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<thead>
<tr class="header">
<th colspan="8"><h1 id="payload-flight-hazard-report">PAYLOAD FLIGHT
HAZARD REPORT</h1></th>
<th>a. NO:</th>
<th colspan="3">AMS-02-F05</th>
</tr>
<tr class="odd">
<th colspan="2">b. PAYLOAD</th>
<th colspan="6">Alpha Magnetic Spectrometer-02 (AMS-02)</th>
<th>c. PHASE:</th>
<th colspan="3">II</th>
</tr>
</thead>
<tbody>
<tr class="odd">
<td colspan="2">d. SUBSYSTEM:</td>
<td colspan="3">Pressurized Systems</td>
<td>e. HAZARD GROUP:</td>
<td colspan="2">Explosion, Contamination</td>
<td>f. DATE:</td>
<td colspan="3">May 25, 2007</td>
</tr>
<tr class="even">
<td colspan="2" rowspan="2">g. HAZARD TITLE:</td>
<td colspan="6" rowspan="2">Rupture of AMS-02 Pressurized Systems: TRD
Gas System (Xe &amp; CO<sub>2</sub>), Cryomagnet Warm Helium Gas System,
Tracker Thermal Control System, Thermal Control Systems,
Cryocoolers</td>
<td>i. HAZARD</td>
<td colspan="2">CATASTROPHIC</td>
<td><strong>X</strong></td>
</tr>
<tr class="odd">
<td>CATEGORY:</td>
<td colspan="2">CRITICAL</td>
<td></td>
</tr>
<tr class="even">
<td colspan="4">h. APPLICABLE SAFETY REQUIREMENTS:</td>
<td colspan="8">NSTS 1700.7B and ISS Addendum: 200.1, 200.1b, 200.2,
200.3, 200.4a, 201.3, 205, 206, 208.1, 208.2, 208.3, 208.4, 208.4a,
208.4b, 208.4c &amp; 208.4e</td>
</tr>
<tr class="odd">
<td colspan="4">j. DESCRIPTION OF HAZARD:</td>
<td colspan="8">Rupture/Explosion of the pressurized systems results in
significant damage to or loss of the STS, ISS, crewmembers and/or other
payloads.</td>
</tr>
<tr class="even">
<td>k. CAUSES</td>
<td colspan="11" rowspan="2"><blockquote>
<p>1. Inadequate design strength for pressure and other loading
environments.</p>
<p>2. Improper material selections and processing.</p>
<p>3. Improper workmanship and/or assembly.</p>
<p>4. Propagation of crack-like defects.</p>
<p>5. Liquefaction/freezing/thawing in lines.</p>
<p>6. Improper filling/over filling of vessel/system.</p>
<p>7. Incorrect commanding of valves.</p>
<p>8. Heater Failure</p>
<p>9. Meteoroid and Orbital Debris (M/OD) impact.</p>
<p>10. Damage to Composite Overwrapped Pressure Vessel</p>
</blockquote></td>
</tr>
<tr class="odd">
<td><em>(list)</em></td>
</tr>
<tr class="even">
<td colspan="12"></td>
</tr>
<tr class="odd">
<td colspan="3">o. APPROVAL</td>
<td colspan="4">PAYLOAD ORGANIZATION</td>
<td colspan="5">SSP/ISS</td>
</tr>
<tr class="even">
<td colspan="3">PHASE I</td>
<td colspan="4"></td>
<td colspan="5"></td>
</tr>
<tr class="odd">
<td colspan="3">PHASE II</td>
<td colspan="4"></td>
<td colspan="5"></td>
</tr>
<tr class="even">
<td colspan="3">PHASE III</td>
<td colspan="4"></td>
<td colspan="5"></td>
</tr>
<tr class="odd">
<td colspan="12"></td>
</tr>
<tr class="even">
<td colspan="10">l. HAZARD CONTROL (CONTROL), m. SAFETY VERIFICATION
METHODS (SVM), n. STATUS OF VERIFICATIONS (STATUS)</td>
<td colspan="2">OPS CONTROL</td>
</tr>
<tr class="odd">
<td colspan="10">1. CAUSE: Inadequate design strength for pressure and
other loading environments.</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.1 CONTROL: The AMS-02 hardware is being designed
to provide positive margins using appropriate factors of safety. The
attached tables provide the MDP, factors of safety and associated
margins per NSTS 1700.7B ISS Addendum paragraph 208.4 for the
pressurized systems addressed in this hazard report. The loading factors
and conditions, mechanical, pressure and thermal have been considered in
establishing a positive margin of safety of the pressure systems
associated with the pressurized systems.</p>
<p>1.1.1 SVM: AMS-02 Pressure Systems Structural/Stress Analysis and
Tests as defined in AMS-02 SVP (JSC 28792).</p>
<p>1.1.1 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>1.2 CONTROL: TRD SYSTEM. The TRD consists of three
zones of pressure control by design. The first zone, referred to as Box
S, contains two pressure zones within it. The high pressure supply and
the low pressure supply to Box C. The high pressure side pressure is
driven by the pressure vessels that provide the Xenon (at 1550 psia,
nominal) and carbon dioxide (at 940 psia). Within these high pressure
tanks the MDP has been established to be 2960 and 2040 psia respectively
in isolation. These values are based on worst case thermal environments
and quantities loaded. As there is a conceivable failure mode that can
cross-link the two high pressure tanks, the mixing of the two gas
supplies yields an approximate <strong>MDP of 3000 psi</strong> (2980
psi calculated), which is the value used for the Box S high pressure
side tanks and lines (3000 psi = 206.8 bar). Within Box S these high
pressure sources are fed through valves and orifices to fill a mixing
