R-8842

TECHNICAL
MAINTENANCE FOR SATURN AND F-l,

MANUAL
SUPPORT H-l, AND PLAN J-2

ROCKETENGINES

(NASA-C_-142831) M AI NTE NA #;CF,;A_D J-2 PLAN FOR SATURN F-l, H-l, AND ENGINES (Rocketdyne) !39 p

SUPPORT ROCKET

N75-74053

00/98
(ROCKETDYNE)

Unclas 17677

TIIISPUBLICATION

REPLACES

R-8842 DATED

14 FEBRUARY

1973

PUBLISHED UNDER AUTHORITY

OF THE NATIONAL

AERONAUTICS

AND

SPACE ADMINISTRATION

t_
_ 4_,, "_e.'U =--_f .... :

":"!:":"_:liiDECEMBER 1973

I LISTOF EFFECTIVEAGESI P
TOTAL NUMBER OF PAGES IN THIS

N()TI'::

The thu

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of u;:lrgil;_;

the ,_f

text the

ati'ected p_U_c.

by

thc

_h;m,_c',

b;

imlicah'd

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vcllical

]me

H,

PUBLICATION

IS

139

CONSISTING

OF

THE

FOLLOWING:

Page No.

Issue

Page No.

Issue

Title A

.............. ................

Original Original Original Original ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ Original Original Original Original Original Original Original Original Original Original Original Original Original

i thru vi ............ 1-1 ............... 2-1 3-1 4-1 5-I 6-1 7-I 8-I 9-1 thru thru thru thru thru 2-12 3-I0 4-15 6-17 7-17

...............

thru 8-8 ...............

A-1 thru A-17 B- 1 ............... C-1 D-1 thru thru C-22 D-4 E- 5

E- 1 thru

This listed

page reflects the current must be in the manual

status to make

of the complete this publication

manual. current

All pages and complete.

CONTENTS Paragraph Introduction

. eoeooooe.ooooo.oooeeO.......''''''''"

Page vi Support Organizations ................................ ................

I.I
0

Program General

2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.3.1 2.4 2.4.1 2.4.2 2.4.3 2.5 2.5.1 2.5.1.1 2.5.1.2 2.5.1.3 2.5.2 2.5.3 2.5.4
0

Support Approach and Responsiblities ............ General ................................ Support Approach ......................... Personnel, Skills, and Training ............... Technical Publications ...................... Spares ................................ Field Site Engineering, Maintenance, and Quality Assurance ......................... Responsibilities of Support Organizations ......... Field Engineering and Logistics Saturn Operations... Field Sites .............................. KSC Operations .......................... MAF Operations .......................... MSFC Operations ......................... Home Office ............................. Field Engineering and Logistics Backup Operations Engineering ............................. Services ........... .................... Spares ................................ Engineering ............................. Manufacturing ........................... Quality Assurance ......................... Field Site operations ...................... General ................................ Field Activity ............................ KSC Support Activities ...................... MAF Support Activities ..................... MSFC Support Activity ...................... KSC and MAF Field Site Operations Engine Interface .......................... Personnel Safety ..........................

2-1 2-1 2-1 2-2 2-2 2-3 2-4 2-6 2-6 2-6 2-6 2-8 2-8 2-8 2-8 2-8 2-9 2-10 2-11 2-12 2-12 3-1 3-1 3-1 3-1 3-7 3-7 3-7 3-7 3-8

. .

3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4 3.5

Support

.......

CONTENTS Paragraph
.

(cont)
(

Page Maintenance ............................. General ............................... Engine Maintenance ........................ Engine Field Site Repair .................... Specialized Engine Repair ................... Launch-Critical Engine Repair ................ Engine Reverification Testing ................. Engine Maintenance Record .................. Engine Configuration Control ................. Component Maintenance ..................... Component Repair - KSC .................... Component Testing ........................ Periodic Retest of Engine Component Spares ....... Preinstallation Retest of Engine Component Spares... Handling and Dispositioning Failed Hardware ....... UCR Reporting ........................... Field Site Component Failures ................ Field Corrections ......................... Failure Analysis .......................... GSE Maintenance ......................... GSE Field Repair ......................... GSE Repair - Canoga Park ................... Calibration of GSE ........................ GSE and Support Equipment Cleanness ........... GSE Configuration Control ................... GSE Records ............................ Special Handling Support General Tools and Test Equipment .............. Government Property - E FL Warehouse Equipment ........................ ............................... .... 4-1 4-1 4-1 4-3 4-5 4-6 4-7 4-7 4-7 4-8 4-8 4-8 4-10 4-10 4-10 4-10 4-11 4-12 4-12 4-13 4-13 4-14 4-14 4-14 4-14 4-14 4-15 4-15 5-1 5-I 6-1 6-1 6-1 6-1 6-1 6-3 6-4 6-4 6-4 6-5

4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.4 4.4.2 4.4.5 4.4.5.1 4.4.5.2 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.7 4.8

6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.5 6.5.1 6.5.2

Support Documentation ...................... General ............................... Engine Program Contract .................... Rocketdyne and Logistics Internal Policies Requirements and Procedures ................. Technical Manuals. ......................... Special Instructions ........................ Work Control Documentation .................. Task Authorization and Traceability ............. Changes to Engine Operating Requirements

........

........

ii

CONTENTS Paragraph 6.5.3 6.5.4 6.6 6.7 6.8 6.8.1 6.8.2 6.8.3
.

(cont) Page

Spares ................................ Engine and GSE Historical Records ............. Discrepancy Reporting ..................... Engineering Documentation .................. Program Status and Information ............... Formal Status Reports ................. Informal Status Reports ..................... General Information .......................

, . . .

6-7 6-7 6-7 6-7 6-9 6-9 6-9 6-9 7-1 7-1 7-1 7-1 7-4 7-4 7-4 7-5 7-5 7-5 7-5 7-5 7-6 7-7 7-7 7-7 7-8 7-8 7-9 7-9 7-9 7-10 7-10 7-10 7-11 7-11 7-11 7-12 7-12 7-12 7-13

7.1 7.2 7.2.1 7.2.1.1 7.2.1.2 7.2.2 7.2.3 7.2.4 7.3 7.4 7.4.1 7.4.2 7.5 7.5.1 7.5.2 7.5.3 7.6 7.7 7.7.1 7.7.2 7.9 7.9.1 7.9.3 7.9.4 7.10 7.10.1 7.10.2 7. I0.2.1 7.10.2.2 7.10.2.3

Significant Time Requirements ................ General ............................... Limited-Life Hardware and Materials ........... Synthetic Rubber Subject to Age Control .......... Shelf/Installed Life for Synthetic Rubber ......... Requirements for Controlling Synthetic Rubber Items. Requirements for Operational Limits of Hardware... Requirements for Controlling Compounds ......... Engine Ordnance Service Life ................ Packaging and Preserving ................... Reports for Time-Sensitive Items .............. Rocketdyne Automated Packaging System (RAPS) Report ................................ List of Time-Sensitive Items (LOTSI) Report ...... Reporting Limited-Life Data ................. Documenting and Reporting Limited-Life Data ..... Launch Status Reporting .................... Documenting and Reporting Waivers and Deviations .. Changes to Limited-Life Requirements .......... GSE Requirements ........................ GSE Hardware Excluded From Limited-Life Control . GSE, Test Equipment, and Tool Calibration Intervals. Engine Requirements ...................... Acceptance Data Requirements ................ Engine Age Control Date Tag ................. Engine Storage Requirements ................. Spares Requirements ...................... Procuring Spares ......................... Warehousing Spares ....................... Stock Control Records ...................... Extension of Service Life .................... Issuing Time-Sensitive Items .................

iii

CONTENTS Paragraph 7.10.2.4 7.10.3 7.11 7.11.1 7.11.2 7.11.3 7.11.4 7.11.5 7.11.6 7.11.6.1 7.11.6.2 7.11.7 7.12 Dispositioning Shipment Hardware Periodic Preinstallation Servicing Documenting Documenting Warehousing Stock Control Field Quality Log Book Personnel Storage General StageSingle Flight Items Exceeding

(cont) Page Storage of GSP and Limits ...... 7-13 7-13 7-14 7-14 7-15 7-15 and Retest Tasks and ........ 7-15 7-16 7-16 7-16 ........... 7-16 7-16 7-17 8-1 8-1 Waivers Deviations...

and Transshipment Retest, Reinspection, Retest ........................... Retest/Reinspection ............................... Reinspection and Reporting of Spares Records Assurance

Spares ........ Servicing ...... .............

...................... ...................... Surveillance. Review .............. .................

Maintenance and Skills Certification ................................ ................................

8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.4 8.4.1 8.4.2 8.4.3 8.5 8.6 8.7 8.7.1 8.7.2

Installed Engine Spare

Engine Storage Engine

Storage ................. ....................... Storage .................. ........

8-1 8-3 8-3 8-3 8-4 8-4 8-5 8-5 8-5 8-6 ........... 8-6 8-7 8-8 8-8 8-8

Engine Evaluation Unassigned Engine Engine Ground Active Short-Term Long-Term Removal

and Verification Storage Storage ................... From Storage ................. ..............

Support Equipment Storage GSE Storage ........................ GSE GSE Storage Storage .................... .....................

Spare Component EFL Warehouse Material Storage

Storage .................... and Inventory Control ..........................

Compound Storage ......................... Raw Material Storage ....................... Facilities A B C D E Authorized Engine Support Terms and Institutional Repair Services at KSC o . . . . . . . . . . . . ...............

9-1 A-1 B- 1 C-1 D-1 E-1

Appendix Appendix Appendix Appendix Appendix

Engine Component Equipment and Definitions

Replacement Lists

Abbreviations

............................

iv

LIST Figure 1-1 Program Support

OF

ILLUSTRATIONS Title Page ............... 1-1 3-2 3-5 4-2 4-4 4-9 6-2 6-6 6-8

Organizations

Saturn Engine and Stage Flow ................ Rocketdyne Review af Stage-Oriented Engine Checkout Procedures at KSC ................. 4-1 4-2 4-3 6-1 6-2 6-3 Engine Engine Canoga Maintenance Activities ................ Repair Activities .................... Park Component Flow ...........

..... ......

Support Documentation ............... FORR System ........................... Support Documentation Response to Hardware Changes .............. . ..........

. .....

LIST Table 3-1 3-2 3-3 3-4

OF

TABLES Page.

Title (Deleted) (Deleted) Joint Operating Agreements ............... Rocketdyne KSC Field Operations and Stage Contractor Integrated Responsibility ............ Launch Support Critical Spares ..................... Summary ..............

. . .

3-3 3-10 4-6 6-10 7-2 7-3

4-1 6-I

Documentation

References Specifications Rocketdyne NASA/Stage Documents H-1 J-2 C-I C-2 C-3 Engine Engine

.............................. ........................... Storage Requirements Contractor Storage .. ........................... Repair Repair Documents Requirements ......

8-2 8-2

...... . ........ ........................ for for for F-1 Engines H-1 Engines J-2 Engines

. .........

A-2 A-7 C-1 C-9 C-15

Support Support Support

Equipment Equipment Equipment

..... .. ...... ............. .... .........

INTRODUCTION

Rocketdyne, the National for

a Division Aeronautics Saturn

of Rockwell and Space

International, Administration V) F-l, H-l,

under

contract

to

(NASA), and J-2

provides engines.

support

Vehicle

(1B and

This support Soyuz during

plan

defines equipment

the

support Saturn to:

requirements resources (1) maintain storage, hardware hardware data

for

Saturn

engines and the

and Apollo

in the (ASTP)

program personnel (2) maintain (engines, deterioration,

Test

Project

capability flight GSE, and reports, hardware spares,

periods

of stage/engine unassigned to preclude to existing etc).

current, etc)

(3) maintain

in a condition change control,

(4) minimize inventory

systems

(manuals,

Deviation If a conflict contract

from

the

concept this

of this plan and

plan the

must engine

have

NASA

approval. the

between prevail.

contract

occurs,

shall

vi

SE CTION PROGRAM SUPPORT

I ORGANIZATIONS

1.1

GENERAL. This section support of the identifies the Rocketdyne (figure manager, to support (ASTP). Saturn 1-1). will the engine These maintain Saturn and support

equipment under engines program the

program direction and and support the

organizations Saturn program in condition Test Project

organizations, the Saturn

equipment Apollo Soyuz

resources

SATURN ,PROGRAM MANAGER

I
FIELD AND SATURN ENGINEERING LOGISTICS OPERATIONS ENGINEERING

1
QUALITY ASSURANCE

I
OPE RATIONS OPE

,
RATIONS | ANDI J FIE LD ENGINEERING

!
___ FIELD NGINEERING MAINTENANCE

IiopE Co: s I
I
-]

I
]

ON-SITE OPERATIONS

I
FIELD ENGINEERING I

SERVICES

__

QUALITY ASSURANCE SPARES 1

-_

WAREHOUSING

Figure

i-i.

Program

Support

Organizations

I-i

SE CTION SUPPORT APPROACH AND

II RESPONSIBILITES

2.1

GENERAL. This section elements and lists describes essential Rocketdyne's to maintaining ASTP assigned approach the for providing of unassigned for launch. support Specific described in the

various Saturn This

support hardware section also

condition stages

for processing responsibilities in section i)in

Saturn

of the participating implementing support the

Rocketdyne approach. are

organizations requirements subsequent

(specified for sections.

accomplishing

significant

activities

2.2

SUPPORT Rocketdyne's

APPROACH. support approach is based on the following ground-

rules:

a.

S-H and

S-IVB

stages

are

stored

at KSC.

b.

S-IC

stages

are

stored

at MAF.

c.

S-IB

stages

are

stored

at MAF

and KSC.

d. stored at KSC and

Flight MAF.

spare

and flight

worthiness

verification

(FWV)

engines

are

e. cation retesting and checkout,

GSE

required component

for

H-1 and

J-2

engine and spare

repair,

system

re verifi-

replacement,

hardware

periodic

is at KSC.

f.

F-1 GSE

and T-tools

are

stored

at KSC and EFL.

g.

Spare

hardware

for

planned

operations

is at KSC.

2-1

h. i.

Dormant spare hardware assets are stored at EFL. F-1 Thermal Insulation Sets (TIS) are stored at MAF.

2.2.1

PERSONNEL,

SKILLS_ AND TRAINING.

Rocketdyne has analyzed the work to be done and determined the technical and administrative after considering
stress, specific work

tasks to be performed.

Based on this analysis,

degrees of people

and

the individual's
and that

ability to work under varying

Rocketdyne individual's has particular

conditions,

environment, that

assigned skill.

to the

organization

requires

To ensure at a high exercises recertification, demonstrations, level and during training problem system

that periods has

knowledge, of infrequent been planned. exercises,

skills, task The task and

and

motivation

are

maintained of skill

performance, program provides

a program for skills

solving

simlflation,

task training.

briefings

and

reorientatlons,

motivational

Skill for Rocketdyne

and

training through Park.

program

activities

are Field are

scheduled Managers

and

coordinated Saturn

personnel at Canoga

the Rocketdyne courses through

and/or

Operations for NASA

Training personnel

scheduled the Saturn

and coordinated Engine Project Office

and

stage

contractor

at MSFC.

2.2.2

TECHNICAL The technical

PUBLICATIONS. publications extensive prepared maintenance Although the by Rocketdyne concepts this data and provides will for Saturn field in proto

use effect

are

based during

on the more the Apollo/Skylab than

capabilities more

programs.

cedural delete

information the information.

is currently As a result,

required, the existence

not be updated repair

of a specific

procedure

2-2

in an engine repair
the plan repairs. site. must The

manual

does section

not

reflect and tables

authority in this

to perform maintenance engine

the and

repair support

at

maintenance

be referred

to for the

scope

of permissible

and component

Technical ensure that the are technical issued

publications publications to meet field

and their are needs is

source

data are Changes,

monitored revisions,

to and A removal will be data.

current. for

supplements single of ASTP delayed release

up-to-date in time and

information. to support distribution for

of updated stages unless

information from there storage;

scheduled preparation urgent

assigned until then

is a prior

requirement

specific

2.2.3

SPARES. Support hardware failure selections and have been data, made and history based number from on maintenance of sites prior contracts

concept, supported. has been enough

task

analysis, The

consumption data and

component analyzed has

usage

overhaul

thoroughly spare hardware Saturn

to predict been acquired

future

hardware the

usage. anticipated

As a result, needs of

to support

the planned

activity.

Procedures of reparable Purchasing support field ASTP with items and hardware are returned

for

repair, to Canoga

overhaul, Park are

servicing developed

and/or

modification with the

in conjunction for procuring returned support and for

Manufacturing items or other

departments. servicing

Procedures effort with for

additional from the the

hardware however, removal

sites

contractually will of the normally replaced

established encompass item.

NASA;

program no repair

component

replacement

2-3

All flight spare components are warehoused at KSC with the exception of ordnance. Laboratories. One flight set of ordnance is stored with test samples Santa Susana Field at KSC. Remaining ordnance is stored at Rocketdyne's

F-1 spare hardware is placed in a "resource no periodic requirements capabilities. 2.2.4 ASSURANCE. Field Engineering the vehicle integration manufacturer contractor FIELD SITE ENGINEERING, MAINTENANCE, retesting planned. It-1 and/[-2 are retested at K_C and Canoga Park,

holding"

status with retest

components with periodic

depending on local

AND QUALITY

is provided to NASA, stage contractors, at MSFC, MAF, and KSC. The primary

and

function of the field engineers is to provide an on-the-spot

interface between

and user for technical assistance and problem resolution. In addition to Field

Engineering, maintenance essential on site skills basis.

maintenance and quality to reliable are

and

quality

assurance personnel

support provide

is provided the special When personnel

at KSC. skills that

The are

assurance and

preventive

corrective

maintenance. Canoga Park

necessary,

supplemented

by sending

to KSC on a trip

When Rocketdyne provide the team

a stage

is

removed

from

storage

and processed to that Details and quality operations VI. for

at MAF, location of the assurance control

a to

of technicians and

and inspectors quality interface assurance for

is dispatched functions. maintenance field

maintenance

Rocketdyne-Stage are in section assurance HI.

Contractor The tracking method

of documenting

and

quality

is described

in section

2-4

Details of the Saturn engine maintenance concept are described in section IV. in total program Important However, facilities, because of changing program scope and reduction

the maintenance concept has been evolutionary.

features of the current method of operation are: Corrective maintenance primarily done on-the-vehicle, components.

and generally by removing and replacing Some thrust chamber weld repairs
disassembly is permissible for

and limited repair.

turbopump

in-place

Discrepant units are

components not repaired,

are but

replaced failure

with analysis

spares. may

The

removed

be performed.

2-5

2.3
2.3.1

RESPONSIBILITIES

OF SUPPORT

ORGANIZATIONS.

FIELD Saturn

ENGINEERING operations is the

AND

LOGISTICS

SATURN medium field changes, affecting site

OPERATIONS. among NASA, office stage

communications and between program

contractors, organizations problems, Program and home NASA technical, tinuously are fulfilled. and

Rocketdyne for and

management, significant support requirements elements, assembly, effectiveness

and home solving the

coordinating

technical support. field site at

implementing and

requirements are so that test,

Logistics

milestones office stage and

communicated total product

to Logistics support facilities. support goals

support contractor support and

is provided The elements and budget,

and launch of Logistics sure Logistics

task

is con-

reviewed

measured

to make

commitments

2.4

FIELD Field

SITES. site operations under are conducted of Field at KSC, Engineering monitoring products. MAF, and and MSFC. Field Saturn all

operations operations, events that

personnel, are may

direction for

Logistics

responsible affect

supervising, delivered

and troubleshooting

Rocketdyne

2.4.1

KSC OPERATIONS. KSC Operations, comprised of engineering for and maintenance, support as quality and

assurance, stage

and warehousing, Specific

is responsible functional

providing are

to NASA

contractors.

responsibilities

follows:

a.

Field

Engineering

and Maintenance:

(1) assembly and storage, (2)

Support

NASA

and the system procedures.

stage tests,

contractor and vehicle

in stage/engine launch operations.

integrated Review field

2-6

(3)

Perform

engine

and

GSE component

maintenance,

repair

and testing.
(4) (5) (6) (7) (8) maintenance Perform Participate Evaluate Coordinate Prepare engine and GSE modifications. reviews. and flight stage data. in stage/engine checkout, interface and approve test, with work

contractor. for engine

documentation

and modification.

b.

Quality Assurance:

(1) (2) (3) (4) (5) (6)

Enforce Review Monitor inspect Inspect Enforce

quality and

assurance work

requirements. documentation. engine-associated work.

approve

stage spare

contractor hardware. testing.

component safety

requirements.

c.

Warehousing:

(I) Inspect, document, (2) Coordinate (3) Provide

and store material received.

selection of support parts. consumption data.

support hardware

(4) Maintain shelf-lifesurveillance of applicable hardware. (5) Coordinate repair and recycle of components.

(6) Maintain support parts accountable stock records. (7) Prepare (8) Prepare and residual property. (9) Perform periodic inventories. of equipment documentation and process for shipping GFP. for disposal of excess

documentation

(10) Maintain preservation and servicing records in storage.

2-7

(11) necessary documentation. (12)

Receive,

stock,

ship,

and

maintain

support

hardware

with

Perform

cyclic

and

special

inventories

as

requested.

2.4.2

MAF MAF

OPERATIONS. Operations, comprised of field engineering, Corporation S-1C stage and F-l is responsible Space engine for Division storage.

providing at MAF

engineering in support of

consultation H-I engine

to NASA/Chrysler operations and

2.4.3

MSFC MSFC

OPERATIONS. Operations, liaison comprised to NASA of field in support engineering, of Saturn is responsible engines and related for

providing support

engineering equipment.

2.5

HOME Home

OFFICE Office Field Operations Engineering Services, of and is responsible and Spares. Quality Logistics for providing backup is Park support comprised backup

to the of Field operations

field

sites.

backup

operations Canoga and

Engineering, is comprised

Rocketdyne Assurance,

Engineering,

Manufacturing.

