Enclosure No. 1 - NASA Barge Pegasus Pedestal Proof Test Fixture Installation and Test Procedure Final 10Apr2019 Signature.pdf

AS42-PROC-19-01

National Aeronautics and BASELINE Space Administration EFFECTIVE DATE: 03-25-2019

George C. Marshall Space Flight Center Marshall Space Flight Center, Alabama 35812

AS42

NASA BARGE PEGASUS

PEDESTAL PROOF TEST

FIXTURE INSTALLATION

AND TEST PROCEDURE

AS42 TECHNICAL STANDARD

Title: NASA Barge Pegasus Pedestal Proof Test Fixture Installation and Test Procedure

Document No.: AS42-PROC- 19-01

Revision: Baseline

Effective Date: 3/25/2019 Page 2 of 49

DOCUMENT HISTORY LOG

Status (Baseline/ Revision/ Canceled)

Document Revision

Effective Date

Description Baseline

- 03/25/2019 Baseline Release;

Installation and Test Procedure

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SIGNATURE PAGE

SUBMITTED BY:

Alan Murphy, Team Lead AS42 / Logistics Engineering and Marine Operations Team

APPROVED BY:

Alan Murphy, Team Lead AS42 / Logistics Engineering and Marine Operations Team

CONCURRED BY:

Robert Rutherford, Supervisor AS42 / Transportation and Logistics Engineering Office

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TABLE OF CONTENTS

PARAGRAPH PAGE

1.0 SCOPE

1.1 Purpose

1.2 Storage of Test Fixture Components

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents

3.0 REQUIREMENTS

3.1 Pedestal Assemblies and Hardware Installation

3.1.1 Pedestal Assemblies Installation on Mounting Pads

3.1.2 Mounting Pad Retention Block Bolt Torqueing

3.1.3 Pedestal-to-Mounting Pad Bolts Torqueing

3.1.4 Bracket-to-Pedestal Bolts/Nuts Torqueing

3.1.5 Bracket Preparation for Test Fixture Installation

3.2 Test Fixture Hardware Installation

3.2.1 Transverse Beam Assembly

3.2.2 Lateral Beam End Cap (2) Installation onto the Pedestal Assemblies

3.2.3 Pedestal Pad Eye End Cap (2) Installation and Longitudinal Jack Assembly Short Beam

(2) Installation

3.2.4 Longitudinal Lever Installation

3.2.5 Final Preparation for Testing

3.3 Proof Testing

3.4 Reconfiguration and Additional Proof Testing

3.5 Removal of Transverse Beam Assemblies (2) and Storage of Tested Pedestal

Assemblies…

4.0 QUALITY ASSURANCE PROVISIONS

4.1 General

4.2 Records

5.0 NOTES

6.0 ACRONYMS

APPENDICES

None

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FIGURES

1. Proof Test Hardware Delivered from Shipyard

2. Pedestal Assembly Installed and Awaiting Hardware Torqueing

3. Bolt Numbering System for Pedestal-to-Pad and Bracket-to-Pedestal Bolts

4. I-Beam L Clamps Installed on Lower Transverse Beam

5. Lateral Beam End Cap to Lower Transverse Beam (Note: End Cap will not be placed on pedestal at this time)

6. Pedestal Pad Eye End Cap to Lower Transverse Beam (Note: End Cap will not be placed on pedestal at this time)

7. Transporting Transverse Beam with Pedestal Pad Eye Attached

8. Lateral Beam End Cap/Lower Transverse Beam on Pedestal Assembly

9. Pedestal Pad Eye/ Lower Transverse Beam lowering to Pedestal Assembly

10. Upper Beam/2 Lower Beams Engaged with Adjustment Clamps

11. Alternate Method of Moving 3 Beams and End Caps

12. Aligning Lateral Beam End Cap on Pedestal Assembly

13. Pedestal-to-lateral beam end cap final configuration

14. Pedestal-to-pedestal Pad Eye End Cap and Longitudinal Jack Assembly Short Beams to

Pedestal Pad Eye End Caps Final Configuration

15. Installing Pull Ram Assembly Enerpac Jack

16. Longitudinal Lever Rigging

17. Positioning Lever Over Pedestal Assemblies and Pad Eye on the End of the Lever Lining up with the Appropriate Pedestal Assembly Pad Eye

