- \n
- SLS Forum Section<\/li>\n
- L2 SLS Section<\/li>\n
- L2 SRB Section<\/li>\n
- Click here to Join L2<\/li>\n<\/ul>\n
The Spacecraft and Offline Operations team processes Orion and SLS upper stage hardware, while the Integrated Operations team processes the SLS Solid Rocket Booster (SRB) and Core Stage hardware and assembles the whole vehicle on the Mobile Launcher (ML) in the Vehicle Assembly Building (VAB), starting with the SRB segments.<\/p>\n
After the boosters are stacked and Core Stage mated to them, the Spacecraft and Offline Operations team will turn their processed hardware over to Integrated Operations in the VAB to complete stacking.<\/p>\n
\u201cWe\u2019re responsible for the Orion vehicle post-turnover from Lockheed Martin to the government and we\u2019re also responsible for the ICPS (Interim Cryogenic Propulsion Stage), which is the upper\/second stage of the SLS vehicle for the servicing prior to it being stacked on the SLS and we\u2019re also responsible for the Orion Stage Adapter (OSA) which has about thirteen cubesat satellites,\u201d Lili Villarreal, Flow Manager for NASA EGS Spacecraft and Offline Operations, said.<\/p>\n
\u201cWe\u2019re responsible for processing, installing those, charging their batteries and getting them ready.\u201d<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/sls_block_1_expanded_view_orion_copy.jpg\")
<\/p>\nMore or less the major components to be assembled at KSC by Exploration Ground Systems. The Solid Rocket Boosters are stacked first in segments, followed by the Core Stage (with the engines fully installed). Then the Launch Vehicle Stage Adapter (LVSA), Interim Cryogenic Propulsion Stage (ICPS), and the Orion stack with the Orion Stage Adapter. Credit: NASA.<\/p>\n
\u201cOur team basically hands over in pieces,\u201d she explained. \u201cFirst, we\u2019ll hand over the ICPS fully serviced in the VAB. Then we\u2019ll hand [over] the Orion Stage Adapter which will get stacked on top of the ICPS and then after we\u2019ll do the Orion vehicle.\u201d<\/p>\n
\u201cAll the work we\u2019re calling \u2018Spacecraft and Offline\u2019 is actually working in parallel,\u201d David Diaz, Flow Manager for NASA EGS Integrated Operations, said. \u201cWe start off what we call \u2018integrated ops\u2019 in the RPSF (Rotation Processing and Surge Facility). Very similar to Shuttle, we start stacking and this whole time we\u2019re starting stacking operations, Lili is off processing on her end getting the spacecraft ready.\u201d<\/p>\n
\u201cAnd then of course we\u2019ll work with the Core Stage once it comes in and then we\u2019ll do some integrated testing with just that stack and then we roll in the LVSA (Launch Vehicle Stage Adapter), and then ICPS, as she just alluded to,\u201d he continued. \u201cSo we\u2019ve essentially stacked the vehicle at that point and then when she\u2019s done with her Orion, she\u2019ll bring that to us pretty much already checked out and then we will go ahead and stack it and then we start our integrated testing at that point.\u201d<\/p>\n
The EGS teams are monitoring the current work by the contractors as they prepare for receiving the hardware for launch operations. \u201cWe do have the capability to go to their sites and do some training with them, because it\u2019s ultimately the best for us to train with them and the hardware before we see the hardware,\u201d Villareal explained.<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/SLS-PLAN-020.Rev-D.Fig6-1.Conceptual-Flow.jpg\")
<\/p>\nDiagram from a NASA publication showing the flow of Orion and SLS hardware through the different processing facilities at KSC. The MPCV Stage Adapter (MSA) is now the Orion Stage Adapter (OSA). Credit: NASA.<\/p>\n
\u201cWherever we feel that certain operations that they\u2019re doing in their facilities are going to complement our eventual ground processing, we\u2019ll go and just basically shadow them and learn from them.\u201d<\/p>\n
\u201cWe work with the flight hardware providers both civil servant and contractor side on the development of the requirements that they give to us to go process and check out the vehicle,\u201d Jeffrey Angermeier, EGS Flow Director for NASA, added.<\/p>\n
\u201cWe\u2019ve been working with the other programs for years in the development and understanding of those requirements,\u201d he explained. \u201cThose are things that we receive from the other programs and we basically put together work authorizing documents that implement those requirements and that\u2019s how we get the vehicle done.\u201d<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/L2-banner@2x.jpg\")