2.5.1

FIELD

ENGINEERING

AND

LOGISTICS

BACKUP

OPERATIONS.

2.5.1.1 responsible between field

ENGINEERING. for coordinating and Canoga

Home all

Office

Saturn elements

Operations and functional is the

Engineering communications

is link are:

support Park.

sites

Specific

responsibilities

a.

Access

and

resolve

technical

problems.

b.

Coordinate

vehicle/engine

interface.

2-8

c.
d.

Identify field requirements.

Prepare field activity and status reports.

e. f. Site Operations

Determine Provide personnel Make sure

program technical

support support

requirements. and administrative direction to Field

at all field support

locations. requirements fulfill contractual commitments

go

and objectives. h. work done Prepare Field Operation Park Requirement & Record forms on all

on GFP i.

at Canoga

and EFL. program historical data and retrieve as

Maintain ASTP.

H-1 and J-2

required

to support j. k.

Coordinate Provide

quality specialized Services,

assurance maintenance comprised for support

procedures support. of Support of field

with

field

site

personnel.

2.5.1.2 tions,

SERVICES. and Training

Engineering, as required.

PublicaSpecific

is responsible are as

sites

functional

responsibilities a. Support (1) (2) (3) (4)

follows:

Engineering: maintenance maintenance maintenance program concepts. and task analyses. operations. plans.

Analyze Perform Analyze Develop

and support and maintenance

2-9

b.

Publications

(1) (2) (3) (4) (5)

Define Prepare

field

support

data

change

requirements. and instructions.

technical technical

procedures data

Coordinate Prepare Publish

and source

information. data.

and maintain field support

configuration data.

Training:

(1) (2) (3) (4) (5)

Analyze Develop Prepare Prepare Provide

training training training training training.

requirements. programs. aids. materials.

2.5.1.3 responsible Test Project.

SPARES. for support Specific

Spares, of the functional

comprised Saturn

of Management program are

and Warehousing and the Apollo as follows:

is Soyuz

resources

responsibilities

a.

Manage

support

hardware

program.

b.

Provision

spare

parts.

c.

Receive

and process

hardware.

d.

Maintain

master

support

hardware

records.

e.

Stock

parts

and equipment.

2-10

f.

Package and ship hardware

and

materials.

g.

Process,

store

and/or

dispose

of excess

hardware.

h.

Monitor

and control

inventory.

2.5.2 nent

ENGINEERING. Reliability, for Materials support Project.

Engineering, and of the Processes, Saturn

comprised Packaging,

of Engine and

Systems, is

Compo-

Metallurgy as requested are

responsible Apollo Soyuz

resources functional

program responsibilities

and the as follows'.

Test

Specific

a. Saturn engine

In conjunction problems.

with

Field

Engineering

and Logistics,

resolve

b. Analysis Report

Administrate (FAR) system.

Unsatisfactory

Condition

Report

(UCR)

and

Failure

c. control documents

Review

and

evaluate

procedures,

specifications, checkout and testing.

and

interface

in support

of stage/engine

d. Change that may Proposals impact

Review (ECP) engine

drawing and

change

requests, and other

stage

contractor

Engineering data

drawings,

NASA/stage

contractor

requirements.

e. specifications

Provide and

current

overhaul

and

component

repair

and

servicing

test

requirements.

f. data to compare

In conjunction engine

with

Saturn with

Operations flight

analyze

and evaluate

flight

performance

predictions.

g. Readiness vehicle Tests launch

Participate (FRT), operations.

in Flight vehicle

Readiness

Reviews

(FRR), Test

vehicle (CDDT),

Flight and

Countdown

Demonstration

2-11

2.5.3

MANUFACTURING. Manufacturing is responsible for component retest and repair as

requested by Spares.

2.5.4

QUALITY Specific

ASSURANCE. functional Saturn responsibilities resources program of quality and assurance at Canoga Soyuz Test

Park Project

in support are

of the

the Apollo

as follows:

a.

Quality

assurance

policy

and

guidance.

b.

Identify

field

inspection

requirements.

c. operations contract

Coordinate sure

with quality

Field assurance

Engineering inspection

and

Logistics requirements

backup fulfill

to make responsibilities.

2-12

SECTION Ill
FIELD SITE OPERATIONS

3.1

GENERAL. This section where include outlines Rocketdyne support launch effort. Field and describes engines effort vehicle Site and the support activities equipment Saturn personnel support are at field located. engine and at

sites These

(figure activities

3-1)

support with

associated operations, Operations

engines, safety, is provided

interface field the site

responsibilities, deactivation sites:

following

Michoud Kennedy Launch

(MAF) Space Operations Space and

- S-IB Center and Flight engine

and

S-IC

Stage

storage. V and IB Vehicle storage. - NASA Program

(KSC) Flight Center

- Saturn Stage (MSFC)

Marshall Management

systems

testing.

3.2

FIELD Field

ACTIVITY. Site Operations (specified support personnel in section at each field site with condition contractor Operating perform maintaining during relationship Agreements the normal and major

field

support GSE,

activites and

1"[) associated

engines, stage/vehicle

hardware flow.

in a serviceable

operational for prepared interface and

Rocketdyne/stage activities are in Joint

responsibilities (table 3-3),

approved

on-site.

3.2.1

KSC

SUPPORT activities

ACTIVITIES. at KSC include, but are not limited to, the following:

Support

a.

Participate

in daily

work

schedule

planning

actions.

b. and launch

Assist

stage

contractors

by reviewing

stage/engine

checkout

procedures.

3-1

INTEGRATED ' _._._______.-_L._r__ . FLIGHT

SYSTEM

TEST TEST TEST

READINESS

COUNTDOWN DEMONSTRATION PRE-LAUNCH INSPECTION

LAUNCH STORAGE - SHIPPING STAGE/ENGINE

1 LAUNCH FACILITIES

STAGE ASSEMBLY CO I L_ DESICCANT STAGE/ENGINE SYSTEM LEAK

FACILITY STAGE RECEIVING INSPECTION

INSPECTION MODIFICATION CHECKS

STAGE/ENGINE

MAINTENANCE

STAGE CHECKOUT VEHICLE VEHICLE VEHICLE INTEGRATION FLIGHT LAUNCH READINESS TESTS

STAGE CHECKOUT

STAGE STORAGE

/
STAGE MAINTENANCE VEHICLE INTEGRATION I T i STAGE/ENGINE STAGE/ENGINE STAGE LEAK TESTS REFURBISHMENT CHECKOUT STACK VEHICLE PERFORM POWER CHECKS TESTS

ELECTRICAL/MECHANICAL MALFUNCTION OATS

POST-STORAGE

"_

STORAGE

S-IVB

AND S-I]

VERTICAL

STORAGE

Figure

3-1.

Saturn

Engine

and

Stage

Flow

Tables 3-1 and 3-2 deleted.

Table 3-3.

Joint Operating Agreements KSC

lo

Joint Space

Operating

Agreement

for Operations Division J-2

Rockwell and

International Rockwell Space

Division/Launch Rocketdyne Stage and

International Center - S-II

at Kennedy

Engine.

Joint

Operating

Agreement Company

for

McDonnell

Douglas

Astronautics Rocketdyne Stage and

and Rockwell at Kennedy Space

International Center - S-IVB

Division J-2 Engine.

c. Office and

Review

and

comment

in writing

to resident

NASA

Engine with

Project engines

Representative (See figure

on stage 3-2.)

contractor

procedures

associated

GSE.

d.

Participate

in all

preshipment

and

flight

readiness

reviews.

e. operation

Analyze

prelaunch

checkout

and

flight

data

to verify

engine

and performance.

f.

Help

stage

contractor

prepare

flight

evaluation

reports

to NASA.

3-3

g.

Prepare Field Operation Requirement

& Record (FORR) forms

on all work done on Rocketdyne hardware by Rocketdyne personnel.

h.

Perform

maintenance,
with

checkout, and inspection on components,

approved documentation.

engines, and CaSE in accordance

i. in accordance

Perform with

engine

and ECP

CaSE modifications modifications and

and EFIR

special

inspections

approved

instructions.

j.

Install

loose

equipment

on engines

per

joint

operating

agreements.

k. plates, throat

Install, plugs,

remove, and engine

and or

replace

engine

closures, test

covers,

test

GSE associated

equipment.

1.

Help

stage

contractor

leak

check

engine

systems.

m.

Participate

in stage/engine

systems

checkout

to verify

engine

integrity.

n. associated tasks.

Provide

quality

assurance

surveillance

for

engine

and

engine

o. inspection points

Perform on the

quality FORR.

assurance

review

and

identify

mandatory

p. due to checkout

Perform operation

special anomalies

engine

systems

and

subsystems by EFIR

inspections instructions.

or as required

q. records. contractors. Prepare

Maintain Engine

engine

and

GSE

configuration sheets Books and for

control distribute accuracy.

and

maintenance to stage

Log Book

change Log

Review

entries

in Engine

3-4

[ Rocketdyne [ Consultation

Field

Operations

] j

as Required

Draft Preliminary

Stage Contractor Reviews and Generates Procedures as Required; NASA Approves Preliminary Draft and Stage Contracto_ Documentation
I

Rocketdyne Field Operations Reviews Draft and Stage Contractor Documentation

Rocketdyne Field Operations Signs Concurrence Sheet

Final Draft

I i
I
NASA Approves Procedures

Rocketdyne Project Operations Canoga Park Concurs

! J1

Written Comments to Procedures

Resolved; Documentation Comments Generated as Required; and Rocketdyne Signs Concurrence Routing Sheet

Contractor NASA Approves Stage Final Draft

Field H

Operations

Reviews Rocketdyne Final Draft

'

Procedure Rocketdyne Page Signs Approval

t
Rocketdyne Project Engineering Canoga Park Concurrence if Required D Rocketdyne signature mandatory before submittal to NASA LVO . Comments to Stage Written _!

r"

--

Commen , '
Resolved Stage With I I t I Contractor] _ / Contractog Rocketdyne Resolution and L..J ]

NASA LVO Approval

on o<or
Recketdyne Review

--_ Not / Reslved

i I |
at KSC

Released Procedure

Figure

3-2.

of Stage-Oriented

Engine

Checkout

Procedures

r. of discrepant

Provide engine and

NASA

with

Rocketdyne

recommendations

for

disposition

GSE hardware.

s.

Initiate

necessary

action

to clear

engines

and

GSE

discrepancies.

t. of delivered

Remove, engine

reinstall,

repair,

service,

test,

and

maintain

integrity

systems.

u. spare components.

Prepare

UCRs

on failed

or discrepant

engine

hardware

and

v. Disposition and

Modify

spare

components NASA

in accordance Engine Project

with Office Canoga

Request

for

approved Officer

by resident

Representative Park.

Contracting

Representative

at Rocketdyne,

w. and program retest.

Retest

spare

components

as prescribed components

by support to Canoga

hardware Park for

planning

documentation

or return

x. from a Rocketdyne

Provide

spare

support and operated

hardware GFP

for

delivered

engines

and

GSE

managed

warehouse.

y. operations

Coordinate

spares

inventory

required

to support

maintenance

at KSC.

z. hardware.

Maintain

inventory

control

records

of engine

and

GSE

support

aa.

Help

checkout

and proof

test

GSE assigned

to stage

contractor.

ab. hoses, and

Coordinate

periodic

proof-loading tools,

of GSE, and test

proof-testing

of flex to

calibration

of gages,

meters,

equipment

assigned

Rocketdyne. 3-6

3.2.2

MAF SUPPORT ACTIVITIES. Support activities at MAF consist of engineering liaison with NASA

and stage contractors 3.2.3

in support of Saturn engines and support equipment.

MSFC SUPPORT
Support activity

ACTIVITY. at MSFC consists of engineering engines and support liaison with NASA

and

stage

contractors

in support

of Saturn

equipment.

3.3

KSC AND Field Site

MAF

FIELD

SITE support for

OPERATIONS services

SUPPORT. at KSC operation through consists storage Technical and Flight consist events of engine during assocstage and assocperis also

Operations contractors

iated flow

support from

to stage

stage/engine and services Stages checkout,

storage, Field Site during

stage

refurbishment support storage. stage H-1 for engine

prelaunch of engine require support

launch. iated sonneI provided Assessment to the provided Review,

Operations stage

at MAF from

support from

removed

KSC to prepare the F-1 (Refer outlined and

shipment Storage

to KSC. Evaluation

during

Worthiness in addition support is

period tasks

to section

VI_,

paragraph 3.2.1, Field

8.3.2,

) At KSC,

support for

in paragraph storage, and prelaunch launch

Site Operations planning, Flight

SII and SIVB

operations operations.

Readiness

and launch

countdown

3.4

ENGINE Rocketdyne

INTERFACE. Field and includes Site Operations personnel to the engine help side test stage contractors stage inter-

make face for

engine (table engine

connections 3-4). system This leak

disconnections installing

of the

and removing All engine

plates

and plugs work and that the Close all are engine stage

and functional assistance is

testing. coordinated work

interface Rocketdyne

requires contractor coordination interface reviewed

Rocketdyne's and included is maintained tasks and are resolved

between

in the Rocketdyne with the stage

documentation to determine interface contractor,

(FORR). that

contractor engine stage

completed. among

Nonroutine Rocketdyne,

problems and NASA.

Figure

3-3

and 3-4

deleted.

3-7

Rocketdyne Field Quality Assurance helps the stage contractor form and document all inspection requirements face work. will be forwarded 3.5 to the stage contractor

per-

associated with the engine interif requested.

A copy of Rocketdyne work and inspection buy-off documentation for his records,

PERSONNEL Rocketdyne

SAFETY. Field Site with at each Operations NASA, field stage site. personnel contractor, The Rocketdyne for safety making standards. assigned and to NASA/stage Rocketdyne Field sure Manager Rocketdyne safety

contractor standards and/or Field

facilities

comply

and procedures Responsible

Representative personnel

is responsible adhere to all

Site

Operations

Rocketdyne engines GSE and related GSE,

technical outline

manuals safety

used

at field for

sites

in support engine

of Saturn and

precautions

hazardous

tasks.

Particular that govern, but are not

emphasis limited

is to,

also

placed

on complying handling, and

with storage

safety of the

standards

the use,

following:

a.

Solvents. Acids, caustics, and gas and and various other chemicals.

b.
Co
do

High-pressure Pyrotechnics Electrical Industrial

systems. other explosives. equipment. and handling devices, welding,

e.

electronic

f. vehicles, etc). g.

equipment

(hoisting

Propellants.

3-8

At each field site the Field Manager or Responsible Representative, designates a Representative NASA/stage requirements contractor and safe working conditions. and GSE are coordinated and Safety Office, to participate in safety reviews and meetings with and enforce safety standards engines Hygiene

personnel,

to help improve

All deviations to existing safety standards or

applicable to the use and handling of Rocketdyne-delivered and approved through the Rocketdyne Industrial Canoga Park.

3-9

Table 3-4.

Rocketdyne KSC Field

Integrated

Operations Responsibility

and

Stage

Contractor

Task Remove Perform Provide Remove Perform Prepare Approve Install internal Perform Perform stage from storage. inspection for of stage/engines. procedures.

Rocketdyne X X X X procedures procedures. plugs, component and and covers

X

Stage Contractor X X

post-storage engine and

requirements engine.

replace

engine

modifications. checkout checkout

stage/vehicle stage/vehicle

X X

and remove test plates, to the engine system. engine systems and functional

leak sequence

checks. tests.

X -

X X

stage/engine

Inspect maintenance tasks field operations personnel. Inspect Inspect Perform Review Proof-load, Perform Periodically Operate Maintain control. Provide Provide Provide Maintain GFP for stage/engine before launch data. and

performed

by Rocketdyne
X m

corrosion. launch. countdown and launch.

X X X

X X X X X

boat-tail vehicle post-launch

calibrate, engine test

service

engine

GSE. testing.

X X X

component engine and

preinstallation components. GSE support and GSE

engine

hardware configuration

center.

engine, engine

component, and GSE quality

X engineering hardware contractor. records. guidance. problems. X X X X

disposition engine Engine

of engine/GSE to stage and

orientation Log Books

associated

3-I0

SECTION IV
MAINTENANCE

4.1

GENERAL This section outlines the and tasks Levels are their various GSE. activities The associated with maintenance outlined phases and engines, of are

of Saturn the baseline engine for and

engines, for GSE

components, maintenance operation. maintenance

maintenance during are the

activities various

and functions of maintenance identified, quality

described that

capabilities spare are made A

performing

to make and

sure

components, to technical for authorized

and

GSE

retain for

reliability. requirements

References

manuals engine

definitive

maintenance

and to appendix

repair

at KSC.

4.2

ENGINE During

MAINTENANCE
s

the

field

site

operations and

flow

of Saturn

engines,

activities

are

performed These 4-1).

to fulfill activities are

engine classified

maintenance

servicing

support

requirements. and repair (figure

as scheduled,

nonscheduled,

Scheduled routine section testing, engine identified events HI, leak activities in the

activities

for

uninstailed operations The activities

and installed such include

engines

support in

in engine/stage/vehicle Site Operations. testing, associated engine

as those

identified

Field and

inspection, and handling.

electrical Scheduled are

functional and their

storage,

servicing,

requirements, manuals.

limits,

and

constraints

following

technical

a. b. c.

R-3896-11, R-3620-11, R-3825-1B,

F-1 H-1 J-2

Rocket Rocket Rocket

Engine Engine Engine

Operating Operating Operating

Instructions Instructions Instructions

4-1

ROUTINE ENGINE/VEHICLE OPERATION REQUIREMENTS (Refer

SCHEDULED to R-3896-11,

ACTIVITIES
v

R-3620-11,

R-3825-1B)

NONSCHEDULED ACTIVITY (Refer R- 3896-11

!

UNSATISFACTORY ENGINE to CONDITION

REPAIR ACTIVITY

-k

--4
DETECTION

(Refer

to

DO

R-3620-11 R-3825-1B)

Paragraphs 4.3 through 4.3.5)

SPECIAL INSPECTIONS (Refer Engine to Field

Inspection Requests)

Figure

4-1.

Engine

Maintenance

Activities

Nonscheduled occur require from and during the routine

activities flow activity

are

performed stage,

when

nonscheduled Events removing launch engine testing, To quickly

events that engines

of an engine, occur

or vehicle.

nonscheduled storage, shipping the

at random engines, The leak

and include recycling nonscheduled the

uninstalled launch

countdown, activities uninstalled return event conthe

rescheduling inspection, shipment stage,

countdown. testing, servicing, to its operations have included been

include engine engine, occurs, straints,

electrical preparation, or vehicle

and functional handling. when

and

flow

a nonscheduled Their listed limits, above.

nonscheduled and procedures

activities are

preplanned. manuals

in the

Repair an unsatisfactory fault isolation,

is begun engine

when

scheduled Following action may also

or nonscheduled initial failure

activities analysis

reveal and

condition. of corrective Repair when

a course is prepared. that

is determined be initiated

and authorizing as a result is of an

documentation EFIR The inspection repair

is made and

an unsatisfactory for this repair operations

condition are

suspected. EFIR. the or off

requirements on the action position selected, 4-2 4.3

authority engine are the 4.5

in the flow and

Depending corrective the level. vehicle.

of the repairs identifies through

in the made repair

at KSC on the vehicle activities the repair for each

Figure

maintenance and serve

Paragraphs for

describe

activities

as a guide

planning.

4.3

ENGINE Engine

FIELD field site

SITE repair

REPAIR consists and facility of activities capabilities, degradation that can be done affecting hardware.

within engine

the personnel, calibration

equipment, and alinement

without of support

and without

4-3

,,-[

ENGINE

DISCREPANCY

NOTED

SCHEDULED

ACTIVITY

IN PLACE REPAIR

REVERIFY SYSTEM

O3
_r

INSTALL
!

DISCREPANT REMOVE COMPONENT

SERVICEAB COMPONENT

LE

DISCREPANT REMOVE ENGINE

i i

SERVICEABLE INSTALL ENGINE

RETURN COMPONENT O CANOGA PARK FOR FAILURE ANALYSIS TO PERIODIC

AND

DISPOSITION E NGINE

PREINSTALLATION TEST

0_>

COMPONENT DISPOSITION

SERVICEABLE SPARES

ENGINES SPARE (KSC)

CANOGA FAILURE ANALYSIS

PARK COMPONENT DISPOSITION ENGINES SPARE (MAF)

Figure

4-2.

Engine

Repair

Activities

All field maintenance activities

are performed

and controlled by NASA/ in the following engine technical

Rocketdyne approved maintenance procedures manuals, and in EFIRS:

a. b. c. d.

R-3896-3, R-3896-6, R-3620-3, R-3825-3,

F-1 F-1 H-1 J-2

Rocket Thermal Rocket Rocket

Engine

Maintenance Installation

and

Repair and Repair

Insulation Engine Engine

Maintenance Maintenance

and and

Repair Repair

Field reliability hardware field factors. requirements

maintenance Support are support

requirements equipment, continuously capabilities and

vary documentation, reviewed

with

hardware facilities,

design and

and spare

and

analyzed

to determine

maintenance

requirements.

KSC repair A. engine

is the only field location authorized The authorized

to remove

and replace

or

hardware. some repairs

level of repair in place, engine

is presented repair

in appendix

Although and

can be made

is primarily or parts. firing

removing Certain

replacing

or removing are could

and reinstalling "matched" adversely these during

components engine

components

and parts

acceptance performance. performing

tests, and their replacement Restrictions another are imposed

affect engine items

upon

replacing The

without

acceptance operating

firing test. instructions

affects of component

replacement

are in

the engine

manual.

4.3.1

SPECIALIZED Specialized

ENGINE engine with repair

REPAIR consists skills are of repair not normally tooling, required at field sites where These are

services personnel, sent from

of personnel equipped Canoga

certain approved

available. and/or

with Park

procedures, sites as

equipment the repair.

to the

field

to perform

4-5

In addition repair GFP

to supporting engines and/or and

the

field

sites, returned

specialized to Canoga

personnel Park for

are

also

used repair,

to

hardware

factory

modification,

overhaul.