18. Installation of Lever Pin

19. Lowering the Lever Down to Engage the Remaining Pad Eyes

20. Installation of Second Lever Pin

21. Installation of Third Lever Pin and Final Lever Pinned Configuration

22. Welding of Pull Ram Assembly to Pegasus Deck

23. Installation of Remaining Three Jacks

24. Hydraulic System Installed

25. Tighten I-beam L Clamp Bolts

26. Lever Support Legs Removed

27. Pull Ram Assembly Base Removed

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1.0 SCOPE

1.1 Purpose

This procedure establishes a documented process for the storage and installation of the Pegasus proof test fixture, and the testing of the pedestals and supporting deck and below-deck supporting structure utilizing the U.S. Army Corps of Engineers drawing 805-B398-02 “NASA Pegasus Proof Testing Fixture”, latest revision. This procedure should be used to install, test and uninstall 4 pedestal assemblies in either the forward or aft set of Pedestal Assembly Mounting Pads (the second and third, if required, set of 4 pedestal assemblies will be installed, tested and uninstalled on different copies of this procedure). Installation and removal of the pedestal assemblies will be performed using the NASA Barge Pegasus Pedestal Assembly and Hardware Storage, Installation and Removal Procedure, AS42-PROC-18-01. These procedures should be followed to assure safe and proper storage, installation, and testing, protecting both personnel and hardware.

1.2 Storage of Test Fixture Components

The proof test fixture components, as identified on the 805-B398-02 drawing, are stored in the Michoud Assembly Facility (MAF) building 485, with the exception of the longitudinal testing lever which is stored outside the building. See Figure 1 for hardware delivery pictures.

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Figure 1. Proof Test Hardware Delivered from Shipyard

The larger components and their approximate weights are:

1 Longitudinal Testing Lever 20k lbs.

6 Transverse I-beams 1500 lbs. each.

2 Lateral beams 250 lbs. each.

1 Pull Ram Assembly Base 1500 lbs.

Other components received from the shipyard contractor include 4 hydraulic cylinders, 6 snap rings and 3 pins.

2.0 APPLICABLE DOCUMENTS

The latest revision of the following document hardcopies should be onboard and ready to support operations:

2.1 Government Documents

NASA

96M42025-001 Mounting Pad, NASA Barge Pegasus 96M42036-101 Pedestal Weldment, NASA Barge Pegasus 96M42037-101 Bracket Weldment, NASA Barge Pegasus 96M42034 NASA Barge Pegasus 805-B398-02 NASA Pegasus Proof Testing Fixture Drawing 805-D215-01 NASA Pegasus General Arrangement AS42-PROC-18-01 NASA Barge Pegasus Pedestal and Hardware Storage, Handling and Installation Procedure MSFC-SPEC-2489 Organic Cleaner Specification

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NRRS 1441.1 NASA Records Retention Schedules

Jacobs Technology S-803.1 TLF Blevit Re-Design CS Forward HIS GF2 Actuator Mounting Block

Notes S-803.6 TLF Blevit Re-Design Pegasus Barge Pedestal Mounting Pad Retaining

Block S-803.7 TLF Blevit Re-Design TLF Barge Pedestal Mounting Pad and MPC

Retaining Blocks Test Load Facility Test Configurations Installation Manual Dated

December 2017

3.0 REQUIREMENTS

3.1 Pedestal Assemblies and Hardware Installation

3.1.1 Pedestal Assemblies Installation on Mounting Pads

3.1.1.1 Assure Pegasus crew is on board and ready to support operation. All personnel involved in the installation and storage are required to wear proper Personal Protective Equipment (PPE).

3.1.1.2 Install 4 pedestal assemblies to be proof tested on the forward or aft set of mounting pads per AS42-PROC-18-01, “NASA Barge Pegasus Pedestal and Hardware Storage, Handling and Installation Procedure,” through section 3.1, “Pedestal Assembly and Hardware Installation.” See Figure 2.