tank which has an <strong>MDP of 300 psia (20.68 bar)</strong>. Pressure
monitors are provided in the system to allow for computer control of the
valves to regulate pressure/gas management by opening and closing a
series of valves in each supply line. This MDP is kept from being
exceeded by the computer-controlled valves and orifice delivery system
(level 1) and two parallel, series coupled pressure relief devices set
to 300 psia (260 ± 25psi). Either branch of the pressure relief devices
(Burst disk and pressure relief valve) is capable of handling the full
flow of the gas supplies if all the valves were to open. The burst discs
are provided up-stream of the pressure relief devices for isolation of
the pressure relief valves from the operating loops (Rated 295 psig by
BS&amp;B Safety Systems). The pressure relief devices will be shown to
be insensitive to any debris that the burst disc may generate in
providing MDP protection.</p>
<p>The next zone of the TRD is fed from the mixing tank into Box C,
which provides pumping of the gas to the manifold and TRD sensor
segments (straws). This section also includes the monitor tubes, which
contain a small radioactive source, that monitor the quality of the gas
mixture. Pressure is regulated to a <strong>maximum of 300 psi</strong>
from Box S through valves and orifices, and computer controlled valves
can vent the gas in addition to two pressure relief valves, these three
levels of control (computer controlled valves, two pressure relief
valves) regulate the pressure to <strong>29.4 psia (2.02 bar)
MDP</strong>. TRD pump design can provide gas flow but is designed not
to add to the overall pressure head within the system.</p>
<p>The third zone is the manifold and sensor “straws” the pressure of
which is controlled by <strong>Box C to 29.4 psia (2.02 bar)
MDP</strong>. Gas flow is supplied through the Box C pumps with an
inconsequential pressure head.</p>
<p>1.2.1 SVM: Manufacturer’s Certification/Testing of relief valves to
verify opening pressure and flow capacity.</p>
<p>1.2.2 SVM: Functional testing of computer controlled valves.</p>
<p>1.2.3 SVM: Flow rate analyses (orifice, valve, relief valve flow)</p>
<p>1.2.4 SVM: Functional testing of gas flow pumps</p>
<p>1.2.5 SVM: Pressure system thermal analyses (included in stress
analysis)</p>
<p>1.2.6 SVM: Manufacturer’s qualification/certification of burst
disk.</p>
<p>1.2.7 SVM: Acceptance Testing of Burst disc</p>
<p>1.2.8 SVM: Ground loading procedures to provide proper filling
conditions, quality and quantities.</p>
<p>1.2.9 SVM: COPV Stress Analysis Per ANSI/AIAA S-081</p>
<p>1.2.1 STATUS: Open.</p>
<p>1.2.2 STATUS: Open</p>
<p>1.2.3 STATUS: Open</p>
<p>1.2.4 STATUS: Open</p>
<p>1.2.5 STATUS: Closed. Main TRD gas tank stress analysis documented
thermal analysis results in EG 10348, Fracture and Stress Report of
CO<sub>2</sub>/Xenon Tank Assembly PN C4810/D4852 for TRD Gas Supply
System, Nov 6, 2001. Tanks are identical to Arde tanks previously flown
on ISS.</p>
<p>1.2.6 STATUS: Open</p>
<p>1.2.7 STATUS: Open</p>
<p>1.2.8 STATUS: Open</p>
<p>1.2.9 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.3 CONTROL: WARM HELIUM GAS SUPPLY. The Warm Helium
Gas Supply is designed to have two distinct pressure zones. The high
pressure helium source has an MDP of <strong>244</strong> <strong>bar
(3538</strong> <strong>psi)</strong>, established by the fill quantity
of the warm helium supply tank and the worst case thermal design
environment (higher than expected worst case). The 8.3 liter gas bottle,
a composite wrapped bottle manufactured by Arde, is filled to have a
pressure of 200 bar (2900.7 psi), and under worst case environmental
thermal conditions the pressure could rise to 244 bar (3538 psi). The
Warm Helium Gas Supply does not utilize any heaters. The high pressure
side with the MDP of 244 bar (3538 psi) comprises the gas bottle,
pressure manifold, fill and drain valve MV42, DV22 (A-D) and the MV40 (6
bar pressure regulator).</p>
<p>The low pressure side of the Warm Helium Gas Supply is nominally
regulated to 6 bar (87.0 psi) and is protected by over pressurization by
an 8 bar (116.0 psi) pressure relief device RV03 and RV04. Pressure
within the PVVV is controlled by 10 bar (145.0 psi) burst disks (if the
normally open vents are failed closed). The plumbing in the low pressure
side is 1/8 inch stainless steel piping. All components and lines meet
the appropriate factors of safety as required by NSTS 1700.7. (Exception
to Proof Testing are noted in Control 1.12)</p>
<p>1.3.1 SVM: Manufacturer’s Certification/Testing of relief valve to
verify opening pressure and flow capacity.</p>
