K0000190545_TSMU_LO2_VJ_FlexHose_Procurement_Spec_doc.pdf

KSC FORM 21-2C NS (REV 06/04) PREVIOUS EDITIONS ARE OBSOLETE

TSMU FLEXIBLE HOSE SPECIFICATION,

VACUUM JACKETED, LO2 SERVICE

K0000190545-SPC

E.L. THOMPSON

C.E. EXLINE

T.O. ADAMS

A.C. LITTLEFIELD

L.C. TAYLOR

V.J.WARD

D.J. ROTH

None —

22264 -

03/02/2015

EAR 99 -- NO LICENSE REQUIRED

The information contained in the document is technical in content, but not technical data as defined by the International Traffic in Arms Regulations (ITAR) or the Export Administration Regulations (EAR), and therefore is EAR 99 NLR, no export license required. [General Prohibition Six (Embargo) applies to all items subject to the EAR, (i.e., items on the CCL and within EAR 99 NLR). You may not make an export or re-export contrary to the provisions of part 746 (Embargos and Other Special Controls) of the EAR and 22 CFR part 126.1 of the ITAR].

EDDR # 1313962 NASA KSC Export Control Office (321-867-9209)

K0000190545-SPC (-.13) RELEASED Verify latest version prior to use

22264 2 34 — None

KSC FORM 21-2D NS (REV 06/04) PREVIOUS EDITIONS ARE OBSOLETE

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 Governmental

2.2 Non-Governmental

3. REQUIREMENTS

3.1 Definition

3.2 General

3.2.1 Fluid Service

3.2.2 Temperature and Pressure

3.2.3 Umbilical Retraction Loads

3.2.4 Material Properties

3.2.5 Heat Leak

3.2.6 Bend Radius

3.2.7 Convolutes

3.2.8 Inner Flexible Hose Assembly

3.2.9 Outer Flexible Hose Assembly

3.2.10 VJ Joint Connections

3.2.11 Weld Fittings

3.2.12 Thermal Life Cycle

3.2.13 Listed / Unlisted Components Usage

3.2.14 Attachments

3.3 Construction

3.3.1 General

3.3.2 Welder Qualification

3.3.3 Non Destructive Evaluation (NDE) Examiners

3.3.4 Non Destructive Evaluation (NDE)

3.3.5 Welding

3.3.6 Low Temperature Toughness

3.3.7 Passivation

3.3.8 Cleaning

3.3.9 Name Plates and Product Marking

3.3.10 Workmanship

3.3.11 Interchangeability

3.3.12 Safety

3.3.13 Human-Factors Engineering

3.3.14 Security

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3.3.15 Government-Furnished Property

3.4 Documentation

3.5 Logistics

3.6 Personnel and Training

3.7 Major-Component Characteristics

3.8 Precedence

4. VERIFICATION

4.1 Responsibility for Inspection

4.2 Special Tests and Inspections

4.2.1 Flexible Hose Measurements

4.3 Verification Inspections

4.3.2 Required Testing Chronology

4.3.3 Cold Shock

4.3.4 Pressure/Leak Testing

4.3.5 Mass Spectrometer Leak Testing

4.3.6 Vacuum Retention Test

4.4 Dimensional Verification

4.4.1 Flexible Hose Assemblies

4.5 Responsibility For Verification / Inspection

4.5.1 Verification/Inspection

5. PREPARATION FOR DELIVERY

5.1 Preservation

5.1.1 Protective pressure cap

5.1.2 Packaging Cleanliness

5.1.3 Vacuum in Annulus

5.1.4 Inner Line Pressure

5.1.5 Recordings

5.2 Packing

6. NOTES

6.1 Intended Use

LIST OF TABLES

Table 1 - 8x10 Flex Hose Retraction Loads Table 2 – 3x5 Flex Hose Retraction Loads Table 3: Minimum Flexible Hose Center-Line Bend Radius Table 4: Convolute dimensional information

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LIST OF FIGURES

Figure 1 - Flex Hose Loads Coordinate System Figure 2: Convolutes Diagram Figure 3 - Concentric Serration Dimensions

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RECORD OF REVISIONS/CHANGES

REV

LTR DESCRIPTION DATE

- Initial Release March 2, 2015

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Abbreviations, acronyms, and symbols

ASME American Society of Mechanical Engineers DP Design Pressure GN2 Gaseous Nitrogen GO2 Gaseous Oxygen GSE Ground Support Equipment KSC Kennedy Space Center LO2 Liquid Oxygen LN2 Liquid Nitrogen MDP Maximum Design Pressure NASA National Aeronautics and Space Administration NDE Non-Destructive Evaluation NPS Nominal Pipe Size TSMU Tail Service Mast Umbilical VJ Vacuum Jacket WPS Weld Procedure Specification WPQ Welder/Welding Operator Procedure Qualifications

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1. SCOPE

This specification provides technical information and requirements for the design, fabrication, and testing of vacuum jacketed flexible hose assemblies used in the transfer of liquid oxygen (LO2), gaseous oxygen (GO2) and liquid nitrogen (LN2).