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Figure 2 – Pedestal Assembly Installed and Awaiting Hardware Torqueing

3.1.2 Mounting Pad Retention Block Bolt Torqueing

3.1.2.1 Assure Government Representative is present to witness torqueing.

3.1.2.2 Record Torque Wrench serial number __________________ and calibration due date ________________________.

3.1.2.3 Torque all retention block bolts to a (lubricated) torque of 1020 Ft-Lbs. using a torque wrench for 8 mounting pad retention blocks. Any signs of locking up or freezing of the bolts in the bolt holes should be reported to and assessed by on-site Government Representative.

3.1.3 Pedestal-to-Mounting Pad Bolts Torqueing

CAUTION: To prevent damage to the high strength bolts and nuts:

For torqueing bolts with wrench, torque no more than 10 revolutions per minute (RPMs) to manage thread heating and to detect any conditions that may adversely impact thread engagement. Bolts should be tightened in a cross pattern, 1-2-3-4-5-6-7-8 per Figure 3.

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Figure 3 – Bolt Numbering System for Pedestal-to-Pad and Bracket-to-Pedestal Bolts

3.1.3.1 Remove the rags from the pedestal elongated holes.

3.1.3.2 Align pedestal assemblies to assure all 4 are positioned squarely with respect to each other and in the middle of each pad to assure test fixture hardware can be installed properly.

3.1.3.3 For one pedestal assembly, torque 8 pedestal-to-mounting pad bolts to 150 +/- 10 ft-lbs, entering the actual torque below. Assure pedestal is positioned approximately in the center of the mounting pad.

Bolt 1 Torque __________ Bolt 2 Torque __________

Bolt 3 Torque __________ Bolt 4 Torque __________

Bolt 5 Torque __________ Bolt 6 Torque __________

Bolt 7 Torque __________ Bolt 8 Torque __________

3.1.3.4 Repeat torqueing sequence for the other 3 pedestal assemblies at the pedestal-to-mounting pad interfaces.

3.1.3.5 For one pedestal assembly, torque 8 pedestal-to-mounting pad bolts to 350 +/- 10 ft-lbs, entering the actual torque below (final torque range is 300-400 ft-lbs based on Test Load Facility Test Configurations Installation Manual (Section 2.6, step 7) specifying 300 ft-lbs torque). Note that maximum allowed torque is 500 ft-lbs based on memo ES22-18-102 “Stress

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Analysis for the Pegasus Barge Pedestals for Space Launch System (SLS) Core Stage” dated 15Nov2018, enclosures.

3.1.3.6 Repeat torqueing sequence for the other 3 pedestal assemblies at the pedestal-to-mounting pad interfaces.

3.1.4 Bracket-to-Pedestal Bolts/Nuts Torqueing

CAUTION: To prevent damage to the high strength bolts and nuts:

For torqueing bolts with wrench, torque no more than 10 revolutions RPMs to manage thread heating and to detect any conditions that may adversely impact thread engagement.

Bolts should be tightened in a cross pattern, 1-2-3-4-5-6-7-8 per Figure 3.

3.1.4.1 For one pedestal assembly, torque 8 bracket-to-pedestal bolts/nuts to 150 +/- 10 ft-lbs, entering the actual torque below. Assure bracket is positioned approximately in the center of the pedestal.

3.1.4.2 Repeat torqueing sequence for the other 3 pedestal assemblies at the bracket-to-pedestal interfaces.

3.1.4.3 For one pedestal assembly, torque 8 bracket-to-pedestal bolts/nuts to 350 +/- 10 ft-lbs, entering the actual torque below (final torque range is 300-400 ft-lbs based on Test Load

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Facility Test Configurations Installation Manual (Section 2.6, step 7) specifying 300 ft-lbs torque). Note that maximum allowed torque is 500 ft-lbs based on memo ES22-18-102 “Stress Analysis for the Pegasus Barge Pedestals for Space Launch System (SLS) Core Stage” dated 15Nov2018, enclosures.