4.3.2

LAUNCH-CRITICAL Engine repair Schedule. of scheduled after

ENGINE the vehicle Engine launch repair

REPAIR is moved tasks that activities 4-1. to the become are launch site can during launchare service

impact

the

launch

necessary considered spares by the

the performance critical. stocked contractor.

countdown in table for

Launch-critical at the KSC warehouse

spares

are except

Launch-critical which is stored

ordnance

To be identified following (2) it can at the site; criteria: be replaced and (1) its

as a launch-critical satisfactory operation by site countdown in the system

spare, is

an item

must for

meet

the

mandatory using the 12 hours.

launch/mission; available part can be

on-the-vehicle the launch verified

personnel has started, within

equipment failed

(3) once and

identified,

replaced,

Table

4-1.

Launch

Critical

Spares

Spare

Component Switch F-l,

Engine H-l, F-1 F-1 F-1 H-1 J-2

Mainstage/Thrust OK Pressure Hypergol Cartridge Gas Generator Igniter Turbine Exhaust Igniter Hypergol Igniter Monitor Switch

4-6

4.3.3

ENGINE REVERIFICATION

TESTING

Engine systems that are violated for scheduled or nonscheduled maintenance operations, including EFIRs and modifications, To prevent redundant testing, activities requirements or modification are tested to verify the engine systems that are during scheduled

engine systems integrity. violated during repair test activities. testing,

are reverified

If reverification

are outside the scope of scheduled tests are tests for

or if delay in testing will delay vehicle schedule, reverification Requirements instructions. Instructions

part of the nonscheduled repair activities. following modification reverification or modification R-3620-11, test activities. 4.3.4 ENGINE MAINTENANCE All maintenance activities NASA are initiated and controlled testing following R-3620-3,

for reverification Requirements

are in the modification and R-3825-3. Stage contractor

repair are in the engine maintenance and repair to be used after repair manuals R-3896-11,

manuals R-3896-3,

are in the engine operating instructions

and R-3825-1B.

procedures are used for scheduled

RECORD on the Saturn engines after delivery to

by approved Rocketdyne and NASA documentaVarious documentation, including the

tion (section VI, Support Documentation).

Rocketdyne FORR, is used to record and provide a history of all maintenance on the engines, during the factory-to-launch operations phase. However, the official NASA record of all engine maintenance that affects the engine's structure, operation, or configuration is the Engine Log Book. The log book is delivered

with each engine and is maintained through vehicle launch operations. 4.3.5 ENGINE CONFIGURATION
A configuration hardware (F-I), identify schedule, approved to prepare configuration. R-7392 and (H-I), describe and the status

CONTROL system is used & Status as required. effectivity, extracted and to report Reports These kit from NASA engine R- 5857 reports delivery FORRs, data, is used

accounting

Configuration R-5788 approved data. (J-2) ECP

Identification are updated

configuration, of data contractor

and ECPs, the

supporting and reports. other

A compilation stage

Rocketdyne,

4-7

4.4

COMPONENT Engine field

MAINTENANCE site repair Canoga is limited Park to KSC and is supported spares and by component at KSC.

repair

activities 4.4.2

at KSC and through

and by hardware component repair

stocked maintenance

Paragraphs activities.

4.4.5

describe

4.4.1

(Deleted)

4.4.2

COMPONENT Limited in-place

REPAIR engine

- KSC component repair or replacement by component, by specialized and procedures engine maintenance that require Park for and comrepair is performed in

at KSC. appendix personnel ponent manuals disassembly position.

The A. and repair

repair This

capability capability

authorized is augmented,

at KSC is noted, as necessary, requirements, A are in the

equipment. as specified R-3620-3, dispositioned

The

limits,

in appendix and

R-3896-3, are

R-3825-3.

Components returned

major for dis-

at KSC or are

to Canoga

4.4.3

through

4.4.4

(Deleted)

4.4.5

COMPONENT Capability for

TESTING limited engine component are testing in the is provided at KSC. and

Component repair calibration are stored returned

test

requirements R-3896-3, analytical

and procedures R-3620-3, testing beyond T-tooling to Canoga

engine

maintenance requiring test

manuals and

and R-3825-3. the capability

Components of the KSC

equipment is retest.

to Canoga

Park.

required Park with

to test the

the components requiring

at KSC and

is returned

component

4-8

LOGISTICS I

ASSURANCE QUALITY

ENGINEERING

GOVERNMENT

MFG PLANNING

MFG

FACTORY

RECEIVE GFP WAREHOUSE

IN

FAILURE ANALYSIS

I ....

-_

= WHEN NORMAL

'

RE

q_
FLOW

ED

,- =

i
F RFD PREPARE

I
APPROVE RFD

I I

I I

SHOP RELEASE

PARTS FROM GFP WAREHOUSE

Figure

4-3.

Canoga

Park

Component

Flow

4.4.5.1 Periodic

PERIODIC RETEST OF ENGINE COMPONENT SPARES retest requirements have been established for spare components that failure modes or have significant failure modes.

are subject to time-oriented

These components (listed in the engine technical manuals) must be functionally retested within a specified time-period installation. (six months or 12 months) before in the engine They are retested in accordance with instructions manuals.

maintenance and repair capabilities 4.4.5.2 failure

Retest of certain components requires

available at Canoga Park. PREINSTALLATION RETEST OF ENGINE COMPONENT SPARES checkout

Preinstallation

retesting is required for some spare components to ensure a

does not exist that could have developed since a fixed interval

was performed. Canoga Park. 4.5

These components (listed in the engine technical manuals) must The testing capability is available at KSC and

be retested before installation.

HANDLING In accordance

AND

DISPOSITIONING the maintenance and

FAILED concept, dispositioning

HARDWARE Rocketdyne failed that enables GFP and NASA

with for

have The

established system

a system provides the and

handling and failed

hardware.

authority handle

documentation GFP hardware.

Rocketdyne

personnel

to analyze

4.5.1

UCR UCRs

REPORTING are does initiated not during a component; or personnel; perform hot fire within 24 hours when: to the once (1) an pertinent engine component operasatisfactory or an a

malfunctions tional

or

according or after

Rocketdyne

specification as to equipment

having

demonstrated cutoff from

performance hazard

(2) a condition

causes

premature is removed

(3) a component

4-10

engine cation

because or other

of a suspected engineering

malfunction; documentation; is in error, of the above

(4) is required (5) a human ambiguous, conditions

by Rocketdyne error occurs

specifior an an omission,

authorized either

Rocketdyne would

procedure permit any

or contains to develop.

of which

When of the

available, UCR

the

stage

contractor

failure site.

report

is entered

on the

UCR.

A copy

is given

to NASA

at the field

UCRs

are

not written

to report:

a. was noted. b. degradation

That

an operation

was

performed

and

no unsatisfactory

condition

Obvious

misuse, life was

mishandling, requirements. replaced and

superseded

configuration,

or

beyond c. That

specified a part

or modified no discrepancies of a part with

in accordance were noted. required

with

Modification d. as scheduled exhibits e. specification f.

Instruction Replacement maintenance no unusual A condition but does

or EFIR

or repair in accordance defects. where the

specifically Logistics

to be serviced and

official

procedures,

which

component

performs

to the

Rocketdyne specification.

not satisfy deficiencies.

a requirement

of a non-Rocketdyne

Cosmetic

g. h. where the

Instrumentation Minor malfunctions results

malfunctions in ground

that

do not

affect

engine

operation. except

support

equipment or engine.

or T-tool

malfunction

in a hazard

to personnel

4.5.2

FIELD When

SITE

COMPONENT component

FAILURES fails, it is removed and returned A UCR the (per to the is prepared damage. NASA GFP listing When for

an engine Site

approval) Warehouse, a brief

by Field and

Operations part

personnel is issued. and

a replacement of the cause

description requires

of failure

apparent

a component

repair

or failure

analysis,

a recommendation

4-11

hardware disposition

is prepared on the back side of the hard copy of the UCR or returned to Canoga Park Office Representative Field Site When a

recommending the component be held for local repair for further determines disposition.

The resident NASA Engine Project

or his representative

at the field site reviews the Rocketdyne recommendation,

the course of action, and signs the UCR, authorizing

Operations personnel to proceed with the disposition component. If NASA or stage contractor

of the component.

component is to be returned to Rocketdyne, the UCR hard copy is attached to the procedures require that the hard copy Review Board and Field Site

of their discrepancy report be attached (to clear the Material GFP Stores), both hard copies are attached to the component. Failure Analysis

Operations personnel are responsible for ensuring that the UCR hard copy and the Rush Tag (if required) are attached to the component before it is (Conditions defined as "Critical and Major Failures" Rush Tag be attached to the part before it is returned to Canoga Park.

require that a Failure Analysis

returned to Canoga Park. ) Copies of the UCR are forwarded to the resident NASA Engine Project Offices at the field site. 4.5.3 FIELD CORRECTIONS When UCRs are written the discrepant against hardware unsatisfactory conditions and

hardware is corrected at the field site, Rocketdyne Field Site Report and forward copies to

Operations personnel prepare a Failure Analysis appropriate 4.5.4 Rocketdyne offices.

FAILURE GFP

ANALYSIS returned analysis. All critical analysis to Canoga A failure Park analysis by UCR plan action of action are assigned when the is assigned is prepared for failure by

hardware for

Reliability for each

Projects failure however,

analysis.

and major may

failures

analysis, mode failures unusual,

a complete

not be required failed

is known are etc,

through

examination for analysis

of previously unless

hardware. condition

Minor is new,

not assigned or an analysis

the failed

is requested

by NASA.

4-12

After are the has returned environment been subjected to the

failure GFP

analysis, warehouse performed,

the for

hardware further

and action,

the

hard along

copy with etc)

of the a record the the

UCR of

(testing

degree analysis as and a flight

of disassembly, a statement spare.

hardware suitability

to in failure for refurbishment,

regarding

of the

hardware

4.5.5

through

4.5.6

(Deleted)

4.6

GSE

MAINTENANCE GSE in the intervals. requires engine field proof site custody of Rocketdyne Also, certain periodic technical site testing, calibrates requires special maintenance, manuals operations and GSE proof in the are test various equipment calibration, followed do to fulfill all maintestage/ levels used and

Delivered of maintenance for engine and

at periodic GSE

maintenance in the Rocketdyne calibration, at the field

servicing. these nance support

Procedures requirements. tasks except

personnel loading. custody

The

contractor

of Rocketdyne.

Field an as-required

Site basis

Operations in support services and

personnel of delivered assist to the the latest stage

provide GSE

maintenance in the custody

services of the stage

on

contractors. in a serviceable

These

contractor

in maintaining configuration.

GSE

condition

approved

4.6.1

GSE GSE

FIE is

LD

REPAIR at the field The site field by repair replacing level discrepant of GSE is part, outlined in

repaired

components, the following

or

subassemblies. manuals:

technical

a. Maintenance b. c. Maintenance and and

R-3896-5, Operation R-3620-3, R-3825-5, Repair

F-1

Rocket

Engine

Ground

Support

Equipment

H-1 if-2

Rocket Rocket

Engine Engine

Maintenance Ground Support

and

Repair Equipment

4-13

4.6.2

GSE GSE

REPAIR requiring

- CANOGA repair for that return

PARK exceeds to Canoga to determine in the the repair capability An analysis if a design Logistics Stock change Record at the field of the is files and GSE

sites failure

may

be dispositioned is made

Park.

mode

by Engineering, of repair IDR is retained

required. the Quality

A record Assurance

retention

records.

4.6.3

CALIBRATION Delivered

OF

G_E on a periodic Assurance basis Manual. as outlined in the

GSE is calibrated and Field

engine

technical

manuals

Quality

4.6.4

GSE GSE

AND and

SUPPORT Support is certified to or used meets All plates, the

EQUIPMEI_ used before

CLEANNESS for use. engine and component of GSE or checkout, support unless specified cleaning the engine the

Equipment clean

purging, equipment cleanness in the (hoses, technical

or flushing is connected of the item

No item

in an engine of the support

system cleanness equipment in accordance

or component requirements requiring with

intent

MSFC-STD-146. lines, plugs,

GSE and etc)

is cleaned

manuals.

4.6.5

GSE CONFIGURATION To maintain configuration for

CONTROL traceability approved configuration ECP/EFIR Identification data on G_E modification control. necessary Reports. modifications or EFIR The and to be contains the

EFIRs, performed item

a FORR

is prepared

each

on items number in the

of CaSE requiring and approved

FORR

and part

to record

information

Configuration

& Status

4.6.6

GSE

RE CORDS of GSE engine configuration, GSE by Field calibration, Operations and personnel. servicing operations

A record is maintained for all

4-14

4.7

SPECIAL Special

TOOLS tools repair, and and

AND TEST test engine equipment

EQUIPMENT (STE) and basis are engine provided servicing. by Rocketdyne This with equipto

perform ment

component is calibrated

checkout,

serviced and

on a periodic assurance

in accordance

Rocketdyne

procedures

quality

standards.

Configuration sites field the will sites released be maintained. will

control The

for

all

special

tools

and tools

test and

equipment test

at field at with are the sure

modification through the When

of special FORR special the Spares

equipment

be accomplished order Park and for

system tools

and in accordance or test equipment will process

tool to Canoga test

drawing. modification, the

returned tool and/or

personnel system

equipment

through and

hardware to the field

servicing site.

and make

the hardware

is modified

returned

4.8

HANDLING Government

GOVERNMENT property program

PROPERTY consisting

- EFL

WAREHOUSE spares, and tooling, stored at

of provisioned items are received

STE, the

GSE, EFL

and related

inventory

warehouse.

Engine and this will are stored hardware be inspected met. This LOX other at EFL will

hardware as residual be used at Canoga for

excess

to current

program

needs

is segregated by NASA that

hardware. production to ensure

If it is determined or flight that all the last support, drawings

the hardware requirements planning (if applicable) Hardware the Hardware that

Park consists

inspection cleanness

of reviewing time since

accompanying test

tickets, and all

integrity, requirements and

functional drawing. under

pertinent

specified subsequently

by the repaired

cannot Servicing

be verified Clause

is tested of the

Contract.

Tooling, at EFL processing current Contracting are handled

STE,

GSE,

and related inventory hardware

program hardware. for with use

inventory The

items removal of the NASA

stored and

as termination inventory

of termination program Officer. is handled

in support of the

in accordance

direction

MSFC

4-15

SECTION V SUPPORT EQUIPMENT

5.1

GENERAL. This section program Support specifies and the the support Soyuz engines Support equipment Test retained Project. C, for to support (Refer table H-1 to C-l) engines Support designated is the

Saturn appendix located (appendix equipment

resources C. ) at sites C, for

Apollo F-1

equipment

for

(appendix equipment

designated table J-2 C-2) engines

in R-5857. is located (appendix

at sites C,

designated table C-3)

in R-7392. is located

at sites

in R-5788.

5-1

SECTION SUPPORT

VI

DOCUMENTATION

6.1

GENERAL. This section identifies Rocketdyne 6-1 lists the among and controlled the support documentation engines used and to define, support and a

manage, equipment. illustrates support information

and perform Figure

support

of Saturn

related

documentation categories. the capability manner.

by functional The

category

the relationship system with

documentation

provides vital

continuity and

of disseminating

program

in a timely

Table application, update

6-1

briefly

describes and

each

document

and

identifies and

program revision/

contractual

obligation,

approval,

distribution,

requirements.

6.2

ENGINE The engine

PROGRAM program

CONTRACT. contract to support (DRL) and specifies Saturn Data the engines Requirement are required the DR lists services and supplies GSE.

to be provided The Data

by Rocketdyne List of support of the requirements.

and associated (DR)

Requirements what items contents approval

in the contract describe printing,

specify the and

documentation data. In addition,

and briefly the update,

minimum NASA

6.3

ROCKETDYNE Internal policies

AND

LOGISTICS the office

INTERNAL for

POLICIES. effectively The policies operations. managing document

provide

guidelines and

Rocketdyne methods

operations and procedures

in the home that provide

the field. and

consistent

effective

6.4

REQUIREMENTS All field maintenance

AND

PROCEDURES. performed on Rocketdyne approved are delivered requirements manuals engines and or

and

GSE is

done The

in accordance requirements

with

Rocketdyne

procedures. special

and procedures

in technical

instructions.

6-1

DESIGN INTERNAL HOP LOM FQAM CONTRACT WORK DATA STATEMENT REQT SCHEDULES DRAWINGS AND POLICIES OPN SUPPORT AND

ENGINEERING ANOMALY RESOLUTION

SPECIFICATIONS MIL, AND CHANGES) FED)

(RKDN, VENDOR, ECP (HARDWARE CLASS H CHANGES Eli) FAR O&FS PLAN

ROCKET ENGINE MAINT AND SUPPORT' PLAN AND FOR F-l, H-l, J-2 ENGINES c_ ! I P_RAM AND STATUS I

REQUIREMENTS AND PROCEDURES OPERATING REQT MANUA I_,S MAINT AND REPAIR MANUALS MOD INSTR EFIR OICN MANUAL DATA SUPPLEMENT SAFETY REQT AND GUIDELINES WORK CONTROL

DISCREPANCY REPORTING UCR FAR FIDCR FIR/R PCS (REQUEST)

INFORMATION IDENT & REPORT

CONFIG STATUS

DATA MANUALS TRAINING DATA ACTIVITY UCR/FAR LIB FIR/R REPORTS SATURN ENGINE STATUS REP ORT

PROGRAM PROGRAM FORR ECP/POICN IPB IX)TSI RAPS

DIRECTIVE AUTHORIZATION (REQT CHANGES)

RSPL RFD IDR HARDWARE ENGINE ELB CTR GSE DATA RELEASE BOOKS SHEETS RECORDS

LOG

(RECORD)

XMTL

MAINTENANCE

Figure

6-1.

Support

Documentation

6.4.1

TECHNICAL Engine

MANUALS. requirements for each are engine in sections system. for coordinated operations Instruction are processed approvals I and II of the These delivered and manuals engines. controlled repreAll due vehicle Notices the ECP

operating Manuals official operating may have

Operating sent

Instructions

Rocketdyne's to engine impact they

operating

requirements are contractor on Operating OICNs signature

changes to the mission (OICNs) system

requirements on stage are engines. coordination issued

and flight Change through from

success. for and H-1 receive

Changes and F-1 total

These and

Rocketdyne

and NASA.

Maintenance (eg, cleaning, servicing, and the repair

tasks repair,

performed test,

by Field etc) are

Site supported

Operations

personnel procedures

by detailed repair Use

in maintenance which cedures exceed

manuals.

The authorized

manuals

provide A.

procedures of those pro-

level

of repair

in appendix

requires

program

authorization.

Engine method This for performing

checkout the

procedurespresent checkout necessary to the stage

Rocketdyne's to satisfy contractors

recommended requirements. their

operating to develop

procedural

data stage

is available procedures.

engine-oriented

Normal is done Data by accumulating

updating

of procedural data into

data

to meet

changing

program

needs Manual data

affected

scheduled OICNs are

manual issued into the

changes. for urgent

Supplements

or non-ECP-controlled and changes. OICNs are

changes. subsequent

Supplements manual

incorporated

manuals

during

6-3

6.4.2

SPECIAL Special

INSTRUCTIONS. instructions are issued (Modification to present Instructions and Engine Field to be nature.

Inspection followed These

Requests)

the technical

requirements nonrepetitive

when

performing have

special tasks

of a nonroutine, GSE, part,

documents

a specific engine, are complied

or component

effectivity. the instruc-

After the instructions tions become

with on all the affected items, revision to reinstate.

inactive and require

6.5

WORK Work

CONTROL control and controls records

DOCUMENTATION. authorizes Management components, internal and records task and GSE accomplishprovides status. of

documentation the Spares of engines, to the not been

ment, official

monitors individual

program, and

field that

Documentation individual

is peculiar units has

day-to-day listed.

operations

functional

At Joint Operating are for

KSC,

in addition

to the between

Rocketdyne Rocketdyne technical

work and the

control S-II and

documentation, S-IVB stage and

Agreements prepared Rocketdyne

contractors guidelines

to provide field site

instructions,

controls,

operations.

6.5.1

TASK Task

AUTHORIZATION authorization These

AND documentation

TRACEABILITY. provides consist the authority Directives that provide to start and program for

and

complete

a task. Authorizations and the FORR

documents

of Program documents

Program authority) Rocketdyne

(Rocketdyne (a with field

internal document task). that

indicates

NASA'

s approval

to proceed

a specific

The in the and daily routine task on

FORR

is

the

most operations. for

important The

item FORR

of

support

documentation documents, personnel for the a brief to describe use of

of field completion

authorizes, task field. Rocketdyne Details however, plan

records

every and Operating has

maintenance GSE in the

perform the FORR

engines, are in the

components, Logistics system

Manual included

(LOM), in this

description its primary

of the use.

FORR

been 6-4

When system

a task

is to be performed by Field Operations

by Rocketdyne as follows:

personnel, (See figure

the 6-2. )

FORR

is implemented a. The task etc)

requirements All

document documents The FORR

(Modification referenced Form

Instruction, require-

EFIR, ments stage

UCR,

is obtained. are also

by the task 612-D-15 for

document contractor signature. b.

obtained.

or subsequent "go-ahead"

documentation

is then

presented

to NASA

approval

After with

approval, the quality Inspection is used

the task assurance Discrepancy to record

is performed requirements

by Rocketdyne in the task Record deviations,

personnel requirements (FIDCR) or in

in accordance document. the FORR

A Field work

and Correction discrepancies,

package during

deficiencies

noted c.

performance progresses, If the task

of the task. the required cannot date Rocketdyne at this location, is placed and NASA time, only in a eg, the

As the task obtained.

signatures additional completed suspense

are testing

be completed or different

is required of the FORR

at a later is signed

portion file. d.

and the FORR

When obtained the The

the task

is completed, FORR work

the

Certificate

of Completion and filed in

signatures accordance

are with e.

and the

package

distributed

LOM. completed FORR work package provides records for and traceGSE.

ability 6.5.2

of all tasks

performed

by Rocketdyne OPERATING operating are

on engines,

components,

CHANGES All changes

TO ENGINE to the engine

REQUIREMENTS. requirements and approved in the F-1 and the are (PCCB). document

H-1

Operation

Instructions system.

manuals

initiated

through

ECP/POICN approved The PCCB

Changes Saturn

to J-2 Program

engine

operating

requirements Control Board source

by Rocketdyne either reviews

Cor_iguration changes

and approves

to the basic

6-5

NASA AUTHORIZES GO-AHEAD BY SIGNING FORR FORM 612-D-15.

