-----------------------------------------------------------------------
  MSFC Problem Reporting and Corrective Action (PRACA) System

  WHOLE RECORD REPORT( + ADDENDUM)
  -----------------------------------------------------------------------

+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **In-Flight   | **C       | **      | *    |        |
| Record \#**\ | Anomaly       | ontractor | JSC#**\ | *KSC |        |
| A08606       | Number**\     | Report    | \--     | #**\ |        |
|              | \--           | Number**\ |         | \--  |        |
|              |               | P-049     |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| PROPELLANT   |               |           |         |      |        |
| FEEDLINE     |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
| WAVINESS     |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **EICN#**\   | **ELEMENT**\  | **Cont    | **F     | **   |        |
| \--          | ET            | ractor**\ | SCM#**\ | FCRI |        |
|              |               | MMMSS     | \--     | T**\ |        |
|              |               |           |         | 1    |        |
+--------------+---------------+-----------+---------+------+--------+
| **HCRIT**\   | **Sys_Lvl**\  | **Misc    |         |      |        |
| \--          | N             | Codes**\  |         |      |        |
|              |               | A **(5)** |         |      |        |
|              |               | B C D E F |         |      |        |
|              |               | G H I J K |         |      |        |
|              |               | L M N O   |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| EIM          | EXTERNAL TANK | 82        | LWT-16  | UFAC |        |
|              |               | 601000000 |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | MMC  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| LRU          | N/A           | N/A       | N/A     | UFAC |        |
|              |               |           |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | N/A  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| NCA          | PROPELLANT    | 809210    | 0000045 | UFAC |        |
|              | FEED INST     | 11009-019 |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | MMC  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Test/      | **Prevailing  | **F /     | **Fail  | **   |        |
| Operation**\ | Condtion**\   | U**\      | Mode**\ | Caus |        |
| A - ATP      | F -           | F         | MV -    | e**\ |        |
|              | FUNCTIONAL    |           | EXT     | MP - |        |
|              |               |           | LEAK    | MFG  |        |
|              |               |           |         | -PRC |        |
+--------------+---------------+-----------+---------+------+--------+
| **System**\  | **Defect**\   | **Ma      | **Work  | **   |        |
| PROPULSION   | DA - ROUGH    | terial**\ | Con     | Fail |        |
|              |               | P - SEAL  | tact**\ | Dat  |        |
|              |               |           | C.      | e**\ |        |
|              |               |           | C       | 07   |        |
|              |               |           | AMPBELL | /09/ |        |
|              |               |           |         | 1984 |        |
+--------------+---------------+-----------+---------+------+--------+
| **Received   | **Date        | **FMEA    | **IFA:  | *    |        |
| at MSFC**\   | Isolated**\   | Ref       | Mission | *Mis |        |
| 09/10/1984   | \--           | erence**\ | P       | sion |        |
|              |               | 2.2.2     | hase**\ | Ela  |        |
|              |               |           | \--     | psed |        |
|              |               |           |         | Tim  |        |
|              |               |           |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               | **S       |         | **   |        |
| *Location**\ |               | ymptom**\ |         | Time |        |
| MAF          |               | MV - EXT  |         | Cycl |        |
|              |               | LEAK      |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               |           |         |      |        |
| *Effectivity |               |           |         |      |        |
| Text**\      |               |           |         |      |        |
| NONE         |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    |               |           |         |      |        |
| Effectivity  |               |           |         |      |        |
| Codes**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    | **Vehicle     | **Vehicle | **      | *    |        |
| 1**\         | 2**\          | 3**\      | Vehicle | *Veh |        |
| \--          | \--           | \--       | 4**\    | icle |        |
|              |               |           | \--     | 5**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Mission    |               |           |         |      |        |
| Effectivity  |               |           |         |      |        |
| Codes**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Mssn 1**\  | **Mssn 2**\   | **Mssn    | **Mssn  | **   |        |
| \--          | \--           | 3**\      | 4**\    | Mssn |        |
|              |               | \--       | \--     | 5**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Estimated  |               |           |         |      |        |
| Completion   |               |           |         |      |        |
| Dates**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **Contractor  | **LVL 3   | *       |      |        |
| Approved     | Req Defer     | Close**\  | *Remark |      |        |
| Defer Until  | Until Date**\ | \--       | /       |      |        |
| Date**\      | \--           |           | Ac      |      |        |
| \--          |               |           | tion**\ |      |        |
|              |               |           | \--     |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **I          |               |           |         |      |        |
| nvestigation |               |           |         |      |        |
| / Resolution |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Last MSFC  | **CN RSLV     | **Defer   | **Add   | *    |        |
| Update**\    | SBMT**\       | Date**\   | Date**\ | *R/C |        |
| 12/02/1991   | 09/17/1985    | \--       | \--     | Code |        |
|              |               |           |         | s**\ |        |
|              |               |           |         | 1 -  |        |
|              |               |           |         | DES  |        |
|              |               |           |         | \--  |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Assignee** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| W. COBB      | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | \--           | R.        | M.      | ject |        |
|              |               | JACKSON   | PESSIN  | MG   |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Approval** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| W. COBB      | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | \--           | R.        | M.      | ject |        |
|              |               | JACKSON   | PESSIN  | MG   |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **PAC        | **PAC Review  | **MSFC    | **St    | *    |        |
| Assignee**\  | Complete**\   | Closure   | atus**\ | *F/A |        |
| L. CUNNINGHM | \--           | Date**\   | C -     | C    |        |
|              |               | 1         | CLOSED  | ompl |        |
|              |               | 0/29/1985 |         | etio |        |
|              |               |           |         | n**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    | **SEV**\      | **Program | **      | **O  |        |
| Type**\      | \--           | Name**\   | REVL**\ | PRIN |        |
| \--          |               | \--       | \--     | C**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **FUNC       | **Software    | *         |         | **SU | **So   |
| MOD**\       | E             | *Software |         | BTYP | ftware |
| \--          | ffectivity**\ | Fail      |         | E**\ | C      |
|              | \-- \-- \--   | CD**\     |         | \--  | losure |
|              | \-- \--       | \--       |         |      | CD**\  |
|              |               |           |         |      | \--    |
+--------------+---------------+-----------+---------+------+--------+
| **RES PERSON | **Approval    |           |         |      |        |
| L2**\        | Signature     |           |         |      |        |
| \--          | L3**\         |           |         |      |        |
|              | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| Status       |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Reliabi    |               |           |         |      |        |
| lity/Quality |               |           |         |      |        |
| Assurance    |               |           |         |      |        |
| Concerns,    |               |           |         |      |        |
| Recomm       |               |           |         |      |        |
| endations:** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| D            |               |           |         |      |        |
| escription** |               |           |         |      |        |
|              |               |           |         |      |        |
| REF: DURING  |               |           |         |      |        |
| ATP, THE LH2 |               |           |         |      |        |
| RECIR.       |               |           |         |      |        |
| LI           |               |           |         |      |        |
| NE/UMBILICAL |               |           |         |      |        |
| CONNECTION   |               |           |         |      |        |