3.1.4.4 Repeat torqueing sequence for the other 3 pedestal assemblies at the bracket-to-pedestal interface.

3.1.5 Bracket Preparation for Test Fixture Installation

3.1.5.1 Remove the bracket protective covers of 4 pedestal assemblies no earlier than 24 hours prior to test fixture installation.

3.1.5.2 Remove protective grease from all surfaces of the brackets using qualified product in MSFC-SPEC-2489. (LPS F-104 Solvent Degreaser or equivalent). Assure slots are clean as well.

3.1.5.3 Visually inspect the hardware for damage/cleanliness, assuring no damage/debris exists.

3.1.5.4 Install all retaining block set screws with jam nuts (3) on each pedestal.

Note: Pedestal assemblies are ready for test fixture installation.

3.2 Test Fixture Hardware Installation

Note: Once the pedestal assemblies are in place and torqued down, the test fixture can be installed on the 4 pedestal assemblies per drawing 805-B398-02.

3.2.1 Transverse Beam Assembly

3.2.1.1 Install I-beam L clamps (4) on each of 2 lower beams per 805-B398-02, Detail 5- C using 5/8” bolts. Do not tighten ¾” bolts. See Figure 4. This step may not need to be performed if step was performed for previous test.

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Figure 4 – I-Beam L Clamps Installed on Lower Transverse Beam

3.2.1.2 Install lateral beam end cap to lower transverse beams at beam end with 2 holes per 805-B398-02, section 7-A. See Figure 5. Note: End cap will not be placed on pedestal at this time. This step may not need to be performed if step was performed for previous test.

Figure 5 – Lateral Beam End Cap to Lower Transverse Beam (Note: End cap will not be placed on pedestal assembly at this time)

3.2.1.3 Install pedestal pad eye end cap to lower transverse beam at end with 2 holes per 805-B398-02, section 7-A. See Figure 6. End cap will not be placed on pedestal at this time.

This step may not need to be performed if step was performed for previous test.

2 Beam Holes

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Figure 6 – Pedestal Pad Eye End Cap to Lower Transverse Beam (Note: End cap will not be placed on pedestal assembly at this time. Upper beam is installed in step 3.2.1.4)

3.2.1.4 Install upper beam onto one of the lower beams and within the adjusting clamps per 805-B398-02, section 7-A (do not tighten at this point). See Figure 6. This step may not need to be performed if step was performed for previous test.

3.2.1.5 Using a crane or forklift, place both beams with end caps on a port and starboard pedestal per 805-B398-02 testing configuration found on pages 2-5, assuring the non-pedestal ends of the beams are supported with roller stands and the beams are parallel with the Pegasus deck. See Figures 7, 8 and 9. Tighten I-beam L clamp ¾” bolts per 805-B398-02, detail 5-C if needed to assure upper beam does not slide. If transverse beam assembly (3 beams and end caps) is still assembled from previous test, reference Figure 11 for lifting/installing transverse beam assembly.

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Figure 7 – Transporting Transverse Beam with Pedestal Pad Eye Attached

Figure 8 – Lateral Beam End Cap/Lower Transverse Beam on Pedestal Assembly

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Figure 9 – Pedestal Pad Eye/ Lower Transverse Beam Lowering to Pedestal Assembly

3.2.1.6 Slide the upper beam to engage both beam’s adjustment clamps per 805-B398-02, section 7-A (Tighten I-beam L clamp ¾” bolts per 805-B398-02, detail 5-C as needed to stabilize the beams). See Figure 10. This step may not need to be performed if step was performed for previous test.

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Figure 10 – Upper Beam/2 Lower Beams Engaged with Adjustment Clamps

3.2.1.7 Repeat for second Transverse Beam Assembly.

Note: The 3 beams and end caps can be assembled and moved as seen in Figure 11. Assure I-beam L clamp ¾” bolts are tightened per 805-B398-02, detail 5-C to assure beams do not slide.

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Figure 11 – Alternate Method of Moving 3 Beams and End Caps

3.2.2 Lateral Beam End Cap (2) Installation onto the Pedestal Assemblies

3.2.2.1 Adjust the lateral beam end cap on the pedestal assembly, assuring bolt holes and slots are aligned. The Pegasus alignment pins can be used. See Figure 12. Assure I-beam L clamp ¾” bolts are loosened to allow beams to slide as needed.

