SRPO Cryogenic Safety Users Guide Revision A Final.pdf

SRPO Cryogenic Safety User’s Guide

Revision A

Sounding Rocket Program Office Wallops Flight Facility (WFF)

Wallop Island, Virginia

SRPO Cryogenic Safety User’s Guide

4/29/2021

810-UG-0001 (Rev. A)

Revisions

Revision Description Date

- Baseline 8/30/2017

A Additional training requirements added per updated GPR

4/29/2021

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Table of Contents

Revisions

1.0 Introduction

2.0 Ground Support Equipment (GSE) Design, Fabrication and Installation

3.0 Cryogenic Procedures

4.0 Training

5.0 Abbreviations and Definitions

ENCLOSURE 1 (Sample GSE Block Diagram) ENCLOSURE 2 (Cryogenic Procedure Template)

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1.0 Introduction

The Sounding Rocket Program Office (SRPO) has developed this user’s guide to aid experimenters, scientist and other individuals in the requirements associated with cryogenic operations and requirements. The field of cryogenics as defined by the U. S.

National Institute of Standards and Technology involves temperatures below -292.0⁰F (- 180⁰C or 93.15⁰K); one exception to this general principle is the cryogen Liquified Methane which has a boiling temperature of -238.0⁰F.

Cryogenic liquids are transported and used in thermally insulated containers specifically designed to withstand rapid temperature changes and extreme differences in temperatures. These containers are usually liquid cylinders which are pressurized containers designed for cryogenic liquids. The container has valves for filling and dispensing the cryogenic liquid and a pressure-control valve with a frangible (burst) disk as overpressure protection. There are usually three major types of cylinders which are designed for dispensing only gas, only liquid or both liquid and gas.

Cryogenic liquids are associated with the following health hazards: fire hazards, extreme cold, toxicity and asphyxiation. Extreme cold affects skin, tissue and eyes if left unprotected. Toxicity varies depending on the type of gas. Refer to Safety Data Sheet, SDS, for information about the toxic hazards of a particular cryogen. Asphyxiation occurs when a cryogenic liquid forms a gas that is heavier than air and the gas displaces air which reduces the oxygen content below a point that is life sustaining. Oxygen deficiency is a serious hazard in enclosed or confined spaces.

Below are the various points of contact (POC) for cryogenic safety within WFF:

SRPO S&MA Manager 757-824-1557

NSROC S&MA Manager 757-824-1402

WFF Pressure Systems Manager 757-824-1625

The following references are cryogenic safety requirements:

1. Goddard Space Flight Center (GSFC) Wallops Flight Facility Range Safety Manual (RSM) Tailoring for Sounding Rocket Program Office (SRPO) (GSFC-

STD-8009T-SRPO)

2. NASA Standard 8719.17; NASA Requirements for Ground-Based Pressure Vessels and Pressurized Systems (PVS)

3. GPR 8710.7 Cryogenic Safety

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2.0 Ground Support Equipment (GSE) Design, Fabrication and

Installation

The Cryogenic system GSE usually consist of a commercial LHe or LN2 storage dewar, relief valves, pressure gauge, liquid fill/supply valve, gas supply valve, emergency shutoff solenoid valve, solenoid valves, monitor/display boxes, transfer hoses, and valve controllers. These components may vary depending on the cryogenic system. Enclosure 1 shows a sample GSE block diagram of a cryogenic cooling system. When submitting a cryogenic (hazardous regardless of pressure) procedure to the WFF Safety and Mission Assurance (SMA) Code 390 for review and approval, a detailed GSE block diagram or schematic needs to be included as part of the procedure or as a separate document.

Cryogenic fluid components including transfer hoses must be properly rated for intended cryogenic temperature and pressure being conveyed and must be compatible with the fluids. The cryogenic system must be properly installed,tighten and leak tested to prevent any leakage during liquid transfer. Any part of the system that may be blocked-in, liquid thermal expansion relief device must be installed to prevent over pressurization of the system.

Design, fabrication and installation of the cryogenic system must meet requirements in the reference documents in Section 1.0 Introductory. System design must be reviewed and approved by WFF Pressure Systems Manager (PSM) prior to usage or activation of the system.

3.0 Cryogenic Procedures

Cryogenic procedures usually involve set-up, backfill and operation of the cryogenic system. The procedures can either be hazardous or nonhazardous. The WFF Safety Office reviews the procedures to decide whether or not they are hazardous. If hazardous, the WFF Safety Office will approve the procedure with NASA approver signature. The step by step hazardous procedure with detailed system design schematic must be submitted for PSM review and approval. Generally, the procedure should be submitted no later than 30 days prior to first usage to allow time for review and potential hardware changes.

The Cryogenic Operating procedure should include the following sections: Purpose, Scope, Definitions, Resource Requirements, Equipment Requirements, Safety Requirements, References, Quality Assurance, and Implementation. A procedure template is included as Enclosure 2.