2. APPLICABLE DOCUMENTS

The following documents form a part of this document to the extent specified herein. The latest revision applies unless a specific revision is indicated. However, when this document is used for procurement, including solicitations, or is added to an existing contract, the specific revision levels, amendments, and approval dates of said documents shall be specified in an attachment to the Solicitation/Statement of Work/Contract.

Copies of specifications, standards, drawings, and publications required by Subcontractors in connection with specified procurement functions should be obtained from the procuring activity or as directed by the Contracting Officer.

In case of conflict between referenced document and this specification, this specification shall take precedence

2.1 Governmental

NASA/Kennedy Space Center

KSC-C-123 Surface Cleanliness of Fluid Systems, Specification For

KSC-STD-E-0015 Marking of Ground Support Equipment, Standard For

Military Specification

MIL-PRF-27407C Propellant Pressurizing Agent, Helium

MIL-PRF-27401F Propellant Pressurizing Agent, Nitrogen

MIL-PRF-25567 Leak Detection Compound, Oxygen Systems

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KSC Drawings

79K14672 Vacuum Valve Assembly

2.2 Non-Governmental

American National Standard Institute (ANSI)

AWS D17.1/D17.1M

2010-AMD1

Specification for Fusion Welding for Aerospace Applications

The American Society of Mechanical Engineers

ASME B31.3 Process Piping

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory-Made Wrought Buttwelding Fittings

ASME 16.25 Buttwelding Ends

American Society of Testing and Materials

ASTM A182 Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High Temperature Service

ASTM A193 Standard specification for alloy-steel and stainless steel bolting for high temperature or high pressure service and other special purpose applications.

ASTM A194 Standard specification for carbon and alloy steel nuts for bolts for high pressure or high temperature service, or both

ASTM A240 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A312 Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

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ASTM A320 Standard specification for alloy-steel and stainless steel bolting materials for low temperature service

ASTM A380 Practice for Cleaning, Descaling, and Passivation of Stainless Steel parts, Equipment, and Systems

ASTM A403 Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

ASTM B575 Standard Specification for Low-Carbon Nickel-Chromium- Molybdenum, Low-Carbon Nickel-Chromium-Molybdenum- Copper, Low-Carbon Nickel-Chromium-Molybdenum-Tantalum, and Low-Carbon Nickel-Chromium-Molybdenum-Tungsten Alloy Plate, Sheet, and Strip

ASTM A580 Standard Specification for Stainless Steel Wire

ASTM A967 Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts

International Organization for Standardization

ISO 14952 Space systems – Surface cleanliness of fluid systems

National Bureau of Standards

NBS Monograph 29 Thermal Expansion of Technical Solids at Low Temperatures. A Compilation from the Literature

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3. REQUIREMENTS

3.1 Definition

The assemblies are vacuum jacketed flexible hose(s) used to deliver cryogenic propellant (LO2, GO2, LN2) as part of the Ground Support Equipment (GSE).

For the purpose of this document, the following definitions shall apply.

a. Annulus – Space between inner and outer piping walls

b. Calendar Day – Consecutive days on a calendar.

c. Field Monitor – Pressure monitoring performed by individual from a dial indicator gage without electronic transmission.

d. Pressure Cap – A pressure retaining cap which may be used for pressurizing flexible hose spool to 150% design pressure. Pressure cap may also be used as shipping cover.

e. shall: - Used to indicate a requirement which must be implemented and its implementation verified;

f. should: Used to indicate a goal which must be addressed by the design but is not formally verified;

g. Will: Used to indicate a statement of fact and is not verified.

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3.2 General

3.2.1 Fluid Service

3.2.1.1 The service shall be for Liquid Oxygen (LO2), Gaseous Oxygen (GO2), Gaseous Helium (GHe), Liquid Nitrogen (LN2) or Gaseous Nitrogen (GN2)

3.2.1.2 All flexible hose assembly components shall be designed and fabricated as normal fluid service in accordance with ASME B31.3.

3.2.1.3 Examination processes and Pass/Fail criteria shall be in accordance with severe cyclic service requirements in ASM E B31.3.

3.2.2 Temperature and Pressure

3.2.2.1 The lowest ambient temperature expected in service shall be +21.2 degrees F.

3.2.2.2 The nominal ambient temperature in service shall be +80 degrees F

3.2.2.3 The maximum ambient temperature in service shall be +100.4 degrees F.

3.2.2.4 The assembled flexible hose shall be designed for -321 degrees F to +158 degrees F at 315 psig. All components shall be designed for -321 degrees F to +158 degrees F at 315 psig.

3.2.2.5 The Design Pressure (DP) for the inner flexible hose shall be 315 PSIG with 0 psia (full vacuum) applied to external surface of inner line (annular space). Reference paragraph

3.2.2.4 for the design temperature range.