| ON LWT-16    |               |           |         |      |        |
|              |               |           |         |      |        |
| INDICATED A  |               |           |         |      |        |
| LEAK RATE    |               |           |         |      |        |
| EXCEEDING    |               |           |         |      |        |
| 4.0 SCIM.    |               |           |         |      |        |
| MAX          |               |           |         |      |        |
| ALLOWABLE IS |               |           |         |      |        |
| .025 SCIM    |               |           |         |      |        |
|              |               |           |         |      |        |
| THIS WAS THE |               |           |         |      |        |
| FIRST ATP    |               |           |         |      |        |
| USING THE    |               |           |         |      |        |
| SEAL CAVITY  |               |           |         |      |        |
| LEAK TEST.   |               |           |         |      |        |
| HOWEVER,     |               |           |         |      |        |
| THIS         |               |           |         |      |        |
|              |               |           |         |      |        |
| IS THE       |               |           |         |      |        |
| ELEVENTH     |               |           |         |      |        |
| SUCH FAILURE |               |           |         |      |        |
| SINCE        |               |           |         |      |        |
| INTRODUCTION |               |           |         |      |        |
| OF THIS      |               |           |         |      |        |
| METHOD AS A  |               |           |         |      |        |
|              |               |           |         |      |        |
| CONFIDENCE   |               |           |         |      |        |
| TEST         |               |           |         |      |        |
| BEGINNING    |               |           |         |      |        |
| WITH LWT-8   |               |           |         |      |        |
| WITH ON,E    |               |           |         |      |        |
| EXCEPTION    |               |           |         |      |        |
| ALL LEAKS    |               |           |         |      |        |
| WERE         |               |           |         |      |        |
|              |               |           |         |      |        |
| ATTRIBUTED   |               |           |         |      |        |
| TO SECONDARY |               |           |         |      |        |
| SEAL SEEPAGE |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| In           |               |           |         |      |        |
| vestigation/ |               |           |         |      |        |
| Resolution** |               |           |         |      |        |
|              |               |           |         |      |        |
| 9/11/84 -    |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
| I            |               |           |         |      |        |
| NVESTIGATION |               |           |         |      |        |
| REVEALED A   |               |           |         |      |        |
| SCRATCH ON   |               |           |         |      |        |
| THE          |               |           |         |      |        |
| UMBILICAL    |               |           |         |      |        |
|              |               |           |         |      |        |
| FLANGE IN    |               |           |         |      |        |
| THE          |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
| SEALING      |               |           |         |      |        |
| SURFACE.     |               |           |         |      |        |
| SUBSEQUENT   |               |           |         |      |        |
| LAPPING      |               |           |         |      |        |
| REVEALED A   |               |           |         |      |        |
|              |               |           |         |      |        |
| WAVINESS     |               |           |         |      |        |
| VIOLATION    |               |           |         |      |        |
| CONSISTING   |               |           |         |      |        |
| OF A RAISED  |               |           |         |      |        |
| RIDGE FROM   |               |           |         |      |        |
| .001 INCH TO |               |           |         |      |        |
| .004         |               |           |         |      |        |
|              |               |           |         |      |        |
| INCH. AFTER  |               |           |         |      |        |
| REWORK, THE  |               |           |         |      |        |
| JOINT WAS    |               |           |         |      |        |
| RETESTED     |               |           |         |      |        |
| S            |               |           |         |      |        |
| UCCESSFULLY. |               |           |         |      |        |
| CAUSE: IS    |               |           |         |      |        |
|              |               |           |         |      |        |
| ATTRIBUTED   |               |           |         |      |        |
| TO UMBILICAL |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
| WAVINESS.    |               |           |         |      |        |
| ADDITIONAL   |               |           |         |      |        |
| TESTING &    |               |           |         |      |        |
|              |               |           |         |      |        |
| I            |               |           |         |      |        |
| NVESTIGATION |               |           |         |      |        |
| IS           |               |           |         |      |        |
| CON          |               |           |         |      |        |
| TINUING.THIS |               |           |         |      |        |
| FAILURE IS   |               |           |         |      |        |
| NOT          |               |           |         |      |        |
| CONSIDERED A |               |           |         |      |        |
| LAUNCH       |               |           |         |      |        |
|              |               |           |         |      |        |
| CONSTRAINT   |               |           |         |      |        |
| TO LWT-8     |               |           |         |      |        |
| BECAUSE THE  |               |           |         |      |        |
| LH2 RECIR    |               |           |         |      |        |
| LI           |               |           |         |      |        |
| NE/UMBILICAL |               |           |         |      |        |
| CONNECTION   |               |           |         |      |        |
| WAS          |               |           |         |      |        |
|              |               |           |         |      |        |
| TESTED       |               |           |         |      |        |
| SUCCESSFULLY |               |           |         |      |        |
| BY THE OLD   |               |           |         |      |        |
| METHOD IN    |               |           |         |      |        |
| BUILDING 420 |               |           |         |      |        |
| PRIOR TO THE |               |           |         |      |        |
|              |               |           |         |      |        |
| INTRODUCTION |               |           |         |      |        |
| OF THE ATP   |               |           |         |      |        |
| SEAL CAVITY  |               |           |         |      |        |
| LEAK TEST.   |               |           |         |      |        |
| THIS         |               |           |         |      |        |
| DECISION HAS |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
|              |               |           |         |      |        |
| COORDINATED  |               |           |         |      |        |
| WITH THE ET  |               |           |         |      |        |
| PROJECT      |               |           |         |      |        |
| OFFICE -     |               |           |         |      |        |
| \_\_\_G. P.  |               |           |         |      |        |
| BRID         |               |           |         |      |        |
| WELL\_\_\_\_ |               |           |         |      |        |
|              |               |           |         |      |        |
| 12/17/84 -   |               |           |         |      |        |
| THIS PROBLEM |               |           |         |      |        |
| IS NOT A     |               |           |         |      |        |
| CONSTRAINT   |               |           |         |      |        |
| TO FUTURE    |               |           |         |      |        |
| LAUNCHES     |               |           |         |      |        |
| SINCE        |               |           |         |      |        |
|              |               |           |         |      |        |
| THESE TESTS  |               |           |         |      |        |
| ARE RUN      |               |           |         |      |        |
| DURING ASSY  |               |           |         |      |        |
| & PRIOR TO   |               |           |         |      |        |
| APPLICATION  |               |           |         |      |        |
| OF           |               |           |         |      |        |
| INSULATION   |               |           |         |      |        |
|              |               |           |         |      |        |
| ALL LEAKS    |               |           |         |      |        |
| ASSOCIATED   |               |           |         |      |        |
| WITH THE LH2 |               |           |         |      |        |
| R            |               |           |         |      |        |