<\/p>\n\u201cSo two opportunities \u2014 we work upstream with them on requirements development and we get upstream with them to get as many opportunities as we can to go see the vehicle and observe some of their operations to give a little bit of OJT (On the Job Training) so to speak on what to expect when that hardware gets here,\u201d he added.<\/p>\n
Current hardware status<\/p>\n
So far, only two of the major hardware elements for EM-1 have been turned over to EGS. The ICPS was turned over to EGS by United Launch Alliance (ULA) late last year and the Orion Stage Adapter that will carry thirteen cubesats on EM-1 and sits between the ICPS and the Orion stack on top was turned over earlier this year.<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/KSC-20180405-PH_GEB01_0004_orig.35pct.jpg\")
<\/p>\nThe ICPS (left, background) and OSA (right, foreground) in the SSPF when the stage adapter was delivered in April, 2018. Credit: NASA\/Glenn Benson.<\/p>\n
Both elements are currently being stored at KSC until their turn for stacking. \u201cRight now the ICPS is currently in storage at the Space Station Processing Facility (SSPF),\u201d Villarreal said. \u201cThe Space Station Program was really nice enough to let us bring the ICPS over to the SSPF for \u2018dwell.’\u201d<\/p>\n
A third piece, the LVSA, is close to completion at the Marshall Space Flight Center in Huntsville, Alabama, but may stay there in the interim. \u201cFor the LVSA, the plan is that comes directly into us, to integrated ops and that will be stored in High Bay 4,\u201d Diaz explained. \u201cWe have some training opportunities from the internal access kits and there\u2019s some checkouts that we\u2019ll do in there.\u201d<\/p>\n
\u201cWe\u2019re still negotiating a date for that, but then we go ahead and stage in High Bay 4 and we\u2019ll keep it maintained and checked out and so forth until we actually need it for stacking.\u201d<\/p>\n
EGS is working backwards from a launch date to plan when the bulk of the processing work would start and when they need certain elements. \u201cWhat we generally do is we establish what\u2019s considered like \u2018no later than\u2019 need dates and so for our flow, when we look at when we need to get everything done to get the vehicle ready to go fly, we essentially start with the launch date and work our way back based on the assumed time we think it takes to do the activities to get the vehicle ready,\u201d Angermeier explained.<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/sls_monthly_highlights_june_2018_web.Page-2.jpg\")
<\/p>\nThe Launch Vehicle Stage Adapter (LVSA) at Marshall Space Flight Center earlier this year. The Exploration programs are still working out when this will be delivered to Florida. Credit: NASA<\/p>\n
SRB hardware for EM-1 is almost ready, but transportation and handover will start closer to the EM-1 launch target date, which is currently forecast for the middle of 2020. The critical paths in the schedule are the Orion European Service Module (ESM) and the SLS Core Stage, and progress in assembly and testing of those first-time builds will continue to influence overall schedule and interim target dates.<\/p>\n
Stacking starts with boosters<\/p>\n
Integration of the full vehicle will begin with processing and stacking of SRB hardware. As with other parts of SLS, the boosters are derived from Space Shuttle designs and retain much of the reusable, Shuttle-heritage motor casing and forward and aft assembly hardware.<\/p>\n
Processing and stacking of the boosters is also similar to Shuttle, with the five-segment motors being the first elements stacked on the launch platform. Start of work will center around the arrival of the ten segments from their Northrop Grumman Innovation Systems (NGIS) production facility north of Salt Lake City, Utah.<\/p>\n
The booster assembly hardware on the top and bottom of the SRBs is being processed by NGIS at KSC facilities, and the Integrated Operations team is planning on those being handed over from NGIS a few weeks before the motor segments arrive by rail. \u201cWe work with the flight programs to determine the appropriate time to receive it,\u201d Angermeier said.<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/Aft-Segment-RPSF-Build-Up.jpg\")