<p>1.3.2 SVM: Flow rate analyses (orifice, valve, relief valve flow)</p>
<p>1.3.3 SVM: Pressure system thermal analyses</p>
<p>1.3.4 SVM: Manufacturer’s qualification/certification of burst
disk.</p>
<p>1.3.5 SVM: &lt;deleted with removal of component, ID retained for
recordkeeping&gt;</p>
<p>1.3.6 SVM: Ground loading procedures to provide proper filling
conditions, quality and quantities.</p>
<p>1.3.7 SVM: COPV Stress Analysis Per ANSI/AIAA S-081</p>
<p>1.3.1 STATUS: Open.</p>
<p>1.3.2 STATUS: Open</p>
<p>1.3.3 STATUS: Open</p>
<p>1.3.4 STATUS: Open</p>
<p>1.3.5 STATUS: &lt;deleted with removal of component, ID retained for
recordkeeping&gt;</p>
<p>1.3.6 STATUS: Open</p>
<p>1.3.7 STATUS: Open</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="odd">
<td colspan="10"><p>1.4 CONTROL: TTCS TWO PHASE LOOP. The nominal TTCS
MDP has been established by TTCS fill and the worst case thermal profile
of the TTCS. Heater failure for this system is addressed under Cause 8
of this hazard report. This value is <strong>160 bar (2320 psi)</strong>
and encompasses the extremely small pressure differential across the
circulation pump. All other components and lines are designed to
maintain a safety factor of 4.0 per NSTS 1700.7B and ISS Addendum. NOTE:
<em>The TTCS has a special consideration addressed in Control 5.4 where
segments of the TTCS are susceptible to freezing of the carbon dioxide
working fluid, these components will have a new MDP established based on
the stress of the freeze/thaw cycle.</em></p>
<p>1.4.1 SVM: Thermal Analysis</p>
<p>1.4.2 SVM: Manufacturer’s Certification of TTCS Filling.</p>
<p>1.4.1 STATUS: Open</p>
<p>1.4.2 STATUS: Open. .</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.5 CONTROL: TTCS RADIATOR HEAT PIPES. The AMS-02
TTCS utilizes a seven sealed heat pipes in each of the two Tracker
Radiators that are situated atop the AMS-02. These heat pipes are of
identical design throughout but with varying length, constructed of Al
6063 and filled with ammonia with pipe quantities varying with length
(44.6 – 52.6 grams), 14 mm diameter with a minimum thickness of 1.25 mm.
This heat pipe is manufactured with a 40 mm flange that is used to
interface with the TTCS condensers. These flanges are milled down for
the rest of the heat pipe’s length along the Tracker Radiator. The MDP
of the heat pipes are based on the worst case thermal profile while
on-orbit for the ammonia filled tubes, considering the worst case heater
failures, with a final temperature of the systems as being 50°C. This
MDP is <strong>290 psi (20 bar)</strong> and is inclusive of all heat
pipes although not all heat pipes could possibly see this particular
temperature and pressure. The heat pipes meet a 4.0 factor of safety
satisfying the required 2.5 factor of safety per NSTS 1700.7B and ISS
Addendum. Heater Failure Tolerance is discussed under Cause 8.</p>
<p>1.5.1 SVM: Thermal Analysis of AMS-02 for worst case thermal
condition of heat pipes</p>
<p>1.5.2 SVM: Manufacturer’s Certification of heat pipe filling.</p>
<p>1.5.1 STATUS: Open</p>
<p>1.5.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>1.6 CONTROL: TTCS OHP. &lt;OHP Removed from AMS-02,
Control number retained as deleted entry to maintain accountability&gt;
</p>
<p>1.6.1 SVM: &lt; OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>1.6.2 SVM: &lt; OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>1.6.1 STATUS: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>1.6.2 STATUS: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.7 CONTROL: TTCS Accumulator Heat Pipe. The TTCS
accumulator heat pipe (one on primary and one on secondary TTCS systems)
is unique in that it is integrated into the TTCS carbon dioxide
accumulator structure, a portion of the heat pipe experiences external
pressure as defined by the TTCS system (160 bar) and the rest (100mm
extending outside of the TTCS Accumulator) it’s own internal pressure
under worst case thermal loading conditions of the ammonia working
fluid. The construction of the TTCS Accumulator heat pipe also differs
from other heat pipes as it has a smooth bore with an inserted artery
wick structure along the periphery of the tube and bridging singularly
across the heat pipe to supply wicking effects. The MDP established by
the thermal condition of the heat load applied by the dedicated heaters
in the worst case environment has been established to be <strong>50.2
bar (728.1 psi)</strong> relative to vacuum and the MDP of the portion
interior to the accumulator has been set to the MDP of the accumulator
<strong>(160 bar, 2320.6 psi).</strong> This “interior” MDP could be set
to 160 bar minus the lowest pressure of the heat pipe, but for
simplicity the worst case is assumed. The heat pipes meet a 2.5 factor