ROCKETDYNE

PERSONNEL

----.(As m_umED)-IP-[__._coRm" ITWE

PERFORM TASK REQ_a; ALL DISCREPANCIES DOCUMENTED ON FIDCR.

I 612-D-1_

--

-- --(AS REQUIRED)--

--

I PAC

STATUS

|COMPLETED |APPLICABLE/NSPEC-

J _

I APPUCABLE I PORTION

Im_;_umm_Emt's DOCU_NTI

I ?J_.., I NAs^.

_GNED OFF

' ..... _ I
c

FO_ I P_CED IN _.J

SUSPENSE FILE. FORR FORMS DISTRIBUTED AND FILED ACCORDANCE WITH ITATUS ENOINE iOM. ENTERED IN LOO BOOK. IN [ ,)

I I

TASK

_:0MPLETED

COC

*LL INSPECnONPOINTS_ I OFTASi cQunumm_rs _ I ...... m I

I PORTION I SIGNED " BY

Figure

6-2.

FORR

System

6-6

(drawings, directly. cause tive for stage

specifications, In addition, impact are

etc) changes informally

or reviews to J-2 engine

the

individual operating to the stage

manual requirements contractor

changes that may

presented

representa-

consideration.

6.5.3

SPARES. Spares documentation disposition, for conveying and and AND includes and monitor spares field sites, the reports, The between IPBs, manuals, and forms used

to procure, a formal Rocketdyne RAPS, 6.5.4

ship, system home

spares.

documentation NASA the and the

provides

information and includes Hardware

office RFDs,

LOTSI

report,

RSPLs,

Logistics GSE

Releases. RECORDS. sheets, provide component test

ENGINE Engine

HISTORICAL and data

Log Books GSE

transmittal records performance of engines,

records for data,

(CTR),

and

maintenance events, past status

authoritive

documents life GSE.

recording and

significant

values,

operational and

servicing/maintenance

components,

6.6

DISCREPANCY Documentation

REPORTING. used FIR and to report discrepancies These to support documents the action includes describe necessary of the problem. the UCR,

FAR,

FIDCR,

PCS

and

(Request). are used

suspected to resolve

or identifiable the 6.7 problem

problems and make

adjustments

to prevent

recurrence

ENGINEERING Engineering

DOCUMENTATION. documentation is the primary design design source data operating Engineering application monitored during for for developing criteria,

requirements and a system

and procedures. for developing and

It provides controlling

features, changes. to field

documentation the development that 6-3 can

is thoroughly of support require shows

analyzed documentation

and adapted and to the

continuously

changes Figure ECP

revision/change an example

support

documentation. and issuance of a hardware

of how the documentation

approval system.

impact

the

support

6-7

_,_TD_E,C_OOA PARK
PUBN ] ENGINEERING l SPARES

II
II ROCKETDYNE -

_
I I

OPE_ONS
NASA 1 STAGE CONTR

I
POIC'N

11
.=.,=,=, ..., _, _. __. ,==. _ .=.. _ ... .==, ... ... ,... ,,.=, ._

I
I _ICN _._ IHARDWAREEcP I I

PREPARE

I
MOD INSTR

P_EPARE i I
I

' I
I

APPROVE

I I
I I
I

I I I
I

I
I

i
I MopNST_ I
P,SPL
PREPARE FORR PACKAGE

FORR

"PREPARE

APPROVE GO-AHEAD

I I
UPDATE

i I i
i_ I I I OFFICIAL ELB UPDATE

I
I OO

ELB DATA TRANSMITTAL_ _KIT SHEET

PREPARE

I I

I.ILR

I
PAPS UPDATE I

ISSUE I WITH FORR

I "
ROC KE TDYNE I

I
UPDATE

I
DATA

I II I
I

[
UPDATE I

'1
I
I

RFD _HARDWARE

zu3
UPDATE

PREPARE

I
& STATUS REPORT UPDATE .q II I RELIABILITY PROJECTS UNIT I_

II
I II" I FOP,.R PACKAGE LI_UPDATE

I
l I

FO_
APPROVE TASK COMPLETION

I I I
I I
l STAGE PROCEDURES 1

I I

I
OICN ISSUE

,
J
I

i
I I I
RECORDS

I
I _1 SPEC AND

UPDATE

UPDATE

Figure

6-3.

Support

Documentation

Response

to Hardware

Changes

6.8

PROGRAM Information

STATUS describing and

AND INFORMATION. the informal engine and the program reports and is provided general program

through information

formal

(contractual)

status

documents.

6.8.1

FORMAL Formal

STATUS (contractual)

REPORTS. status hardware reports provide the status These and of delivered reports Saturn and

engines, include Engine distributed

support the Status

hardware,

and

discrepancies. & Status reports Report

Configuration Report. on a schedule

Identification The data in the

UCR/FAR revised,

is monitored,

dictated

by contract.

6.8.2

INFORMAL Rocketdyne

STATUS Logistics

REPORTS. internal policies dictate that a continual be maintained status. site activity This is

exchange to provide done reports.

of home

office/site and

activity NASA with

and program current overall home

information program and

Rocketdyne

by preparing,

approving,

and issuing

office

6.8.3

GENERAL General

INFORMATION. information describes schedules. and Logistics documentation engine This design provides and a formal system for

distributing and tentative manuals,

data

that

operations consists Bulletins.

characteristics of the data

program training data,

documentation Information

6-9

Table

6-1.

Support

Documentation

Summary
Program Application

(Sheet

1 of 8)
NASA Approval Resident Representative By ECP CCN Formal Distribution Update Frequency

d
Z

2
INTERNAL 1. POLICIES

Purpose

Report / Form No.

H-1

F-1

J-2

Contract Reqt

Stg Rkdn NASA Conb

As Reqd Other

R0CKE"I'DYNE OPERATING POLICIES Provide the administrative applicable to Rocketdyne

AND PROCEDURES

(ROP) and procedures

(None)

and operating policies internal requirements.

2.

LOGISTICS

OPERATING MANUAL (LOM)

(None)

Define the policies and procedures that govern Logistics personnel in day-to-day activities. Instructions are provided for guidance in the administration of personnel services at Canoga Park and field i sites. Applicable Rocketdyne Operating Procedures are expanded to !provide the needed degree of detail for Logistics use. The L0M must !be used for specific instructions in such areas as hiring_ transfer, and termination of field personnel; provisioning, shipping, handling, and storage of hardware; field site activation and deactivation; and field task documentation through the Field Operation Requirement and

,_
i..a.

R,cord (F0_) 5.

,yste..
578-4)--5 x X x X X

'_

FIELDQm-_I_ ASSURANCE MANUAL (FQ_)

Provide an authoritative document for defining the procedural requirements of the Field Operations Quality Program and implementing the basic elements of the Rocketdyne Quality Program Plan, R-6158-b.

_. QUALI_

ASSURANCE

INSTRUCTIONS

(QAI) requireetc.

Supplement the ments applicable 5.

I_AH vifh procedural instructions for specific to a particular assignment, engine program, (FQOI) Assurance signed,

(Correspond_ to FQAM procedure number (Correspond_ to FQ_4 procedure number

FIELD QUALITY 0PlaCATING INSTRUCTIONS Supplement operations issued at

the FOAMwith the necessary detail Quality peculiar %o each site, FQOIe are prepared, the field sites.

and

ROCKET AND J-2

ENGINE ENGINES

MAINTENANCE

AND

SUPPORT

PLAN

FOR

F-I,

H-I,

R-88_2

Define support

Rocketdyne's support planning information.

functions

and

provide

maintenance

and

Table

6-1.

Support

Documentation

Summary
Program Application

(Sheet

2 of 8)
NASA Approval Resident Formal Distribution Update Frequency

Purpose REQUIREMENTS ROCKET _GINE AND PROCEDURES MANUAL

Report/ Form No.

Contract Reqt

Representative

0PlaCATING INSTRUCTIONS

P_-3620-11

X (SectIII) X (SectIII) X

Provide Rocketdyne/NASA authorized field operating requirements for fligh_ engines during a complete operational flo_. Specific and general engine requirements, including acceptability criteria and limitsp special constraints, and safety precautions are in sections and II. Rocketdynels recommended procedures for fulfilllng the requirements are in section III. 0PI_ATING INSTRUCTION CHANGENOTICES (0ICN) Rocketdyne/NASA in the Operating authorized Instructions

R-3896-11 I R-3823-1B

bum Sec_i
(Numbered x consecutively by program)

Provide a method for issuing urgent %0 operating requirements contained Manuals for F-1 and H-1 programs. ROCKE_ I_GINE MAINTENANCE AND REPAIR Provide Rocketdyne authorized procedures applicable %o the H-l, the manual also contains and procedures. ) GSE MA_CE

changes

MANUAL

maintenance and repair requirements and specific engine and its components. (For GSE maintenance and repair requirements

R-3620-3 R-3896-3 I%-3825-3

x x x

x x X

AND REPAIR/0PKRATI(_

Ka3qUAL repair requirements and supplied GSE applicable and procedures for H-1

R-3896-5 R-3825-3

x x

X X

Provide Rocketdyne authorized maintenance and procedures_ and parts listings for Rocketdyne %o the specific engine program. (Requirements GSE is in R-3620-3. ) F-I ROCKET _NGINE THERbIAL INSULATION

INSTALLATION

AND REPAIR

R-3896-6

Provide Rockefdyne authorized maintenance and repair requirements and procedures for F-1 engine thermal insulation. (Requirements and procedures for H-1 and J-2 thermal insulation are in R-3620-3 and R-3825-3, respectively. ) F-I ROCKET _NGINE TRANSPORTATION MANUAL i%-3896-9 Log _r direction)

Provide Rocketdyne authorized requirements and procedures for preparation and shipment of F-1 engines_ nozzle extensions, thermal insulation and loose equipment. (Requirements and procedures for transporting H-1 and J-2 engines are in R-3620-3 and R-3825-3, respectively.) STANDARD HAINTIg_ANCE AND REPAIR MANUAL FOR LIQUID ROCKET ENGINES AND ASSOCIATED SUPPORT EQUIPbl]_r Provide a central source of Rocketdyne authorized general maintenance and repair information and fundamental reference material for liquid R-8262 X

Table

6-1.

Support

Documentation

Summary
Program Application

(Sheet

3 of 8)
NASA Approval Resident By ECP CCN Formal Distribution Update Frequency

Z Report / Form No. Contract H-1 F-1 x ,1-2 x Reqt x

Representative x

Purpose 8. MANUAL DATA SUPPLR_qTS Provide a rapid method for issuing urgent authorized changes ons %o technical manuals (except for Operating Instructions on the F-1 and H-1 programs.) 9. MODIFICATION Provide changes XNSTRUCTIONS authorized hardware. instructions for making ECP-approved or additiManuals

Rkdn X

NASA X

Stg Contt X

As Reqd X

Other

X (Numbered consecutively by manual,ex: R-3620-3-1 ) R-1591(ECP NO. ) R-5266X

L

x x x x x

X X X

X X X

X X X

X X X

Rocke%dyne %o delivered

(EcPso.)
R-5436-

Crop_o.)
10. ]_GINE FI]_) INSPECTION REQUESTS (EFIR) instructions or work for performing non-ECP nature nonroutine, on (Numbered consecutively by X x x x x X X x

Provide Rocketdyne nonrepetitive field idelivered hardware. S__FETY REQ_S

authorized inspections,

of

AND GUIDELINES

Provide guidance and direction necessary to conduct Rocketdyne field operations in a safe manner. Specific precautions and warnings relatlve %o performing maintenance and operating procedures are appropriately located within the requlrement/procedural documen_atlon. General policies, responelbillties, and guidelines are in Rocketdynep stage contractor, and NASA generated documentation, eg, Joint 0peratlngAgreemen%, site operating directives, etc. Government documentation (Military, Federal, and Civil) is also referenced for specific safety requirements applicable %o the aerospace industry in general.

WORK
l.

CONTROL

DOCUMENTATION

PRO_,a DnmCT_E

(PD)

Form 605Y-16/17

An internal document issued by Program Control to provide authority and direction to the Subdivision of Works Manager for completion of the work specified in the directive.
2,

_A_mORIZATION

(PA)

An internal document issued by the Subdivision of Works Manager %o provlde authority and direction to the functional (doing) organization for oompletion of the-work specified in the authorization.

Form 610-C- X 195 or Form 639-_

Table

6-I.

Support

Documentation

Summary
Program Application

(Sheet

4 of 8)
NASA Approval Resident Representative By ECP CCN Formal Distribution Update Frequency

8
Z

H
Purpose
_e

Report Form

`/ No. H-1 X F-11J-2 X X

Contract Req't

Rkdn X

NASA

Stg Cont

As Reqd X Other

x,x_v op_,_Ti_

m_Q_m_-r

& aECORV(FO_)

Provide a system to plan, implement, and doemaent quality approval, previde evidence of completion for tasks performed in the field by Rseketdyne personnel. The FORR is prepared by Field Engineering to detail the requirements of a specific engine/GSE/component task. When approved by NASA, the FC_R is authority for Rocketdyne to perform the work specified on the FORR. When the task is completed and approved on the F_R, the F_tR constitutes a Certificate of Completion.

Forms: 612--D-15 & and 612.-D-16

(NAS_ _kuagemmt at site)

' ]_tGINEERING

CHANGE PROPOSAL/PROPOSED 0PI_?ATING INSTRUCTI(_I CHANGE

(Nmmbered
consecutively

by

Previde a positive system for obtaining Rocketdyne Engineering and NASA approval of proposed changes to the requirements contained in seetion I and II of the Operating Instructions _anuals. The POICN beemlea an attachment to an ECP and is processed through the formal ECP _hannels. Upon approval the POICN is issued as an 0I_ for inelusion in the Operating Instructions Manual.

pregra_)

5.

ILLUS_U_ED PARTS BRE_K_

MANUAL (_PB)
of engine parts, provide reco-zzended aid in repair/

Provide identification and interrelationship the requisition of replacement parts, and recoverability codes. 6. LI_ OF TIME SENSITIVE I_S (LOTSI)

R-_20-_ R-3896-_ R-3825-_

X x X

X x X

X X X

X X X

X X X

X X X

X X X

R-8720

To identify time-sensitive (limited life) items containing synthetic _ibber, items subject to a preinstallation or periodic retest, service life based on cycles, seconds of operation or star_s, periodic servicing, ordnance service life, and storage and usability requirements for i eempon_ds. Z ROCKETDY_rE A_TOHATED PACKAGING SYSTEM (RAPS) Identify shipment the elements or storage. necessary to prepare LIST or part for
(None)

a component

Table

6-I.

Support

Documentation

Summary
Program Application

(Sheet

5 of 8)
NASA Approval Formal Distribution Update Frequency

d
Z Report/
_=_

Resident !Contract No. H-I F-I J-2 Req't

By ECP CCN Stg Rkdn X NASA X Cont: As Reqd X Other

Purpose

Form

Representative X

s.j

SUPPORT PARTS

(RSPn)
to support the engine Spares Management site capabilities, for approval. Upon and procurement

(No.o)

Prowlde a list of reoo_ended hardware necessary programs. The list is developed by Rocketdyne based on Im.aualy_is of maintenance requirements, and stag_ scheduling, and is submitted to NASA approval, NASA issues a Supplemental _T_ement, laz_edures are initiated. 9. REQUEST FOR DISPOSITI(_I" (RFD)

Form 5._-0016 and description specific situation. approval by NASk, comply with the of work The Spares

P_ovide NASA with Rocketdyne's recommendation to be performed on an item of hardware for a form is prepared by Spares Management. Upon Nmm4_ement initiates the effort necessary to disposition. 10. INSPECTI(I_ Document the AND DISPOSITI(I_ of a REPORT discrepant (IDR)

Forms

X &

condition

component/part

after and inspection. describes a dispoIt

601-U-2 601--.U-.4

Rocketdyne manufacturing defines in detail all sition for each. 11. LOGISTICS Anthorize modification Logistics. basic task# 12. _GINE LOG HARDK_RE Rocketdyne

has completed disassembly discrepancies detected and

RELEASE

(SHOP

EELEASE) to perform overhaul, repair, tasks to and for the

Fore

X in

610-F-1_ _mufacturing Purchasing contains instructions (Listed tasks, and Each release plus shipping BOOK to perform procurement specific details relative and schedules.

R-8735)

Provide official document for recording the operational status, configuuration, and transfer records of the engine from delivery to launch The official log book accompanies the engine. A duplicate log book is maintained by Rocketdyne Field Engineering to provide Rocketdynewith engine status Luformation. 13. _NGINE LOG BOOK DATA TRANSMITTAL SHEETS

(CQrrespond tO Engine Serial No. ):

(Engine receives log

Custodla_ official book)

(Contained in Operatin Instruction, Manual)

(Correspondt to able applicFORR No, )

Convey engine status information for inclusion in the Engine Log Book. All Modification Instruction and EFXRs completed by Rocketdyne personnel, plus certain tasks done in accordance with FTVPs, require the completion of this form and subsequent distribution to _he custodian of the log book.

Table

6-1.

Support

Documentation

Summary
Program Application

(Sheet

6 of 8)
NASA Appr Resident oval By ECP CCN t_-:dn X NASA Formal Distribution Update Frequency

g H
Purpose Report,' Form (None) Contract No. H-1 X J-2 Req't

Representative

Stg Cont X

As Reqd X Other

1_

com,_

RECORD (C_a)

Provide functional test data on specific serialized engine components which are subject to field maintenance, repair, or periodic functional te_rting. The CTRs for installed components are kept in the Engine Book. CTRs for uninstalled (spare) components must accompany the component whenever it is transferred. 15. GSE Kk_CE RECORDS
q

Log

Form

61'2--D-20 Provide a maintenance record system for periodic maintenance, inspections, and modifications of GSE at field sites. _lso applicable %o F-1 T-_ooling at field sites. These records do not include calibration data; calibration records are maintained bythe on-site calibration recall system.

DISCREPANCY ! J1 1.

REPORTING

DOCUMENTATION

UNSATISFACTORY

C(NDITION

REPORT

(UUR) Plan, R-7150, the conditions on _ procedures, and (Not all discrepancies which type is UCR provides a in the field and human errors that are recorded described in the

Forms 610--C-I_0
or

To support the Reliability Program system for reporting unsatisfactory st Csnogs Park, errors in authorized cause unsatisfactory conditions. on UCRs; LOM.) the criteria for determining

610-C-156

2.

FAILURE ANALrSm _0aT

Provide reported pleted a

(FAR)(r_

us_)
in this condition case, com-

record of the analysis of an unsatisfactory by a I_R. The analysis and record are, by Field Engineering and/or the customer. INSPECTION DISCREPANCY to noted rectify AND CORRECTION RECORD

3.

FIELD

(FI])CR) It provides FORR task 0nly discrepanthe (Use disa

The FIDCR is an attachment record of discrepancies and the action taken to

the FORRwork package. during performance of or disposition them. are for a

the

cies directly related to the FOP_work package of the FIDCR does not negate the requirement crepaney satisfies UCRrequirements.) _. F1-ELD Provide have a INFOI_TION an REQUEST (FIR) traceable create a hazard record %o of

recorded. UCR if

(Numbered
consecu-

authoritative, impact,

field

problems or personnel, (The FIR may or PCS. Refer

that

may or

program

hardware

require Home Office coordination and resolution. cate information that has been reported on a 5_R LOM-%o determine when each form should be used.)

duplito the

by program, site, & Yea:

tively

Table

6-1.

Support

Documentation

Summary
Program Application

(Sheet

7 of 8)
NASA Approval Resident By ECP CCN Rkdn X NASA Stg Cont As Reqd x Other Formal Distribution Update Frequency

d
Z Purpgse Report/ Form No.
Form H-I'

F-I X

J-2 X

Contract Req't

Representative

5.

PUBLICATION CHANGE SUGGESTION (PCS) Provide a standard positive method for reporting apparent or discrepancies in, or suggested improvements to, data produced Logistics Product Support and Administrative Support Services provide timely, coordinated authoritative replies. suspected by and

609K-II

PROGRAM 1.

STATUS

AND

INFORMATION _TUSP,

DOCUMENTATION EP01_ and indithe current modificaAlso proF-1 and R-7392 R-.5857 R-5788 x X x x X x x x x x x x x x x x x x

C01FIGURATION IB_JTICATION&

List the engines, by serial number, assigned to the program cate their allocation and configuration status and identify associated technical documentation, kit delivery schedules, tions, special tasks, and Apollo/SkTlab vehicle schedules. vides configuration and location information for GSE on the J-2 programs. 2, DA_Ab_LS

R-3620-1

R-_20-_
engineer to acquathe for R-3896-I R-3825-1

x
x x x x

x x

x x

x x

x x

Provide engine design and performance information to the stage and descriptive and operational information to the technician int him with the construction, configuration, and function of engine training and its components. discussions and Also handout provide material. the primary source

data

x x

X X

X X

X X

x Negotiation req'd for update ) X X

TRAINING DATA Training data, consisting of data available to students and customer (excluding data used to prepare and manage a course of instruction), provides information to familiarize personnel with particular aspects of engine and GSE design and operation. The data is generally considered supplementary to classroom activities.

(Sone)

(Am Required)

Table

6-1.