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Figure 12 – Aligning Lateral Beam End Cap on Pedestal Assembly

3.2.2.2 Remove four (4) 92167-24H-96 bolts, four (4) 80992C-24 washers (beveled), four

(4) 8099P-24 washers, and four (4) 80221M-2412 nuts from the storage box and clean the hardware, if needed, using qualified product in MSFC-SPEC-2489. (LPS F-104 Solvent Degreaser or equivalent). Note: parts should have been cleaned before placed in storage after last use.

3.2.2.3 Visually inspect the hardware for damage/cleanliness, assuring no damage/debris exists.

3.2.2.4 After inspection, if required, run the bolt/nut threads with the appropriate tap/die to ensure thread form.

3.2.2.5 Lubricate all bolt threads using the dry film lubricant. Follow the manufacturer’s instructions for application.

3.2.2.6 Assure bolt/nut threads and washers remain clean of debris.

Note: The 80992C-24 (beveled) washer is placed on the 92167-24H-96 bolt with bevel facing bolt head, the bolt with washer is inserted into the bracket hole from below, the 8099P-24 washer is placed on the bolt on top of the end cap, followed by the 80221M-2412 nut.

3.2.2.7 Start bolts through washers and end cap and into nuts by hand avoiding cross threading. Tighten by hand as much as possible.

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3.2.2.8 Install all 4 bolts/nuts/washers by hand before proceeding. If excessive force is required, stop. Pull the bolt out and inspect the hole and bolt for damage/cleanliness.

Reminder: Turn bolts slowly to manage thread heating and to detect any conditions that may adversely impact thread engagement. Pay particular attention to thread engagement at the start of bolt installation.

3.2.2.9 Continue tightening bolts/nuts using hand operated wrench to approximately 1/16” from the bolt head touching the lateral beam end cap. Any signs of locking up or freezing of the bolts in the bolt holes should be reported to and assessed by on-site Government Representative.

3.2.2.10 Repeat the lateral beam end cap installation for the other pedestal-to-lateral beam end cap interface.

Reminder: Torque each bolt/nut no more than 10 RPMs to manage thread heating and to detect any conditions that may adversely impact thread engagement.

3.2.2.11 Torque 4 bolts/nuts to 150 +/- 10 ft-lbs, entering the actual torque below.

3.2.2.12 Torque 4 bolts/nuts to 350 +/- 25 ft-lbs, entering the actual torque below (final torque range is 300-400 ft-lbs based on Test Load Facility Test Configurations Installation Manual (Section 2.6, step 7) specifying 300 ft-lbs torque). Note that maximum allowed torque is 500 ft-lbs based on memo ES22-18-102 “Stress Analysis for the Pegasus Barge Pedestals for Space Launch System (SLS) Core Stage” dated 15Nov2018, enclosures.

3.2.2.13 Repeat torqueing of bolts/nuts for the other pedestal-to-lateral beam end cap interface.

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Note: See Figure 13 for pedestal-to-lateral beam end cap final configuration.

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Figure 13 – Pedestal-to-lateral beam end cap final configuration

3.2.3 Pedestal Pad Eye End Cap (2) Installation and Longitudinal Jack Assembly Short Beam (2) Installation

3.2.3.1 Adjust the pedestal pad eye end cap onto the pedestal assembly, assuring bolt holes and slots are aligned. The Pegasus alignment pins can be used.

3.2.3.2 Remove four (4) 92167-24H-96 bolts, four (4) 80992C-24 washers (beveled), four

(4) 8099P-24 washers, and four (4) 80221M-2412 nuts from the storage box and clean the hardware, if needed, using qualified product in MSFC-SPEC-2489. (LPS F-104 Solvent Degreaser or equivalent). Note: parts should have been cleaned before placed in storage after last use.

3.2.3.3 Visually inspect the hardware for damage/cleanliness, assuring no damage/debris exists.

3.2.3.4 After inspection, if required, run the bolt/nut threads with the appropriate tap/die to ensure thread form.

3.2.3.5 Lubricate all bolt threads using the dry film lubricant. Follow the manufacturer’s instructions for application.

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3.2.3.6 Assure bolt/nut threads and washers remain clean of debris.