3.2.2.6 The outer jacket piping and outer jacket expansion bellows shall have an annular space design pressure (as defiandned by ASME B31.3) of 35 psig. Reference paragraph 3.2.2.4 for the design temperature range.

3.2.2.7 The outer jacket piping and outer jacket expansion bellows shall be designed for external pressure of 20 psig (above ambient) with 0 psia (full vacuum) annular space pressure.

Reference paragraph 3.2.2.4 for the design temperature range.

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3.2.3 Umbilical Retraction Loads

3.2.3.1 The flexible hose assemblies are subjected to externally applied loads. These loads result from the retraction of the system during launch conditions. See Appendix A for the representative retraction motion.

3.2.3.2 The retraction loads are applied at the QD interface flange. These forces and moments result in acceleration, deceleration and displacement of the flanges from their initial position to their final retracted position. Figure 1 identifies the locations of the QD interface flanges and the coordinate directions of the applied loads.

Figure 1 - Flex Hose Loads Coordinate System

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3.2.3.1 The externally applied loads are shown in Table 1 and Table 2. The forces and torsional moment shall be applied to any section of the flex hose assembly. The transverse moment applies only to the sections including the connection point of the convolutes to the rigid sections and the attachment of the braid to the rigid sections. The forces and moments shall be applied independently to the flex hose assembly.

3.2.3.2 The flex hose assembly shall be designed and fabricated to meet all performance requirements, without damage, before, during and after the application of the retraction loads.

Table 1 - 8x10 Flex Hose Retraction Loads

Load Type Axis Max Load Units

Torsion Moment X 3,000 in-lbs Transverse Moment Y, Z 54,000 in-lbs

Axial Force X 1,600 lbf Transverse Force Y, Z 600 lbf

Table 2 – 3x5 Flex Hose Retraction Loads

Load Type Axis Max Load Units

Torsion Moment X 5,000 in-lbs Transverse Moment Y, Z 28,000 in-lbs

Axial Force X 600 lbf Transverse Force Y, Z 400 lbf

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3.2.4 Material Properties

3.2.4.1 All materials used as pressure containing components shall meet the requirements of

ASME B31.3.

3.2.4.2 Thermal properties of materials at cryogenic temperatures shall be as described from the National Bureau of Standards - Thermal Expansion of Technical Solids at Low Temperatures. A Compilation from the literature, NBS Monograph 29.

3.2.4.3 All materials for construction are specified in this specification. However, the contractor may use materials not specifically called out in this specification provided that chemical and mechanical analysis for the material are submitted to the owner for approval prior to start of fabrication. All materials including those in the vacuum annulus space shall be compatible with the fluid commodity (LO2, LN2, GN2, GHe).

3.2.5 Heat Leak

3.2.5.1 The maximum heat leak for the flexible hose, including spacers and materials in annular space but not end fittings, shall be determined by test or analysis. For analysis calculations the temperature shall be -321 degree F cryo conditions to a maximum ambient temperature of 100.4 degree F.

Nominal ID of Inner Line (in) Btu/hr/ft 2x4 2.75 3x5 3.4 8x10 7.5

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3.2.6 Bend Radius

3.2.6.1 The bend radius shall be as specified in Table 3.

Minimum Center-Line Bend Radius

VJ Flex Hose Size (inner x outer wall -

NPS)

Dynamic Flexing (inches)

Static Bend (inches)

2”x4” 27 11

3”x5” 28 11

8”x10” 56 24

Table 3: Minimum Flexible Hose Center-Line Bend Radius

3.2.7 Convolutes

3.2.7.1 Reference Figure 2 for values listed

3.2.7.2 Convolutes shall meet dimensions shown in Table 4.

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Figure 2: Convolutes Diagram

Inside Convolute (δ ) δ = λ - ơ Inside Convolute Spacing (λ) λ = 1 / (Nc/12) Root Convolute Inside Width (ơ ) ơ = λ/2 + t Np

Bellows Inner Diameter, Di

(inches)

Wall Thickness, t (inches)

Number of Plys Np

Mean Inside Convolute Height h (inches)

Number of Convolutions

Nc

2 0.02-0.024 1 0.3-0.34 24-30 3 0.016-0.02 1 0.5-0.525 44-58 8 0.02-0.024 1 0.3-0.34 24-27

Table 4: Convolute dimensional information

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3.2.8 Inner Flexible Hose Assembly

3.2.8.1 Inner pipe shall be constructed of annealed dual grade ASTM A312 TP316/TP316L. For these dual grade steels, the design shall be based on the allowable stresses tabulated in ASME B31.3 for the standard grade. ASTM A312 TP304L or TP316L pipe shall not be used. Cold worked material shall not be acceptable. Welds must be 100% radiographed.