Support

Documentation

Summary
Program Application

(Sheet

8 of 8)
NASA Approval Resident By Stg CCN P_d.n NASA Cont As Reqd Other Formal Distribution Update Frequency

H
_4

Purpose

Report Form

/ No,

Contract H-1 F-1 J-2 Req't

Repre-ECP sentative

AC_REPORTS Provide an interchange of information betveen home-office functional

(_'onc)

Wkly

elements and field sites. and hardware status that and list accomplishments, 5. UCR/FAR SATUI_ _TGINE

The reports describe have occurred since the problems, and general STATUS and last REPORT of all period. open

changes in program last reporting period, schedule information. X X X

(_[on

qtly

Provide a been closed

description since

the

status report

UCRs

and

UURs

that

have

6.

FIELD m,o_.A_

m_co,m (r_)
method of recording be_een the and home transmitting office and field informasites.

(Nunbered
consccG _,-

X by

O_ I

Provide an authoritative tion for-record-purposes-only

tively program site, and

y, ar)
7. LOGISTICS INFORMA_ BULLETIN (LIB) Ex: LIB--71-3 X X

Disseminate skills-type information on technical subjects and subjects of general interest. LIBs supplement other technical documentation, however, LIBs are not the authority for making changes on any Rocketdyme product and do not supersede any existing field data sources.

SECTION SIGNIFICANT TIME

VII REQUIREMENTS

7.1

GENERAL. This section identifies and defines and the requirements and essential component GSE test Limitedsubassembly, synthetic rubber,

to the periodic

management and and

of limited-life retest,

hardware reinspection personnel any

materials, or skills servicing,

preinstallation tool and part, calibration, materials kit, loose that

equipment life hardware

and includes equipment, have time.

certification. assembly, such as

engine, material life and spare

component, ordnance, seconds, inspection, defined these or

compounds or

a service Periodic for 7. 11.7. 7-1.

sensitive preinstallation engine

to operational retest, are re-

cycles, and

elapsed

servicing

requirements 7.11.1 through in table

components

in paragraphs requirements is

Documentation

supporting

listed

7.2

LIMITED-LIFE

HARDWARE

AND

MATERIALS.

7.2.1

SYNTHETIC Materials

RUBBER subject Table 7-2

SUBJECT control the synthetic

TO AGE are made

CONTROL. primarily of the Except or assembly to age for from parts those manucontrol. the

to age

Buna-N and

compounds. made listed to the in the

identifies

specifications rubber. any 7-2 part is

assemblies

of or

containing

deviations factured

following

paragraph, listed in table

specifications

subject

GSE, fueling, composite age control. and launch, flat

or

other are

equipment not subject dust

not to age

required control. and

for

prelaunch Dielectric

servicing, materials, are excluded from

gasket

materials,

seals,

mountings

Material Teflon TFE, Teflon

manufactured FEP, Mylar, or

from KEL-F

silicone, are not

neoprene, subject

butyl, to age

viton, control.

7-1

Table 7-1.

References

Contractor Responsibilities for Use With NASA Contracts, Section XI (MSFC-STD-105A and Amendment No. 4) Age Control of Synthetic Rubber, R- 3950A Field Quality Assurance Manual, 578-D- 5 List of Time-Sensitive Items Report, R-8720 for Spares

MSFC Component Retest Requirements

Process Specification RA0115-122, Age Control and Marking for Synthetic Rubber Parts, and Assemblies Containing Synthetic Rubber Parts Process Specification RA0116-096, Package Marking for Customer Shipment

Rocketdyne Automated Packaging System (RAPS) Report Configuration Identification H-l, and R-5788 for J-2 Logistics Operating Manual, Section
R-11, J-515, Component Shelf Life

& Status Reports; R-5857 for F-l,

R-7392 for

Rocketdyne Operating Policies,

Quality Rocketdyne Technical series for Assurance Standards Manuals; if-2 Manual, Manual, R-3896 series

Section

for

F-l,

R-3620

for

H-l,

and

R-3825

Specification Packing, and

STOII6GA00020, Marking Requirements

O-Ring for

and

Other

Rubber

Items,

Packaging,

Shipment

7-2

Table 7-2.

Specifications

Parts

and

assemblies to the listed

made

of or

containing are

synthetic subject

rubber to age control:

conforming

specifications

MIL-P-5315 MIL- P- 5510 MIL-P-5516 MIL-R-6855, MIL-R-7362 MIL-P-25732 AMS 7260 AMS AMS AMS AMS 7270 7271 7272 7274 Class I

Hoses cations

and are

hose

assemblies to age MIL-H-

conforming control: 5593

to the

following

specifi-

subject

MIL- H- 6000 MIL-H-7061 MIL-H-7938 MIL-H-8788 MIL-H-8790 MIL-H-8794 MIL-H-8795

7-3

7.2.1.1

SHELF/INSTALLED

LIFE FOR SYNTHETIC RUBBER.

Synthetic

rubber material

may be stored for a maximum period of twelve (12) quarters

from the time of cure date. Assemblies with

have a maximum hydraulic The stored/installed control maximum rubber items I. systems time-sensitive life that synthetic of 40 quarters are exposed rubber except to RP-I life defined for material for for RP-1 in Engine those used

in RP-I time control Instructions

extended hydraulic Operating

periods. synthetic

acceptable is 32

installed quarters as

Manual

R-3896-1

7.2.

I. 2

REQUIREMENTS for Specification synthetic titled, and "Contractual XI).

FOR rubber

CONTROLLING to be controlled Rubber,

SYNTHETIC on Age NASA Control

RUBBER Programs of, Standard in are

ITEMS.

Requirements in MSFC For" the

"Synthetic contractually

(MSFC-STD-105A); document titled, section ,,establishes marking, operations entitled, Containing storage, hardware

implemented for Policy Use

at Rocketdyne With NASA

Responsibility Operating

Contracts"

(R-3950A, Shelf package internal Specifications and Assemblies Life

Rocketdyne organizational and life

titled for

"Component determining life, Rocketdyne

responsibilities of limited-life requirements and Rubber Marking Parts." for are

inspection limit

hardware. in Process Rubber

"Age

Control Synthetic

Synthetic

Goods

Requirements implemented Quality through Assurance On installed & Status 7.2.2 in flight Reports. REQUIREMENTS The recorded cumulative in the times engine Engine are F-I

for procedures

synthetic in the technical the

rubber Logistics manuals. dates are

control

within

Logistics Manual,

are Field

Operating

Manual, and stages J-2 and

and

engines, spare

of the in the

oldest

component

on

engines

engines

Configuration

Identification

FOR firing Log time Book for

OPERATIONAL (seconds), and maintained and cycle and

LIMITS component continuously. time.

OF

HARDWARE. cycling time are and limits

Separate Operational

recorded

firing 7-4

of hardware are listed in the engine operating manuals (R-3896-11 for F-l, R-3620-11 for H-l, limited R-3825-1B for J-2), and the actual operations that are life-

are on data forms in the Engine Log Book that accompanies each engine. review and monitor these items during

Field Operations personnel continually engine tests. 7.2.3 REQUIREMENTS

FOR CONTROLLING

COMPOUNDS. storage period from (Refer

Selected compounds are subject to a limited manufacturing date. If necessary, or recertified be tested for usability to R-3896-3 for F-l, usability

compounds exceeding their storage life may and the storage period extended. and R-3825-3 for J-2.) Determining

R-3620-3 for H-l,

of compounds before use may also be required

even though the item

has not exceeded its storage life, 7.2.4

if the compound appears unusable.

ENGINE ORDNANCE SERVICE LIFE. The service life established for each item of ordnance is controlled

in accordance with the engine technical manuals. System Start Sets/Ordnance is procured maximum storage life in support of launch schedules. surveillance, 7.3 and issuance is controlled similarly and delivered to provide Packaging, stock hardware. to other limited-life

PACKAGING Rocketdyne

AND Operating as

PRESERVING. Policy part is of the packaged requires Rocketdyne and preserved that a tabulation Automated of hardware Packaging with RAPS.

with System

life

limits (RAPS).

be

prepared A component

in accordance

7.4

REPORTS

FOR

TIME-SENSITIVE

ITEMS.

7.4. i

ROCKETDYNE The RAPS

AUTOMATED report parts. is an IBM Service

PACKAGING

SYSTEM

(RAPS)

REPORT. to

tab that contains life expiration

all the data needed

package

and preserve spares

data for packaging

labels

of selected

is also given. 7-5

The enable shipping Label

RAPS personnel all

report

and

manufacturing package, for data

record preserve, packaging

received and and

with identify

the part on the GFP denotes

to prepare,

Acceptance items assembly data. subject

required life. date,

information Age control

shipping Label

to limited expiration

on the Acceptance and component

date,

date

packaged,

identification

Engineering replacement Engineering inclusion on the prepares in the RAPS

establishes or in the forwards

the

requirement

for

synthetic and

rubber Systems Engineering for

drawing and

specification. age control data

Design

to Packaging

report.

7.4.2

LIST The

OF TIME-SENSITIVE LOTSI report (R-8720) Logistics The LOTSI synthetic service life for life,

ITEMS

(LOTSI)

REPORT. of limited-life hardware reports,

is a summary Maintenance report rubber, spares is used items requiring It also servicing. basis and the for and

listed bulletins, (limited

in technical

manuals,

Support

plans,

and log books. life) items

to identify subject

time-sensitive to operational desiccant that are

containing ordnance

seconds/cycles, inspection, subject the part and to retest, by part of cycle contains

periodic items report

storage

compounds. and periodic

identifies The start after and

reinspection, number, in quarters blank columns name,

identifies freThe

program,

of life

cycle,

quency report

or months, to record

disposition quantity

expiration. of spares.

location

Update organizations additions, required.

information

comes

from Data

all

Field

Engineering The report sheet

and is used

Logistics to request as

on a LOTSI changes,

Supplemental

Sheet. The

or deletions

to the report.

is updated

7-6

7.5

REPORTING

LIMITED-

LIFE

DATA.

7.5.1

DOCUMENTING The FORR data

AND package

REPORTING include to the

LIMITED-UFE requirements for

DATA. verifying and

recording

information

pertaining

maintenance

of Engine

Log Books.

The are sites titled, data completed report "Age transmittal Park

Log Book and distributed for

Data

Transmittal after tasks for

Sheets each control

in the FORR

FORR are

data

package Field sheet of the

completed. transmittal " A copy

changes Control sheet for

items

subject Component

to age

by a data Items.

Log for

Synthetic

Rubber FORR

is attached

to the copy

of the

returned Identification

to Services & Status

at Canoga Reports.

inclusion

in applicable

Configuration

Milestone assembly date during

FORR receiving

Inspection and

Checklists shipment and

record VAB

the

oldest

component

rollout.

Distribution Engine Operation Log Books

of FORRs

to site with "

personnel LOM

responsible titled,

for

maintaining

is in accordance & Record.

Instructions

"Field

Requirement

7.5.2

LAUNCH

STATUS

REPORTING. program management engine data at MSFC is being reviews for limitedflight. the all results

Rocketdyne/NASA life hardware at the Certification Final tests, the same time

other

analyzed to document

An Engine of this EFIRs, completed,

of Flight signoff and engine(s)

Worthiness certificate have considered been

is prepared is done resolved

review. UCRs, and

of the

at KSC when and/or for

ECPs,

checkouts are

successfully flight.

to be acceptable

Engine FRR. are Items reported subject

documentation to limited-life and at FRR.

is reviewed requirements

approximately are assessed

two weeks and the

before results

by letter

7-7

7.5.3

DOCUMENTING AND REPORTING WAIVERS AND DEVIATIONS. Limited-life requirements, waived while engines are in storage, Waivers and deviations

require program

management approval for the deviation.

are documented in the Engine Log Books. The Test Specification stage contractor, Rocketdyne, criteria and Criteria (TSC) document, prepared by the

is changed and approved for new component cycle life limits. implement specification
for

Canoga Park, has the stage contractor

and

changes and obtain NASA agreement.

in the TSC document before

A waiver is submitted
launch.

changes

not incorporated

Waivers exceeded at the time

and

deviations are

for

limited-life for

requirements consideration

that at FRR.

will

be

of launch

submitted

7.6

CHANGES The approved

TO

LIMITED-LIFE limited-life

REQUIREMENTS. requirements listed in Engine Log Books

are

changed

by an ECP.

: Data Form

The from

RAPS

report

is changed Project

by a RAPS Office

Supplemental

Packaging Engineering.

the Engineering

to Packaging

Technical changed servicing by an approved requirements

manual ECP, are

requirements specification, changed

for

limited-life

hardware change. Retest direction.

are and

or drawing

by program

management

The Manual control are and

Logistics

Operating

Manual to provide

and the operational

Field

Quality instructions

Assurance for the changes,

changed

as necessary

implementation management F-1 and J-2 the oldest is received

of the above directives. engine

changes,

contract

requirement

and program

Configuration assembly

Identification date when in the oldest

& Status a Log

Reports Data

are

changed

to show Sheet

component showing

Book

Transmittal subject

a change

component

or part

to age

control. 7-8

7.7

C_E

REQUIREMENTS.

7.7.1

GSE

HARDWARE (referenced

EXCLUDED

FROM

UMITED-UFE 7.2.1.2) the states: actual flight servicing,

CONTROL. "Only those and

R-3950A items, components, service which a part

in paragraph comprising

and assemblies equipment require of this to prelaunch is not required. essential age

vehicle, fueling,

the ground and launching, be considered V) is not of synthetic

to the pre-launch as determined All Rocketdyne fueling, and

control

by Engineering, delivered launching GSE and

shall (section age control

standard." servicing,

essential parts

Rocketdyne-delivered proof load, and pressure test

GSE

is controlled,

however,

by calibration, manuals.

requirements

in Rocketdyne

technical

7.7.2

GSE,

TEST

EQUIPMENT, Field Quality GSE, test

AND TOOL Assurance equipment, Periodic manuals.

CALIBRATION maintain

INTERVALS. and monitor

Rocketdyne calibration custody instructions ments custody contractor, are that records require are for

personnel and tools

all

in Rocketdyne requirement requirein the the stage

periodic

calibration.

calibration These test

outlined

in the technical

calibration equipment assist

applicable stage

to Rocketdyne contractor.

delivered Field

GSE and

of the

Operations with the

personnel calibration

as required,

in complying

requirements.

7.8

through

7.8.2

(Deleted)

7-9

7.9

ENGINE

REQUIREMENTS.

7.9.1

ACCEPTANCE The Engine

DATA Log Book document for

REQUIREMENTS. identifies for all age-controlled the operational limited-life of the items on the It

engine has from package the

and is the official log sheets through

recording and

status. hardware

individual acceptance and

recording The delivery

controlling is part

launch. after

log book

acceptance custody

data of

is maintained

by the contractor

having

engine.

For on the package record. Shipping markings data entered in the The

components and an age has

containing control log

synthetic sheet are

rubber, included

an acceptance as part of the

label acceptance

log

sheet

the information that with component drawing

required

by the process identification specifications. data package

specification. and The and When

inspection are

verified

and packaging and packaging to the FORR

in accordance on the log Engine sheet

is transferred when Test the item Record

entered specified shipped

Log Book Component

is installed data is sent

on an engine. with components

by contract, to GFP

warehouses.

7.9.2

(Deleted)

7.9.3

ENGINE A new

AGE date tag

CONTROL is attached

DATE

TAG. whenever for the with replacing engine. the a component A marking

to the engine date

or part machine "Oldest date.

changes is used

the

oldest

assembly/installation mark a strip

to impression

of aluminum oldest

words

Assembly/IustaUation" The strip is attached

followed

by the

assembly/installation strut where it is readily visible.

to an accessible

mount

7-10

7.9.4

ENGINE Field

STORAGE Operations

REQUIREMENTS. personnel any date identify, item from established before on the storage is the spare that launch. in or will Any

installed expire deviation accordance

engines before to the with the

are

stored,

controlled for removal date

engine or

scheduled scheduled paragraph

replacement 7.5.3.

reported

7.10

SPARES

REQUIREMENTS.

7.10.1

PROCURING Limited-life

SPARES. spares with are procured to support projected program

requirements Plans.

in accordance

Spares

Hardware

Provisioning

New the inventory rates, are and

configuration replenished,based the available

spares

are on the

procured lead time,

or

spares item

removed usage,

from

condem-

nation

assets.

The and components by

maximummaintained frequency

minimum at of use. the field

stock site

levels for

for

limited-

life items

assemblies are

limited-life

established

The on the blies anticipated and

maximum-minimum random replacement

stock rate

levels and

for planned

O-ring/packing servicing

are of assem-

based

components.

Limited-life compatible configuration.

hardware

is

replaced

with

hardware

of the

latest

Spares latest are compatible to be overhauled.

that

have

exceeded are

their placed

service in dormant

life

and storage

are

not

to the they

configuration

unless

7-11

7.10.2

WAREHOUSING

SPARES.

7.10.2.1 inventory monitored. shelf/installed the item records date, and

STOCK of GFP

CONTROL warehouses, stock (synthetic part number,

RECORDS. except record rubber) and cure files

All

time-sensitive storage

items facilities,

in the are subject to a identify The

at dormant are

Separate life

maintained compounds. when

for

items The

and for serial

records

by name, reflect

number

applicable.

the quantity,

date, dates.

assembly/installation

or manufacturing

expiration

and reorder

A file and index etc, and a two-year tab. for The which

for

shelf/installed before expiration review is required. years of life

life

items date, the

is established under the

for

a six-month monthly parts, assemblies requirespare.

review

applicable

six-month a reorder with two

identifies The

assemblies, review

components, analyzes program

two-year

components The item

remaining

to determine

ments.

may

be retained

in stock

or overhauled

to a serviceable

The item.

records

are

set

up by expiration

date

to permit

use

of the

oldest

7.10.2.2 an engine

EXTENSION are periodically of the data,

OF

SERVICE

LIFE.

Synthetic

rubber

items

used

within

evaluated life data,

by Rocketdyne is possible. hardware life The

and NASA/MSFC evaluation may

to determine be based etc. on

if an extension previous evaluation Operating test

service

storage an extension Manuals

disassembly can be made, the

analysis,

If the and the

shows

of service are changed

the contract new requirements.

Instruction

to reflect

When FIR from to update removing life. released, Saturn records items

an extension Operations. and hardware from the

is approved, The

the

field

locations

are

notified

by a

FIR authorizes the new are

Spares expiration

and Quality date the

Assurance

to show that

and to prevent service and when

inventory are

approaching the new

end of their

Control

procedures

changed

to include

requirements,

supersede

the letter

of authorization.

7-12

7.10.2.3

ISSUING TIME-SENSITIVE

ITEMS.

Materials

and assemblies,

approaching the end of their service life are issued first if enough service life remains to support engine mission objectives. Assemblies, components, and

parts subject to age control and issued for use on an engine must not be older than the oldest component on the engine except when launch schedules indicate the hardware will be expended before the installed life of limited-life expires, or when directed by NASA/Rocketdyne checkout, and launch. synthetic rubber material with less than four (4) program management. parts Items

having a limited-cycle subsequent testing,

life must have enough cycle life remaining

to support

Limited-life

quarters is not shipped from Canoga to field sites unless needed immediately. 7.10.2.4 DISPOSITIONING ITEMS EXCEEDING STORAGE LIMITS. exceeding the storage life limits Compo-

nents and assemblies

established for the item

are removed and condition-tagged.

Low cost items are condemned locally. are condition-tagged and placed

Components and assemblies coded unserviceable in stock at the field site pending disposition. 7.10.2.5 7.10.3 (Deleted) SHIPMENT AND TRANSSHIPMENT Serviceable preserved spares transshipped

OF GFP SPARES.

from site to site are packaged and in the RAPS report and the Field

in accordance with the requirement

Quality Assurance Manual. Each unit and intermediate

age control data. Date marking for

container any of the

shipped following

or transshipped categories

bears

is applied

to the intermediate

and unit

containers.

a. dates are marked

Containers with the

with earliest

multiples date

of identical only.

parts

bearing

different

7-13

b.
materials, show

Containers no date.

with

mixed

parts,

other

than

kits

and

sensitized

c. marked with the

Kit

containers date

with only.

mixed

parts

bearing

different

dates

are

earliest

d. shown on each

When kit

packing

two is the

or more earliest

identical dated part

kits,

the

age

control

date

container

in the

shipment.

Log sheets, company parts,

Component

Test

Records,

and

condition

tags

ac-

as applicable.

Reparable analysis Quality date useful for are packaged

limited-life and preserved The entered

items

returned

to Canoga with cycling tag.

Park

for

failure Field

in accordance engine firing, condition item must

RAPS time,

and the and

Assurance age control

Manual. are

expiration is

on the extent the

(This

information )

in determining

to what

be refurbished.

The control dates for

DD Form limited-life

1149

or MSFC

Form

57 shipping

document

shows

age

items.

7.11

HARDWARE

RETEST,

REINSPECTION,

AND

SERVICING.

7.11.1

PERIODIC To increase

RETEST. confidence replacement are periods before before in the reliability of engine are systems, certain

flight

configuration These to extended a specified that

engine

components retested

function-tested any malfunction integrity of the A list from spare of engine an and technical

periodically. attributed within

components storage period retest

to detect the

and to verify installation installation failure are history. outlined

time require

on an engine. was prepared The

components engineering retest manuals. periods

evaluation established

of component

components engine

by Rocketdyne

in the

7-14

7.11.2

PREINSTALLATION Certain flight

RETEST/REINSPECTION. configuration are engine considered checkout. replacement to These have components a failure mode are listed that checked may out

in the not be

engine detected

technical by

manuals interval

a fixed

components

before

installation.

Parts inspection system verifies degradation.

are that

also there

visually are no

inspected contaminants

before or

installation. damage that

The will cause

7.11.3

SERVICING. Lubrication, preservation, are required is is and at required maintained humidity established to prevent indication intervals. engine checks for

certain maintenance dation

engine

components of these

Periodic system degra-

components sure the engine

and

to

make

in a serviceable

condition.