4.0 Training

Cryogenic designers and operators are be trained in the following areas:

GSFC Cryogenics Safety and Oxygen (O2) Deficiency Hazard (ODH) Basic Safety Training (WFF)

GSFC Cryogenic Safety: Design, Construction and Operations Cryogenic Operation On-the–Job-Training (OJT)

As operators, there shall be evidence of completion of the above areas. WFF offers instructor led Cryogenics and ODH Basic Safety Training classes currently about twice a year. Cryogenic Safety – Design, Construction, and Operations is offered less frequently than the other class. Designers will take both classes. Once taken, training is to be refreshed every three (3) years. The OJT should occur once the classroom instruction is complete enabling the individuals to gain experience with the cryogenic system they are operating. In lieu of the WFF classes, equivalent training can be substituted for allowance of designer and operator qualifications. It is responsibility of the designer’s and/oroperator’s organization/management to ensure that their employee has adequate OJT and is qualified to safely operate cryogenic systems.

5.0 Abbreviations and Definitions

GSE: Ground Support Equipment O2: Oxygen ODH: Oxygen Deficiency Hazard OJT: On-the-Job-Training POC: Point of Contact PVS: Pressure Vessel System PSM: Pressure Systems Manager RSM: Range Safety Manual SRPO: Sounding Rocket Program Office WFF: Wallops Flight Facility

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ENCLOSURE 1 (Sample GSE Block Diagram)

ENCLOSURE 2 (Cryogenic Procedure Template)

THIS LOCAL PROCEDURE/WORK INSTRUCTION

CONTAINS HAZARDOUS OPERATIONS

LOCAL PROCEDURE/WORK INSTRUCTION

EXPREIMENT NAME CRYO-001

EXPERIMENT NAME

Liquid Nitrogen Cryogenic Operating Procedure

Document Owner: PI or ONE RESPONSIBLE FOR PROCEDURE

Rev - Official Release Date:

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1.0 Purpose:

The EXPERIMENT NAME payload requires Liquid Nitrogen (LN2) to cool the INSTRUMENT BEING COOLED. Cold LN2 will be piped directly to EXPLAIN

HOW INSTRUMENT WILL BE COOLED SPECIFICALLY.

This procedure provides instruction on the safe transfer and use of LN2 for cooling on the EXPERIMENT payload. This procedure also covers the safe handling, storage and operation of cryogenic systems using LN2 for test and integration, and launch operations. In addition, procedures for related tasks and troubleshooting will be covered.

A LN2 standard Dewar is connected to a control panel on the launch rail supplying LN2 to a LN2 solenoid valve manifold (see Figure 4). There are two small differences in operation on the rail verses the integration.

1) During integration operations, the solenoid valve manifold will connect directly to a Dewar.

2) During integration operations, the LN2 manifold is plugged directly to an 110V wall plug supply. During rail operations, the 110V electrical plug supply is remote controlled at the block house.

The manifold is protected with its own 150PSI relieve valve. Both cases are documented in this procedure.

This procedure describes instructions for:

1) Inspection and Protection of Cryogenic System;

2) LN2 Transfer;

3) Warming or Backfilling; and

4) Troubleshooting and Problem Remediation (Contingency)

a. Troubleshooting Plugged Storage Dewar;

b. Removing a Frozen-in Transfer Line; and

c. Ice Plug Removal

This procedure must be used for any and all of the above operations.

2.0 Scope:

This procedure is applicable to cryogenic operations conducted for the integration, testing, and launch of the EXPERIMENT NAME experiment on a sounding rocket mission launching from LAUNCH Range. LN2 use during integration will be required for cooling the experiment during integrated payload

This below section may vary depending on the cryogenic system set-up. The control panel may not be used.

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810-UG-0001 (Rev. A) testing at BUILDING OPERATION IS BEING PERFORMED. LN2 flow will be required on the LAUNCHER launcher during launch operations up to T-3 seconds. This procedure does not include instruction for re-filling a storage Dewar during integration or on the rail.

3.0 Definitions/Acronyms:

• COTS – Commercial Off The Shelf

• CSC – Cryogenic Safety Committee (Goddard)

• ESD – Electrostatic Discharge

• EXP - Experiment Team Member

• GSE - Ground Support Equipment

• GSFC – Goddard Space Flight Center

• GHe – Gaseous Helium

• GN2 – Gaseous Nitrogen

• LN2 – Liquid Nitrogen

• MSFC – Marshall Space Flight Center

• NSROC – NASA Sounding Rocket Operations Contract

• ODH – Oxygen Deficiency Hazard

• OJT – On the Job Training

• OSS—Operations Safety Specialist

• PPE - Personnel Protective Equipment

• PSI – Pounds per Square Inch

• PTFE - Polytetrafluoroethylene

4.0 Resource Requirements:

• System operator (Only personnel trained in handling Cryogenics, i.e., Liquid Nitrogen (LN2), are authorized to transfer cryogens for the EXPERIMENT NAME payloads. Attach training certification letter to this procedure for records retention.