3.2.8.2 Inner pipe shall be NPS schedule as specified in drawing.

3.2.8.3 Inner flexible hose shall be closed pitch annular convolutions using stainless steel ASTM A240 dual grade 316/316L. When using stainless steel materials that meet ASTM requirements for two grades, the design may be based on the allowable stresses tabulated in ASME B31.3, Table A-1 for the straight grade

3.2.8.4 Compression length shall be designed to include braid tension required for full engagement of convolutes with vacuum in outer annulus, inner hose at minimum design temperature, and 0 psig in inner hose.

3.2.8.5 Length of hose shall be controlled by the inner line braid. The inner line braid shall be installed so that the inner line convoluted section is compressed a sufficient amount to maintain the inner line braid in tension and prevent any reduction in length of the line when the vacuum annulus is evacuated

3.2.8.6 The inner line shall be supported with spacers that center it within the outer jacket. The design, location, and material of the spacers will be determined by Subcontractor.

3.2.8.6.1 Details of the design and material selection shall be submitted to the owner for approval prior to fabrication.

3.2.8.7 Spacers shall allow for motion of the convolutes.

3.2.8.8 Spacers shall not be located within 3/4" of a circumferential hose weld

3.2.8.9 If a multi-layer insulation (MLI) system is utilized to meet heat leak requirements, the MLI shall consist of alternating layers of aluminized Mylar or aluminum foil and a microfiber insulating sheet.

3.2.8.10 Each vacuum jacket annulus space shall be equipped with a chemical gettering system consisting of a molecular sieve desiccant, and hydrogen converter.

3.2.8.11 All inner flexible hose pressure boundary welds, as defined per ASME B31.3, shall accommodate 100% radiography.

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3.2.8.11.1 If inner flexible hose primary weld cannot accommodate 100% radiography, the inner flexible hose primary welds shall accommodate dye penetrant testing

3.2.8.11.2 Inner pipe branch connection which cannot utilize a standard ASME 16.9 fitting or reducing tee shall be fabricated with an ASME listed Bonney Forge Vesselet style branch connection.

3.2.8.11.3 Pipe fittings shall be in accordance with ASME B16.9

3.2.8.11.4 Inner pipe elbows shall be long radius per ASME B16.9. Mitered tee and elbows are not permitted on inner line.

3.2.9 Outer Flexible Hose Assembly

3.2.9.1 Outer pipe shall be constructed of annealed dual grade ASTM A312 TP316/TP316L. For these dual grade steels, the design shall be based on the allowable stresses tabulated in ASME B31.3 for the standard grade. ASTM A312 TP304L or TP316L pipe shall not be used. Cold worked material shall not be acceptable.

3.2.9.2 Outer pipe shall be NPS schedule as specified in drawing.

3.2.9.3 The outer vacuum jacket shall be closed pitch annular convolution using ASTM B575 N06022 (Hastelloy C22).

3.2.9.4 The outer line convolutions shall be covered with braided wire reinforcement per dual grade ASTM A580 316/316L stainless steel.

3.2.9.5 Compression length shall be designed to include braid tension required for full engagement of convolutes with vacuum in outer annulus, inner hose at minimum design temperature, and 0 psig in inner hose.

3.2.9.6 The outer flexible hose welds shall accommodate 100% dye penetrant examination per

ASME B31.3.

3.2.9.7 All mitered corners shall be closely spaced geometry per ASME B31.3.

3.2.9.8 Vacuum Valve

3.2.9.8.1 Each section of vacuum jacketed flexible hose shall be equipped with a vacuum valve assembly in accordance with 79K14672-3.

3.2.9.8.2 Vacuum pump-out valves shall be located as per shown in the flexible hose drawings and will be government furnished equipment.

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3.2.10 VJ Joint Connections

3.2.10.1 Gasket size, material, type and part number shall be specified and provided to owner

3.2.10.2 Bayonets shall be designed in accordance with ASME B31.3 Paragraphs 302.2.3, 304 and qualified by Paragraph 304.7.2(c) or (d) either individually or as part of the pipe spool assembly. Paragraph 304.7.2(e) may not be utilized to qualify the component.

3.2.10.3 All bayonets shall be close tolerance type with a flange face O-ring seal, and a nose seal.

3.2.10.4 All bayonet design shall be pre-qualified by the vendor by testing including a leak check at liquid nitrogen temperatures, and a mass spec leak check at ambient temperatures.

Historical data may be submitted in place of test data with NASA approval.

3.2.10.5 The outer jacket of all bayonets shall equal the nominal sizes listed in 3.2.4.2.

3.2.10.6 Alternate bayonet designs may be submitted to NASA. All alternate bayonet designs shall require NASA approval.

3.2.10.7 Bayonets shall be supplied with a slip-on style bolted flange.

3.2.10.8 Bolt hole dimensions on flanges shall meet the requirements of ASME 16.5 for a class 150 or 300 flange as specified on the drawings, of a diameter matching the jacketed pipe dimensions.

3.2.10.9 Flanges shall be constructed from dual grade ASTM A182 F316/F316L stainless steel.

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3.2.10.10 All non-bayonet flanges shall be raised face with concentric serrations as specified on the drawings. If the drawing does not specify the flange serrations the dimensions shall be as shown in Figure 3. Note not all flange serrations are the same dimensions.