Note: The 80992C-24 (beveled) washer is placed on the 92167-24H-96 bolt with bevel facing bolt head, the bolt with washer is inserted into the bracket hole from below, the 8099P-24 washer is placed on the bolt on top of the end cap, followed by the 80221M-2412 nut.

3.2.3.7 Start bolts through washers and end cap and into nuts by hand avoiding cross threading. Tighten by hand as much as possible.

3.2.3.8 Install all 4 bolts/nuts/washers by hand before proceeding. If excessive force is required, stop. Pull the bolt out and inspect the hole and bolt for damage/cleanliness.

Reminder: Turn bolts slowly to manage thread heating and to detect any conditions that may adversely impact thread engagement. Pay particular attention to thread engagement at the start of bolt installation.

3.2.3.9 Continue tightening bolts/nuts using hand operated wrench to approximately 1/16” from the bolt head touching the pedestal pad eye end cap. Any signs of locking up or freezing of the bolts in the bolt holes should be reported to and assessed by on-site Government Representative.

3.2.3.10 Repeat the pedestal pad eye end cap installation for the other pedestal-to-pedestal pad eye end cap interface.

3.2.3.11 Assure that distance from center of one pedestal pad eye to the center of the other pedestal pad eye is 95.10 +/- .25 IN per drawing 805-B398-02, detail 4-D.

Reminder: Torque each bolt/nut no more than 10 RPMs to manage thread heating and to detect any conditions that may adversely impact thread engagement.

3.2.3.11 Torque 4 bolts/nuts to 150 +/- 10 ft-lbs, entering the actual torque below.

3.2.3.12 Torque 4 bolts/nuts to 350 +/- 25 ft-lbs, entering the actual torque below (final torque range is 300-400 ft-lbs based on Test Load Facility Test Configurations Installation Manual (Section 2.6, step 7) specifying 300 ft-lbs torque). Note that maximum allowed torque is

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500 ft-lbs based on memo ES22-18-102 “Stress Analysis for the Pegasus Barge Pedestals for Space Launch System (SLS) Core Stage” dated 15Nov2018, enclosures.

3.2.3.13 Repeat torqueing of bolts/nuts for the other pedestal-to-pedestal pad eye end cap interface.

Note: See Figure 14 for pedestal-to-pedestal pad eye end cap final configuration.

3.2.3.14 Install 2 Longitudinal jack assembly short beams to pedestal pad eye end caps at end with 2 holes per 805-B398-02 Elevation view. See Figure 14.

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Figure 14 – Pedestal-to-pedestal Pad Eye End Cap and Longitudinal Jack Assembly Short Beams to Pedestal Pad Eye End Caps Final Configuration

3.2.4 Longitudinal Lever Installation

3.2.4.1 Place pull ram assembly in approximate location per 805-B398-02, elevation view.

3.2.4.2 Install the pull ram assembly Enerpac jack per 805-B398-02, Detail 2-B. See Figure 15. For configurations after the first test, pull ram assembly jack may already be installed.

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Figure 15 – Installing Pull Ram Assembly Enerpac Jack

3.2.4.3 Using a crane, rig and lift the longitudinal lever in preparation for installation as seen in Figure 16.

Figure 16 – Longitudinal Lever Rigging

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3.2.4.4 Position lever above 2 pedestal pad eyes and the pull ram assembly. Lower lever so that the pad eye on the end of the lever lines up with the appropriate pedestal pad eye. See Figure 17.

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Figure 17 – Positioning Lever Over Pedestal Assemblies and Pad Eye on the End of the Lever

Lining up with the Appropriate Pedestal Assembly Pad Eye

3.2.4.5 Insert a pin (see 805-B398-02, Detail 3-C) into the pad eye and secure with snap rings. Use metal wedges or equivalent to adjust the pad eye holes during alignment. See Figure 18.

