Composite Overwrapped Pressure Vessels Chris Tutt AMS-02 Project Manager Chris Tutt AMS-02 Phase II Safety Review

AMS-02 Phase II Safety Review Review of Hazard Hazard to be controlled is structural failure of Composite Overwrapped Pressure Vessels (COPVs). Structural failure from overpressurization. Structural failure from damage to overwrap. AMS-02 has three COPVs Xenon Tank and Carbon Dioxide Tanks for the TRD Gas Supply. Warm Helium Tank for the Cryomagnet. Chris Tutt AMS-02 Phase II Safety Review

AMS-02 Phase II Safety Review Review of Tank Design All tanks designed and manufactured by Arde’. Each is a duplicate of an existing tank with previous space flight history. Xe tank previously used in Plasma Contactor Unit currently on ISS. CO2 tank previously used on X-33. Warm Helium Tank previous used on Pegasus ELV. Tank manufacturing done per AIAA-S-081 requirements. Chris Tutt AMS-02 Phase II Safety Review

AMS-02 Phase II Safety Review TRD Gas Supply Chris Tutt AMS-02 Phase II Safety Review

TRD Heaters and Thermostats Heaters and thermostats were added to the outside surface of the TRD tanks. Procedure reviewed by MIT and Arde’. Work done by MIT technician with Arde’ QA present. Tank reinspected and proof pressure test redone after installation. Chris Tutt AMS-02 Phase II Safety Review

AMS-02 Phase II Safety Review Warm Helium Tank Chris Tutt AMS-02 Phase II Safety Review

COPV Structural Analysis and Testing Tanks have all been verified against AIAA-S-081 design requirements. Required burst factor of 1.5 x MDP Xenon tank: 3.1 x MDP CO2 tank: 2.0 x MDP Helium tank: 2.5 x MDP Required proof test to 1.5 x MOP Xenon tank: 1.8 x MOP CO2 tank: 3.3 x MOP Helium tank: 2.5 x MOP Chris Tutt AMS-02 Phase II Safety Review

Proof Test Requirements KNPR 8715.3 para 13.18.1c and d require an inspection and proof pressure test prior to first pressurization at KSC. All COPVs will arrive at KSC filled. No top-offs of these vessels are currently planned. COPVs will have already demonstrated structural integrity for KSC environment. All vessels will have already held pressure for months. Thermal environment from thermal/vac testing will envelope anything seen at KSC. All vessels will have seen vibration environment from multiple plane and truck transports. Tanks will not be emptied and refilled. Chris Tutt AMS-02 Phase II Safety Review

Special Ground Handling Requirements KNPR 8715.3 paras 13.8.1e, f, and g have special handling requirements if tanks are pressurized above 1/3 design burst pressure. None of the AMS-02 tanks will pass this limit: Xenon Tank: Burst pressure 9300 psid, MOP 2500 psid (26.9%) CO2 Tank: Burst pressure 6400 psid, MOP 1440 psid (22.5%) Warm Helium Tank: Burst pressure 8845 psid, MOP 2900 psid (32.8%) Chris Tutt AMS-02 Phase II Safety Review

Warm Helium Tank Damage Protection Warm Helium Tank was inspected at Arde’ prior to shipment and found to be free of defects. Upon delivery to SM, tank has been stored in its shipping crate physically separate from main work area. Tank will be installed on Vacuum Case concurrently with its rigid MMOD shield, which will protect the tank from incidental contact. Chris Tutt AMS-02 Phase II Safety Review

Warm Helium Tank Debris Shield Chris Tutt AMS-02 Phase II Safety Review

TRD Tanks Damage Protection TRD tanks inspected by Arde’ after manufacturing and found to be free of defects. Fiberglass covers installed to protect tank surface during ground handling and installation. Removed on three occasions. Allow installation of the tank heaters. Allow installation of the tank thermostats. Allow installation of the tank MLI. Covers will remain on until flight MMOD shields installed, which will protect tanks from incidental contact. Chris Tutt AMS-02 Phase II Safety Review

TRD Gas Supply Debris Shield Chris Tutt AMS-02 Phase II Safety Review

Proposed Safety Controls AMS-02 COPVs are low risk for sudden failure. Tanks have been fully certified to all design and analysis requirements in KNPR 8715.3 and AIAA-S-081. Tanks will be filled prior to arrival and will have held pressure for months. Tanks will be protected by MMOD shields during all KSC operations. Tanks will never be loaded above 1/3 of burst pressure. No additional controls apart from standard pressure vessel regulations should be required. Chris Tutt AMS-02 Phase II Safety Review