• OSS certified for cryogenic systems

5.0 Equipment Requirements:

The following equipment is required as a minimum (items marked italic are to be provided by NSROC):

• Standard high pressure liquid nitrogen storage Dewar;

• Two cryogenic gloves;

• Safety goggles;

• Face shield;

• Lab coat and cryogenic apron;

• Applicable operations GSE for experiment;

• Two-piece (supply and return) liquid nitrogen transfer line (PTFE tubing);

Include any additional Definitions or Acronyms.

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• Insulating material for nitrogen transfer lines;

• Hose-clamps;

• Closed toe shoes;

• Post hazard warning signs on all door entries (ODH, applicable Level and/or

Level1); and

• Oxygen monitor (fixed and/or portable).

• Range supplied ESD heat gun to defrost frozen lines

6.0 Training Requirements:

• The Operations Safety Specialist (OSS) must have a working knowledge of the EXPERIMENT NAME LN2 cooling control systems and/or be thoroughly briefed prior to operations.

• The operator must be familiar with the EXPERIMENT NAME LN2 cooling control systems.

• All personnel working with cryogenic systems shall be thoroughly familiar with the hazards involved as defined in Table 1 of GPR 8710.7. They shall also be familiar with all emergency measures that may be required in the event of an accident. Any contractor organization that has an equivalent training program may be equivalently certified to these training requirements with approval of the Goddard Cryogenic Safety Committee

(CSC).

7.0 Safety Requirements:

NOTE: This procedure contains operations which are considered HAZARDOUS, and thus requires an OSS in addition to the system operator.

The OSS must be an independent observer and shall not perform or assist in the performance of any hazardous operation.

Personnel working in the area should be informed that hazardous cryogenic operations are going to be conducted. The payload shall be oriented at all times such that, if a fast vent or bottle rupture were to occur, the output will not injure personnel.

Note: During the hazardous portions of the operations covered in this procedure, only personnel directly involved with the hazardous portions of the operation are permitted access to the payload and must wear the proper PPE.

7.1 This procedure contains operations, which are considered HAZARDOUS.

7.2 For multiple operations, no hazard areas will be permitted to overlap each other.

7.3 Prior to beginning a hazardous operation, the OSS shall define a hazard area that will contain all components of the article during assembly, including liquid spills. Refer to the most recent release of the GSP/GSDP.

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7.4 Under direction of the OSS, the hazard area shall be cleared of nonessential personnel prior to beginning of pressurization/cryogenic operations. The defined hazard area must take into account all possible contingencies that may lead to inadvertent projectiles, and shall make an announcement that a hazardous operation is about to commence.

7.5 Any facility where personnel may inadvertently enter into a hazard area must be clearly identified prior to beginning pressure/cryogenic operations.

Door identification shall prevent personnel from entering into the hazard area while permitting personnel to exit at any given time.

7.6 If a hazardous operation is being performed, the OSS or operator doing the operation shall conduct a safety briefing prior to any operation being performed. The briefing will include all essential personnel involved in the hazardous operation. The briefing shall cover all details of the operation, specify procedures to be used, and ensure a clear understanding of the hazardous operation about to be performed and hazards involved.

7.7 Once the procedure is completed and the hazard is safeguarded, the technician and the OSS shall indicate an “All Clear” status that the article is now in the safe condition.

7.8 All completed procedures must be collected and reviewed by the OSS for safety deviation.

7.9 Special Cryogenic Requirements:

7.9.1 The owner/operator of the system shall complete a hazard analysis checklist form GSFC 23-81 to be reviewed by the OSS prior to system operation at either the BUILDING and/or at the launch site.

7.9.2 To verify compliance with GSFC cryogenic safety requirements, cryogenic equipment and systems shall be subjected to a safety review by the CSC prior to their first operation and are prohibited from being operated without formal approval from the CSC. Systems that utilize commercial cryogenic-pumps in which the cold head has its own overpressure protection when physically isolated from the inside of the vacuum chamber are exempt from this requirement. The owner/operator of the system shall notify the OSS of any operating system configuration change that significantly alters the safety documentation for review and approval. The following documentation is required for review of the system: Functional system diagrams or schematics; components list documenting appropriateness for use at cryogenic temperatures; operating procedures; operator training; list of discharge valves or ports; maintenance requirements; pressure relief valve size analysis under worst case failure conditions; and Oxygen Deficiency Hazard (ODH) analysis, under worst case failure conditions.

7.9.3 Commercial Off the Shelf (COTS) items shall be clearly designated for use at cryogenic temperatures. These items shall be used in strict accordance with manufacturer’s specifications and operated as described in GPR 8710.7.

7.9.4 Custom fabricated equipment which will operate at cryogenic temperature shall be designed and constructed in accordance with

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810-UG-0001 (Rev. A) good cryogenic safety practices and made as safe as practicably possible. Pressure vessels shall conform to PVS requirements documented in NPD 8710.5, GPR 8710.3, and NASA-STD-8719.17.