of safety per NSTS 1700.7B and ISS Addendum (they are self imposed
against a 4.0 FOS for exterior exposure). Heater Failure Tolerance is
discussed under Cause 8.</p>
<p>1.7.1 SVM: Thermal Analysis of TTCS and TTCS Accumulator Heat Pipe
Operations including failure conditions.</p>
<p>1.7.2 SVM: Manufacturer’s certification on filling the TTCS
Accumulator Heat Pipe</p>
<p>1.7.1 STATUS: Open</p>
<p>1.7.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>1.8 CONTROL: HEAT PIPES. The AMS-02 utilizes a
number of sealed heat pipes throughout its TCS design. These heat pipes
are of axial grove design, constructed of Al 6063. The MDP of the heat
pipes are based on the worst case thermal profile while on-orbit for the
ammonia filled tubes, considering the worst case heater failures. This
MDP for the Wake and Ram Radiator Heat Pipes are <strong>362.5 psi (25
bar)</strong> and is inclusive of all heat pipes although not all heat
pipes could possibly see this particular temperature and hence this
pressure. The USS-02 heat pipes have an MDP of <strong>20.3 bar (294.4
psi)</strong>. The CAB heat pipes have an MDP of <strong>20.0 bar (290
psi)</strong>. The heat pipes meet a 4.0 factor of safety satisfying the
required 2.5 factor of safety per NSTS 1700.7B and ISS Addendum. Heater
Failure Tolerance is discussed under Cause 8.</p>
<p>1.8.1 SVM: Thermal Analysis of AMS-02 for worst case thermal
condition of heat pipes</p>
<p>1.8.2 SVM: Manufacturer’s Certification of heat pipes for proper
filling.</p>
<p>1.8.1 STATUS: Open</p>
<p>1.8.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.9 CONTROL: CAB LOOP HEAT PIPE. The CAB Loop Heat
Pipe is a continuous open loop composed of an evaporator, reservoir,
vapor, liquid and condenser tubes. The entire loop’s MDP is established
based on the worst case thermal profile of the system and the fill
quantity of ammonia. This MDP has been established to be <strong>294.4
psi (20.3 bar)</strong>. The components and lines of the CAB Loop Heat
Pipe will meet the factors of safety required by NSTS 1700.7B and the
ISS Addendum.</p>
<p>1.9.1 SVM: Thermal Analysis of AMS-02 for worst case thermal
condition of CAB Loop Heat Pipe</p>
<p>1.9.2 SVM: Manufacturer’s Certification of CAB Loop Heat Pipe for
proper filling.</p>
<p>1.9.1 STATUS: Open</p>
<p>1.9.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>1.10 CONTROL: CRYOCOOLER LOOP HEAT PIPE/ZENITH
RADIATORS. There are four Cryocooler Loop Heat Pipes systems, internally
each of the four loop heat pipes have parallel, redundant heat loops.
The heat is taken from the Cryocoolers through evaporators (AISI 321)
connected to the Cryocooler collar. The heat pipe at the junction of the
evaporator are stainless steel (AISI 321) tubing, this tubing goes to
the bimetallic transition joint to connect to the AL 6063 tubing (4mm
OD, 3mm ID) which is soldered to the underside of the zenith radiator
panel. The MDP of the Cryocooler Loop Heat Pipe system is established
based on propylene quantity (working fluid) and the maximum temperature
that system can attain. This has been established considering the
thermal load from the Cryocooler, heaters (failed on at 68.5 W) and the
environment. The MDP has been assessed to be <strong>261 psi (18
bar)</strong> with a maximum propylene fill of 42 grams. A bypass valve
has been implemented in the Loop to allow for bypass of the radiators at
low temperatures for performance. This valve does not create any
entrapped volume, only directs flow although its operation is based on
the thermal response of a sealed argon environment within the bypass
valves. All components and lines of the Cryocooler Loop Heat Pipe meet
the appropriate factors of safety of NSTS 1700.7B and ISS Addendum.</p>
<p>1.10.1 SVM: Thermal Analysis of Cryocooler Loop Heat Pipe to
establish MDP.</p>
<p>1.10.2 SVM: Cryocooler Loop Heat Pipe Filling Certification from
Manufacturer</p>
<p>1.10.1 STATUS: Open</p>
<p>1.10.2 STATUS: Open</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.11 CONTROL: CRYOCOOLERS. The Cryocooler is a
Sterling cycle heat pump that consists of the single component that
interfaces thermally with the Cryomagnet system and the Cryocooler Loop
Heat Pipe, but does not interconnect with those pressure systems. The
linear piston (magnetically operated) creates a maximum operating
pressure of 20 bar (294 psi). The MDP has been established not by
operations but while inert at the worst case design temperature of 80°C
(176 °F), this value is <strong>20.3 bar</strong>. This non-operational
condition is a worst case thermal condition compared to full operations
with the heater failed on meant to encompass all possible thermal loads.