| ECIRCULATION |               |           |         |      |        |
| LINE/        |               |           |         |      |        |
| UMBILICAL    |               |           |         |      |        |
|              |               |           |         |      |        |
| CONNECTION   |               |           |         |      |        |
| ARE REPAIRED |               |           |         |      |        |
| & RETESTED.  |               |           |         |      |        |
| ALL LEAKS    |               |           |         |      |        |
| ARE RESOLVED |               |           |         |      |        |
| PRIOR TO     |               |           |         |      |        |
|              |               |           |         |      |        |
| APPLYING     |               |           |         |      |        |
| INSULATION & |               |           |         |      |        |
| ACCEPTANCE   |               |           |         |      |        |
| TESTING -    |               |           |         |      |        |
| \_\_\_G. P.  |               |           |         |      |        |
| BRIDWELL     |               |           |         |      |        |
|              |               |           |         |      |        |
| 12-          |               |           |         |      |        |
| 11-84\_\_\_. |               |           |         |      |        |
| 3/5/85       |               |           |         |      |        |
| UPDATE FROM  |               |           |         |      |        |
| PRB DATED    |               |           |         |      |        |
| 2-25-85 -    |               |           |         |      |        |
| ENGR\'G      |               |           |         |      |        |
| TESTS NEED   |               |           |         |      |        |
|              |               |           |         |      |        |
| TO BE        |               |           |         |      |        |
| COMPLETED.   |               |           |         |      |        |
| WILL ALSO    |               |           |         |      |        |
| DETERMINE IF |               |           |         |      |        |
| PRACTICE OF  |               |           |         |      |        |
| USING        |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
|              |               |           |         |      |        |
| SEALS WITH   |               |           |         |      |        |
| SCRATCHES    |               |           |         |      |        |
| (BY MRD)     |               |           |         |      |        |
| NEEDS TO BE  |               |           |         |      |        |
| REVIEWED.    |               |           |         |      |        |
| ECD FOR CAPS |               |           |         |      |        |
|              |               |           |         |      |        |
| CLOSURE IS   |               |           |         |      |        |
| END OF MAY,  |               |           |         |      |        |
| 1985 (AFTER  |               |           |         |      |        |
| LWT-23).     |               |           |         |      |        |
| 4/30/85      |               |           |         |      |        |
| UPDATE FROM  |               |           |         |      |        |
| PRB          |               |           |         |      |        |
|              |               |           |         |      |        |
| DATED        |               |           |         |      |        |
| 4-16-85 -    |               |           |         |      |        |
| TWO LEAKS ON |               |           |         |      |        |
| LWT-23 WILL  |               |           |         |      |        |
| EXTEND       |               |           |         |      |        |
| COMPLETION   |               |           |         |      |        |
| APPROX 2     |               |           |         |      |        |
|              |               |           |         |      |        |
| MONTHS.      |               |           |         |      |        |
| CURRENTLY    |               |           |         |      |        |
| THE SILVER   |               |           |         |      |        |
| COATED SEALS |               |           |         |      |        |
| IN STOCK ARE |               |           |         |      |        |
| BEING        |               |           |         |      |        |
| CHECKED      |               |           |         |      |        |
|              |               |           |         |      |        |
| FOR          |               |           |         |      |        |
| FLATNESS.    |               |           |         |      |        |
| WILL         |               |           |         |      |        |
| EVALUATE THE |               |           |         |      |        |
| USE OF A     |               |           |         |      |        |
| TEFLON       |               |           |         |      |        |
| COATED SEAL. |               |           |         |      |        |
| 6/5/85       |               |           |         |      |        |
|              |               |           |         |      |        |
| UPDATE FROM  |               |           |         |      |        |
| PRB DATED    |               |           |         |      |        |
| 5-9-85 -     |               |           |         |      |        |
| THREE LEAKS  |               |           |         |      |        |
| ON LWT-23.   |               |           |         |      |        |
| TAPER        |               |           |         |      |        |
| PROBLEM      |               |           |         |      |        |
|              |               |           |         |      |        |
| WITH NAFLEX  |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
| SEALS.       |               |           |         |      |        |
| WORKING WITH |               |           |         |      |        |
| VENDOR TO    |               |           |         |      |        |
| TIGHTEN      |               |           |         |      |        |
| TOLERANCE    |               |           |         |      |        |
|              |               |           |         |      |        |
| ON SEALS.    |               |           |         |      |        |
| WILL REQUIRE |               |           |         |      |        |
| SPEC CHANGE. |               |           |         |      |        |
| ALSO, WILL   |               |           |         |      |        |
| CHANGE TO    |               |           |         |      |        |
| TEFLON       |               |           |         |      |        |
| COATED       |               |           |         |      |        |
|              |               |           |         |      |        |
| SEALS. ECD   |               |           |         |      |        |
| FOR CAPS     |               |           |         |      |        |
| CLOSURE      |               |           |         |      |        |
| EXTENDED 30  |               |           |         |      |        |
| DAYS TO      |               |           |         |      |        |
| 7-17-85.     |               |           |         |      |        |
| 7/2/85       |               |           |         |      |        |
| UPDATED      |               |           |         |      |        |
|              |               |           |         |      |        |
| FROM PRB     |               |           |         |      |        |
| DATED        |               |           |         |      |        |
| 6-20-85 -    |               |           |         |      |        |
| ALL CLOSURE  |               |           |         |      |        |
| ACTION TASKS |               |           |         |      |        |
| HAVE BEEN    |               |           |         |      |        |
| COMPLETED    |               |           |         |      |        |
|              |               |           |         |      |        |
| EXCEPT ONE,  |               |           |         |      |        |
| WHICH IS     |               |           |         |      |        |
| AWAITING ECP |               |           |         |      |        |
| APPROVAL.    |               |           |         |      |        |
| MMC EXPECTS  |               |           |         |      |        |
| TO HAVE      |               |           |         |      |        |
| CLOSURE      |               |           |         |      |        |
|              |               |           |         |      |        |
| TO MSFC BY   |               |           |         |      |        |
| 7-17-85.     |               |           |         |      |        |
| 8/15/85 PRB  |               |           |         |      |        |
| STATUS -     |               |           |         |      |        |
| ACTION TO    |               |           |         |      |        |
| GENERATE ECP |               |           |         |      |        |
| TO           |               |           |         |      |        |
|              |               |           |         |      |        |
| TIGHTEN SEAL |               |           |         |      |        |
| TOLERANCE    |               |           |         |      |        |
| REMAINS      |               |           |         |      |        |
| OPEN. ECD    |               |           |         |      |        |
| FOR CLOSURE  |               |           |         |      |        |
| HAS BEEN     |               |           |         |      |        |
| SLIPPED      |               |           |         |      |        |
|              |               |           |         |      |        |
| TO 8-31-85.  |               |           |         |      |        |
| 9/20/85 -    |               |           |         |      |        |
| SINCE THE    |               |           |         |      |        |