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Figure 18 – Installation of Lever Pin

3.2.4.6 Lower the lever down to engage the remaining 2 lever pad eyes to the remaining pedestal pad eye and the pull ram assembly pad eye. Move pull ram assembly to line up vertically with pad eye holes. Adjust pull ram assembly pad eye to align pad eye hole completely with lever pad eye hole. See Figure 19.

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Figure 19 - Lowering the Lever Down to Engage the Remaining Pad Eyes

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3.2.4.7 Insert a pin (see 805-B398-02, Detail 3-C) into the middle pad eye and secure with snap rings. Use metal wedges or equivalent to adjust the pad eye holes during alignment.

See Figure 20.

Figure 20 - Installation of Second Lever Pin

3.2.4.8 Insert a pin (see 805-B398-02, Detail 3-C) into the pull ram assembly pad eye and secure with snap rings. Use metal wedges or equivalent to adjust the pad eye holes during

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Effective Date: 3/25/2019 Page 35 of 49 alignment. Install blocks under lever support legs per 805-B398-02, Section 7-A. See Figure 21, which also shows the final pinned configuration.

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Figure 21 - Installation of Third Lever Pin and Final Lever Pinned Configuration

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3.2.4.9 Weld the pull ram assembly base to the Pegasus deck per 805-B398-02. See Figure 22.

Figure 22 – Welding of Pull Ram Assembly to Pegasus Deck

3.2.5 Final Preparation for Testing

3.2.5.1 Install the remaining 3 Enerpac jacks per 805-B398-02. See Figure 23.

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Figure 23 – Installation of Remaining Three Jacks

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3.2.5.2 Set up hydraulic system per Drawing 805-B398-03, “Proof Testing Fixture Hydraulics.” See Figure 24.

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Figure 24 – Hydraulic System Installed

3.2.5.3 Assure I-beam L clamp ¾” bolts are loosened to allow beams to slide during test.

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Figure 25 – Loosen I-beam L Clamp Bolts

3.2.5.4 Remove blocking from beneath lever support legs. See Figure 26.

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Figure 26 – Lever Support Legs Blocking Removed

3.3 Proof Testing

3.3.1 Record which configuration is being tested (1 through 8 or 12) using drawing 805- B398-02, where configuration 1 is at the top of page 2 of 5 and 12 is on the bottom of page 5 of

5. Configuration ______

3.3.2 Apply pressure to the vertical jack first by increasing pressure in 5000 lb.

increments until required load is reached. Verify load via pressure gages and cylinder effective area. See 805-B398-02, Elevation view for appropriate load (146.1 KIPs +5%/-0%).

3.3.3 Apply pressure to remaining jacks simultaneously by increasing pressure in 5000

lb. increments until required load is reached. Verify load via pressure gages and cylinder effective area. See 805-B398-02, Plan view and Elevation view for appropriate loads (Longitudinal Jack – 89.8 KIPs +5%/-0%; Transverse Jacks – 80.9 KIPs +5%/-0%).

3.3.4 Document pressure gage readings:

-Vertical Jack Pressure Gage ______________________

-Longitudinal Jack Pressure Gage __________________

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-Transverse Jack 1 Pressure Gage __________________

-Transverse Jack 2 Pressure Gage __________________

3.3.5 Hold load for ten (10) minutes, assuring pressure levels held within specified ranges.

3.3.6 Release pressure from horizontal jacks.

3.3.7 Release pressure from vertical jack.

3.4 Reconfiguration and Additional Proof Testing

3.4.1 Install blocking under lever support legs.

3.4.2 Disconnect hydraulic system lines. Do not remove jacks.

3.4.3 Using a crane, rig lever to prepare for pin removal and lift of lever.

3.4.4 Remove 3 pins.

3.4.5 Lift and move lever to designated area.

3.4.6 Remove pull ram assembly base by cutting away weld material. Grind both the pull ram assembly base and the Pegasus deck to return to original configuration. See Figure 27.

The pull ram assembly may need to be refabricated at some point as repeated grinding cannibalizes the base.

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Figure 27 – Pull Ram Assembly Base Removed

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3.4.7 Perform steps of section 3.2.4 “Longitudinal Lever Installation” with lever rotated 180 degrees from previous installation (Reference layouts in 805-B398-02, pages 2-5).