The Cryocooler will meet the factors of safety required by NSTS 1700.7B
for pressurized components.</p>
<p>1.11.1 SVM: Thermal Analysis of AMS-02 for worst case thermal
environment</p>
<p>1.11.2 SVM: Manufacturer’s Filling Certification for the
Cryocooler</p>
<p>1.11.1 STATUS: Open</p>
<p>1.11.2 STATUS: Open</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="odd">
<td colspan="10"><p>1.12 CONTROL: Sensitive components on the Cryosystem
preclude testing to the nominal 1.5 margin over MDP. The Weka heliomatic
valve’s activation bellows will distort at pressure 1.5 x MDP making
their continued operations in regulating cryogenic cooling flows
unlikely. For these limited components, a proof test to 1.1 x MDP will
be accomplished.</p>
<p>1.12.1 SVM: Review of AMS-02 Cryosystem Pressure System Proof Test
Plan,</p>
<p>1.12.1 STATUS: Closed. Proof Testing of AMS-02 Pressure System Test
Plan, Space Cryomagnetics, Issue 01, Dated February 15, 2007</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.13 CONTROL: Warm Helium Pilot Valves could
experience a reverse pressure (supplied outside the valve relative to
the internal pressure) of 4 bar. This is established in a blocked PVVV
at 10 bar (just prior to burst disk release) and an internal regulated
pressure of 6 bar. These pilot valves, enclosed by the PVVV have a
calculated to have a minimum 1.7 factor to yield against this pressure
differential. NSTS 1700.7B and the ISS addendum requires a FOS of 1.5
for secondary volumes (the sensitive location is the housing of the
pilot valves made of Acetyl.) At the thermal conditions sufficient to
achieve the 10 bar condition, the Acetyl has passed out of its glass
transition phase and fracture is not its nominal failure more. Any
debris from this event would be contained in the PVVV and would not
propagate a hazard to the pressure system. (See Control 7.3)</p>
<p>1.13.1 SVM: Fracture Analysis of Pilot Valves</p>
<p>1.13.1 STATUS: CLOSED. Scientific Magnetics Memo 2904 from Mark
Gallilee, “Phase 2 Safety:Fracture Control for Pilot Valve in Pilot
Valve Vacuum Vessel (PVVV), dated 02/14/2007.</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">2. CAUSE: Improper material selections and
processing.</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>2.1 CONTROL: All AMS-02 pressure system materials
will be selected to meet the requirements of MSFC-STD-3029 for stress
corrosion cracking. Materials with high resistance to stress corrosion
cracking will be used where possible. Where materials with moderate to
low resistance to stress corrosion cracking are utilized, MUAs have been
prepared and will be submitted for approval.</p>
<p>2.1.1 SVM: Stress Corrosion Evaluation of materials list and
drawings.</p>
<p>2.1.2 SVM: ES4/Material and Processes Branch Certification for
materials usage.</p>
<p>2.1.1 STATUS: Open</p>
<p>2.1.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>2.2 CONTROL: Working fluids/gasses are inert and
will be non-reactive, with the exception of ammonia and propylene. All
working fluids are compatible with all materials of construction.
Materials of construction are principally stainless steel and aluminum.
The TRD (working fluids carbon dioxide and xenon) and Warm helium gas
bottle (Arde) are stainless steel lined, composite overwrapped tanks.
The TRD also has composite-wound sensors through which gas is pumped at
low pressure.</p>
<p>2.2.1 SVM: Materials Compatibility Assessment</p>
<p>2.2.2 SVM: Approval of material use and MUAs by JSC ES4/Materials and
Processes Branch</p>
<p>2.2.1 STATUS: Open</p>
<p>2.2.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>2.3 CONTROLS: Cleaning materials will be compatible
with working fluid and materials of construction.</p>
<p>2.3.1 SVM: Materials Compatibility Assessment/Review</p>
<p>2.3.1 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>2.4 CONTROL: Metallic materials that touch in the
pressure system will be assessed for potential galvanic reactions that
could degrade welds and other joints.</p>
<p>2.4.1 SVM: Material Compatibility Assessment</p>
<p>2.4.2 SVM: Approval of material use and MUAs by JSC ES4/Materials and
Processes Branch</p>
<p>2.4.1 STATUS: Open</p>
<p>2.4.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10">3. CAUSE: Improper workmanship and/or assembly.</td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>3.1 CONTROL: Manufacturing and Assembly AMS-02
pressurized systems will be done in accordance with approved drawings
and procedures. Manufacturing and Assembly processes have certification
processes in place to document compliance with approved drawings and
procedures.</p>
<p>3.1.1 SVM: All discrepancies and deviations from approved
drawings/procedures are reconciled through a MRB process to assure
compliance with requirements.</p>
<p>3.1.1 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>3.2 CONTROL: All welds will be compliant to the
standards of the AMS-02 weld policy (compliant with JSC standards for
welding).</p>
<p>3.2.1 SVM: Review of weld plans, processes and certification of welds
of the AMS-02 systems. ES4 approval.</p>
<p>3.2.2 SVM: Proof Pressure Testing, Dye Penetrant inspection,
Radiological (or ultrasound) inspection of welds.</p>
<p>3.2.1 STATUS: Open</p>
<p>3.2.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">4. CAUSE: Propagation of crack-like defects.</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>4.1 CONTROL: The AMS-02 pressurized systems uses JSC
25863A to implement the fracture control requirements of NASA-STD-5003
and SSP 30558C.</p>
<p>4.1.1 SVM: Compliance with the fracture control requirements of
NASA-STD-5003 and SSP-30558C will be verified by approval of fracture
control summary by JSC ES4/Materials and Processes Branch.</p>
<p>4.1.1 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">5. CAUSE: Liquefaction/freezing/thawing in lines</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>5.1 CONTROL: TRD GAS SUPPLY. The TRD Gas Supply
system (CO2 &amp; Xenon) will not freeze under the worst case thermal
conditions that the system will experience on-orbit. The high pressure