| INTRODUCTION |               |           |         |      |        |
| OF THE SEAL  |               |           |         |      |        |
| CAVITY LEAK  |               |           |         |      |        |
|              |               |           |         |      |        |
| TEST         |               |           |         |      |        |
| FAILURE,     |               |           |         |      |        |
| OTHER        |               |           |         |      |        |
| RELATED      |               |           |         |      |        |
| PROBLEMS     |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| DISCOVERED & |               |           |         |      |        |
| IDENTIFIED   |               |           |         |      |        |
|              |               |           |         |      |        |
| THESE        |               |           |         |      |        |
| PROBLEMS     |               |           |         |      |        |
| WERE: SEAL   |               |           |         |      |        |
| DAMAGE;      |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
| WAVINESS DUE |               |           |         |      |        |
| TO           |               |           |         |      |        |
| MACHINING;   |               |           |         |      |        |
|              |               |           |         |      |        |
| BOLT         |               |           |         |      |        |
| SHANKING; &  |               |           |         |      |        |
| NAFLEX SEAL  |               |           |         |      |        |
| TAPER.       |               |           |         |      |        |
| DISASSY OF   |               |           |         |      |        |
| THE AFFECTED |               |           |         |      |        |
| JOINT ON     |               |           |         |      |        |
|              |               |           |         |      |        |
| LWT-16       |               |           |         |      |        |
| REVEALED A   |               |           |         |      |        |
| SCRATCH ON   |               |           |         |      |        |
| THE          |               |           |         |      |        |
| UMBILICAL    |               |           |         |      |        |
| FLANGE IN    |               |           |         |      |        |
| THE          |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
|              |               |           |         |      |        |
| SEALING      |               |           |         |      |        |
| SURFACE. IT  |               |           |         |      |        |
| IS NOT KNOWN |               |           |         |      |        |
| DURING WHAT  |               |           |         |      |        |
| OPERATION    |               |           |         |      |        |
| THE SCRATCH  |               |           |         |      |        |
| WAS          |               |           |         |      |        |
|              |               |           |         |      |        |
| INFLICTED.   |               |           |         |      |        |
| SUBSEQUENT   |               |           |         |      |        |
| LAPPING OF   |               |           |         |      |        |
| THE FLANGE   |               |           |         |      |        |
| TO REMOVE    |               |           |         |      |        |
| THE SCRATCH  |               |           |         |      |        |
|              |               |           |         |      |        |
| REVEALED A   |               |           |         |      |        |
| WAVINESS     |               |           |         |      |        |
| VIOLATION    |               |           |         |      |        |
| CONSISTING   |               |           |         |      |        |
| OF A RAISED  |               |           |         |      |        |
| RIDGE FROM   |               |           |         |      |        |
| .001\"       |               |           |         |      |        |
|              |               |           |         |      |        |
| TO .004\"    |               |           |         |      |        |
| RUNNING      |               |           |         |      |        |
| ALONG THE    |               |           |         |      |        |
| INNER        |               |           |         |      |        |
| C            |               |           |         |      |        |
| IRCUMFERENCE |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| FLANGE. THE  |               |           |         |      |        |
|              |               |           |         |      |        |
| UMBILICAL    |               |           |         |      |        |
| WAS LAPPED   |               |           |         |      |        |
| UNTIL ALL    |               |           |         |      |        |
| EVIDENCE OF  |               |           |         |      |        |
| THIS RIDGE   |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| ELIMINATED   |               |           |         |      |        |
|              |               |           |         |      |        |
| CONSIDERING  |               |           |         |      |        |
| SUCCESSFUL   |               |           |         |      |        |
| REWORK &     |               |           |         |      |        |
| RETEST, THE  |               |           |         |      |        |
| CAUSE OF THE |               |           |         |      |        |
| LEAK IS      |               |           |         |      |        |
|              |               |           |         |      |        |
| ATTRIBUTED   |               |           |         |      |        |
| TO THE       |               |           |         |      |        |
| UMBILICAL    |               |           |         |      |        |
| WAVINESS     |               |           |         |      |        |
| VIOLATION.   |               |           |         |      |        |
| THIS ISSUE   |               |           |         |      |        |
| HAS BEEN A   |               |           |         |      |        |
|              |               |           |         |      |        |
| TOPIC OF     |               |           |         |      |        |
| DISCUSSION   |               |           |         |      |        |
| WITH JSC,    |               |           |         |      |        |
| MSFC,        |               |           |         |      |        |
| ROCKWELL &   |               |           |         |      |        |
| MMC & HAS    |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
| ADDRESSED    |               |           |         |      |        |
|              |               |           |         |      |        |
| ON CAPS      |               |           |         |      |        |
| P-046. IT    |               |           |         |      |        |
| HAS BEEN     |               |           |         |      |        |
| DETERMINED   |               |           |         |      |        |
| THAT MSRMNT  |               |           |         |      |        |
| TECHNIQUES   |               |           |         |      |        |
| AT MAF &     |               |           |         |      |        |
|              |               |           |         |      |        |
| PROPULSION   |               |           |         |      |        |
| LINE VENDORS |               |           |         |      |        |
| HAVE NOT     |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
| ADEQUATE;    |               |           |         |      |        |
| THEREFORE, A |               |           |         |      |        |
|              |               |           |         |      |        |
| SATISFACTORY |               |           |         |      |        |
| MSRMNT       |               |           |         |      |        |
| TECHNIQUE    |               |           |         |      |        |
| WILL BE      |               |           |         |      |        |
| ESTABLISHED  |               |           |         |      |        |
| BY MAF       |               |           |         |      |        |
| METROLOGY.   |               |           |         |      |        |
| AS           |               |           |         |      |        |
|              |               |           |         |      |        |
| AN INTERIM   |               |           |         |      |        |
| TECHNIQUE,   |               |           |         |      |        |
| THE METHOD   |               |           |         |      |        |
| ESTABLISHED  |               |           |         |      |        |
| BY ARROWHEAD |               |           |         |      |        |
| PRODUCTS     |               |           |         |      |        |
| WILL         |               |           |         |      |        |
|              |               |           |         |      |        |
| BE UTILIZED  |               |           |         |      |        |
| UNTIL SUCH   |               |           |         |      |        |
| TIME AS      |               |           |         |      |        |
| METROLOGY    |               |           |         |      |        |
| MAKES        |               |           |         |      |        |
| REC          |               |           |         |      |        |
| OMMENDATIONS |               |           |         |      |        |
| & MSRMNT     |               |           |         |      |        |
|              |               |           |         |      |        |
| EQUIPMENT IS |               |           |         |      |        |
| PROCURED.    |               |           |         |      |        |
| MAF          |               |           |         |      |        |
| METROLOGY    |               |           |         |      |        |
| PROPOSED THE |               |           |         |      |        |