All specifications for custom fabricated equipment shall be reviewed by the CSC (or designee), and all operating cryogenic systems shall be reviewed by the CSC as set forth in this document.

7.9.5 Cryogenic Safety Hazard Guidelines: Hazards associated with cryogens, include asphyxiation or ODH, extreme cold contact burns or frost bite, oxygen enrichment, potentially high pressures, ice buildup, and ice plugs can jeopardize the safety of personnel and cause damage to flight hardware and test equipment. Equipment design and handling procedures should eliminate hazards wherever possible or mitigate risks to an acceptable level.

Asphyxiation: Personnel shall not enter or occupy an area where the oxygen level is less than 19.5% by volume. An ODH assessment shall be conducted whenever an area containing enough displacing gas to pose a potential oxygen deficiency is established or modified, and wherever cryogens are used, stored, or dispensed. Areas determined to have a potential for oxygen deficiency shall be identified by signage, at all entrances. Visitors or temporary workers who have not had ODH training may enter a posted ODH area ONLY after the ODH hazard has been explained to them by personnel familiar with the hazards in the area. Fixed Oxygen monitors shall alarm at an oxygen concentration of 19.5% and have a siren and flashing strobe light. The siren and strobe shall be distinctive from other alarms in the immediate area, such as fire alarms. Oxygen monitors shall be installed with consideration of the buoyancy of the displacing gas. Fixed oxygen monitors shall not be disabled except by qualified personnel. Portable oxygen monitors shall be readily accessible to ODH designated areas.

Portable oxygen monitors will alarm at 19.5% oxygen. The organization issuing personal oxygen monitors is responsible for compliance with this requirement.

Table 1. Recommended Oxygen Monitor Placement

GAS TEMPERATURE LIGHTER OR

HEAVIER THAN AIR

MONITOR

PLACEMENT

Helium Any Lighter Ceiling

Nitrogen Cold Heavier Floor

Warm Lighter Ceiling Argon Any Heavier Floor

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Cold Contact Burns/Frostbite: Minimize exposure to cryogens when transferring fluids. Review operating procedures and think the process through before beginning. Know the location of relief valves and potential cold surfaces. Wear PPE. If exposed, do not apply direct heat to the area. Call 911 or emergency response and arrange transport if necessary. Do not remove frozen clothing, massage or rub frozen areas, use a safety shower or eyewash or apply ointment.

Oxygen Enrichment: At temperatures less than 82 K, metal surfaces will condense oxygen and form enriched air which can drip and form pools. Liquefied air enriches to 50% O2. Nitrogen, which has a lower boiling point than oxygen, will evaporate first, leaving an oxygen enriched condensate on the surface. These surfaces will readily ignite and support combustion. Insulate lines whenever possible, use heaters, and use drip pans. No smoking, open flames, or ignition sources. Try to eliminate combustible material in the vicinity of cryogenic systems. MINIMIZE EXPOSURE OF ANY CRYOGENIC

SYSTEM TO AIR.

Pressurization: All potential trapped volumes must have over pressure protection. Vacuum vessels must have over pressure protections as well. Cold leaks can build up pressure when the vessel warms. Relief valves protect Dewars from over pressurization.

Ice Buildup: Ice build-up on un-insulated areas can cause damage to surrounding equipment by making sensitive materials brittle and adding additional weight to supports. Ice build-up can block relief valves or access to critical valves. Ice build-up can freeze O-rings and compromise insulating vacuums. Insulate lines whenever possible, use heaters, and extending relief valves away from cold lines.

Ice Plugs: Frozen plugs can form in Dewar plumbing if the cryogenic system is exposed to air. Moisture in air can also block lines. The smaller the vent line the more susceptible to plugging. Sometimes fill or vent lines are also the path to relief valves. Plugs in these lines could potentially prevent the vent valves, as well as pressure relief valves, from releasing pressure from the Dewars as the cryogen vaporizes. Over time this will result in a pressure buildup that can cause structural failure of the Dewar. Any valves that lead to ambient air should be kept closed as much as possible and only be opened when required by procedure. Purge transfer line prior to inserting it into cold Dewar. Use check valves or extended length tubes on vents normally open to air.

7.9.6 Dewar Handling: A standard storage Dewar represents a possible tipping hazard and shall be moved by pulling on the handles on the side of the vacuum shell and not by the top ring. Handle gently -sloshing can move liquid to warmer regions of the Dewar and cause pressure spikes. Inspect wheels prior to moving. Wear proper shoes.

Never lay a Dewar on its side. Use a lift gate or loading dock when loading or unloading from a truck. Dewars must be clearly labeled with contents. Do not make assumptions about an unlabeled Dewar.

7.9.7 Personal Protective Equipment (PPE): Appropriate PPE is required when handling, transferring or working with cryogenic fluids. If personnel are within an established exclusion zone, as determined by the OSS, PPE is required regardless of activity. PPE should be selected based on the specific cryogenic material to be used to prevent material compatibility issues.