Figure 3 - Concentric Serration Dimensions

3.2.10.11 Flanges shall be forged type only. Fabricated and flared type is not permitted.

3.2.10.12 Flange fastener Bolt studs, washer and nut materials shall be in accordance with ASTM A193, A194, or A320.

3.2.10.13 Socket weld joints shall not be used.

3.2.10.14 Butt welded joint designs shall meet the requirements of ASME B16.9.

3.2.10.15 Butt welded end designs shall meet the requirements of ASME B16.25.

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3.2.11 Weld Fittings

3.2.11.1 Fittings shall be as per ASME B16.9 and ASTM A403 class WP-S (seamless) or WP-WX (welded with 100% x-ray) and shall be WP316/WP316L (dual graded) and shall be of schedule as specified in the drawing.

3.2.12 Thermal Life Cycle

3.2.12.1 The flexible hose assemblies shall have a designed thermal cycle life of a minimum of 3,000 cycles. A thermal cycle is defined as the flexible hose assembly starting at ambient temperature, then being taken down to minus 321 degrees F, held at that temperature for a minimum of 15 minutes, and then allowed to return to ambient temperature. A pressure cycle for the assembled VJ flexible hose shall be 0 psig to 315 psig and back to 0 psig.

These requirements are design requirements only and do not require verification by test.

3.2.13 Listed / Unlisted Components Usage

3.2.13.1 The flexible hose assembly shall be qualified in accordance with ASME B31.3 paragraph

304.7.2 (c) or (d). Paragraph 304.7.2(e) of ASME B31.3 shall not be utilized to qualify the flexible hose.

3.2.13.2 Charpy impact testing shall be required for flexible hose welds for listed components per

ASME B31.3.

3.2.14 Attachments

3.2.14.1 All plates, rings or other items attached to the outer jacket or inner line shall be fabricated from dual grade 316/316L per ASTM 240.

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3.3 Construction

3.3.1 General

3.3.1.1 All work on vacuum jacketed flexible hose assemblies which exposes the annular area between the inner and outer line shall be performed in a controlled environment which will minimize the exposure to moist air, oil, grease or other contaminants. A dry GN2 purge shall be maintained whenever possible, after annulus closure. The annulus area of the vacuum jacketed lines shall be maintained clean at all times. Application of tape, grease pencil, and chalk marks shall be avoided. Exposed surface areas shall be thoroughly degreased before the annulus is closed.

3.3.2 Welder Qualification

3.3.2.1 All welding shall be performed by qualified welders per weld procedure specifications for each weld in accordance with AWS D17.1, clause 9, paragraph 9.1, option 2, and ASME B31.3. Weld traceability maps of welder and procedure number at each joint are required for each flexible hose.

3.3.3 Non Destructive Evaluation (NDE) Examiners

3.3.3.1 Weld examiners shall be qualified in accordance with AWS D17.1, clause 9, paragraph 9.1, option 2, and ASME B31.3 paragraph 342.

3.3.4 Non Destructive Evaluation (NDE)

3.3.4.1 All welding inspections shall be performed in accordance with AWS D17.1, clause 9, paragraph 9.2, Severe Cyclic Conditions and ASME B31.3 by qualified weld examiners

3.3.4.2 Weld examination pass/fail criteria shall be per ASME B31.3, Severe Cyclic Conditions.

3.3.4.3 All welds shall be 100% examined per AWS D17.1, clause 9, paragraph 9.2, Severe Cyclic Conditions and ASME B31.3 as follows:

3.3.4.3.1 All welds shall be 100% visually examined.

3.3.4.3.2 All fillet welds shall be 100% dye penetrant inspected.

3.3.4.3.3 All welds located on outer flexible hose jacket shall be dye penetrant examined

3.3.4.3.4 All welds located on inner flexible hose pressure boundary shall be 100% radiographed. Radiograph exception per 3.3.4.4.

3.3.4.3.5 All longitudinal seam welds shall be radiographed.

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3.3.4.4 If welds located on inner flexible hose cannot be radiographed due to the inherent design of the flexible hose, all welds shall be 100% dye penetrant tested. Pass/Fail criteria shall be per ASME B31.3 for severe cyclic service. Dye penetrant shall be removed from the annular space in order to meet the vacuum retention requirements of this specification.

3.3.4.5 Dye penetrant will be removed from the annular space in order to meet the vacuum retention requirements of this specification.

3.3.4.6 Seams on convoluted sections shall be 100% radiographed prior to the forming process.

Pass/fail criteria shall be per ASME B31.3 for severe cyclic criteria.

3.3.5 Welding

3.3.5.1 All inner circumferential welds shall be full penetration welds for severe cyclic conditions in accordance with AWS D17.1, clause 9, paragraph 9.1, option 2 and ASME B31.3. Filler metal selection shall be in accordance with ASME B31.3.