| USE OF A     |               |           |         |      |        |
| MODIFIED     |               |           |         |      |        |
|              |               |           |         |      |        |
| GRANITE      |               |           |         |      |        |
| SURFACE      |               |           |         |      |        |
| PLATE WITH A |               |           |         |      |        |
| PRECISION    |               |           |         |      |        |
| DIAL         |               |           |         |      |        |
| INDICATOR &  |               |           |         |      |        |
| HOLDING      |               |           |         |      |        |
| DEVICE       |               |           |         |      |        |
|              |               |           |         |      |        |
| A PROTOTYPE  |               |           |         |      |        |
| UNIT WAS     |               |           |         |      |        |
| FABRICATED & |               |           |         |      |        |
| SUCCESSFULLY |               |           |         |      |        |
| TESTED.      |               |           |         |      |        |
| AFTER MINOR  |               |           |         |      |        |
|              |               |           |         |      |        |
| MODIFICA-    |               |           |         |      |        |
| TIONS,       |               |           |         |      |        |
| PROCUREMENT  |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| INITIATED    |               |           |         |      |        |
| FOR          |               |           |         |      |        |
| PRODUCTION   |               |           |         |      |        |
| UNITS        |               |           |         |      |        |
|              |               |           |         |      |        |
| PRESENTLY,   |               |           |         |      |        |
| THE TOOL IS  |               |           |         |      |        |
| IN USE BY    |               |           |         |      |        |
| MAF REC\'G   |               |           |         |      |        |
| INSPECTION & |               |           |         |      |        |
| ARROWHEAD    |               |           |         |      |        |
|              |               |           |         |      |        |
| PRODUCTS FOR |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
| INSPECTION.  |               |           |         |      |        |
| FIVE         |               |           |         |      |        |
| R            |               |           |         |      |        |
| ECIRCULATION |               |           |         |      |        |
| LINES WERE   |               |           |         |      |        |
| INSPECTED    |               |           |         |      |        |
|              |               |           |         |      |        |
| FOR FLANGE   |               |           |         |      |        |
| WAVINESS     |               |           |         |      |        |
| VIOLATIONS.  |               |           |         |      |        |
| ALL FIVE     |               |           |         |      |        |
| PARTS FAILED |               |           |         |      |        |
| WAVINESS     |               |           |         |      |        |
| CHECKS       |               |           |         |      |        |
|              |               |           |         |      |        |
| VIOLATIONS   |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| MEASURABLE   |               |           |         |      |        |
| FROM .001\"  |               |           |         |      |        |
| TO .003\"    |               |           |         |      |        |
| (SPEC REQMNT |               |           |         |      |        |
| IS +/-       |               |           |         |      |        |
|              |               |           |         |      |        |
| .0003\").    |               |           |         |      |        |
| THE PARTS    |               |           |         |      |        |
| WERE THEN    |               |           |         |      |        |
| LEAKED       |               |           |         |      |        |
| CHECKED      |               |           |         |      |        |
| USING A      |               |           |         |      |        |
| BLANK-OFF    |               |           |         |      |        |
| PLATE        |               |           |         |      |        |
|              |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
| PRODUCED     |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
| LEAKAGE ON   |               |           |         |      |        |
| FOUR OF THE  |               |           |         |      |        |
| FIVE UNITS.  |               |           |         |      |        |
| THE LINES    |               |           |         |      |        |
|              |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| REWORKED BY  |               |           |         |      |        |
| LAPPING & A  |               |           |         |      |        |
| SCAR WAS     |               |           |         |      |        |
| ISSUED TO    |               |           |         |      |        |
| THE VENDOR.  |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
|              |               |           |         |      |        |
| HISTORY FOR  |               |           |         |      |        |
| THE CAVITY   |               |           |         |      |        |
| SEAL LEAK    |               |           |         |      |        |
| CHECK        |               |           |         |      |        |
| INDICATES    |               |           |         |      |        |
| THAT MOST    |               |           |         |      |        |
| PROBLEMS ARE |               |           |         |      |        |
|              |               |           |         |      |        |
| TRACEABLE TO |               |           |         |      |        |
| A WAVINESS   |               |           |         |      |        |
| NON          |               |           |         |      |        |
| CONFORMANCE. |               |           |         |      |        |
| C/A FOR THE  |               |           |         |      |        |
| VENDOR (SCAR |               |           |         |      |        |
|              |               |           |         |      |        |
| 3761-84-082) |               |           |         |      |        |
| STATES THAT  |               |           |         |      |        |
| EQUIPMENT &  |               |           |         |      |        |
| PROCESSES    |               |           |         |      |        |
| USED ARE     |               |           |         |      |        |
| ADEQUATE TO  |               |           |         |      |        |
|              |               |           |         |      |        |
| PRODUCE      |               |           |         |      |        |
| REQ\'D       |               |           |         |      |        |
| RESULTS, &   |               |           |         |      |        |
| PERSONNEL    |               |           |         |      |        |
| WILL BE      |               |           |         |      |        |
| REINSTRUCTED |               |           |         |      |        |
| IN PROPER    |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCEDURE.   |               |           |         |      |        |
| THIS IS      |               |           |         |      |        |
| EFFECTIVE AS |               |           |         |      |        |
| OF 4-19-84.  |               |           |         |      |        |
| PROPULSION   |               |           |         |      |        |
| ENGR\'G WILL |               |           |         |      |        |
|              |               |           |         |      |        |
| IMPLEMENT A  |               |           |         |      |        |
| DWG CHANGE   |               |           |         |      |        |
| TO REQUIRE A |               |           |         |      |        |
| SPECIFIC     |               |           |         |      |        |
| NUMBER OF    |               |           |         |      |        |
| WASHERS BE   |               |           |         |      |        |
| USED         |               |           |         |      |        |
|              |               |           |         |      |        |
| ON           |               |           |         |      |        |
| THROUGH-BOLT |               |           |         |      |        |
| APPLICATIONS |               |           |         |      |        |
| & ALLOW A    |               |           |         |      |        |
| REDUCTION OF |               |           |         |      |        |
| WASHERS AS   |               |           |         |      |        |
|              |               |           |         |      |        |
| NECESSARY,   |               |           |         |      |        |
| TO ACHIEVE   |               |           |         |      |        |
| THE MINIMUM  |               |           |         |      |        |
| TWO THREAD   |               |           |         |      |        |
| PROTRUSION   |               |           |         |      |        |
| REQMNTS OF   |               |           |         |      |        |
| PI           |               |           |         |      |        |
|              |               |           |         |      |        |
| 2014\. IN    |               |           |         |      |        |
| ADDITION, AN |               |           |         |      |        |
| ANALYSIS     |               |           |         |      |        |
| WILL BE      |               |           |         |      |        |