The following PPE will be worn during liquid cryogenic operations per person involved in the operation:

o Safety goggles;

o Full face shield;

o Cryogenic Gloves;

o Lab coat;

o Cryogenic Apron; and o Oxygen monitor (fixed and/or portable) as many as needed.

Safety goggles: Required when handling or transferring fluids which might result in exposure to cold boil off gases such as an open system.

Full face shield is recommended for pressurized systems. Safety glasses with side shields are acceptable when working with closed cryogenic systems. Eye protection shall be in conformance with ANSI Z87.1.

Cryogenic safety gloves: Must be rated for use with cryogenic fluids.

Loose fitting, grease free nylon gloves are recommended. Keep gloves dry and grease free. Use waterproof type. Do not immerse gloves in liquid nitrogen and use tongs instead.

Clothing: Nonabsorbent shirts and pants that minimize skin exposure are acceptable. Lab coats and cryogenic aprons are required for all personnel involved in the cooling operation.

Footwear: Nonabsorbent footwear is required. Sandals or open-toed shoes are not permitted.

8.0 References:

• GPR 8710.7 Cryogenic Safety

• WFF Range Safety Manual (RSM)-2002 Rev C (use Current Rev)

• Attachments:

1. Components spec/data sheets;

2. ODH calculations, including worst case release rates;

3. Hazards Analysis Checklist (GSFC Form 23-81);

4. Liquid Nitrogen (LN2) and/or Gaseous Nitrogen (GN2) Safety Data

Sheet (SDS)

5. Gaseous Helium (GHe) SDS

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9.0 Quality Assurance:

9.1 All operators participating will print their name below and initial beside their name.

Printed Name Initials/Date

Printed Name Initials/Date

Identify OSS for this work instruction. ______________________________

Printed Name Initials/Date

9.2 Operator will verify that the required procedural steps are accurately performed and complete. To attest that this has been accomplished the operator will initial and date each sign-off indicating satisfactory completion of each step as performed.

9.3 Each step shall be signed prior to proceeding to the next step. If it is necessary to perform steps out-of-order, a red line shall be added to the work instruction identifying the steps that were performed out-of-order and the reason for the deviation. Prior to proceeding with the re-sequenced steps, concurrence from the principal investigator (PI), OSS and Mission Manager (MM) must be obtained. OSS approval (initials) of the red line is required prior to proceeding. Additionally, the PI, or the MM must approve (initial) redline prior to proceeding. An NCR must be generated for all steps performed out-of-order and an OSS must approve redlines. For the non-hazardous section, the OSS can approve the redline at a later time.

9.4 If a task is stopped prior to completing the section describing that task, the time, date, and nature of the stoppage (lightning, lack of parts, etc.) shall be noted on the bottom of the step where the stoppage occurred. A note at the bottom of the page shall also describe any steps that were required to put the system into a SAFE condition and any other pertinent information.

9.5 Upon re-starting the stopped operation, another note shall be generated indicating when the operation was resumed and the safety precautions performed prior to re-starting the task. Examples of these precautions include (but are not limited to) checkout of GSE, verification of proper PPE, clearance of danger areas, and hazardous operations briefing.

9.6 If the work stoppage was in a section requiring an OSS, the OSS must initial the notes describing the nature of the work stoppage and also a note before starting a stopped operation.

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9.7 After completing each section, the technician will sign indicating satisfactory completion of each section. If an OSS was required for the section, the OSS shall also sign at the end of the section indicating successful completion of the section.

9.8 Participating personnel (technicians and/or OSS’s) are encouraged to note any pertinent information in notes section on the bottom of section 10.0 pages. If additional space is required, the margins or backs of pages can also be used for notes.

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10.0 Implementation:

10.1 Inspection and Protection of Cryogenic System

(Hazardous, OSS Required)

NOTE: The last person to leave the vicinity of a storage Dewar for an extended period of time must visually verify that the liquid valve , vent valve and gas use valve (SV-3, SV-2, and SV-5) in Figure 1 (for high pressure Dewar) or Figure 3 (for low pressure Dewar), are closed. The Back Pressure Regulator will be preset at 100 psi and tagged as such.

WARNING: Operator, throughout operation should monitor vents, valves, etc.

to anticipate and avoid freezing and plugging and the subsequent possibility of a rupture of the test Dewar.

WARNING: Ensure the direction of any safety relief valve venting is pointed away from workers and work areas.

10.1.1 Verify OSS is present and is aware that the operation is about to begin.

OSS’s Printed Name: ____________________________

OSS/DATE

OPERATOR/DATE

10.1.2 Hazard Analysis form (GSFC 23-81) has been completed by operator.

OSS/DATE

OPERATOR/DATE

10.1.3 Confirm OSS HAZOP briefing has been performed.

OSS/DATE

OPERATOR/DATE

10.1.4 Verify operations are to be conducted in a well-ventilated area.

This note may change depending on the GSE set-up.

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10.1.5 Ensure operator and OSS are wearing cryogenic gloves, safety goggles, lab coat and cryogenic apron.