TRD system is mounted on a common thermal plate to keep the entire high
pressure side thermally uniform. The lowest temperature that has been
assessed for the TRD system, using an indefinite period at the worst
possible cold attitude with no other attitudes occurring (extremely
conservative), to be -50°C (-43°C at 200 hours of exposure with
asymptotic approach to approximately -50°C). Even with TRD heaters
failed on for the tank only (more than two failures), driving the
pressure up, and heaters off for the lines and components, the
pressure-temperature curve for CO<sub>2</sub> will not transition to
solid phase. Xenon’s physical properties make it more difficult to
freeze than CO<sub>2</sub>. The low pressure side does not have a
constant supply of carbon dioxide sufficient to fill a potentially
frozen segment with CO<sub>2</sub>. Liquid CO<sub>2</sub> is prevented
from going from the CO<sub>2</sub> tank to the lines by a dual heater
system (Side A and B) that will keep the CO<sub>2</sub> gaseous before
entering the high pressure lines. If power is lost for the heaters,
power is also lost for operating the valves (normally close) that would
allow for the introduction of liquid CO<sub>2</sub> into potentially
isolated segments. Heater operations on these isolated segments are
controlled in a 2 fault tolerant manner, reference Control 8.1.</p>
<p>5.1.1 SVM: AMS-02 Thermal Assessment</p>
<p>5.1.2 SVM: TRD Thermal Assessment for Freezing of CO<sub>2</sub> and
Xenon</p>
<p>5.1.3 SVM: Review of TRD Heater Design for fault tolerant design.</p>
<p>5.1.1 STATUS: Open</p>
<p>5.1.2 STATUS: Open</p>
<p>5.1.3 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>5.2 CONTROL: WARM HELIUM GAS SUPPLY. The Cryomagnet
Warm Helium Supply will utilize the same quality of helium as used to
fill the Cryomagnet for superfluid helium, minimizing the potential for
contaminants that could freeze solid, plug lines and create a pressure
build up. In order to achieve solid (frozen) helium a pressure in excess
of 25 atmospheres is required to compress the cryogenic helium, a
pressure the AMS-02 can not achieve.</p>
<p>5.2.1 SVM: Loading procedures to assure purity of helium loaded into
Warm Helium Gas Supply.</p>
<p>5.2.2 SVM: Analysis/Review of Helium Freezing Potential</p>
<p>5.2.1 STATUS: Open</p>
<p>5.2.2 STATUS: Closed. Memo ESCG-4390-06-SP-MEMO-0002, “Freezing of
Helium withing AMS-02” dated 8 December 2005, from AMS-02 Chief Engineer
Chris Tutt.</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>5.3 CONTROL: TTCS TWO PHASE LOOP. The Tracker
Thermal Control System (TTCS) will freeze under a loss of power from the
ISS under worst case thermal conditions at the condensers, located on
the Tracker Radiators. The TTCS components subject to freezing have had
their MDPs established based on a freezing event and subsequent
heating/thawing that results in a trapped volume of carbon dioxide. The
condenser tubes of the TTCS could freeze and thaw and the resulting MDP
has been established to be 3009 bar (43641.9 psi). Special proof testing
and NDE will be conducted on the sample lot of the tubing used in the
construction of the condensers to allow for a reduction in the
acceptable factor of safety (per ES4). Using standard techniques of
analysis, the tubing indicates a burst proof factor of safety of 2.14,
but if the material’s strain hardening is taken into account this value
rises to 4.6. Thermal Analysis indicates that all other TTCS system
components and lines are not subjected to freezing potential.</p>
<p>5.3.1 SVM: Testing of carbon dioxide freezing/heating cycles</p>
<p>5.3.2 SVM: Thermal Analysis</p>
<p>5.3.3 SVM: MDP Analysis based on worst case thermal profiles and two
failures (if applicable)</p>
<p>5.3.4 SVM: Review and approval of testing plan for freezing/thawing
lines by JSC/ES4.</p>
<p>5.3.5 SVM: Testing/analysis of flight hardware per testing plan of
5.3.4.</p>
<p>5.3.6 SVM: Thermal Analysis of TTCS System to establish
freezing/non-freezing elements.</p>
<p>5.3.1 STATUS: Open</p>
<p>5.3.2 STATUS: Open</p>
<p>5.3.3 STATUS: Open</p>
<p>5.3.4 STATUS: Open</p>
<p>5.3.5 STATUS: Open</p>
<p>5.3.6 STATUS: Closed. ESCG-4470-06-TEAN-DOC-0032, "Alpha Magnetic
Spectrometer (AMS-02) Tracker Thermal Control System (TTCS) Cold
Environment Temperatures), Dated March 22, 2006, from ESCG/E. L. Yagoda
indicates no other system elements will freeze.</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>5.4 CONTROL: TTCS ACCUMULATOR HEAT PIPE. The TTCS
Accumulator Heat Pipe is filled with 3 grams of ammonia and will not
reach temperatures that can freeze the ammonia. NOTE: Even if the
ammonia were capable of freezing, the straight pipe construction with
interior mesh and fill quantity of the heat pipe would preclude an
accumulation of a solid block of ammonia.</p>
<p>5.4.1 SVM: Thermal Analysis</p>
<p>5.4.1 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>5.5 CONTROL: HEAT PIPES. The design of the ammonia
heat pipes allows for the ammonia to condense and freeze without damage
to the heat pipes. The low quantity of ammonia, interior shape of heat
pipes and the melting/vaporization of the ammonia cannot create trapped
volumes that can generate elevated pressures.</p>
<p>5.5.1 SVM: Review of design</p>
<p>5.5.2 SVM: Vendor Certification/Testing</p>
<p>5.5.1 STATUS: Open</p>
<p>5.5.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>5.6 CONTROL: &lt; OHP Removed from AMS-02, Control
number retained as deleted entry to maintain accountability&gt;.</p>
<p>5.6.1 SVM: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>5.6.2 SVM: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>5.6.3 SVM: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>5.6.1 STATUS: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>5.6.2 STATUS: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>5.6.3 STATUS: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>5.7 CONTROL: CAB LOOP HEAT PIPE. The Cryogenic
Avionics Box Loop Heat Pipe was established to have a small segment that
had the potential to freeze ammonia with the loss of AMS-02 power.
