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SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Solid Rocket Booster Processing Kennedy Space Center SRB Mechanical.

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Presentation on theme: "SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Solid Rocket Booster Processing Kennedy Space Center SRB Mechanical."— Presentation transcript:

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2 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Solid Rocket Booster Processing Kennedy Space Center SRB Mechanical Engineering NE-M7

3 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Shuttle Processing and Launch Postflight Hardware Recovery and Evaluation KSC – Solid Rocket Booster (SRB) Processing Areas

4 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida KSC – Solid Rocket Booster (SRB) Processing Areas RPSF VAB Pad

5 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida SHUTTLE LANDING SRB RETRIEVAL SHIP HANGAR AF RPSF SRB STACKING ET/SRB OPERATIONS ET STANDALONE LCC INTEGRATED VEHICLE OPS/VAB Offload Buildup HORIZONTAL PAYLOAD INT PAYLOAD FACILITIES HYPERGOLIC FACILITY ORBITER PROCESSING FACILITY Pad Ops VERTICAL PAYLOAD INSTALLATION Design Centers Element Refurbishment and Manufacturing Logistics and Shipping Delivery Offload and Inspect Aft Booster Build Field Joint Mate Leak Test Field Joint Protection System S&A Launch Recovery Disassembly and Assessment KSC – Solid Rocket Booster (SRB) Processing Flow

6 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Forward Assembly and Aft Skirt arrive from SRB Element in the Assembly Refurbishment Facility (ARF) at KSC. ARF Aft SkirtParachutes Nose Cone Frustum Forward Assembly Nose Cone Frustum Parachutes Forward Skirt

7 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Segments arrive from ATK in Corrine, Utah in rail cars. The segments go to the Rotation, Processing and Surge Facility (RPSF) at KSC. RPSF

8 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida At the Rotation, Processing and Surge Facility (RPSF), the rail cover is removed, propellant grain & metal surfaces inspected, the segments are rotated to vertical, secured on a pallet and stored in the surge facilities. Break-over of the forward segment from horizontal to vertical

9 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Aft Segment Breakover to Vertical AEC Breakover Aft Skirt Mate AEC Mate Build-up to Aft Booster Configuration (see following charts) Aft Booster Build-up Stand At the RPSF, the aft booster is assembled and processed in the build- up stands. Other hardware processed in the RPSF includes: - Stiffener Rings Assembly and Closeouts - Thermal Curtains - External Tank Assembly (ETA) ring and hardware - Thermal Protection System (TPS) closeouts - Systems tunnel and cables installation and closeouts - Heater power cable installation - Nozzle severance cable connection

10 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Aft Booster Build Stand Pin Retainer Steel Strap Cork Band Aft Skirt Clevis Aft Skirt Mate The aft skirt is placed in the build-up stand and the booster segment is mated. 177 pins are installed and secured with a steel pin retainer strap. The joint is closed out with cork and RT-455 ablative compound.

11 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Aft exit cone is assembled to the forward exit cone at the RPSF. Aft Skirt Not Shown for Clarity Forward Exit Cone Aft Exit Cone RTV Thermal Barrier Primary Seal Secondary Seal Phenolic AEC Mate Phenolic mating surfaces are primed with DC1200 primer prior to assembly. Primary and secondary seals (O- rings) are installed. Exit cone is raised on an elevator and floated on an air bearing for mating. The joint is bolted with 96 fasteners. Leak test is performed at 83 and 30 psig with the mass flow meter prior to joint RTV backfill. The joint gap is backfilled (injected) with RTV silicone sealant as part of thermal barrier system.

12 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida If needed, the aft booster will be put into surge for storage. The SRM transporter transfers the aft booster from the RPSF to the surge or the Vehicle Assembly Building (VAB) for the stacking operations. Surge buildings protect hardware from elements (rain, wind, etc.) –Not climate controlled Segments have weather proof covers on top RPSF VAB Surge

13 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida The segment is connected to the beam and the 325-ton crane in the transfer isle of the VAB. Circularity measurements, tang preps, metal parts inspections, abrade J-leg, and assemble/connect curtain.