3.3.5.2 If full penetration welds are not possible for the convolute to pipe and or wire braid to pipe due to the inherent design; alternate welds for these areas can be submitted to NASA for consideration. All alternate weld designs and waivers to the full penetration requirement specified in 3.3.5.1 shall be approved by NASA prior to the start of fabrication.

3.3.5.3 Backing rings are not permitted.

3.3.5.4 Brazing and soldering are not permitted.

3.3.5.5 Attachments of ASTM A240 material shall be welded per AWS D 17.1, clause 9, paragraph 9.1, option 2, Class B inspection and ASME B31.3. Filler metal selection shall be in accordance with ASME B31.3

3.3.5.6 Remove scale, burrs and break sharp edges

3.3.5.7 Pull braids tight to ensure contact with all convolutes after bellows compression and prior to welding braid in ferrule.

3.3.6 Low Temperature Toughness

3.3.6.1 All welds and materials shall meet the requirements for low temperature toughness (impact test) in accordance with ASME B31.3, paragraph 323.2.2.

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3.3.7 Passivation

3.3.7.1 Welds and heat affected areas shall be passivated per ASTM A967. Passivation chemicals/fluid/materials shall be removed from the annular space in order to meet the vacuum retention requirements of this specification.

3.3.8 Cleaning

3.3.8.1 The inner surfaces of all flexible hose assemblies and components shall be cleaned to KSC-C-123J level 300, ISO 14952 level 300, or vendor submitted equivalent (requires NASA approval). All cleaning processes and cleanliness level inspections shall be as specified in KSC-C-123J level 300, ISO 14952 level 300, or NASA approved equivalent.

3.3.9 Name Plates and Product Marking

Electrochemical Etch (Type II), Engrave (Type VII), or Laser Engrave (Type VIII) using 0.125 inch minimum characters per provisions in MIL-STD-792 and the General Requirements (Paragraph 3.1) and Quality Assurance provisions (Paragraph 4) of KSC-STD-E-0015. Do not engrave or etch directly on the jacket flexible hose. Stainless steel name plate may be tack welded to outer line prior to testing.

At a minimum, the data indicated below shall be included:

• Manufacturing vendor’s name

• Contract Number

• KSC Part Number

• KSC Spool Number

• Design Pressure

• Test pressure

• Test date

• Service

• Year Built

• Temperature Range

• Weight

3.3.10 Workmanship

Hardware shall be fabricated and finished so appearance, fit, and adherence to specified dimensions and tolerances are observed and in a manner that ensures reliable operations in accordance with the requirements specified herein. Particular attention shall be given to the neatness and thoroughness of construction and to the freedom of parts from burrs and sharp edges that might damage associated equipment or cause injury to personnel. Any item failing the acceptance criteria shall be repaired or replaced and reexamined to the same acceptance criteria as required for the original work.

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3.3.11 Interchangeability

Hardware assemblies, components, and parts with the same part number shall be physically and functionally interchangeable

3.3.12 Safety

N/A

3.3.13 Human-Factors Engineering

N/A

3.3.14 Security

N/A

3.3.15 Government-Furnished Property

79K14672 vacuum valve assemblies

3.4 Documentation

N/A

3.5 Logistics

N/A

3.6 Personnel and Training

N/A

3.7 Major-Component Characteristics

N/A

3.8 Precedence

In case of conflict between referenced document and this specification, this specification shall take precedence.

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4. VERIFICATION

4.1 Responsibility for Inspection

Unless otherwise specified in the contract or order, the Subcontractor shall be responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the Subcontractor may use his own facilities or any commercial laboratory acceptable to the Government.

The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

4.2 Special Tests and Inspections

4.2.1 Flexible Hose Measurements

4.2.1.1 Measure and record the weight of flexible hose +/- 5 pounds.

4.2.1.2 Measure and record the length of the flexible hose under the following conditions:

4.2.1.2.1 Ambient pressure and temperature with the annulus evacuated to a pressure of 50 microns of Hg or less.

4.2.1.2.2 Measure the length of the hose in the straight position

4.2.1.3 Subcontractor shall provide to the owner convolute dimensions including but not limited to pitch, material thickness, convolute height, minimum inside dimension between bottom of convolutes.

4.3 Verification Inspections

4.3.1.1 Testing commodities shall conform to specifications as follows:

• Gaseous helium to MIL-PRF-27407C, Type I, Grade A

• Gaseous nitrogen to MIL-PRF-27401F, Type I, Grade B

• Liquid nitrogen to MIL-PRF-27401F, Type II, Grade B

4.3.2 Required Testing Chronology

4.3.2.1 The testing in sections 4.3.2 to 4.3.5 shall be performed sequentially.

4.3.3 Cold Shock

4.3.3.1 The completed vacuum jacketed flexible hose will have the vacuum annulus evacuated to

27 34 — None a pressure of 10 microns of HG or less.