7. II.

DOCUMENTING A FORR is prepared periodic for recording more

REINSPECTION in accordance reinspection, one item for

AND with or it includes

RETEST LOM servicing the

TASKS. Instructions task. requirements for If the for of each a

preinstallation FORR identifying spare. is prepared and

or

retest, than

essential

data

subsequent

traceability

Procedures level cleanness is

used maintained.

for

visual Repackaging

inspection is

or

testing

ensure with

that the

system RAPS.

in accordance

The is completed and tasks.

Log

Book

Data

Transmittal each FORR

Sheets is

within completed

the for

FORR

data

package

distributed

after

hardware

servicing

A Servicable and attached to items that

Condition are retested

Tag

showing and

next

retest

due

date

is

prepared

returned

to inventory.

7-15

7.11.5

DOCUMENTING Suspension

AND

REPORTING

WAIVERS

AND

DEVIATIONS. while for the in

of lubrication will approved require for

and preservation program servicing management deviations

requirements approval will

engines deviation. the

are

in storage Waivers Log Book.

be documented

Engine

Servicing are submitted for

requirements

that at the

will Flight

be exceeded Readiness

at the Review

time (FRR).

of launch

consideration

7.11.6

WAREHOUSING

OF

SPARES.

7.11.6.1 tained for

STOCK each

CONTROL

RECORDS. inventory identify applicable.

Stock of GFP the The

control

records that by part also

are are

mainsubject

component The number retest date.

in the records when

warehouse

to a periodic name, tested and

retest. serial

component records

number, the date

include

and next

The tion retest for are reviewed and retest

records

for

components

requiring The

periodic component

retest with stock

and

reinspec-

and dispositioned date is

monthly. removed from with

an expired recycled manuals.

reinspection and reinspection

serviceable Rocketdyne

and

in accordance

technical

7.11.6.2 Operations sensitive Surveillance shelf life

FIE LD QUALITY Quality hardware of items packaging Assurance to verify

ASSURANCE conducts that

SURVEILLANCE. a monthly surveillance dates a reinspection etc. are

Field

Site

on timenot exceeded. for

retest/servicing also includes

in storage desiccant,

of spares

deterioration,

7.11.7

LOG BOOK Engine Log

MAINTENANCE Book entries are

AND REVIEW. reviewed the with each receiving of time inspec-

tion engine

and before hardware.

shipment

or launch

to determine

status

sensitive

7-16

The official

Engine Log Book is maintained by the stage contractor. log book is maintained by Field Site Operations

A duplicate copy of the official personnel. 7.12

PERSONNEL Rocketdyne

SKILLS assigns

CERTIFICATION. technical tasks personnel necessary in the to field to satisfy following intervals. sites who are and skills

certified NASA must

to perform requirements.

specialized Personnel

Rocketdyne specialized

certified

be re-certified

at the following

maximum

a. b. c. d. e. f. g. h.

Manual Stylus Solderer Soldering In-place

Brazing - Nickel Plating

6 mo 6 mo 6 mo

Inspection Tube Welding Inspection

6 mo 6 mo 12 mo 6 mo

Dye-Penetrant Stud Welding

Resistance

Welding

6 mo

The responsible He monitors ing and certified for

Field the

Manager status

or Resident for

Representative personnel arranges personnel tasks.

at a field under his

site

is

of certification due

control. retrain-

personnel

certification and for requests specific

dates,

for personnel with special

re-certification, skills necessary

additional maintenance

7-17

SECTION VIII STORAGE

8.1

GENERAL. Rocketdyne delivered products condition storage that when are not correctly to various have with material been conditioned can

deteriorate conditions and ments

beyond in storage.

a serviceable Therefore,

exposed

environmental established storage require-

requirements Complying spares, The and

implemented permits the

by NASA Saturn

and Rocketdyne. engines, GSE, limits. for

these

placed for hardware

in storage

to be maintained preparation materials ments and and are all

within inspection

serviceable control

requirements delivered VI.

storage and require-

Rocketdyne in section

defined changes are

in documents resulting complied from with.

listed

These storage

storage studies

current

engineering

(paragraph

8.3.2)

8.2

STAGE-INSTALLED The facility, for 8-1

ENGINE

STORAGE. equipment, and inspection engines are requirements, in the documents storage storage are

environment, long-term storage

and the procedures listed inspected environment requirements. Books is reviewed limits while the by the requiring the current in tables

of installed engines corrosion with current

and 8-2. intervals

Stage-installed to make sure

in long-term control

at 30-day are

and the

maintained The engine periodically. (section stage stage

in accordance component Engine the

technical data exceed

manual in the the Engine synthetic will from that be storage, have Log

synthetic

soft-good that are stage engines

components stage/engines or after F-1 the

soft-goods replaced as

VII) while is in storage, contractor.

in storage is removed in storage are handled

scheduled

and H-1

components ance with

periodic technical

servicing manual

and preservation procedures.

in accord-

8-1

Table 8-1.

Rocketdyne Storage Requirements

Document R-3896-11 R-3620-II No. F-1 Engine Manual H-1 Engine Manual 3-2 Engine Manual 3-2 Engine Manual F-1 and

Documents
Title Operating Operating Operating Instructions Instructions Instructions

Item

S-IC Stage/Installed F-1 Engine S-IB Stage/Installed H-1 Engine S-II Stage/Installed J-2 Engine S-IVB Stage/Installed 3-2 Engine F-1 H-1 J-2 GSE GSE GSE

R-3825-1B R-3825-1B

Operating

Instructions

R-3896-5 R-3620-3

Engine GSE Maintenance Operations Manual and

H-1 Engine Maintenance Repair Manual 5-2 Engine and Repair GSE Maintenance Manual

R-3825-5

Table

8-2.

NASA/Stage

Contractor

Storage

Requirements

Documents

Item

NASA/Contractor MSFC

Document

No. S-IC Plan

Title Stage Storage for FTC Extended Storage

S-IC Stage/ F- 1 Engine S-IC Stage/ F-1 Engine S-IB Stage/ H-1 Engine S-II Stage/ J-2 Engine S-II Stage/ J-2 Engine

MSFC-STD-500A

MSFC

66B10932

S-IC Stage Storage S-IB Stage

MSFC

MSFC-STD-499A

MSFC

MSFC-STD-498A

S-II

Stage

Storage

SD-NR

SD70-555

S-II Stage KSC Storage Plan, Stages S-II-12, -13, -14, and -15 S-IVB Stage Storage Plan for FTC Spare F-1 Engine Storage Requirements

S-IVB Stage/
3-2 Engine Spare F-1 Engine

MDAC

GO-142

MSFC

66BI0934

8-2

8.3

SINGLE

ENGINE

STORAGE.

8.3.1

FLIGHT F-1

SPARE

EN(HNE

STORAGE. as flight are stored spare at KSC. engines Before and are EFIRs for Saturn engine

and H-1

engines J-2

designated engines

vehicles is placed

are

stored

at MAF; it has condition. the

each

in storage

latest While

approved in storage, so minimum When are

modifications the engines

and is in

in a "ready-state" a relatively the engines

maintained to ready

moisture-free for use storage, manuals level.

condition stage.

effort are

is necessary placed

in a flight desiccants

engines

in short-term in the applicable

or long-term technical humidity

inspected engine as flight has

as indicated not exceeded engines

to ensure Engines

that

the

a 30 percent are as follows:

designated

spare

F-1 _-2049 F-2090 (a) (a)

H-1 H-4108 H-4109 H-7112 H-7113

J-2 3-2107 J-2146

8.3.2

ENGINE The

EVALUATION Saturn

AND VERIFICATION engines of engines are designated exposure The

STORAGE. to be used to assess storage engines H-5041 with is the

following

reliability conditions. the exception

and flight The F-1

worthiness engines engine are

after at MAF.

to long-term H-1 H-1 and J-2

stored are

of H-1

H-5041

stored

at KSC.

engine

stored

at MSFC.

F-1

H-1

J-2

-2023
F-2036 (a)

-4081( )
H-4107 H-5041 H-7097 (a) (b) (a)

J-2--039-1
3-2103 J-2148

(a) (b)

Stored Aging

with study

vehicle. engine.

8-3

These engines are conditioned for long-term the requirements Support Program Plan for the Apollo/Soyuz Test Project

storage to evaluate and Flight R-8300, Task A3600.

outlined in Saturn Engines Contract Operational

Certain engines have been selected to be stored with their flight stages and will be exposed to the same storage conditions as the stage. corrosion control inspection are made at 30-day intervals, engines. stage-installed Desiccant and concurrent with

Engines not stored with flight stages have been constorage under environmental protective protective covers. cover desiccants are inspected at

ditioned and placed in long-term The single engine environmental 30-day intervals. 8.3.3

UNASSIGNED ENGINE STORAGE. Unassigned engines are placed in long-term storage in their present

configuration Identification

with outstanding ECPs and EFIRs noted in the Configuration & Status Reports. The desiccant is inspected at 30-day intervals for H-1 engines. These engines and use at a future are accomplished as

for F-1 and J-2 engines, and 7-day intervals are reviewed periodically date. EFIRs are incorporated required. 8.3.4

by NASA for possible modification and general servicing requirements

When engines are removed from storage,

all outstanding ECPs and

ENGINE REMOVAL FROM STORAGE. Engines removed from short-term or long-term storage are

inspected,

checked out (unless otherwise directed by NASA), and prepared into a flight stage. An engine removed from storage for modififor corrosion control before being is reconditioned

for installation

cation and/or servicing returned to storage. the servicing,

When engines are removed from storage for any purpose,

soft goods, and cycle life records are reviewed to determine that requirements and a stress corrosion

the engine systems meet all serviceable inspection is performed.

8-4

8.4

GROUND GSE

SUPPORT

EQUIPMENT placed in storage Warehouse. it is

STORAGE. at various When conditioned field an item and such category (For sites supporting is placed one short-

is currently and

the

Saturn

Programs at a NASA categories

at the

EFL

of GSE stored

in storage of three term,

designated

location, as defined in storage manual refer

under

of storage, GSE placed the technical

by Rocketdyne, under each

as active,

or long-term. with

is maintained pertaining

in accordance to GSE location,

requirements. to the applicable

information Configuration

type, & Status

and quantity, Report. )

Identification

8.4.1

ACTIVE GSE

GSE STORAGE. in a serviceable is periodically established located and condition calibrated, approved sites. for and can be used without and GSE stored

is maintained equipment

qualification. inspected under this

This

proof-loaded, the item.

at time-intervals category is usually

at the field

8.4.2

SHORT-TERM Serviceable

GSE GSE that

STORAGE. is used occasionally The may be placed calibration, in shortproof-

term loading,

storage and

for

a maximum

of two years. may

periodic

servicing conditions

requirements are met:

be waived

by NASA

and Rocketdyne

if the following

a. placed mental established maintain the in storage controls for

The

item

receives

the

minimum correct

servicing packaging date repackaging

necessary and years

when environis and

to prevent are maintained;

deterioration; and

an expiration and

of two

reinspecting, state.

reservicing,

to verify

servicable

b. technical manual

Calibration requirements

and proof-loading before use.

is done

in accordance

with

the

8-5

8.4.3

LONG-TERM

GSE STORAGE. storage if a reactivation or if the scheduled storage period exceeds two packaging, and the environment with a minimum of the storage of inspection

Inactive GSE is conditioned for long-term date has not been established years. Servicing,

preservation,

area must be adequate to prevent deterioration surveillance. inspection. GSE removed from long-term All calibration, proof-loading,

storage must receive a complete and servicing must be done in

accordance with technical manual requirements. 8.5

SPARE Spare with They requirement are controlled (NASPR) and COMPONENT engine and STORAGE. are packaged for storage in accordance System.

GSE parts in the

documented during appendix shipment

Rocketdyne by requirements

Automated

Packaging Procurement

storage B.

in NASA for

Regulation from stored Susana storage,

Spares the

are Spares Engine

selected system ordnance

storage, II).

removal They at Santa are

through

(section

in warehouses Field Laboratory.

at KSC and

EFL.

is stored

During performed VII and for certain

storage, spares

periodic

retesting

and with

desiccant

surveillance

are

in accordance FORRs.

the

requirements

in section

as directed

in approved

When flight that engine enough

a spare

component cycle on the life

is removed and soft

from goods life use,

storage are the

for

use

on a to verify are and

the remaining life remains

reviewed components

component. if the

Before

visually

inspected

to determine If the component

component

is free

of contamination verification technical removed

is serviceable. functional before storage the test, installation is rejected

requires

a preinstallation in the engine component

the

testing on the for

is done engine.

as outlined If an engine

manual from component, GFP

failure

to pass

inspection

as a serviceable as failed

component

is immediately

dispositioned

and handled

hardware.

8-6

8.6

EFL

WAREHOUSE GSE, for

AND tooling,

INVENTORY special test

CONTROL. equipment, are sent and provisioned to the EFL from as to H-l, hard-

Engines, spare parts not for

required long-term are

the Saturn

program Items

warehouse Rocketdyne appropriate, contract and ware records are J-2

dormant preserved,

storage. packaged, items

sent

to EFL

facilities before needs engines; declared indicate by

boxed, are classified

or palletized as excess of the F-l, spare

shipment.

These

as a result (2) contract excess the Logistics for

of: (1)

contract

termination

cancellations; to program

or (3) provisioned forecasts. and Accountable quantity of this

being that

inventory hardware consideration programs. intervals All Regulation, hard-

condition, Warehouse possible

status,

maintained this

personnel. in current are

Continuous or forecasted inspected free

is given The

hardware and major the

use desiccants

engine

assembly

at 30-day

to ensure ware

that

hardware

remains

relatively with NASA

of moisture.

at EFL B.

is stored

in accordance

Procurement

appendix

8-7

8.7

MATERIAL

STORAGE.

8.7.1

COMPOUND The shelf-life provide

STORAGE. requirements the warranty placed of compounds limits for the (RTV, storage Thermolite of compounds. can than used tests its be shelf12, A

Eccobond, compound, removed life limits

etc)

however, from storage

in a controlled over have a longer been

storage period devised at field

environment of time and sites. are The

and used Simple tests

indicate.

to determine are sites is and examined immediate for use in the

the usability engine where done technical

of age-controlled manuals. are stored

compounds Quality ensure Assurance that in the storage from

personnel storage technical containers

at the field and testing

compounds in accordance

compound engine and

with

procedures The

manuals are if the

supporting when the

documentation. compound had

area storage

is removed an effect test on its criteria

to determine Accepting however,

environment under to the

usability. does not,

a compound recertify the

the usability original

compound compounds, be returned

specification

standards. Quality

Recertification Representative,

of certain must

as deemed to Rocketdyne

necessary for

by the local analysis and

recertification.

8.7.2

RAW Raw

MATERIAL materials are stored

STORAGE. (paints, lubricants, with are fluids, the gasket vendor material, and/or at the field etc)

used

at field

sites

in accordance When materials

NASA/ site, are

Rocketdyne they noted are

requirements. inspected that and and the the

received storage

vendor/manufacturer's is stored A periodic of engine, under audit GSE,

requirements storage that hardware all

to ensure

material

the

prescribed to ensure

environment raw stored materials

conditions. in support with

is made and

used

component

are

in accordance

specified

requirements.

8-8

SECTION IX FACILITIES AND INSTITUTIONAL SERVICES

This section deleted.

9-1

APPENDIX AUTHORIZED ENGINE

A REPAIR AT KSC

Unscheduled and decision

maintenance consists and limited

(engine of removing in-place engine

repair) and repair.

permitted replacing

without or removing

engineering

evaluation

and reinstalling components are repair imposed permitted is specified and on for

components parts can

Replacement and level

of certain restrictions

adversely these

affect

performance The

replacing H-1 for

components

and parts. in tables are

of engine

and J-2 F-1

engines

is specified the engines

A-1

and A-2.

No repair

engines,

since

dormant

and in storage.

Maintenance

codes

denoting

repair

limits

in repair

tables

are

as follows:

Maintenance RR Remove Engine and Replace. calibration and

Codes (With a like serviceable are not affected. item. )

alinement

RI

Remove

and Reinstall. could )

(The

same if the

item. same

Engine item is

performance not reinstalled.

be affected

A-1

Table

A-1.

H-1

Engine

Repair Engine Repair KSC

(Sheet

1 of 5)

Nomenclature

Remarks

ENGINE . . . . .

ASSEMBLY installation

RR

Propellant feed system . . . . . . Turbopump . . . . . Oxidizer Fuel assembly inducer

RI(a) RR RR RI(a) RI(a) RR Seal and mating ring must be replaced aS a unit. Seal and mating ring must be replaced as a unit. Seal and mating ring must be replaced as a unit. Seal and mating ring must be replaced as a unit.

inducer impeller

Oxidizer Fuel

impeller

Oxidizer shaft seal

Fuel

shat_

seal

RR

Oxidizer sh_t

seal mating ring

RR

Fuel

shaft

seal

mating

ring

RR

. .... . .

. .

. .

Fuel

inlet

adapter inlet inlet adapter liner

RR RR RR RR RI(a)

Oxidizer Oxidizer

. . .

. . .

Heater Turbine Magnetic

harness

pickup

RR

(a) Replacement

requires hot-fire retest of engine assembly. A-2

Table

A-I.

H-1

Engine

Repair Engine Repair KSC RR

(Sheet

2 of

5)

Nomenclature

Remarks

. o .

. . .

Lube Lube Gear No. Lube

filter drain nozzles 1 bearing restrictor nozzle body relief valve

RR RR RR RR Replacement flow calibrated installation. item must before be

. . . o . . .

. o . . . . . o . . .

. .

No.

1 bearingthermocouple harness mount

RR RR RR RR RR RR RR

Thermocouple forward valve

Turbopump Main oxidizer

Oxidizer Igniter Main

valve

heater

fuel valve fuel valve Joint (LOX duct)

Oxidizer Fuel Main Main duct fuel LOX

RR RR

orifice orifice valve

RR (b) RR_) RR

Unitized

check

(b)

Must

be replaced

with

a calibrated,

like

item

A-3

Table A- i H- 1 Engine

Repair Engine Repair KSC

(Sheet

3 of 5)

Nomenclature

Remarks

Gas generator installation . . . . . . Gas Gas Gas Fuel Fuel Fuel generator generator generator bootstrap

and

controls

. . . . . . .

control injector combustor line orifice seal line orifice line

valve

RI (a) Ri(a) RI (a) RR

bootstrap bootstrap

plate plate

RR (b) RR RR_)

LOX bootstrap LOX bootstrap Engine control disconnect Ignition Thrust Hypergol monitor

plate

RR(b) RR

quick-

. . . .

valve switch switch (other than

RR RR RR

OK pressure detector

Lines and manifolds LOX bootstrap line) Quick-disconnect

coupling

RR

(a) (b)

Replacement requires Must be replaced with

hot-fire retest of engine a calibrated, like item

assembly.

A-4

Table

A-1.

H-1

Engine

Repair

(Sheet

4 of 5)

Nomenclature

Engine Repair KSC system

Remarks

Pneumatic installation

and lube

Check valves (gearcase pressurizing, GG LOX injector purge, thrust chamber fuel injector purge) . Gearcase fitting pressurizing cross

RR

RR

Replacement item must be flow checked before installatiom Replacement flow checked installation. item must before be

LOX seal fitting

cavity

purge

orifice

RR

Fuel additive (FABU) FABU

blender

Unit

RR

. .

heater assembly

RR RR RR

Lines and manifold Quick-disconnect coupling

Thrust chamber installation . . Thrust .

and gimbal

chamber

assembly body

RI(a) (c)
Field repair limited to minor tube brazing on the engine. Field repair limited to minor welding on the engine. RR

Thrust

chamber

Aspirator

(H-1D)

Exhaust

duct

(H-1C) injector

Thrust LOX

chamber dome

(c) (c)

(a) (c)

Replacement Removal and

requires hot-fire retest of engine assembly reinstallation requires hot-fire retest of engine A-5

Table A-1.

H-1

Engine

Repair

(Sheet

5 of 5)

Engine
Nomenclature Repair KSC Remarks

. .

. .

. .

Turbopump Turnbuckle (H-lC)

support assembly

fittings

RR RR Length of replacement item muSt be same as original length recorded in Engine Log Book.

. . . .

. .

Stabilizing

lug (H- 1C)

RR RR

Gimbal

assembly installation

Turbine . . .

exhaust System

Exhaust hood Heat exchanger Heat exchanger system harness LOX supply llne

RR RR RR

Electrical . Engine

installation assembly seals (Naflex, RR RR Return replaced item to Rocketdyne, Canoga Park for inspection and repair.

Pressure-actuated all systems)

A-6

Table A-2.

J-2 Engine Repair (Sheet 1 of II)

Engine Repair KSC

Nomenclature

Remarks

E NG1NE Control .

ASSE MB LY system installation solenoid adapter

RR

STDV control assembly Electrical Ignition-dummy Electrical ASI spark assembly

RR assembly detector RR RR RR Replacement part injector assembly and RR control manifold RR control RR of ASI

. . . .

control

harness igniter

assembly and cable

Gas generator cable assembly Bleed valve assembly

spark

igniter

Gas generator opening manifold assembly Ignition assembly control manifold

RR purge manifold RR control manifold RR manifold RR probe assembly RR RR

LOX dome assembly Mainstage assembly

OTBV control assembly Ignition Helium detector regulator

. .

. .

assembly

A-7

Table A-2.

J-2 Engine Repair (Sheet 2 of Ii)

Engine Repair KSC valve RR

Nomenclature

Remarks

3-way helium assembly . 3-way valve 4-way valve . 4-way valve helium assembly ignition assembly mainstage assembly

control

vent

control RR

phase

control RR

control RR relief valve RR

High pressure assembly

Main regulator exhaust check valve assembly . Vent port assembly Helium Helium check valve

RR

RR tank vent valve valve filter filter RR RR

. .

control

Low temperature valve Mainstage OK switch purge

relief RR assembly check RR purge valve RR shutoff valve RR RR

Oxidizer dome valve assembly Pressure-actuated assembly Pressure-actuated assembly 4-way STDV assembly

control

valve RR

A-8

Table A-2.