3.4.8 Perform steps of sections 3.2.5 “Final Preparation for Testing”.

and 3.3 “Proof Testing”.

3.4.9 When proof testing is complete, perform steps 3.4.1 through 3.4.6.

3.4.10 Disconnect hydraulic system lines and remove 3 horizontal jacks. Vertical jack can remain in pull ram assembly.

3.4.11 Remove 2 Longitudinal jack assembly short beams from pedestal pad eye end caps.

3.4.12 Loosen the sixteen 80221M-2412 nuts slowly on the four MPC-to-Bracket interfaces.

3.4.13 Once loosened, remove the sixteen 80221M-2412 nuts, 80992C-24 washers (beveled), 8099P-24 washers, and 92167-24H-96 bolts.

3.4.14 Wrap the hardware in plastic and place in proper pelican case.

3.4.15 Using a crane, rig first transverse beam assembly (3 beams connected with L clamps, see Figure 11), lift, rotate 180 degrees, and place beam assembly with end caps on a port and starboard pedestal per 805-B398-02 testing configuration found on pages 2-5, assuring the non-pedestal ends of the beams are supported with roller stands and the beams are parallel with the Pegasus deck (reference step 3.2.1.5).

3.4.16 Assure I-beam L clamp ¾” bolts are tightened to assure beams do not slide. Using a crane, rig second transverse beam assembly (3 beams connected with L clamps, see Figure 11), lift, rotate 180 degrees, and place beam assembly with end caps on a port and starboard pedestal per 805-B398-02 testing configuration found on pages 2-5, assuring the non-pedestal ends of the beams are supported with roller stands and the beams are parallel with the Pegasus deck (reference step 3.2.1.5).

3.4.17 Return to section 3.2.2 “Lateral Beam End Cap (2) Installation onto the Pedestal Assemblies” to complete installation, preparation for testing and proof testing for the next 2 configurations, completing all steps through 3.4.14 (wrapping hardware in plastic). Once a group of 4 pedestals (4 configurations/tests) have been proof tested, proceed to the next section.

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3.5 Removal of Transverse Beam Assemblies (2) and Storage of Tested Pedestal Assemblies

Note: At this point in the procedure, the 3 pins have been removed, the lever has been moved to a designated area, the pull ram assembly base weld has been grinded away, I-beam L clamp ¾” bolts have been loosened, the hydraulic system lines have been disconnected, the 3 horizontal jacks have been removed, the 2 Longitudinal jack assembly short beams have been removed and the 16 pedestal-to-pad eye bolts/nuts have been removed.

3.5.1 Using a crane, rig first transverse beam assembly (3 beams connected with L clamps, see Figure 11), lift and set aside.

3.5.2 Using a crane, rig second transverse beam assembly (3 beams connected with L clamps, see Figure 11), lift and set aside.

3.5.3 Disassemble and store the pedestal assemblies per the NASA Barge Pegasus Pedestal Assembly and Hardware Storage, Installation and Removal Procedure, AS42-PROC-18- 01, section 3.2.

3.5.4 If four more tests are required, close this procedure and start a new procedure. If testing is complete, continue to next step.

3.5.5 Disassemble the two transverse beam assemblies and store on Pegasus per government representative direction.

3.5.6 Remove vertical jack from pull ram assembly.

3.5.7 Store remaining test fixture components/support equipment on Pegasus per government representative direction.

4.0 QUALITY ASSURANCE PROVISIONS

4.1 General

The specifications of this procedure do not require any Quality Assurance concurrences.

4.2 Records

5.0 NOTES

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6.0 ACRONYMS

AS42 Marshall Space Flight Center, Office of Center Operations, Transportation and Logistics Group CS Core Stage GF2 means G2F = Ground to Flight HIS Hardware Interface Structure KIP 1000 pounds-force MAF Michoud Assembly Facility MPC Multi-Purpose Carrier NASA National Aeronautics and Space Administration PPE Personal Protective Equipment RPM Revolutions Per Minute SLS Space Launch System TLF Test Load Facility