4.3.3.2 The assembly shall be cold shocked with LN2 by tilting the line at least 15 degrees and introducing the LN2 into the assembly at the low end, allowing the boil off gas to vent from the high end. The chilldown and tilting of the assembly shall continue until a steady stream of LN2 is forced out the high end. The LN2 supply shall then be maintained to keep LN2 within 6 inches, at the farthest point, from the end of the spool, and allowing the assembly to cold-soak for 1 hour

4.3.3.3 .The vacuum readings shall be recorded before, during, and after the cold shock test. The vacuum reading after the cold-shock test shall be taken when the assembly returns to ambient temperature. Post cold shock vacuum reading shall be less than 50 microns of Hg pressure

4.3.4 Pressure/Leak Testing

4.3.4.1 The leak pressure test shall be conducted via hydrostatic testing at a minimum of 150% of the design pressure per ASME B31.3.

4.3.4.2 The pressure shall be maintained for a minimum of 10 minutes. The vacuum readings shall be recorded prior to test and after the pressure has been reduced to DP and at end of test where pressure is less than 10 psig. The vacuum jacketed flexible hose undergoing test shall exhibit no leakage while undergoing leak testing and show no permanent deformation or damage as result of the leak testing.

4.3.4.3 Leak test of the outer jacket (by pressurizing the annular space) is not required.

4.3.4.4 Leak testing shall be performed at ambient temperature.

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4.3.5 Mass Spectrometer Leak Testing

4.3.5.1 The vacuum jacket annulus shall be evacuated to a pressure of 10 microns of HG or less.

4.3.5.2 One of the following two testing procedures shall be used. Do not introduce helium into the vacuum annulus for any testing.

4.3.5.2.1 With inner line pressurized to MDP with 100% helium and holding at MDP for 1 minute minimum, the mass spectrometer leakage indication shall be below 10-7 std-cc/sec. To accomplish this test, a mass spectrometer capable of sensitivity to 10-9 std-cc/sec shall be used.

4.3.5.2.2 As an option with inner line pressurized to MDP with 10% helium/90% nitrogen and holding at MDP for 1 minute minimum, the mass spectrometer leakage indication shall be below 10-9 std-cc/sec. To accomplish this test, a mass spectrometer capable of sensitivity to 10-10 std-cc/sec shall be used.

4.3.5.3 The outer jacket shall be tested with all jacket welds surrounded by a 100% GHe atmosphere.

4.3.5.3.1 GHe leakage shall be less than 10-7 std-cc/sec using a Helium Mass Spectrometer Leak Detector set to a minimum sensitivity of 10-9 scc/s

4.3.6 Vacuum Retention Test

4.3.6.1 Each section of the vacuum jacketed flexible hose outer vacuum jacket shall be evacuated to a pressure of 10 microns of Hg or less at ambient temperature.

4.3.6.2 The vacuum level in the annular space of each section of the vacuum jacket pipe shall be measured and recorded every twenty-four (24) hours for a period of at least seven (7) days.

4.3.6.2.1 The final pressure at the end of the test period within each section of the vacuum jacket must stabilize at or below 50 microns of Hg pressure to be acceptable.

4.4 Dimensional Verification

4.4.1 Flexible Hose Assemblies

4.4.1.1 Flexible hose assemblies shall be dimensionally verified to be in accordance with the Subcontractor’s fabrication drawings prior to packaging for shipment.

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4.5 Responsibility For Verification / Inspection

4.5.1 Verification/Inspection

4.5.1.1 The Subcontractor shall be responsible for the performance of all verification (test, demo or inspection) requirements as specified herein. Except as otherwise specified, the Subcontractor may use his own facilities or any commercial laboratory acceptable to the Government. The Government reserves the right to witness or perform any of the inspections set forth in the specification where such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

4.5.1.2 The Subcontractor shall formulate acceptance test procedures for all components and will provide the facility and instrumentation to perform all relevant tests to ensure compliance with this specification. The acceptance test procedures shall include but not be limited to all of the testing procedures specifically outlined in this document.

4.5.1.3 All items purchased or manufactured by a subcontractor used in the Subcontractor’s work shall be clearly identified and tabulated.

4.5.1.4 All material and components shall be traceable to original Subcontractor via material certification records.

4.5.1.5 The Government reserves the right to have access to the Subcontractor’s facility at any time during the design, fabrication and code testing. The Government shall have the right to witness any manufacturing or testing procedures upon request. When requested, the Subcontractor shall provide a minimum of 7 work days’ notice in advance of any test date to allow for the Government (or its designated contractor representative) to make the necessary travel arrangements.

4.5.1.6 Review of analysis data and procedures by the Government shall not release the Subcontractor from its responsibility to correct errors, oversights and omissions to ensure conformance to the requirements in this document and ASME code requirements.

5. PREPARATION FOR DELIVERY

5.1 Preservation

5.1.1 Protective pressure cap

5.1.1.1 The VJ flexible hoses shall be furnished with stainless steel protective pressure cap to prevent damage or contamination during storage, transportation and handling.