<\/p>\nInert SRB aft segment in the RPSF, December, 2016. The aft segments are joined to a nozzle extension and an aft skirt in the RPSF prior to being moved to the VAB for stacking on the Mobile Launcher. Credit: NASA<\/p>\n
\u201cBasically about two weeks before we start that work we\u2019ll receive the aft skirts and then the segments arrive basically the first day of our processing flow over there on rail car,\u201d he continued.<\/p>\n
\u201cIf there is a need, program to program, where they want to get the segments down here a little bit earlier or give us the aft skirts earlier then we\u2019ll work with them to find the appropriate time to take those over. So that\u2019s what we do with the aft skirts.\u201d<\/p>\n
\u201cFor the forward assemblies, essentially the first day that we start stacking boosters in the VAB is the day we tell them we\u2019d like to have our forward assemblies delivered to us and same thing, if they want to turn them over a little bit earlier we\u2019re not going to fight that,\u201d Angermeier said. \u201cWe\u2019d take them a couple of weeks early if that\u2019s something that they desire.\u201d<\/p>\n
As noted, the booster hardware will first be prepared for stacking in the RPSF. The loaded motor segments will be offloaded from their rail car transportation canisters and the assemblies will be moved from the Booster Fabrication Facility.<\/p>\n
\u201cWe start our segment offloads into the RPSF,\u201d Diaz said, starting with the aft segments. \u201cWe do offload those first, because we know that that assembly is going to take a little bit longer, so during that time-frame as we work on that, we\u2019ll be offloading our center segments. We\u2019ll do our grain inspections and our clevis inspections and we\u2019ll get those onto our stands and then we\u2019ll roll those over into the Surge facility.\u201d<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/29215978008_fb7f70e86c_o.35pct.jpg\")
<\/p>\nAn inert center segment is rotated in the RPSF during handling practice activities earlier this year. Credit: NASA\/Ben Smegelsky.<\/p>\n
Talking about the aft segments, Diaz said \u201cWhat we\u2019ll do is our right-hand first, we\u2019ll get that set up, get it onto the stand, and then we\u2019ll go ahead and move over to our left-hand.\u201d<\/p>\n
\u201cEssentially when we start offloading our segments you\u2019ve got the aft skirts already staged in the build up stand and you offload the aft motor, mate it to the skirt, you install the nozzle extension and then you go through the rest of the buildup, which is the Core Stage attach ring, instrumentation, linear-shaped charge, that type of stuff, and that\u2019s about a month of work for each one of those afts.\u201d<\/p>\n
One at a time the aft segments will be placed on a transporter and moved the short distance from the RPSF to High Bay 4 of the VAB, for final preparations to go on the Mobile Launcher. \u201cWe\u2019ll take it off, move it over to the slap stand, prep the surfaces, and then we bring it up and over to High Bay 3,\u201d Diaz explained.<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/KSC-20180130PH_KLS01_0008orig.25pct.jpg\")
<\/p>\nInert SRB hardware in High Bay 4 of the VAB during stacking prep activities earlier this year. The five segments loaded with propellant and the forward assemblies will be staged in HB-4 for lifting up and over the transfer aisle onto the Mobile Launcher in HB-3. Credit: NASA\/Kim Shiflett.<\/p>\n
It\u2019s still very preliminary, but the plan is to alternate work building up the left and right boosters. \u201cWe really haven\u2019t figured that one out yet, but we\u2019re definitely looking to go left, right, so we\u2019ll stagger them and the idea is as we start moving up and we pass our leak checks we can start doing the closeouts on one side as we start stacking on the other side,\u201d Diaz noted.<\/p>\n
\u201cThat\u2019s kind of how we\u2019re going to go all the way until we get to the top.\u201d<\/p>\n
Orion and ICPS servicing prior to stacking<\/p>\n
The first ESM, Flight Model-1, is currently expected to arrive at KSC at the start of November, kicking off a little more than one year\u2019s worth of integration and testing of the Orion spacecraft. The stack of the ESM, Crew Module (CM), and Crew Module Adapter (CMA) will be mated and checked out by Lockheed Martin at the Operations and Checkout (O&C) Building at KSC and then go through a series of tests at the Plum Brook Station at the Glenn Research Center in Ohio before final installs back in Florida.<\/p>\n