| CONDUCTED ON |               |           |         |      |        |
| BLIND-HOLE   |               |           |         |      |        |
|              |               |           |         |      |        |
| I            |               |           |         |      |        |
| NSTALLATIONS |               |           |         |      |        |
| TO DETERMINE |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
| CONNECTIONS  |               |           |         |      |        |
| WILL         |               |           |         |      |        |
| EXPERIENCE   |               |           |         |      |        |
| BOLT         |               |           |         |      |        |
|              |               |           |         |      |        |
| SHANKING     |               |           |         |      |        |
| DURING A     |               |           |         |      |        |
| WORST CASE   |               |           |         |      |        |
| TOLERANCE    |               |           |         |      |        |
| BUILD UP. IN |               |           |         |      |        |
| THESE AREAS, |               |           |         |      |        |
|              |               |           |         |      |        |
| ADDITIONAL   |               |           |         |      |        |
| WASHERS WILL |               |           |         |      |        |
| BE ADDED TO  |               |           |         |      |        |
| AVOID        |               |           |         |      |        |
| SHANKING.    |               |           |         |      |        |
| THIS ACTION  |               |           |         |      |        |
| WILL         |               |           |         |      |        |
|              |               |           |         |      |        |
| ALSO BE      |               |           |         |      |        |
| ACCOMPLISHED |               |           |         |      |        |
| BY DWG       |               |           |         |      |        |
| CHANGE.      |               |           |         |      |        |
| THREE LEAKS  |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| EXPERIENCED  |               |           |         |      |        |
| AT THE       |               |           |         |      |        |
|              |               |           |         |      |        |
| ECO SENSOR   |               |           |         |      |        |
| BLANK-OFF    |               |           |         |      |        |
| PLATES.      |               |           |         |      |        |
| THESE LEAKS  |               |           |         |      |        |
| WERE ALSO    |               |           |         |      |        |
| ATTRIBUTED   |               |           |         |      |        |
| TO BOLT      |               |           |         |      |        |
|              |               |           |         |      |        |
| SHANKING.    |               |           |         |      |        |
| THIS         |               |           |         |      |        |
| PARTICULAR   |               |           |         |      |        |
| INSTALLATION |               |           |         |      |        |
| WAS NOT A    |               |           |         |      |        |
| SUBJECT OF   |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| TOLERANCE    |               |           |         |      |        |
| ANALYSIS     |               |           |         |      |        |
| CONDUCTED BY |               |           |         |      |        |
| ENGR\'G. AS  |               |           |         |      |        |
| THE ECO      |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| MOUNTING     |               |           |         |      |        |
| BOSS         |               |           |         |      |        |
|              |               |           |         |      |        |
| IS DELETED   |               |           |         |      |        |
| AT LWT-23, A |               |           |         |      |        |
| DWG CHANGE   |               |           |         |      |        |
| WAS NOT      |               |           |         |      |        |
| IMPLEMENTED  |               |           |         |      |        |
| DUE TO THE   |               |           |         |      |        |
|              |               |           |         |      |        |
| LIMITED      |               |           |         |      |        |
| NUMBER OF    |               |           |         |      |        |
| E            |               |           |         |      |        |
| FFECTIVITIES |               |           |         |      |        |
| A DCN WOULD  |               |           |         |      |        |
| SERVE &,     |               |           |         |      |        |
| THAT         |               |           |         |      |        |
| SHANKING     |               |           |         |      |        |
|              |               |           |         |      |        |
| COULD BE     |               |           |         |      |        |
| DETECTED     |               |           |         |      |        |
| DURING LEAK  |               |           |         |      |        |
| TESTING.     |               |           |         |      |        |
| FIVE LEAKS   |               |           |         |      |        |
| HAVE BEEN    |               |           |         |      |        |
| ATTRIBUTED   |               |           |         |      |        |
|              |               |           |         |      |        |
| TO NAFLEX    |               |           |         |      |        |
| SEALS WHICH  |               |           |         |      |        |
| EXHIBIT A    |               |           |         |      |        |
| TAPERED      |               |           |         |      |        |
| CONDITION IN |               |           |         |      |        |
| THE          |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
|              |               |           |         |      |        |
| SEALING      |               |           |         |      |        |
| SURFACE.     |               |           |         |      |        |
| SEALS ARE    |               |           |         |      |        |
| THICKER AT   |               |           |         |      |        |
| THE OUTER    |               |           |         |      |        |
| EDGE OF THE  |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
|              |               |           |         |      |        |
| THAN AT THE  |               |           |         |      |        |
| INBOARD      |               |           |         |      |        |
| EDGE.        |               |           |         |      |        |
| THICKNESS    |               |           |         |      |        |
| VARIA- TIONS |               |           |         |      |        |
| OF .001\" TO |               |           |         |      |        |
| .002\" HAVE  |               |           |         |      |        |
|              |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
| RECORDED     |               |           |         |      |        |
| (SPEC IS     |               |           |         |      |        |
| .001 MAX.).  |               |           |         |      |        |
| ONE GFP SEAL |               |           |         |      |        |
| WAS WITHIN   |               |           |         |      |        |
| TOLERANCE,   |               |           |         |      |        |
|              |               |           |         |      |        |
| BUT ALLOWED  |               |           |         |      |        |
| SECONDARY    |               |           |         |      |        |
| LEAKAGE. THE |               |           |         |      |        |
| SEALS        |               |           |         |      |        |
| EXHIBIT A    |               |           |         |      |        |
| POLISHED     |               |           |         |      |        |
| AREA AT THE  |               |           |         |      |        |
|              |               |           |         |      |        |
| OUTER        |               |           |         |      |        |
| PERIPHERY,   |               |           |         |      |        |
| OUTSIDE THE  |               |           |         |      |        |
| BOLT CIRCLE, |               |           |         |      |        |
| INDICATIVE   |               |           |         |      |        |
| OF THE POINT |               |           |         |      |        |
| AT           |               |           |         |      |        |
|              |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
| SEATING      |               |           |         |      |        |
| OCCURS. THIS |               |           |         |      |        |
| CONDITION    |               |           |         |      |        |
| PROVIDES     |               |           |         |      |        |
| VENTING AT   |               |           |         |      |        |
| ATMOSPHERE   |               |           |         |      |        |
|              |               |           |         |      |        |
| THROUGH THE  |               |           |         |      |        |
| BOLT HOLES.  |               |           |         |      |        |
| AT THIS      |               |           |         |      |        |
| TIME, THE    |               |           |         |      |        |
| VENDOR HAS   |               |           |         |      |        |
| NOT ISOLATED |               |           |         |      |        |
| THIS         |               |           |         |      |        |
|              |               |           |         |      |        |
| DEFECT TO A  |               |           |         |      |        |