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5.1.2 Packaging Cleanliness

5.1.2.1 All flexible hose assemblies shall be packaged per KSC-C-123J level 300, ISO 14952 level 300, or NASA approved equivalent. Packing design shall be approved by the Government prior to use.

5.1.3 Vacuum in Annulus

5.1.3.1 Vacuum levels at delivery to the owner shall be 50 microns of Hg pressure or less

5.1.3.2 Annulus shall be sealed and maintained at vacuum levels from acceptance tests.

5.1.3.3 All flexible hose assembly vacuum levels shall be checked and recorded prior to shipment for validation at KSC receiving site prior to acceptance.

5.1.4 Inner Line Pressure

5.1.4.1 Cleanliness of KSC-C-123J level 300, ISO 14952 level 300, or vendor submitted equivalent (requires NASA approval).shall be maintained.

5.1.4.2 Seal inner pipe ends and ports with pressure retaining caps equipped with pressure gage and gas charging tee (1 set per pipe assembly).

5.1.4.3 Establish a minimum dew point of minus 65F (24 ppm) using 2 micron filtered MIL- PRF-27401F, Type I, Grade B GN2 in accordance with Test Method III (A.3.3) of KSC- C-123 then establish a 5 +/-2 psig GN2 blanket pressure

5.1.4.4 Leak check shall be performed on pressure ports using MIL-PRF-25567 Type 1 or 2 leak check fluid. Verify no bubble formation for one minute minimum.

5.1.5 Recordings

5.1.5.1 All flexible hose assembly vacuum levels shall be checked and recorded prior to shipment for validation at KSC receiving site prior to acceptance.

5.1.5.2 All flexible hose assembly GN2 blanket pressures shall be checked and recorded prior to shipment for validation at KSC receiving site prior to acceptance.

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5.2 Packing

The Subcontractor shall package each vacuum jacketed flexible hose section within a hard sided container (at a minimum wood construction) using standard commercial practice, ensuring each vacuum jacketed flexible hose section is protected against damage during shipment. Entire flexible hose section length must also be protected against damage using isolation / separation means between segments during shipment. Boxes shall be strong enough to support being picked up using a forklift and/or using lifting straps. The boxes should be capable of being stacked. Flexible hoses may be shipped on saddle supports with hold-downs, or equivalent means. More than one flexible hose may be contained in a box. The boxes do not need to be weatherproof. Shipping containers shall conform to freight classification rules and applicable container specifications. These shipping containers shall be capable of being picked-up by fork lift or lifting straps.

6. NOTES

6.1 Intended Use

This document is intended to establish the requirements for fabrication and testing of LO2 vacuum jacketed flexible hose.

NOTICE. The Government drawings, specifications, and/or data are prepared for the official use by, or on behalf of, the United States Government. The Government neither warrants these Government drawings, specifications, or other data, nor assumes any responsibility or obligation, for their use for purposes other than the Government project for which they were prepared and/or provided by the Government, or any activity directly related thereto. The fact that the Government may have formulated, furnished, or in any way supplied the said drawings, specifications, or other data is not to be regarded, by implication or otherwise, as licensing in any manner the holder or any other person or corporation nor conveying the right or permission to manufacture, use, or sell any patented invention that may relate thereto.

Custodian:

Preparing Activity:

NASA – John F. Kennedy Space Center Kennedy Space Center, Florida 32899

John F. Kennedy Space Center

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Appendix A - Representative Flex Hose Retraction Motion

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Signature History

DETAILS

NUMBER K0000190545-SPC NAME TSMU FLEXIBLE HOSE SPECIFICATION,

VACUUM JACKETED, LO2 SERVICE

DRAWING TYPE Procurement Specification CONTAINER EGS - ML - TSMU Product -

WCP0120

TECHNICAL POC Christian Bechtold AFFECTED END ITEMS

ASSIGNEE ROLE COMMENT COMPLETED

Brett Lannie Assignee routed for signature approval routed per

KDP-P-2718

Aug 26, 2014

Brett Lannie Assignee re-routed for signature approval per KDP- P-2718

Mar 05, 2015

David Roth Signatory Mar 09, 2015

Jennie Ward Signatory Mar 11, 2015

ZZ-AlanLittlefield-(Disabled) Signatory Approve Mar 09, 2015

ZZ-MarkMinich-(Disabled) Signatory Mar 09, 2015

William Patrick Signatory rework per Ed Thompson Sep 05, 2014

Edward Thompson Signatory Mar 05, 2015

Theodore Adams Signatory Mar 10, 2015

Frank Trimboli Signatory Mar 13, 2015

Ronald Phillips Signatory Mar 13, 2015

Brett Lannie Assignee routed for signature approval per KDP- P-2718

Mar 17, 2015

ZZ-EmilioCruz-(Disabled) Signatory Mar 17, 2015

ZZ-DouglasKverek-(Disabled) Signatory Mar 17, 2015