J-2 Engine Repair (Sheet 3 of 11)

Engine Repair KSC

Nomenclature

Remarks

Customer . . . Bracket Electrical Fluid

connect assembly

installation RR assembly assembly check valve RR check valve RR RR RR

harness hose purge

lines

Fuel jacket assembly Engine purge assembly

Gas generator installation . Fuel turbine assembly

and exhaust

system

exhaust

duct RR

Temperature transducer (turbine outlet)

RR

. .

. .

Heat exchanger turbine exhaust Oxidizer assembly turbine

oxidizer bypass valve

Ri(a ) RR If replaced, orifice nozzle must be removed and installed in replacement unit.

. .

Variable

resistor relief valve

RR

Low temperature assembly

RR installation

. (a)

Instrumentation . Electrical

harness requires approval

assembly Rocketdyne

RR engineering evaluation and decision and

Replacement NASA EPO

A-9

Table A-2.

J-2

Engine

Repair Engine Repair KSC

(Sheet

4 of 11)

Nomenclature

Remarks

Auxiliary package .

flight instrumentation assembly transducers

RR RR

. .

. .

Pressure

Primary package .

flight instrumentation assembly transducers

RR RR

. . . . . .

Pressure equipment shaft feed heat

Loose . Quill

RR system exchanger installation inlet line RR

%

Propellant . . Helium

Oxidizer bleed valve strap line assembly Fuel inlet assembly low pressure

and bootRI (a) duct RR thrust assembly Replacement calibration. requires flow

Fuel high pressure chamber inlet duct Fuel high discharge Oxidizer assembly Oxidizer chamber Oxidizer discharge

RR

pressure turbopump duct assembly inlet low pressure duct

RR

RR high inlet pressure thrust duct assembly turbopump RR Replacement requires flow calibration.

RR

high pressure duct assembly

(a)

Replacement NASA EPO

requires approval.

Rocketdyne

engineering

evaluation

and decision

and

A- 10

Table

A-2.

J-2

Engine

Repair

(Sheet

5 of

11)

Engine
Nomenclature Repair KSC RR Remarks

Fuel

flowmeter

Replacement calibrated Replacement calibrated

to be flow with duct assembly to be flow with duct assembly

Oxidizer

flowmeter

RR

. . . .

Fuel

flow

straightener flow straightener hose assembly line

RR RR RR

Oxidizer Fuel

bootstrap

Oxidizer assembly

bootstrap

RI (a) exchanger inlet RR assembly assembly mount RR pressure duct assembly tie-rod RR RI(a) Field repair limited to onthe- engine removal and replacement of subassemblies and parts. RR RR

Oxidizer heat line assembly Lower Fuel fuel

. . .

ASI line line

turbopump

Oxidizer assembly Fuel Fuel high

turbopump

. .

turbopump

. . .

. . .

Rotor Turbine

stud torque plate turbine wheel

RI RR

Second-stage assembly

RI

(a)

Replacement NASA EPO

requires approval.

Rocketdyne

engineering

evaluation

and

decision

and

A-11

Table

A-2.

J-2

Engine

Repair Engine Repair KSC

(Sheet

6 of 11)

Nomenclature

Remarks

. .

. .

Turbine

stator

retainer seal

RI

Second-stage turbine assembly (honeycomb) Turbine assembly First-stage assembly Turbine First-stage assembly Circumferential stator blade

RR

RI turbine seal (honeycomb) stator ring assembly wheel RI turbine seal RR Mating ring must be replaced when seal is replaced.

RI (a) RI

. o

. .

. o

turbine

o o .

. o o

. . .

Turbine Secondary Secondary

seal

gasket ring assembly

RR RR RR Mating ring must be replaced when seal is replaced

mating seal

. . . . .

. . . . .

. . . . ,

Secondary Mating Omniseal Primary Primary ring

seal

shim

RR RI RR

spacer

mating

ring

RR RR Mating ring must be replaced when seal is replaced. evaluation and decision and

sealassembly

(a)

Replacement NASA E PO

requires approval.

Rocketdyne

engineering

A-12

Table A-2.

J-2 Engine Repair (Sheet 7 of 11)

Engine Repair KSC

Nomenclature

Remarks

. . . .

. . . .

Primary Speed

seal transducer

shim

RR RR

Temperature Gas generator injector poppet Gas generator assembly Access Variable Vent port assembly

transducer oxidizer assembly control valve

RR

RI

RR cover resistor check valve RI RR RR

.... .... ....

Oxidizer turbopump

assembly

RI (a)

Field repair limited to onthe-engine removal and replacement of sub- assemblies and parts.

Inducer ring Inducer

shroud

restraining RR

. .

shroud

(KEL-F)

RI Rl(a)(b) Field repair limited to threaded insert replacement

Inducer shroud carrier assembly

Inducer shroud retainer

carrier RR RR

Seal carrier piston ring

(a) Replacement requires Rocketdyne engineering evaluation and decision and NASA EPO approval (b) Replacement requires hot-fire retest of engine assembly or component.

A-13

Table

A-2.

J-2

Engine

Repair

(Sheet

8 of

11)

Engine
Nomenclature Repair KSC Remarks

Impeller retaining Impeller assembly Inducer inducer Impeller Impeller retaining Impeller assembly Accessory Turbine assembly Turbine bolts

inlet nut inlet

seal RR seal Rl(a)(b)

, . .

. . . o

. . . _

bolt

RR RI(a)(b) RI(a)(b)

outlet nut outlet

seal RR seal RI(a)(b)

o o

. .

. o

drive stator

adapter blade

RI

RI(a)(b) wheel retaining RR Any two of the six bolts may be replaced if the total weight is within 0. 5 gram of the bolts replaced.

Stator

bolts mounting

RR

Turbine stator ring assembly Turbine assembly stator

RI(a)(b) clamp ring

Ri(a)(b)
RR engineering retest A- 14 of engine evaluation assembly and or decision component. and

Temperature transducer (turbine inlet) (a) Replacement NASA EPO (b) Replacement requires approval. requires Rocketdyne hot-fire

Table

A-2.

J-2

Engine

Repair Engine Repair KSC

(Sheet

9 of 11)

Nomenclature

Remarks

. . . .

. .

First-stage Second-stage check

turbine turbine valve

wheel wheel

RI(a)(b)
RI(a)(b) RR

Antiflood Augmented assembly Fuel Main . . bleed fuel

assembly valve

spark

igniter

RR valve valve assembly assembly RR RR RR relief RR assembly assembly relief RR orifice RR Replacement determined orifice size by calibration. RR (c) RR

. .

. . . .

Position

indicator

Low temperature valve assembly oxidizer valve indicator

. . .

Main . .

Position

Low temperature valve assembly Compensator

. . .

Filter

housing bleed

assembly assembly

RR RR

Oxidizer .

valve

Oxidizer bleed valve temperature transducer

RR

(a) (b) (c)

Replacement requires Rocketdyne engineering evaluation NASA EPO approval. Replacement requires hot-fire retest of engine assembly Center engine on SII stage has restricted access

and decision or component.

and

A-15

Table

A-2.

J-2

Engine

Repair Engine Repair KSC

(Sheet

10 of 11)

Nomenclature

Remarks

Mixture assembly . . Valve

ratio

control

valve RR

position

transducer relief

RR

Low temperature valve assembly Vent port assembly 3-way check

RR valve RR

. .

valve

assembly inlet line

RR RR

Heat

exchanger

Start . .

system

inatatlation tank cover assembly line assembly RR RR assembly RR RR

Helium STDV

hose

Start tank refill (gaseouS)

. .

Start tank support links Start tank assembly Start tank refill manifold (liquid) struts tank

RR RR

. .

Integral assembly

start/helium

RR(C) discharge valve RR resistor RR

Start tank assembly . Variable

(c) _ Center

engine

on SII stage

has

restricted

access.

A-16

Table

A-2.

3-2

Engine

Repair Engine Repair KSC

(Sheet

11 of 11)

Nomenclature

Remarks

Vent port assembly Start tank assembly .

check

valve RR and fill valve RR

support

Emergency assembly vent

vent

valve RR

Start tank assembly Thrust chamber installation . . .

o Q

and

relief

valve RR(C)

and

gimbal

ASI assembly Gimbal Thrust

Q

RR assembly assembly body Field repair limited minor tube brazing/ welding and insulation repair on engine. to RR

boot

chamber

Thrust chamber assembly

Thrust chamber assembly Thrust chamber transducer Gimbal assembly

injector

RI(a)

Replacement calibration

affects engine and alinement.

temperature RR Ri(a) Replacement affects engine alinement. Return replaced item to Rocketdyne, Canoga Park for inspection and repair. and decision and

Pressure-actuated all systems)

seals

(Naflex, RR

(a) (c)

Replacement requires Rocketdyne engineering evaluation NASA EPO approval. Center engine on SII stage has restricted access.

A-17

APPENDIX ENGINE COMPONENT

B REPLACEMENT

This

appendix

deleted.

B-1

APPENDIX SUPPORT EQUIPMENT

C LISTS

The

following

tables to fulfill

list

Saturn

engine

support outlined

equipment in section

items V.

that

are

necessary

the requirements

Table

C-1.

Support

Equipment

for

F-1

Engines

(Sheet

1 of 8)

Number AT1385883 Pressure

Nomenclature Adapter

Use Perform pressure thrust OK pressure tests on switches.

G2030

Oxidizer

Dome

Flushing

Kit

Blend trichloroethylene and gaseous nitrogen into a fog for cleaning dome and injector and GG ball valve and injector; a portable manifold unit. Install thermal installation.

G2035 G2037

TIS Installation Fuel Drainage

Set Kit

Drain fuel from engine after aborted launch, or any time fuel has entered engine system. Install or remove transducers. temperature

G2038

Temperature Installer and Scavenge

Transducer Remover

Kit

G2039

Pump

Remove fuel and preservative from turbopump lubrication system during preservation of turbopump. Tester Measure flowrates. pneumatic leakage

G3104

Pneumatic

Flow

G3130

Pneumatic (Fuel)

Flow

Monitor

Measure upstream flowrates during leak-tests; a multitube flowmeter set.

C-1

Table

C-1.

Support

Equipment

for

F-1

Engines

(Sheet

2 of 8)

Number G3131 Pneumatic (Oxidizer)

Nomenclature Flow Monitor

Use Measure upstream flowrates during leak-tests; a multitube flowmeter set. Kit Test actuation of hypergol switch and to plug hypergol container during leak-and function-tests while purging hypergol container. Seal TC throat leak-tests. Seal ing Test turbine leak-test. high voltage engine. igniters. area during

G3135

Hypergol

System

Tool

G3136

Thrust

Chamber

Throat

Plug

G3144

Turbine Exhaust Exit Pressure Check Fixture High Engine Engine Voltage Air Igniter Transport Tester Handler

exhaust

exit

dur-

G3153 G4044 G4047

Transport

Cover

Cover engine after removal from stage and during storage or shipment. Protective Protect thrust chamber tubes.

G4048

Thrust Cover Engine

Chamber

G4049

Vertical

Installer

Install or remove or nozzle extension a vertical stage. and position

engine from

G4050 G4052

Engine Engine

Rotating Handier

Sling Sling

Rotate

engine.

Lift air transport handler with or without engine installed, or lift G4080, G4081, and nozzle extension. Hold gimbal shipment. stationary during

G4059

Gimbal

Bearing

Lock

C-2

Table C-1.

Support

Equipment

for

F-1

Engines

(Sheet

3 of 8)

Number G4060 G4067 Vertical Engine

Nomenclature Installer Shipping Sling Buttress Lift G4049. Secure airplace

Use

engine and handler in during air shipment. Installer storage. and for dur-

G4077

Vertical

Installer

Adapter

Support Vertical ing shipping and

G4079

Nozzle Tool

Extension

Alinement

Aline nozzle extension thrust chamber flanges nozzle installation. Handle thrust extension. Transport chamber

G4080

Nozzle Fixture Nozzle Adapter Band

Extension

Handling

nozzle

G4081

Extension

Handling

nozzle

extension.

G4087

Clamp

Tool

Kit

Compress installation.

band

clamps

during

G4088 or 99-9026814

Turbopump Fixture

Shaft Preload

Prevent excessive turbopump shaft shipping. Prevent to thrust

vibrating during

of

G4089

Thrust Security MT- 109

Chamber Closure

Throat

unauthorized access chamber injector.

Model

Flowmeter and outlet)

(3/4-inch

inlet

Provide a way to measure flow during timing and actuation tests. Perform tests. Perform resistance electrical continuity

Model

630A

Multimeter

Model

1630C

Megohmeter

electrical tests.

high

T- 5021812

Depth

Micrometer

Take depth dimensions of turbopump during repair.

C-3

Table

C-1.

Support

Equipment

for

F-1

Engines

(Sheet

4 of 8)

Number T- 5023955 Special

Nomenclature Wrench Install secure flange Fixture

Use and remove bolts that gas generator outlet to turbine inlet.

T- 5026302

Pressure

Test

Seal engine control valve ports during component leak and function testing. Hold turbopump shaft when removing and/or and torquing oxidizer retaining bolt. stationary installing inducer

T-5026432

Torque

Bar

T- 5026436

Protection

Sleeve

Protect oxidizer pump from damage during maintenance.

volute

T- 5026440

Pressure

Test Fixture

Seal oxidizer volute area primary seal during leak of primary and intermediate seals.

around test

T-5028673

Lift

and

Holding

Tool

Lift and handle oxidizer pump inlet during removal and installation of inlet. Compress and hold oxidizer pump inlet piston rings in place during installation of inlet. Pressure-test intermediate Remove pump and mating turbopump seal. install ring oxidizer nut.

T- 5028674

Ring

Compressor

T- 5028675

Pressure

Test Fixture

T- 5028680

Wrench

T-5028689

Pressure

Test

Fixture

Seal oxidizer pump outlet flanges during an oxidizer leak test.

pump

C-4

Table

C-1.

Support

Equipment

for

F-1

Engines

(Sheet

5 of 8)

Number T- 50294 52 Hydraulic

Nomenclature Torque Tool Torque oxidizer up to 4,000 ft-lb bolt. Tool Measure

Use retaining bolt and to loosen

T- 5029467

Torque

and

Inspection

bolt stretch when

torquing turbopump inducer locking bolt. (Similar to adapter T- 5035940. ) T- 5029619 Torque Adapter Primarily to remove, and install and torque bolts that secure propellant valves and ducts to engine. Adapter Remove and install nuts that secure GG ball valve oxidizer outlet to GG injector. Seal checkout ing component function-testing. valve leakports and dur-

T-5029642

Special

Wrench

T-5031167

Pressure

Test

Fixture

T-5031700

Pressure

Test

Fixture

Seal engine control valve ports during component leak and functiontesting. Perform pressure tests propellant feed (oxidizer) system of engine. on

T-5035571

Pressure

Test

Fixture

T-5035912

Pressure

Test

Fixture

Seal ports while pressure testing turbopump bearing coolant control valve and valve to No. 1 and No. 2 bearing lube feed tubes. Remove inducer turbopump oxidizer from turbopump shaft.

T- 5035933

Inducer

Puller

C-5

Table

C-1.

Support

Equipment

for

F-1 Engines

(Sheet

6 of 8)

Number T- 5035934 Impeller

Nomenclature Coupling Puller Pull turbopump coupling from

Use LOX impeller turbopump shaft. from bolt shaft.

T-5035937

LOX Inducer

Cap Puller

Remove fairing cap in end of turbopump

T- 5035940

Adapter

Measure bolt stretch when torquing turbopump inducer locking bolt. (Identical to T-5029467 except for length). Tool Install filter in control body hydraulic control valve. Proof-, leak-, and functiontest inert prefill check valve. Press bearings onto of checkout valve. Fixture Measure distance to ball to establish ness on assembly valve. ball shafts of

T-5036718

Assembly

T- 5037801

Pressure

Text Fixture

T- 5037803

Holding

Fixture

T- 5037817

Inspection

Check

from retainer shim thickcheckout

T-5037831

Ball

Position

Indicator

Adapt a torque wrench to ball shaft and indicate position of ball during torque-check of the checkout valve. Measure gap between cover and switch foot and housing and finger to determine thickness of shim during installation of switch into GG ball valve. Seal fuel overboard drain during leak test of bearing coolant system. lines

T- 5037832

Inspection

Check

Fixture

T- 5039241

Pressure

Test Fixture

C-6

Table

C-1.

Support

Equipment

for

F-1

Engines

(Sheet

7 of 8)

Number T- 5041233 Gimbal

Nomenclature Yoke Alinement

Use Aline gimbal sections lic and pressurization wrap-around lines. of hydrausystem

T- 5041258

Dummy

Seal

Set

Simulate seal plates during fit-check of fuel and oxidizer high-pressure ducts. Tool Remove and install actuator

T-5041500

Actuator

Installation

from a cylinder solenoid valve. T-5041501 Assembly Jig Install engine

of four-way

parts in a cylinder control valve. of three-way for pressure

of

T-5041521

Pressure

Test Fixture

Seal openings solenoid valve testing.

T- 5041812

Clearance

Pins

Measure clearance between turbopump oxidizer inducer wall of oxidizer inlet. Simulate fuel-valve-to-fuel-

and

T- 5043413

Shim

manifold seal plate or oxidizervalve-tooxidizer-dome seal plate during alinement of engine propellant valves and ducts. T- 5044645 Seal Installation Tool Install oxidizer a tool on turbopump shaft.

T- 5044743

Alinement

Gage

Determine that allowable lateral misalinement of line flanges is not exceeded. Obtain acceptable axial dimensions between collar of shaft and tubular spacer of TC throat plug when throat plug is being installed in TC.

T- 5046431

Washer

C-7

Table

C-l.

Support

Equipment

for

F-I

Engines

(Sheet

8 of 8)

Number T- 50482 59 Solenoid

Nomenclature Removal Tool

Use

Remove and install solenoids in four-way solenoid valve. Perform test. Filter testing electrical resistance

1432-T

Decade

Resistance

Box

19065

Fiiter

hydraulic fluid start and stop check

when solenoids. valve

88-557487

Check

Valve

Cap

Pressure-test after repair.

9026560

Welding

Set, Spot-Weld

Spot-weld materials 0. 004 inch thick. Spot-weld materials 0.032 inch thick. Percussion welding. During and fusion

less

than

9026561

Welding

Set, Spot-Weld

0. 004 to

9026570

Welding

Set,

Stud

Welding

stud

9026622 99-9012908

Inert

Igniter

CDDT.

Fuel Drain Vent Adapter Kit Engine Environmental Cover Set

Drain fuel from engines installed in stage. Protect thermal insulation, engine and nozzle extension from impingement of liquids.

99-9014130

C-8

Table C-2.

Support

Equipment

for

H-1

Engines

(Sheet

1 of

6)

Number

Nomenclature Flowmeters: 10% of Full (Accuracy Scale) 0-5 of Scim

Use Leak-check FABU, MOV, MFV, IMV, GG control valve, and check valves. Flow- check LOX seal cavity and gearcase orifices, when required by replacement. Leakcheck FABU. GG control valve.

0-4

Scim

0-10 0-30 0-80

Scim Scim Scim (Upstream)

Leak-check

Leak-check MOV, IFV, IMV, unitized check valve, and turbopump shaft seals. LeakLeakLeakCoil Test Seal leakcheck check check IMV. IMV. turbine seal. coil during

0-200 0-3000 O- 5000

Scim Scim Scim

Heat Exchanger Plates Heat Exchanger Plates

heat exchanger checks.

Shell

Test

Seal heat exchanger water submersion required.

shell during test, when

Megohmeter,

500 VDC

Check insulation resistance electrical components and harnesses. 35

of

Relief psig

Valves,

13 and

Prevent overpressurization of TC, turbopump, and gearcase during checkout. Indicate level preflll during operations. of TC jacket prelaunch fuel

Flowrator,

0-25

Gallons

C-9

Table

C-2.

Support

Equipment

for

H-1

Engines

(Sheet

2 of 6)

Number Balance Grams, Within

Nomenclature Scale (0-I000 Sensitive to One Gram) Tank

Use Weigh hypergol igniter before installation.

Cryogenic

Submerge unitized check valve in LN 2 during cold tests. (0. 001 inch Determine turbopump axial movement. shaft

Dial Indicator increments) Precision

Parallel

Bar

For use with depth micrometer to obtain turbopump seal compression and clearance measurements. Protect pressure operator tests. during

Protective

Enclosures

Three-Way Valve

N.C.

Solenoid

Rapidly pressurize IMV control port during pneumatic testing (a manual 3-way toggle valve NA5-11058 is an acceptable alternate). _ Measure leakage leak tests. Support position trailer. during system

G3004

or G3104

Pneumatic

Flow

Tester

G4039

Handler

Adapter

engine in horizontal on transportation

G4040

Transportation

Trailer

Support adapter Repair

engine during TC tube

and handler transportation. dents.

Model

22-25

Portable tronics Wheatstone

Plater (BrookEngineering Corp) Bridge

Model

5305

Measure contacts. Perform tests.

resistance

of TOPS

Model

630A

Multimeter

electrical continuity

C-10

Table C-2.

Support Equipment

for H-I Engines

(Sheet 3 of 6)

Number NA5-11058 Manual

Nomenclature 3-Way Toggle Valve

Use

Rapidly pressurize IMV control port and rapidly depressurize MOV closing control port during checkout. (An electric solenoid valve is an acceptable alternate.

RX-20887

GG Combustion Seal Assembly

Chamber

Seal GG combustor and isolate combustor from exhaust system. Provide during Adapt spline Seal positive IMV and accessory to torque LOX pump inlet FABU pressure checkout.

S-2-3-25

Accumulator, 20 Cu. Capacity Minimum Turbopump Adapter LOX Pump Torque

In.