| PARTICULAR   |               |           |         |      |        |
| LOT OR DATE  |               |           |         |      |        |
| OF MFR. AT   |               |           |         |      |        |
| VENDOR       |               |           |         |      |        |
| REQUEST, TWO |               |           |         |      |        |
|              |               |           |         |      |        |
| NAFLEX       |               |           |         |      |        |
| CONSUMERS    |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| INFORMED OF  |               |           |         |      |        |
| THIS         |               |           |         |      |        |
| CONDITION    |               |           |         |      |        |
| (ROCKWELL    |               |           |         |      |        |
| /ROCKETDYNE) |               |           |         |      |        |
|              |               |           |         |      |        |
| DISSECTION   |               |           |         |      |        |
| OF A         |               |           |         |      |        |
| DEFECTIVE    |               |           |         |      |        |
| SEAL         |               |           |         |      |        |
| REVEALED THE |               |           |         |      |        |
| PROBLEM TO   |               |           |         |      |        |
| BE A         |               |           |         |      |        |
| VARIATION    |               |           |         |      |        |
|              |               |           |         |      |        |
| OF SUBSTRATE |               |           |         |      |        |
| THICKNESS,   |               |           |         |      |        |
| NOT PLATING  |               |           |         |      |        |
| OR COATING   |               |           |         |      |        |
| THICKNESS.   |               |           |         |      |        |
| ALL FIVE     |               |           |         |      |        |
|              |               |           |         |      |        |
| SEALS WHICH  |               |           |         |      |        |
| FAILED LEAK  |               |           |         |      |        |
| TESTS ARE    |               |           |         |      |        |
| SILVER       |               |           |         |      |        |
| PLATED. IT   |               |           |         |      |        |
| IS THE       |               |           |         |      |        |
| OPINION OF   |               |           |         |      |        |
|              |               |           |         |      |        |
| RELIABILITY  |               |           |         |      |        |
| ASSURANCE    |               |           |         |      |        |
| THAT TEFLON  |               |           |         |      |        |
| COATED SEALS |               |           |         |      |        |
| ARE MORE     |               |           |         |      |        |
| FORGIVING OF |               |           |         |      |        |
|              |               |           |         |      |        |
| THE TAPERED  |               |           |         |      |        |
| CONDITION    |               |           |         |      |        |
| DUE TO THE   |               |           |         |      |        |
| TEFLONS      |               |           |         |      |        |
| THICKNESS &  |               |           |         |      |        |
| ABILITY TO   |               |           |         |      |        |
| COLD         |               |           |         |      |        |
|              |               |           |         |      |        |
| FLOW. IT IS  |               |           |         |      |        |
| ALSO         |               |           |         |      |        |
| BELIEVED     |               |           |         |      |        |
| THAT THE     |               |           |         |      |        |
| MAN- HOLE    |               |           |         |      |        |
| COVER LEAKS  |               |           |         |      |        |
| MAY HAVE     |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
|              |               |           |         |      |        |
| THE RESULT   |               |           |         |      |        |
| OF SECONDARY |               |           |         |      |        |
| TAPER. THE   |               |           |         |      |        |
| INCREASED    |               |           |         |      |        |
| TENSION      |               |           |         |      |        |
| PLACED ON    |               |           |         |      |        |
| THE SEAL     |               |           |         |      |        |
|              |               |           |         |      |        |
| BY REMOVAL & |               |           |         |      |        |
| RE           |               |           |         |      |        |
| INSTALLATION |               |           |         |      |        |
| OF THE BOLTS |               |           |         |      |        |
| MAY HAVE     |               |           |         |      |        |
| CAUSED       |               |           |         |      |        |
| SUFFICIENT   |               |           |         |      |        |
|              |               |           |         |      |        |
| YIELD IN THE |               |           |         |      |        |
| TEFLON       |               |           |         |      |        |
| COATING TO   |               |           |         |      |        |
| STOP THE     |               |           |         |      |        |
| LEAKAGE.     |               |           |         |      |        |
| A            |               |           |         |      |        |
| DDITIONALLY, |               |           |         |      |        |
| IT HAS       |               |           |         |      |        |
|              |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
| DEMONSTRATED |               |           |         |      |        |
| THAT         |               |           |         |      |        |
| RELATIVELY   |               |           |         |      |        |
| LOW TORQUE   |               |           |         |      |        |
| VALUES USED  |               |           |         |      |        |
| AT THE       |               |           |         |      |        |
|              |               |           |         |      |        |
| UMBILICALS   |               |           |         |      |        |
| WILL         |               |           |         |      |        |
| INCREASE THE |               |           |         |      |        |
| AMOUNT OF    |               |           |         |      |        |
| LEAKAGE      |               |           |         |      |        |
| THROUGH THE  |               |           |         |      |        |
| BOLT         |               |           |         |      |        |
|              |               |           |         |      |        |
| PATTERN.     |               |           |         |      |        |
| RESOLUTION - |               |           |         |      |        |
| SEAL CAVITY  |               |           |         |      |        |
| LEAK TESTING |               |           |         |      |        |
| RESULTED IN  |               |           |         |      |        |
| NUMEROUS     |               |           |         |      |        |
|              |               |           |         |      |        |
| LEAKS ON     |               |           |         |      |        |
| LWT\'S       |               |           |         |      |        |
| 16-23. THESE |               |           |         |      |        |
| LEAKS WERE   |               |           |         |      |        |
| ATTRIBUTED   |               |           |         |      |        |
| TO SECONDARY |               |           |         |      |        |
| SEALING      |               |           |         |      |        |
|              |               |           |         |      |        |
| PROBLEMS     |               |           |         |      |        |
| RELATED TO   |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
| WAVINESS,    |               |           |         |      |        |
| BOLT         |               |           |         |      |        |
| SHANKING &   |               |           |         |      |        |
| SEAL TAPER.  |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
|              |               |           |         |      |        |
| WAVINESS WAS |               |           |         |      |        |
| RESPONSIBLE  |               |           |         |      |        |
| FOR LEAKAGE  |               |           |         |      |        |
| ON VEHICLES  |               |           |         |      |        |
| PRIOR TO     |               |           |         |      |        |
| LWT-18. THE  |               |           |         |      |        |
|              |               |           |         |      |        |
| VENDOR\'S    |               |           |         |      |        |
| NEW PROCESS- |               |           |         |      |        |
| ING HAS BEEN |               |           |         |      |        |
| EFFECTIVE IN |               |           |         |      |        |
| REDUCING MAF |               |           |         |      |        |
| REJECTIONS   |               |           |         |      |        |
|              |               |           |         |      |        |
| FOR WAVINESS |               |           |         |      |        |
| TO           |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       |               |           |         |      |        |
| Response/C   |               |           |         |      |        |
| oncurrence** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+