14 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida The aft booster segment is lifted from the transfer isle to the high bay of the VAB to be connected to the Mobile Launch Platform (MLP). The booster is bolted to the hold down post of the MLP with a frangible nut that separates at launch.

15 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Forward Segment Forward Center Segment Aft Center Segment Aft Booster Aft Field Joint Forward Field Joint Center Field Joint SRB Forward Assembly At KSC, the center and forward segments are stacked. When two segments are mated at KSC, this joint is called a field joint. The SRB forward assembly mated. Then, all field joints are all closed out in the VAB.

16 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Field joint is a clevis and tang configuration with 177 pins –Three alignment slots/pins ensure correct segment clocking Tang “capture feature” and insulation “j-leg” added during redesign Tang Clevis Field Joint Example –Tang capture feature “captures” inner clevis leg to limit seal surface movement (joint rotation) during motor pressurization –Insulation j-leg prohibits combustion gas from reaching seals Capture Feature Inner Clevis Leg Insulation J-leg All the field joints are configured with a tang and clevis design with a capture feature. The 3 O-rings and J-leg help prohibit a combustion gas leak at the joints.

17 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida For a segment mate, the segment is lowered over the SRB stack. The field joint assembly fixture (FJAF) acts as a “shoehorn” to align the tang/clevis and prevent flat-on-flat metal conditions. Leak test of the joint and the vent port plug are the final acceptance of a successful joint mate. Field joint mate with 3 feet between the segments. Field joint mate with 1/8” between the segments. Segment mates require a controlled environment within the curtain room. Also, the controlled area requires personnel to wear flames, eyes-only hoods, gloves and meet maximum static levels. O-rings FJAF PSA Application

18 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Each field joint is closed out with the field joint protection system (FJPS). The FJPS provides thermal protection, weather protection and retains joint pins. Cork Heater Retainer Strap and Thermal Barrier Joint Temperature Sensor Joint Heater Pin Retainer Band RT-455 Ablative Cork Field joint after mate, before FJPS Field joint with FJPS

19 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida The forward assembly is mated to the forward segment and also closed out with FJPS. Since no propellant is exposed in this mate, a controlled environment is not needed. Forward Skirt JPS Cork Band Forward Skirt Fwd Segment Pin Retainer Strap Forward Skirt Joint

20 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida The systems tunnel, cables, heater power cables, and linear shaped charge (LSC) are all assembled and closed out. In addition, TPS, cabling and closeouts are completed in other areas of the boosters. Systems Tunnel Closeout LH side (fwd 3 segments) Tunnel Cover Cork RT-455 Forward and Center Field Joint Tunnel Closeout Heater Power Cables

21 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida After the boosters are assembled, the external tank (ET) is then brought over from the ET check-out cell in the VAB for the ET/SRB mate.

22 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Next, the orbiter is mated to the ET with the boosters supporting the weight of the whole shuttle.

23 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida The crawler transports the MLP and the shuttle to the pad where all processing is completed.

24 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida After launch, the boosters separate at around L+128 seconds. The boosters continue to climb to around 42 miles high. Then, boosters tumble until the drogue shoot deploys at 1600 feet, which orientates the boosters upright. The main parachutes deploy at 6300 ft to slow down the boosters to impact the ocean at about 60 mph. Before impacting the ocean, the aft exit nozzle separates to prevent deformation on the reusable motor.

25 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida The Liberty Star and Freedom Star each retrieve a booster in the ocean to tow it back to Hanger AF at KSC.

26 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida The boosters are received at Hanger AF and evaluated for any off nominal conditions in the post-flight assessment.

27 SPACE SHUTTLE PROGRAM Solid Rocket Booster Processing NASA Kennedy Space Center, Florida Every aspect of the boosters is inspected and compared to past post-flight data. The segments are disassembled and sent back to ATK and USA.


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