10.1.6 OSS post the ODH and any other applicable hazard signs at this time to all door entries.

10.1.7 Observe the O2 monitors and ensure that they are properly located in the area of operation. Also utilize portable O2 monitors to test for leaks at payload connection areas. See Table 1 for proper locations for oxygen monitors.

10.1.8 Conduct a visual inspection of the Dewar, checking for the following:

Relief Valve Pressure: ____ PSI Set Regulator Pressure required: ____ PSI Dewar pressure gauge reading: ____ PSI

Verify Back Pressure Regulator set to 100 psi.

Verify relief valves are the proper values, configured appropriately, in calibration and that no isolation valve upstream of the relief valve exists.

No rust, dents, crack, or inappropriate frost buildup on the outside surface of the Dewar (*questionable Dewars must be removed from service).

No cracks or damage on valves or pressure gauges.

Valves are tightened securely, no rust, leaks or frost buildup apparent.

No cracks or damage to pressure relief /rupture disk.

Unobstructed vent path, no frost or rust buildup.

Adequate vertical and horizontal clearance for all positions of the transfer line.

Personnel have a sturdy, safe position to stand to easily handle the transfer line during all aspects of the transfer.

The vertical and horizontal distances from the storage Dewar outlet port to the test Dewar inlet port shall be estimated so the transfer line can be shown to easily reach.

Ensure exhaust hose or tubing is routed properly and venting gas to the outside the facility either through a port or under launcher shelter. Ensure hose or tubing is not a tripping hazard by using sandbags, cable protectors or other methods for securing hoses.

OSS/DATE OPERATOR/DATE

10.1.9 Certification that section 10.1 of this procedure has been completed.

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10.2 Integration: Liquid Nitrogen Transfer (Hazardous, OSS Required)

OSS_________________________ Operator_________________________

10.2.1 Transfer Lines and Transfer Liquid Nitrogen

NOTE: Section 10.1 must be completed before proceeding. For operations, the wavier titled “Cryogenic Liquid (LN2) Transfer with 12 inch PTFE tubing” must be adhered to along with the operations that are described in this procedure.

NOTE: The payload should be evacuated to below 1x10-1 Torr or lower prior to beginning transfer of LN2 into the experiment.

WARNING: Transfer of liquid into warm lines or containers must be done slowly to prevent thermal shock and possible buildup of pressure as well as to minimize splashing. In the event of a spill or leak: Stop the leak if it is possible to do so without risk. Let a spill evaporate.

10.2.1.1 Stand clear of vent valve and slowly OPEN SV-2 to relieve pressure in tank if required to relieve pressure CLOSE once low pressure is achieved.

OPERATOR/DATE

10.2.1.2 Verify Dewar Liquid Valve SV-3 (see Figure 1) is CLOSED.

OPERATOR/DATE

10.2.1.3 Verify Dewar Vent Valve SV-2 is CLOSED.

OPERATOR/DATE

10.2.1.4 Verify Dewar Gas Use Valve SV-5 is CLOSED

OPERATOR/DATE

10.2.1.5 Verify the Back Pressure Regulator is CLOSED.

OPERATOR/DATE

10.2.1.6 If either SV-2, SV-3 or SV-5 have been OPEN for several minutes, it is possible that air may have condensed in the central tube, possibly blocking the transfer tube path from the Dewar.

This section may vary depending on the GSE set-up

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10.2.1.7 Ensure the transfer line is in good physical condition and meets NASA requirements for cryogenic temperature and pressure ratings. The tubes should be free of foreign matter including water. If necessary they can be blown out with GHe or GN2 using standard shop practice.

10.2.1.8 OPEN the Dewar Pressure Building Valve SV-4 to start Dewar pressurization. Verify the regulator pressure specified in 10.1.8.

OPERATOR/DATE

10.2.1.9 Verify the Solenoid manifold 110V power supply is NOT plugged into 110V source.

OPERATOR/DATE

10.2.1.10 Connect the LN2 supply line from the Solenoid Manifold to the Liquid port of the LN2 storage Dewar.

OPERATOR/DATE

10.2.1.11 Verify Back Pressure Regulator is connected properly to the LN2 use valve (SV-5) of the Dewar and verify tag that it is set for range use.

OPERATOR/DATE

10.2.1.12 Verify the cable connection from the Solenoid Manifold to the Relay Control Box is connected.

OPERATOR/DATE

10.2.1.13 Verify the Relay Control Box is connected to the computer via Ethernet.

OPERATOR/DATE

10.2.1.14 Verify the AC power supply to the relay control box is connected to 110V supply and the switch is ON. Note: Refer to Figure 4 EXPERIMENT NAME Rail/Integration Cooling System Configuration on Page 27.

OPERATOR/DATE

10.2.1.15 Connect the supply PTFE hose from solenoid SOV1 on the solenoid manifold to the Cold Plate LN2 port on the payload. Note: For EXPERIMENT NAME a single cold plate only port SOV1 is used.