Thermal MLI insulation has been applied to these segments to allow a
greater than 10°C margin over the freezing temperature of ammonia
(-78°C).</p>
<p>5.7.1 SVM: Thermal Analysis of CAB Loop Heat Pipe</p>
<p>5.7.2 SVM: Review of Design</p>
<p>5.7.3 SVM: Inspection of as built hardware.</p>
<p>5.7.1 STATUS: Closed. AMS-02-TN-CGS-010. 7/03/2005</p>
<p>5.7.2 STATUS: Open</p>
<p>5.7.3 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>5.8 CONTROL: Cryocooler Loop Heat Pipe/Zenith
Radiator. Propylene freezes at a temperature of -185.25°C (-301.4°F),
this temperature is substantially colder than the worst case thermal
environment that the Cryocooler Loop Heat Pipe/Zenith Radiator can
achieve.</p>
<p>5.8.1 SVM: Thermal Analysis showing worst case cold temperature for
Cryocooler Loop Heat Pipe/Zenith Radiator</p>
<p>5.8.2 SVM: Filling Procedure/Certification of Fill</p>
<p>5.8.1 STATUS: Open</p>
<p>5.8.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>5.9 CONTROL: Cryocoolers. The working fluid for the
Cryocoolers is 0.72 grams of helium, and the Cryocooler is incapable of
achieving temperatures (77 K, temperatures must approach &lt;2 K to
freeze) and pressures needed (MDP 20 bar, 25+ bar needed to freeze
helium) to freeze helium. In addition as the system does not have lines
and fittings of a traditional sort where freeze/thaw is considered to be
a hazard, the cryocoolers have no risk even if the helium could
freeze.</p>
<p>5.9.1 SVM: Analysis/Review of Helium Freezing Potential</p>
<p>5.9.2 SVM: Manufacturer’s certification of fill.</p>
<p>5.9.1 STATUS: Closed. Memo ESCG-4390-06-SP-MEMO-0002, “Freezing of
Helium withing AMS-02” dated 8 December 2005, from AMS-02 Chief Engineer
Chris Tutt.</p>
<p>5.9.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">6. CAUSE: Improper filling/over filling of
vessel/system.</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>6.1 CONTROL: All pressurized systems will be filled
with high purity gases and appropriate quantities.</p>
<p>6.1.1 SVM: Review of TRD Ground Filling Procedures.</p>
<p>6.1.2 SVM: Review of Warm Helium Gas Supply Filling Procedures.</p>
<p>6.1.3 SVM: Review of Tracker Thermal Control System Filling
Procedures.</p>
<p>6.1.4 SVM: Manufacturers’ certifications on filling of Ammonia Heat
Pipes.</p>
<p>6.1.5 SVM: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>6.1.6 SVM: Manufacturer’s certification on filling of CAB Loop Heat
Pipe</p>
<p>6.1.7 SVM: Manufacturer’s certification on filling Cryocooler Loop
Heat Pipe/Zenith Radiators</p>
<p>6.1.8 SVM: Manufacturer’s certification on filling Cryocooler.</p>
<p>6.1.1 STATUS: Open</p>
<p>6.1.2 STATUS: Open</p>
<p>6.1.3 STATUS: Open</p>
<p>6.1.4 STATUS: Open</p>
<p>6.1.5 STATUS: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>6.1.6 STATUS: Open</p>
<p>6.1.7 STATUS: Open</p>
<p>6.1.8 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">7. CAUSE: Incorrect commanding of valves.</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>7.1 CONTROL: TRD SYSTEM. The TRD system has a
potential for entrapping gas and liquid between controlling valves.