The Orion vehicle will then be handed over to EGS and the Spacecraft and Offline Operations team for launch processing. \u201cOur handover point with the Orion vehicle is actually at the O&C,\u201d Villarreal said. \u201cWe\u2019re responsible for going to quote \u2018pick up\u2019 the Orion vehicle.\u201d<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/2014-3838.60pct.jpg\")
<\/p>\nOrion EFT-1 vehicle when it was turned over to NASA in 2014. A similar handover will occur with EM-1. The EM-1 vehicle integrates the second flight Crew Module with the first active Service Module, which includes the European Service Module and Crew Module Adapter. The EFT-1 vehicle substituted mass simulators for most of the Service Module hardware. Credit: NASA\/Daniel Casper.<\/p>\n
\u201cWe\u2019ll use our payload transporter to go pick up the vehicle and then we\u2019ll bring it to the MPPF (Multi-Payload Processing Facility) for servicing. At the MPPF we have a servicing stand that we developed particularly to position Orion and connect to the vehicle from a power, commanding, and servicing panel perspective.\u201d<\/p>\n
\u201cWe\u2019ll hook up all of our GSE (Ground Support Equipment), and the first thing that we do when the vehicle gets there is power up the vehicle and do some post-transportation checkouts before we move into our servicing operation,\u201d she continued.<\/p>\n
\u201cWe have to service some nitrogen tanks and then some helium tanks and then after that we\u2019ll do ammonia servicing for the vehicle\u2019s active thermal control system. And then we\u2019ll go into the [propellant] loading operations for both the CM (Crew Module) and the SM (Service Module).\u201d<\/p>\n
The Spacecraft and Offline Ops team will also service the ICPS in the MPPF before it can be stacked on top of the LVSA. The ICPS is a modified United Launch Alliance (ULA) Delta 4 upper stage, and its attitude control system thrusters use hydrazine.<\/p>\n
![\"\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2018\/10\/2014-4436.65pct.jpg\")
<\/p>\nFully completed Orion launch assembly for EFT-1 rolls past the VAB in late 2014, headed to its Delta 4 Heavy launch vehicle at Pad 37. The EM-1 Orion vehicle will be stacked in the VAB on top of the first SLS vehicle. The Launch Abort System on top is attached to Orion in the Launch Abort System Facility (LASF). Credit: NASA\/Frankie Martin.<\/p>\n
Orion has more commodities that need to be serviced and in larger quantities, and it will go through the MPPF first. \u201cWe\u2019re going to have to wait until we get Orion out of the MPPF to avoid like a traffic jam kind of thing, but when the Orion vehicle is in the LASF (Launch Abort System Facility), that\u2019s when we bring the ICPS over to the MPPF and we\u2019ll go ahead and do the hydrazine load on that prior to going to the VAB and that\u2019s really the only work we\u2019ll do in the MPPF with respect to the ICPS.<\/p>\n
While the ICPS will more or less be ready to stack once it leaves the MPPF, after fueling Orion still has to be integrated with its Launch Abort System (LAS) before it will be transported to the VAB.<\/p>\n","protected":false},"excerpt":{"rendered":"
The processing teams within NASA\u2019s Exploration Ground Systems (EGS) Program are focusing their plans for how they\u2019ll put together the first integrated Orion and Space Launch System (SLS) vehicle to launch Exploration Mission-1 (EM-1). After the spacecraft and launch vehicle components have individually completed all of their first-time and acceptance testing, they will be transported […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":"","_links_to":"","_links_to_target":""},"categories":[2],"tags":[],"class_list":["post-38246","post","type-post","status-publish","format-standard","hentry","category-news"],"acf":[],"_links":{"self":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts\/38246"}],"collection":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/comments?post=38246"}],"version-history":[{"count":0,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts\/38246\/revisions"}],"wp:attachment":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/media?parent=38246"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/categories?post=38246"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/tags?post=38246"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}