SOV2 and SOV3 will not be used and remain plugged.

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OPERATOR/DATE

10.2.1.16 Connect a PTFE hose from the Cold plate Vent Port on the payload skin and redirect the LN2 gas in a safe direction venting to atmosphere if operating in an enclosed area. In the BUILDING, a PVC cap is located on the west wall leading outside.

OPERATOR/DATE

10.2.1.17 Cooling control GSE setup: Select “Control Cold Block” for channel “1”.

10.2.1.18 Cooling control GSE setup: Enter set point: -95C

10.2.1.19 Cooling control GSE setup: Enter CCD ramp rate: 2.5 C/min,

10.2.1.20 Cooling control GSE setup: Cold Plate ramp rate limit: 5.0 C/min

10.2.1.21 With Dewar Liquid Supply Vent SV-3 still CLOSED, check audible solenoid operation.

OPERATOR/DATE

10.2.1.22 Plug power to 110V outlet, which enables cooling control GSE systems, confirm audible operation of SOV4.

OPERATOR/DATE

10.2.1.23 Operate the LabView Software cooling control for channel 1 and get audible confirmation of solenoid valve operation for SOV1. There is no intended operation of solenoid valves SOV2 and SOV3.

OPERATOR/DATE

10.2.1.24 Confirm experiment is at 1e-1 torr or lower.

OPERATOR/DATE

10.2.1.25 Confirm Dewar pressure regulator is set to 100 PSI and SV-4 is open.

OPERATOR/DATE

10.2.1.26 Open SV-5 Back Pressure Regulator and then slowly OPEN Liquid Supply SV-3 on the storage Dewar.

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10.2.1.27 LIQUID OPERATION START: All personal remain 15 feet away from operations without proper PPE.

OPERATOR/DATE

Note: Opening either SV-5 and/or Vent SV-2 will vent GN2 into the room and is hazardous up to one foot away. Do not place Dewar in direction of personnel. Once operation is done remember to close SV-5 and/or the Vent valve SV-2 once operation is done or the GN2 will continue to vent in to the room.

10.2.1.28 Slowly OPEN Vent Valve SV-2 on the Dewar.

OPERATOR/DATE

10.2.1.29 Once required pressure is met, CLOSE Vent Valve SV-2 on the Dewar.

OPERATOR/DATE

10.2.1.30 Begin controlling LN2 flow with the LabView computer software

OPERATOR/DATE

10.2.1.31 Confirm experiment pressure remains at <1e-1 torr.

OPERATOR/DATE

10.2.1.32 Confirm CCD’s are cooling at no more than 2.5 C/min rate.

OPERATOR/DATE

10.2.1.33 Verify the system is stable, and that there are no ice blocks, icing over, frozen lines, or possible leaks.

OPERATOR/DATE

10.2.1.34 Verify the experiment vent gas line outside is not obstructed and venting properly.

OPERATOR/DATE

10.2.1.35 Certification that section 10.2 of this procedure has been completed.

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10.3 STOP Liquid Nitrogen Flow

OSS_________________________

Operator_________________________

10.3.1 CLOSE the Dewar Pressure building Valve SV-4

OPERATOR/DATE

10.3.2 CLOSE Liquid Supply SV-3.

OPERATOR/DATE

10.3.3 CLOSE Vent Valve SV-2.

OPERATOR/DATE

10.3.4 Verify SV-2, SV-3, SV-4 and SV-5 are CLOSED.

OPERATOR/DATE

10.3.5 Vent Manifold System: Software continues to open SOV1 for 2 minutes to verify system is warming up.

OPERATOR/DATE

10.3.6 CLOSE SOV-1 solenoid by unplugging the power cord from the 110V outlet.

OPERATOR/DATE

10.3.7 Ensure Pressure Relief Valve SV-1 is not plugged by frost or ice.

OPERATOR/DATE

10.3.8 Certification that section 10.3 of this procedure has been completed.

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10.4 RAIL: Liquid Nitrogen Transfer (Hazardous, OSS Required)

OSS_________________________ Operator_________________________

10.4.1 Transfer Lines and Transfer Liquid Nitrogen

NOTE: Section 10.1 must be completed before proceeding. For pad operations, the wavier titled “Cryogenic Liquid (LN2) Transfer with PTFE tubing” must be adhered to along with the operations that are described in this procedure.

NOTE: The payload should be evacuated to below 1x10-1 Torr or lower prior to beginning transfer of LN2 into the experiment.

WARNING: Transfer of liquid into warm lines or containers must be done slowly to prevent thermal shock and possible buildup of pressure as well as to minimize splashing. In the event of a spill or leak: Stop the leak if it is possible to do so without risk. Let a spill evaporate.

