test article and facilities (B-1 and B-2)

7. High speed video capability (B-2)

The B-1 and B-2 low speed DAS also provides digital interfaces for the acquisition of discrete events. These channels are digitized and transmitted via fiber optics to the B-1 and B-2 control rooms in the B-TCC where they are recorded and displayed. Displays are provided in the Test Control Centers and on the test stand for monitoring of channels and blue/redline limit checking.

Test Control Center The B Test Control Center (B-TCC), Building 4210, is a dual control room facility for the B-1 and B-2 test positions. This facility houses control system equipment and serves as the central command location for the test conductor and personnel, who are required to observe, monitor, supervise, and control test operations at the B-Test Stand. The B-2 TCC is currently not operational in Building 4210. The active B-2 TCC is currently located in Building 4995, the Data Acquisition Facility (DAF). Underground tunnels connect the B-Stand to the B-TCC and DAF to facilitate data connections.

Each TCC area contains the following hardware:

• Computer(s) for data collection

• A facility control console with meters, indicator lights, and operating devices

• Low speed closed circuit television (CCTV) cameras, recorders, and monitors for test stand surveillance

• Audio communications

• Real time graphical display instrumentation system(s)

Separate B-1/B-2 operated control systems are capable of monitoring critical test functions and initiate corrective actions or terminate a test.

The B-1 and B-2 control system is a PLC based system with standard commercially available industrial PLCs communicating over a dedicated fiber optics network. The operator interface (OI) is accomplished with workstations running operator interface software for displaying system schematics, status, alarms, and commands. Communication between the PLCs and the workstations is via fiber optics. This PLC based system also provides control of the LOX and LH transfer systems for both B-1 and B-2. PLCs for this system are powered by the 28 V uninterruptible power supply at the Test Stand. The B-2 control system can be readily reconfigured to meet the requirements of the test article.

Appendices

Appendix A: Publicly available photo showing dual position capability of the B-1 Test Stand during the RS-68 Engine Test Program

Appendix B: Photo of North explosive storage building (B-4500) in B-Test Complex

Appendix C: Photo of South explosive storage building (B-4235) in B-Test Complex

Appendix D: Photo of B-Test Complex Test Control Center (Building B-4210)

Appendix E: Photo of High Pressure Inert-Gas Battery in the B-Test Complex

Appendix F: Photo of High Pressure GH storage area at the B-Test Complex

Appendix G: Photo of B-1 Observation Bunker (Building B-4225)

Appendix G: Photo of B-2 Observation Bunker (Building B-4226)

Appendix H: Photo of North Facing Side of B-Stand