Attach_3_-_ML_EM-2_Mod_Overview.pdf

National Aeronautics and Space Administration

GSDO-TEMPL-001, Rev. 14, 09/21/2016

EM-2 ML Modification Overview

EM-2 Block 1B Vehicle Configuration

ML GSE Modifications Required to Support EM-2/EUS Configuration

• Significant modifications required to GSE systems on the ML to support EM-2/EUS configuration

– Umbilical System impacts

Shifting of CAA and OSMU higher

• Requires shifting of 18+ fluid and EGSE GSE end items to new levels

• Requires significant demo and tower modifications to support the moves

• Large number of cable and piping/tubing to require removal and re-routing

Major Re-design of VSS required and 20+ supporting fluids and EGSE systems

2 new umbilicals and approx. 30 fluid and EGSE systems that support these systems, 100+new cables and large amount of piping/tubing

Demo and removal of ISCPU

• 20 GSE fluids and EGSE end items will require remove along with large number of cables and tubing

– GSE System impacts

All systems above the 220 ft level will require significant installation redesign

EGSE modifications

Pneumatic system mods and additions

ML has run out of real estate in the base on the tower for new GSE

Moving GSE will drive significant structural changes not accounted for in the study

100s of long run and short run cables impacted

GSELH2/LO2 will require major redesign to support EUS

• New LH2/LO2 skids, VJ piping, support EGSE end items

– Facility System impacts

Major redesign of AC power, lighting, elevator, fire alarm, fire protections, potable/septic water and KCCS

New electrical room required on the 325 ft level

Significant cable plant demo and rework required

• Bottom Line-ML modifications are significant and pose a significant challenge to meet EM-2 schedules

• Approx. 19 month window between EM-1 (H/W availability) and EM-2 need date for ML

Overview of ML Structural Reinforcement Study March 2015

Overview of ML Structural Reinforcement Study March 2015

A&E study completed in 2015 to determine structural feasibility of ML modifications to support 1B

ML reinforcement structurally is feasible, but implementation will be problematic

Adds approx. 530,000 lbs of steel to ML

Tower Impacts

• 8 levels will require diagonal modifications

• 10 levels will require column modifications

• 2 levels will require significant rework to add electrical rooms

• Crew level will need to relocated

• Umbilical Arm mounting will require major structural mods

ML Base Impacts

• Significant Girder reinforcement required

• Truss reinforcement

• Significant demo required to complete

ML Modifications Required for Block 1B

CAA

(moved)

OSMU

(moved)

ICPSU

VSS

CSFSU

CSITU

TSMU (2) VSP (8)ASPU (2)

EFAU (New)

EAFU (New)

ICPSU

LH2 F/D Flow Control (Skid)

EUS

LH2 F/D Flow Control (Skid)

Notional

EUS may require upgrade feed lines and skids (LO2 and LH2) to support timely launch processing.

Incompatible with ICPS configuration.

Propellant quality

Tower increase

Mobile Launcher Mods for Block 1B

SubSystem New

Design and/or

Re-design

Add Level to ML

Tower

Struct

Mods &

Stiffening

Relocate

CAA

Relocate

OSMU

Remove

ICPSU

2 New

EUS

Umbilicals

Mod &

Upgrade

VehStab

Detailed Design X X X X X X X

GSE Installation Design X X X X X X

Construction Contract Scope X X X X X X X

ECS Mods X X X X

GMPS Mods X X

1 new GMPS RIO

New/Mod GSP X X X

X

3 new pwr racks

2 new term dist

1 new RIO

X

HGLDS Mods X X X

HAASP Mods X demo new

Hydraulics X new new design

Pnuematics X 4 new Panels (2 GN2; 2

Ghe)

Struct/Mechanical X X X X X X mod ICPSU hinges new hinges

Major Change from

Passive VS to Active

Hyd Sys

Add new passive stay

New/Mod EGSE X 1 new OSMU RIO

3 new GCS RIOs demo mod/re-use ICPSU RIO

4 new term dist

1 new LH2 RIO

1 new LO2 RIO

1 new LRS RIO

1 new VS RIO

GCS X New

KGCS X

new GCS LCD& PLC new cabling

LACC mods

Pnuem Controls mods

LACC mods

Pnuem Controls mods mod GMPS cabinet

LACC mods

Pnuem Controls new PLCs/networks recording

LACC mods

CRYOs X 2 new upper stage skids

LRS Mods X 1 new Rack

1 new Term Dist

RSCS Mods X

2 mod RIOs

1 RF enclosure

1 new RF tower

SDAS mods X mods demo new new/mods

TCS mods X 1 new RIO

1 pwr dist

New Tubing/Piping/Hoses X X X demo new - a lot new

New Cabling X demo/instl demo/instl demo new - a lot some

LETF Testing (VMS & VSTF) X X2 X

Standalone V&V X X X X X

Fac.Elect. X X

Fire Prot. X X

Elevator X X

Comm. X X

ML EM 2 ScheduleML EM 2 Schedule 2016 2017 2018 2019 2020 2021

A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J

9/30/16

ML EM2 Schedule

ML EM2 Design

EES / Struct. Mods

GSE / EES / Struct.

Pneumatics Panels

LH2/LO2

ML EGSE Design Mods

TCS

SDAS

RSCS

GSP

HGLDS

GMPS

Wx

LRS

KGCS

EGSE Fab

LETF EUS Umbilicals

LETF EUS Umbilical

Struct. Mods, Umbilical & GSE Installation, EES

ML Standalone V&V

Multi-Element V&V

Delta DCRs, Reqs.

A&E / SOW Dev.

Arch / Req. Dev. Studies

EES Reqs Dev. Study

A&A ML A&E

4/13

Start

GSE / EES / Structural Mod / A&E Design

100% Design

7/25

SRD Dev Pneumatics Panel Design 100% Design Release

A&A Panels Fabrication

SRD Dev LH2 / LO2 Design Mods 100% Design Release

A&A LH2/LO2 Fabrication

SRD Dev EGSE Design Mods EGSE Fabrication

TCS Design Mods 100% Release

SDAS Design Mods 100% Release

RSCS Design Mods 100% Release

GSP Design Mods 100% Release

HGLDS Design Mods 100% Release

GMPS Design Mods 100% Release

Wx Design Mods 100% Release

LRS Design Mods 100% Release

KGCS Design Mods 100% Release

A&A EGSE Fabrication

SRD Dev VS / Umbilical Design EUS Fwd/Rear

EUS Rear 100% Design

EUS FWD & VS

100% Design Release

EUS Rear 100% Design

VS / EUS Umbilical Fab

5/11

EUS Umb FWD & RR Fab Start

5/17

VS Umb. Fab Start

GSE Umb. Fab Complete (9/30)

LETF Testing

1/30

Testing Comp.

Const. A&A

ML Available for Mods (Post EM-1) (1/2)

EES / Struct Mods / GSE Install

1/3 Start

Complete

Standalone V&V Start 8/11 10/5 Complete

Multi-Element V&V Start 10/6 11/30 Complete

Delta DCRs, Reqs Closure

DRAFT