10.4.1.1 Verify Liquid Supply Valve SV-3 Closed (Different than integration, Liquid controlled with remote switch).

OPERATOR/DATE

10.4.1.2 Verify Dewar Liquid Transfer Solenoid Valve is OFF at the Block House.

OPERATOR/DATE

10.4.1.3 Verify the Dewar Gas Use Valve SV-5 OPEN.

OPERATOR/DATE

10.4.1.4 Verify the Dewar Vent Valve SV-2 CLOSED.

10.4.1.5 Verify Dewar Pressure Building Valve SV-4 is open and the Dewar pressure is at the valve set by the regulator pressure specified in 10.1.8.

OPERATOR/DATE

10.4.1.6 Connect the LN2 supply line to the Solenoid Manifold directly.

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810-UG-0001 (Rev. A)

OPERATOR/DATE

10.4.1.7 Ensure the transfer line is in good physical condition and meets NASA requirements for cryogenic temperature and pressure ratings. The tubes should be free of foreign matter including water. If necessary they can be blown out with GHe or GN2 using standard shop practice.

OPERATOR/DATE

10.4.1.8 Verify the cable connection from the Solenoid Manifold to the Relay Control Box is connected.

OPERATOR/DATE

10.4.1.9 Verify the Relay Control Box is connected to the computer via Ethernet.

OPERATOR/DATE

10.4.1.10 Verify the AC power supply to the relay control box is connected to 110V supply and the switch is ON.

OPERATOR/DATE

10.4.1.11 Connect the supply PTFE hose from solenoid SOV-1 on the solenoid manifold to the Cold Plate LN2 port on the payload. Note: For EXPERIMENT NAME a single cold plate only port SOV1 is used.

SOV-2 and SOV-3 will not be used and remain plugged.

OPERATOR/DATE

10.4.1.12 Line will be secured to the rail by range personnel and verified by experimenter team members.

OPERATOR/DATE

10.4.1.13 Install the vent line and direct the vent under the side of the enclosure if the enclosure is in place. Note: Vent line removed when enclosure is rolled back. This line will not be secured since it will not be used going vertical.

OPERATOR/DATE

10.4.1.14 Cooling control GSE setup: Select “control cold block” for channels 1.

10.4.1.15 Cooling control GSE setup: Enter set point of: -95C

10.4.1.16 Cooling control GSE setup: Enter CCD ramp rate: 2.5 C/min,

10.4.1.17 Cooling control GSE setup: Cold block ramp rate limit: 5.0 C/min

10.4.1.18 Open SV-3.

OPERATOR/DATE

10.4.1.19 Open SOV1 from the Block house remote switch to supply power to the solenoid system, confirm audible operation of SOV1.

OPERATOR/DATE

10.4.1.20 Operate the LabView Software cooling control for channel 1 and get audible confirmation of solenoid valve operation for SOV-1. There is no intended operation of solenoid valves SOV-2 and SOV-3.

OPERATOR/DATE

10.4.1.21 Confirm experiment is at 1e-1 torr or lower.

OPERATOR/DATE

10.4.1.22 Confirm Dewar pressure is at required 100 PSI.

OPERATOR/DATE

10.4.1.23 LIQUID OPERATION START!!!!!! All personal remain 15 feet away from operations without proper PPE.

10.4.1.24 OPEN Remote Switch at the Block House to Dewar Liquid Supply.

OPERATOR/DATE

10.4.1.25 Begin controlling LN2 flow with Labview computer software.

OPERATOR/DATE

10.4.1.26 Confirm experiment pressure remains at <1e-1 torr.

OPERATOR/DATE

10.4.1.27 Confirm CCD’s are cooling at no more than 2.5 C/min rate.

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810-UG-0001 (Rev. A)

10.4.1.28 Confirm camera operations.

OPERATOR/DATE

10.4.1.29 Verify the system is stable, and that there are no ice blocks, icing over, frozen lines, or possible leaks.

OPERATOR/DATE

10.4.1.30 Certification that section 10.4 of this procedure has been completed.

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810-UG-0001 (Rev. A)

Note: The cryogenic system will continue to be monitored for icing until flow has been stopped.

10.5 STOP Liquid Nitrogen Flow

OSS_________________________

Operator_________________________

10.5.1 Turn OFF RANGE’s Remote Switch on the Dewar from the Block house.

OPERATOR/DATE

10.5.2 Close SV-5 on Dewar when available.

OPERATOR/DATE

10.5.3 After 2 minutes of operation without LN2 supply open, turn OFF the remote switch to SOV-1 in the Block house. If this procedure is the actual Launch venting will not be necessary.

10.5.4 Certification that section 10.5 of this procedure has been completed.

Figure 1: Example schematic of a typical high pressure LN2 Dewar (1 of 2).

May change per mission.

Figure 2: Example schematic of a typical high pressure LN2 Dewar (2 of 2)

Figure 3: EXPERIMENT NAME LN2/VAC Horizontal Launch Rail Configuration

Figure 4: EXPERIMENT NAME Rail/Integration Cooling System Configuration

NSROC Supplied

SV-6 150 PSI

Relief Valve

4/29/2021

REVISION CONTROL PAGE

Revision Effective Date Description of Change Rev - DATE Establish Baseline