  -----------------------------------------------------------------------
  MSFC Problem Reporting and Corrective Action (PRACA) System

  ASSESSMENT ADDENDUM REPORT
  -----------------------------------------------------------------------

  ----------------- ----------------- ---------------- ----------- ----------- ------------
  **MSFC Report#**\ **IFA#**\         **Contractor     **JSC#**\   **KSC#**\   **EICN#**\
  A08606            \--               RPT#**\          \--         \--         \--
                                      P-049                                    

  **Asmnt Part#**\  **Asmnt Part      **Asmnt                                  
  80921011009-019   Name**\           Serial/Lot#**\                           
                    LH2 RECIR. LINE   45                                       

  **HCRIT CD**\     **FCRIT CD**\     **CAUSE CD**\    **FAIL                  
  \--               1                 MP - MFG-PRC     MODE**\                 
                                                       MV - EXT                
                                                       LEAK                    

  **Asmnt FMEA**\   **Asmnt FM**\     **FMEA CSE**\    **FMEA                  
  2.6.1.1           1                 C                SCSE**\                 
                                                       1                       

  **Asmnt FMEA**\   **Asmnt FM**\     **FMEA CSE**\    **FMEA                  
  \--               \--               \--              SCSE**\                 
                                                       \--                     

  **Asmnt FMEA**\   **Asmnt FM**\     **FMEA CSE**\    **FMEA                  
  \--               \--               \--              SCSE**\                 
                                                       \--                     

  **Correlated      **Correlated      **Correlated                             
  Part#**\          Part#**\          Part#**\                                 
  \--               \--               \--                                      

  **Associated      **Associated      **Associated                             
  LRU#**\           LRU#**\           LRU#**\                                  
  \--               \--               \--                                      

  **MAJOR DESIGN                                                               
  CHANGES**                                                                    

  **APRV DATE**\    **DESCRIPTION OF                                           
  \--               CHANGES**\                                                 
                    \--                                                        

  **ASSESSMENT                                                                 
  TEXT**                                                                       
  ----------------- ----------------- ---------------- ----------- ----------- ------------