T-5001167

Wrench

drive pad wrench. inlet. turbine

T-5016017 T- 5020999

InletTest Plate Nut

Turbine Torquing Pressure

Attaching Wrench

Remove and attach nuts.

install

T- 5027946

Test Fixture

Cryogenic and ambient leak test gas generator LOX injector purge check valve. Proof test Engine Adapter Handler G4039 and Rocket Engine Trailer G4040. Compress snapring on shaft free turbine for removal. Remove and TC manifold install inlet. MFV on to

T- 5028992

Engine Dummy

Weight

T-5044644

Turbine Tool

Snap

Ring

Removal

T- 504 542 5

RachetWrench

T-5045841

Pressure

Te_tFixture

Seal hypergol container during system leak and function tests.

C-If

Table

C-2.

Support

Equipment

for

H-1

Engines

(Sheet

4 of 6)

Number T-5045842 Pressure

Nomenclature Test Fixture

Use Seal LOX dome bootstrap port during system leak and function tests. Seal thrust chamber fuel port tests. mani-

T- 504 5843

Pressure

Test

Fixture

fold fuel bootstrap leak and function T-5100775 Test Plates Seal MFV and outlet Test Fixture

during

gate housing inlet during testing.

T-5100778

Pressure

(Spool)

Seal MOV gate housing inlet and outlet during ambient or cold testing (provides an LN 2 standpipe for cold testing). Adapt setup. Adapt setup. IMV outlet port to test

T-5100779

Text

Fixture

T-5100782

Fixture

IFV

to pneumatic

test

T-5100783

Dummy

Inducer

Tool

Simulate turbopump LOX inducer when obtaining assembly measurements. Tool Compress LOX during assembly. Replace flow. Plug vent Conax duct bellows

T-5100955

Bellows

Compression

T-5102517

Conax Plate

Valve

Manifold

Test

valve;

prevent

T-5102518

HypergoI Container Plug (Long) Pressure Test

Test

hypergol flow into

container; TC.

pre-

T-5102520

Fixture

Adapt GG control valve inlet to test equipment. Adapt GG control valve port to test equipment.

LOX

T- 5102521

Pressure

Test

Fixture

actuator

C-12

Table

C-2.

Support

Equipment

for

H-I

Engines

(Sheet

5 of 6)

Number T- 5102523 Conax Plate SPGG Plate Fuel

Nomenclature Valve Manifold Test

Use Replace Conax valve; simulate fired valve, allow flow. Seal SPGG combustor, Seal Plug drain Bend tabs. fuel attach flange on GG

T- 5102524

Replacement

Test

T-5102539 T-5103792

Pump

Inlet

Test Drain

Plate Line

pump

inlet. lube overboard

Lube Overboard Pressure Plug Tab Bender

gearcase line. turbopump

T-5104317

inducer

washer

T- 5104417

Lockwasher

Tab

Bender

Bend tabs turbopump.

of lockwasher

on

T-5105437

Pressure

Test

Fixture

Adapt unitized check valve openings to test setup. Proof test Rocket Engine Adapter Handler G4039 and Rocket Engine Trailer G4040. Seal LOX duct leak-test. bleed port during

T-8200756

4,200

Pound

Proof

Fixture

405773

LOX Duct Adapter

Bleed

Port

408380

Cover

Plate

Seal TOPS opening on gate housing during testing. (Full-Open) Valve Rapidly pressurize FABU inlet during checkout. (An electric solenoid or fast-acting manual toggle valve is acceptable alternate. ) Encase during (1/2-inch) Flush lube drain checkout. LOX dome. slipper seal relief valve

43F4-316

1/4-Turn

552475, 552513, or equivalent 57508 88-556666

Test

Envelope

Check Probe

Valve

Leak-test IMV and diaphragm.

C-13

Table

C-2.

Support

Equipment

for

H-1

Engines

(Sheet

6 of 6)

Number 9011722 Seal

Nomenclature Puller Remove pump fueI cavity. seal seal

Use from turbo-

9014617

Turbopump LOX Cavity Swab Inert Inert GG Igniter GG initiator Duct

Seal

Inspect LOX contamination. Simulate Simulate Plug

cavity

for

9026002 9026003 9024399

igniter initiator

installation. installation. exit on

Exhaust

Pressure

Seal turbine exhaust H- 1C engines.

9026077

Fuel Seal

Bootstrap

Pressure

Replace .fuelbootstrap seal plate and isolate GG from TC. (Delivered with engine. ) Replace main fuel orifice and isolate fuel pump from TC. (Delivered with engine. ) Seal T C combustion z one.

9026078

Main

Fuel

Pressure

Seal

903404-31

Thrust Plug

Chamber

Throat

906907

Aspirator

Pressure

Plug

Seal turbine exhaust H-1D engines. Flush LOX dome.

exit

on

9529-41013

LOX Dome

Nozzle

C-14

Table

C-3.

Support

Equipment

for

J-2

Engines

(Sheet

1 of 8)

Number EWR 129666

Nomenclature STW Swing Gasket Gate Test Plate

Use Seal test plate on start tank discharge outlet flange when vacuum drying start system. Replace during Install Protect damage installing vent port check valve vacuum drying MRCV. ECA valve core.

EWR168312 and 168313 EWR183648 EWR915725

Universal

Fitting

Torque Split

Adapter Barrel (Fuel)

fuel turbopump from when removing or fuel inlet duct. from when fuel

EWR915726

Top

Plate

(Fuel)

Protect fuel turbopump damage/contamination removing or installing inlet duct.

EWR

972056

Bottom Plate (Oxidizer Duct)

Protect oxidizer inlet duct outlet flange when duct is removed or installed. Protect fuel inlet duct outlet flange when duct is removed or installed.

EWR

972057

Bottom Plate (Fuel Duct)

G3104

Pneumatic

Flow

Tester

Measure leak-tests. Seal thrust leak-tests.

leakage

during

system

G3120

Thrust Chamber Plug Kit Single Kit Head Special

Throat

chamber

during

G3127

Tool

Used with Automatic Inert Arc Welding Set G3128. Perform in-place tube

Gas

G3128

Automatic Inert Welding Set Engine Vertical

Gas

Arc

welding.

G4035

Installer

Remove vehicle

and install stage site.

engine

at

C-15

Table C-3.

Support

Equipment

for

J-2

Engines

(Sheet

2 of 8)

Number G4042 Engine Sling

Nomenclature Forward Handling

Use

Lift and rotate engine between horizontal and vertical positions; used with G4045. Lift and rotate engine between horizontal and vertical positions; used with G4042. Lift and handle during removal either turbopump or installation.

G4045

Engine

Aft Handling

Sling

G4046

Turbopump

Sling

G4063

Turbopump

Rotating

Sling

Rotate either turbopump to correct position for mounting on engine or maintenance stand. Support engine after removal from a stage, during transportation, and while in limited storage.

G4064

Engine

Handler

G4071

Engine

Components

Installer

Remove and install components in S-II

engine stage.

G4072

Engine

Components

Installer

Remove and install engine components in S-1VB stage. Attach to oxidizer turbopump primary seal drain line for determining leakage.

KSC-J2-R066967

Test

Fixture

RL

681000

Spark Igniter Sample Bottle Pin Puller

Cable

Gas

Sample spark pressurizing Remove detection

igniter gas.

cable

T- 5044445

brass plugs ports.

from

leak

9016701

Bypass

Test

Plate Kit

Seal oxidizer duct during leak-testing.

turbine bypass exhaust system

C-16

Table

C-3.

Support

Equipment

for

J-2

Engines

(Sheet

3 of

8)

Number 9016705 Thrust Pad

Nomenclature Chamber Protective

Use Protect TC tubes during maintenance in TC and TC throat plug. Seal tem hot-gas leak-tests. system during sys-

9016710

Hot-_s Exhaust Plate Kit Turbopump Kit Torque

Test

9016711-21

Wrench

Adapt torque wrench fuel turbopump shaft inspections.

to perform torque

9016712-11

Turbopump Kit

Torque

Wrench

Adapt torque wrench to perform LOX turbopump shaft torque inspection when hydraulic pump is not installed. Seal propellant feed system inlet ducts during system leaktests when engine is not installed in stage. Seal and provide an inlet fitting for pressurizing heat exchanger helium inlet customer connection. Actuate bypass valve closed to permit installation of bypass duct test plate. Seal and apply pressure to closing port of OTBV to permit valve removal or installation. Provide a fitting for pressurization of start tank vent valve control during sequence checkout and start tank leak-tests. Adapt all component for slings. handlers

9016713

Turbopump Plate Kit

Inlet

Ducts

Tests

9016719

One-inch, 30-psig, Customer-Connection, Test Plate Kit Bypass Valve Plate Kit Actuation

9016723-11

9016724

5/8-Inch, CustomerPlate Kit

600 psig, Connection

Test

9016779

Component Universal

Handler Sling

C-17

Table

C-3.

Support

Equipment

for

J-2

Engines

(Sheet

4 of

8)

Number 9016783-11 Start

Nomenclature Tank Installer Handle removal engine

Use start tank during or installation while is horizontal. duct bellows used with other

9016784

Fuel

Inlet

Duct

Handler

Compress inlet and handle duct lifting facilities.

9016785-

II

Oxidizer

Inlet

Duct

Handler

Compress inlet duct bellows and handle duct; used with other lifting facilities. Adapt oxidizer feed system components to lifting sling 9016779. Adapt fuel feed system ponents to lifting sling 9016779. Adapt electrical control assembly to lifting sling 9016779. Compress exhaust duct bellows and handle heat exchanger; used with other lifting facilities. Plates and fixtures for component tests. Also, a mass spectrometer with portable test station, a high-potential test set, and a portable liquid nitrogen tank. Adapt torque wrench to perform oxidizer turbopump shaft torque inspection when hydraulic pump is installed. com-

9016786

Oxidizer Handlers

Feed

System

9016787-11

Fuel

Feed

System

Handler

9016789

Electrical Handler

Control

Assembly

9016790-11

Oxidizer Handler

Heat

Exchanger

9016796

Components

Adapter

Set

9017259

Turbopump Kit

Torque

Wrench

C-18

Table C-3.

Support Equipment for J-2 Engines

(Sheet

5 of 8)

Number 9017273

Nomenclature 5/8-Inch 500-psig CustomerConnection Test Plate Kit Seal sf_ connection leak-tests.

Use tank ground fill during start tank

9017274

5/8-1nch, CustomerPlate Kit 1-1/2 Inch, Connection

2,000-psig Connection

Test

Provide fitting for helium fill connection during leakand function-tests of engine system. Provide fitting for pressurizing GG fuel bleed and hydrogen tank pressurization customer connections. Seal and provide an inlet fitting for pressurizing turbopump, GG oxidizer bleed, start tank vent and relief, and thrust chamber jacket purges. Seal accessory fuel turbopump provide fittings and monitoring during system drive pad and torque pad and for pressurizing test pressures leak-tests. accumulator test.

9018840

30-psig CustomerTest Plate Kit

9018843-11

5/8-Inch, Connection

30-psig CustomerTest Plate Kit

9O18846

Turbine Exhaust Plate Kit

Leak-Test

9019960

Accumulator

Hose

Plate

Kit

Seal hose

disconnected during engine

9019968

Heat Exchanger Oxidizer Supply Line Test Plate Kit

Apply vacuum to heat exchanger oxidizer supply line, and vacuum or purge dry start tank gaseous refill line. Open GG control valve to permit drying bootstrap line, and provide a means to vacuum or purge dry Start tank Liquid refillRue.

9019969

Gas Generator Test Plate Kit

Conf_rol

Valve

C-19

Table

C-S.

Support

Equipment

for

J-2

Engines

(Sheet

6 of 8)

Number 9020266

Nomenclature Oxidizer Tank CustomerConnection Pressurization Test Plate Kit

Use Seal and provide an inlet fitting for pressurization of heat exchanger oxidizer tank pressurization customer connection. Tool Move bypass duct flanges apart to permit installation of bypass duct test plate during leaktests and to permit removal of bypass valve; used with plate kit 9016723. Support customer connections (fluid) during engine installation and maintenance. Seal oxidizer dome purge line during leak-tests of engine pneumatic system. Equipment oxidizer Maintenance to repair turbopump. and test

9020269

Bypass

Valve

Removal

9020628-51

Fluid Support

Lines

Interface

9020784-11

Oxidizer Shutoff

Dome Purge Plug Kit

9020798-11

Oxidizer Turbopump Maintenance Set Fuel Set Start Turbopump

9020799-31

Equipment to repair fuel turbopump. Lift and handle installer. Connect turbine start

and test

9022985

Tank

Sling

tank

from

9024496

Oxidizer and Fuel Turbine Drain Lines Test Adapter Kit ASI and GG Oxidizer Purge Lines Test Plate Kit

oxidizer and fuel seal bleed lines.

9024497

Connect to downstream flanges in ASI oxidizer and GG oxidizer purge purge and GG oxidizer check valves. cavity

9024540

Propellant Adjuster

Inlet Set

Duct

Null

Equipment inlet ducts a null

to adjust propellant torsion bellows to

position.

C-20

Table C-3.

Support Equipment for J-2 Engines (Sheet 7 of 8)

Number 9O24994 Insulator

Nomenclature Installer Tool Kit Install connector insulators pins.

Use

on electrical

9024997

Thrust Chamber Start Tank Refill Flange Test Plate Kit Gas Generator Equalization Line Leak Test Adapter Kit Flight Instrumentation Pressure Transducer Removal Tool Kit

Enable correct purging of liquid refill check valve. Leak-test vent port GG control check valve valve boss.

9024998

9024999

Equipment for removal and installation of pressure transducers in primary and auxiliary instrumentation packages. and Engine Weight Proofload Engine Vertical Installer G4035, Engine Aft Handling Sling G4045, and Engine Forward Handling Sling G4042. Proof-load Turbopump G4063 and G4046. Oxidizer and Fuel

9025145

Vertical Installer Slings Proof-Test

9025146

Turbopump Weight

Sling

Proof-Test

Rotation Sling Turbopump Sling

9025150

Inlet Duct Assembly

Support

Installer

Install and remove inlet duct supports for fuel and oxidizer inlet ducts. Conserve helium during engine leak-test through installation of plate at inlet port of purge control valve. Check malnstage switches. Leakcavity. and flow-test OK pressure

9025400

Pressure-Actuated Valve Test Plate

Purge Kit

9025405

Calibration Test Adapter

Pressure Kit

Switches

9025419

Fuel Pump Leak Adapter Kit

and Flow

fuel

seal

C-21

Table

C-3.

Support

Equipment

for

J-2

Engines

(Sheet

8 of 8)

Number 9025424

Nomenclature Vent Adapter Kit Conserve checkout. Leak-test, seal cable helium

Use

during

engine

9025425-31

Spark Igniter Pressurization Electrical Insulation Connector

Cable Tool

Kit

pressurize, assembly.

and

9025591

Control Resistance Kit

Test

Resistance-to-ground electrical system.

testing

9025817

Oxidizer Turbopump Seal Cavity Drain Line Test Adapter Kit Vacuum Manifold

Adapt drain

to turbopump line for leak

seal tests.

cavity

9025826

Connections drying start

for manifold tank.

C-22

APPENDIX TERMS

AND DEFINITIONS

The listed

following for

terms

and definitions only.

are

used

on Saturn

engine

programs

and

are

reference

D-1

Definition Critical (Code Major (Code #1) Failure #5) Failure An unsatisfactory to personnel condition and condition but does

of Terms that equipment. that could result not cause hazard includes launch does conscrub. not sigin to could result in

hazard

An unsatisfactory abort of mission personnel ditions or that

equipment. can cause

This a definite that

Minor (Code

Failure #6)

An

unsatisfactory

condition

nificantly affect mission success. This classification includes unsatisfactory conditions that could result in information loss when no significant effect on mission concerned, and conditions short launch. that operation could is cause a

Leak-Check

A check

is performed

to verify

integrity by use such

of a of leakas flow-

pressurized test solution meters, Functional-Check A check capability mechanical mechanical To rqueCheck A check torques a. b. gages, is

system/component and/or instruments, or mass

spectrometers. to verify functional source, or such electroas

performed by use hydraulic,

of a dynamic pneumatic,

is performed are within

to verify specified Torque

that limits:

the

following

Breakaway. Dynamic. maintain inspection

applied applied (to

to

start

rotation. to

Torque rotation.

turbopump)

Visual

Inspection

An

is performed thereafter, excessive and appropriate verification maintenance as

upon

receiving

and if con-

at specific times there is corrosion, tamination, configuration Task Verification A quality during delivered system. per assurance checkout, hardware,

to determine moisture, to verify records.

or damage,

hardware

is performed and repair by the of FORR

Inspection

established

D-2

Definition Special Inspection

of Terms

An inspection is performed resulting from a suspected deficiency of design, manufacturing, contamination, or use, as initiated by an Engine Field Inspection Request (EFIR). Cleanness flushing, iS achieved and purging, heating, maintained by draining, and desiccation. for storage desiccants,

Drying/De

contamination

Preservation

A system or component is prepared through the use of sealing/wrapping_ covers, and enclosures.

Preparation

The engine and GSE are readied for checkout or operation by removing protective closures, installing loose equipment, and connecting GSE. The engine and GSE are secured to original configuration by disconnecting GSE, removing expended loose equipment, and installing protecfive covers and closures. Handling rotating, Maintenance consists primarily and intrafacility of positioning, transporting.

Securing

Handling

Scheduled

Planned maintenance events to be performed resulting from hardware activity and hardware design limitationS. Maintenance requirements have been established and are defined in the contractor's technical manuals. Unplanned maintenance events that occur resulting from hardware activity and hardware anomalies. Maintenance requirements are determined through design evaluation and maintenance analysis A modification is a physical change to the equipment resulting from a design change. As used herein, modification includes compliance with retrofit kits and installation of Stage Contractor Hardware. Calibration consim+J of the tests and adjustments which determine that an instrument or special tool meets the performance requirements of a given set of standards. Engine calibration consists of orfficing propellant flow to provide engine performance with model specification requirements. D-3

Nonscheduled Maintenance

Modification

Calibration

Definition Alinement

of Terms

An operation performed to determine that the location of the geometric thrust vector, with reference to the engine centerline and center of the gtmbal block, is within model specification requirements. Inspection An inspection performed during functional checkout to determine that the hardware will operate within appropriate specifications. An inspection performed ware size and configuration determined tolerances. Preparing operation closures, the thrust to determine are within that hardpre-

Functional

Dimensional

Inspection

Engine and GSE Preparation

the engine and GSE for checkout or and consists of removing protective installing loose equipment, prefilling chamber, and connecting GSE to flush the turbopump with preservative compound preservative coating on

Turbopump Preservation

An operation performed gearcase lube System to provide a protective gears and bearings. Hardware that can Storage Serviceable processed semi-ready Hardware periods

Active

Storage

maintained in a serviceable be used without qualification. hardware and placed State. processed exceeding

condition

Short_Term

used occasionally that is in storage in a ready or

Long

Term

Storage

and placed two years.

in storage

for

D-4

APPENDIX ABBREVIATIONS

The for

following reference

abbreviations only.

are

used

on

Saturn

engine

programs

and

are

listed

E-1

Abbreviations ASl ASTP CCN CDDT CEI CM&R COC CONTR COR CTR DR DRL ECP EFIR EFL EID ELB EPO FABU FAR FLD FIDCR ENGRG Augmented Apollo Contract Countdown Contract Component Certificate Contractor Contracting Component Data Data Officer Test Soyuz Spark Test

Item Igniter Project Notice Test

Change

Demonstration End Item Maintenance of Completion

and Repair

Representative

Record

Requirement Requirements Change List Proposal Request

Engineering Engine Edwards Engine Engine Engine Fuel Field

Inspection Laboratory

Field Interface

Document

Log Book Project Additive Analysis Engineering Discrepancy and Correction Office Blender Report (NASA) Unit

Failure Field

Field Inspection Record

E-2

Abbreviations FIR FORR FQAM FQOI FRR FRT FTC FWV GFP GG GOX GSE ]DR IFV IMV IPB IU KSC LC LHR LIB LOM LOTSI Field Field Field Information Operation Quality

Item

Request/Report Requirement Assurance Operating Review Test Manual Instructions & Record

Field Quality

Flight Readiness Flight Readiness Florida Test

Center Verification Property

Flight Worthiness GovernmentGas generator oxygen support

Furnished

Gaseous Ground

equipment Report

Inspection

and Disposition

Igniter fuel valve Ignition monitor Illustrated Parts Instrumentation Kennedy Launch Space valve Breakdown Unit Center

Countdown Hardware Information Operating Release Bulletin Manual Items

Logistics Logistics Logistics

List of Time

Sensitive

E-3

Abbreviations LOX LV LVO MAF MCR MD MFV MGT ML/LUT MOD MOV MSFC NASA NASPR OATS O&FS OICN OPN OTBV PA PCR PCS

Item Liquid Launch Launch Michoud Master Modified Main oxygen Vehicle Vehicle Operations Facility (KSC/NASA)

Assembly Change Design

Record

fuel valve

Management Mobile Launcher/Launch Umbilical Tower

Modification Main Marshall National NASA Overall Operations Operating Operation(s) Oxidizer Program Procedure Publication turbine bypass valve oxidizer Space valve Flight Center and Space Administration

Aeronautics Procurement Tests and Flight

Regulation

Support Change Notice

Instruction

Authorization Change Change Request Suggestion '

E-4

Abbreviations PCCB PD POICN PSC PWR QA QAI RAPS REQT RFD RKDN ROCKWELL ROP RSPL SAS SECT STDV STE STG TC TIS TOPS TSC UCR VAB Program Program Proposed Post Power Quality Quality Rocketdyne Requirement Request Rocketdyne Rockwell Rocketdyne Recommended Site Associated International Operating for Assurance Assurance Automated Storage Configuration Directive Operating Checkout

Item Control Board

Instruction

Change

Notice

Instructions Packaging System

Disposition

Policies Parts List

Support Support

Section Start Special Stage Thrust Thermal Thrust Test chamber Insulation OK Pressure and Condition Building Set Switch Criteria Report Tank Test Discharge Equipment Valve

Specification

Unsatisfactory Vehicle Assembly

E-5