Nominally redundant line heaters on the gas feed lines from the tanks
will prevent liquid from being present in the lines and thus taken into
the entrapped volume. Heater operations may individually fail, but a
total power loss for the system would preclude opening the valves as the
valves are normally closed. Computer operations will not allow the
valves to cycle if the temperature of the line is not at a level to
prevent the introduction of liquid into the lines. A pressure relief
device set to leak back starting at a 25 psi differential and full flow
capability at a 100 psi differential is provided in the first entrapped
volume to allow any liquid in the line to be relieved back into the tank
(which can not be at or near MDP to have liquid present to cause this
condition). <em>NOTE: In addition to these three levels of control, the
TRD valves (Marotta MV 197) will relieve under a back pressure
differential of 1535 psid (Manufactuer’s Data). Assuming that the
highest pressure upstream is the MDP of the system (which can not be the
case and have liquid to ingest into the lines to cause it to occur) the
maximum pressure of this segment considering two failures would be 4535
psia. In this extreme unrealistic case of compounded failures, after
<strong>three</strong> failures, the factor of safety of the lines, and
fittings are 2.8 not the required 4.0 (after two failures).</em></p>
<p>7.1.1 SVM: Review of TRD Design</p>
<p>7.1.2 SVM: Inspection of TRD Flight hardware</p>
<p>7.1.3 SVM: Functional testing of thermal interlock of valve
operations</p>
<p>7.1.4 SVM: Testing of Pressure Relief Valves</p>
<p>7.1.5 SVM: Thermal Analysis</p>
<p>7.1.1 STATUS: Open</p>
<p>7.1.2 STATUS: Open</p>
<p>7.1.3 STATUS: Open</p>
<p>7.1.4 STATUS: Open</p>
<p>7.1.5 STATUS: Open</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="odd">
<td colspan="10"><p>7.2 CONTROL: TTCS TWO PHASE LOOP. &lt;VALVES HAVE
BEEN DELETED FROM DESIGN&gt;</p>
<p>7.2.1 SVM: &lt;DELETED&gt;</p>
<p>7.2.1 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>7.3 CONTROL: WARM HELIUM GAS SUPPLY. Valve
operations within the Warm Helium Gas Supply do not result in entrapped
volumes that can exceed the established MDPs for the systems. Normal
Valve operations of the Weka valves will release helium within the Pilot
Valve Vacuum Vessel as part of normal operation. Nominally this volume
is vented through valves DV 20 A-D, and in the event these redundant
valve systems fail closed or are commanded closed burst disks (in
parallel) provide a third level of control to preclude pressures
exceeding 10 bar (145 psi). In the failure case prior to burst disk
operation, the exterior pressurization of the housings of the valves
maintains a 1.7 margin of safety over the damage threshold. The possible
damage to the housing of the pilot valve is not considered a pressure
system failure in the usual sense, but a component damage event,
secondary pressurized volumes. This design meets the design factor of
safety of 1.5 per NSTS 1700.7B and ISS Addendum by analysis. (See
Control 1.13)</p>
<p>7.3.1 SVM: Design margin analysis on Pilot Valve damage from
externally supplied pressure.</p>
<p>7.3.1 STATUS: Closed. Scientific Magnetics Memorandum 2904, Phase 2
Safety: Fracture Control for pilot Valves in Pilot Valve Vacuum Vessel
(PVVV), from Mark Gallilee, dated February 14, 2007</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">8. CAUSE: Heater Failure</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>8.1 CONTROL: TRD GAS SUPPLY. The TRD utilizes
heaters to allow for pressure sensing within the TRD tanks (unable to
measure liquid state). These heaters are capable of causing a condition
where the MDP would be exceeded if the heaters are failed on and the
system is exposed to the worst case thermal environment. To preclude
these heaters from failing on, there are four thermostatic control
devices controlling the operation of the heaters (two in return leg of
heaters) in addition to a computer control of the heater’s operations
through heater power application and thermal feedback from temperature
sensors. Four are used to assure that there are no proximity failures
(of heaters) that would make a thermostatic control less responsive
assuring two fault tolerance. Each of the TRD tanks utilizes two strings
of heaters, and each string has independent controls (computer is not
tallied as a safety control). Thermal set points for the TRD system are
attached to this hazard report. TRD Gas Supply isolated segments from
the xenon and carbon dioxide tanks, used to control the mass of gas
introduced into the system, are protected from thermal extremes
generated by the valve block heater runaway by the use of two fault
tolerance thermostatic control on each heater, with one of the
thermostatic devices in the return leg of the heater circuit.</p>
<p>8.1.1 SVM: Review of Design</p>
<p>8.1.2 SVM: Thermal Analysis (establishing maximum temperature
settings and thermal sensitivity of thermostatic control locations.</p>
<p>8.1.3 SVM: Functional testing/Acceptance testing of thermostatic
switches.</p>
<p>8.1.4 SVM: Inspection of flight hardware for proper installation of
thermostatic switches.</p>
<p>8.1.1 STATUS: Open</p>
<p>8.1.2 STATUS: Open</p>
<p>8.1.3 STATUS: Open</p>
<p>8.1.4 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>8.2 CONTROL: WARM HELIUM GAS SUPPLY. The Warm Helium
Gas Supply does not utilize any heaters nor is the warm helium gas
supply tank subject to excessive heating.</p>
<p>8.2.1 SVM: Review of Design</p>
<p>8.2.1 STATUS: Open</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="even">
<td colspan="10"><p>8.3 CONTROL: TTCS HEAT PIPES. The heaters on the
TTCS radiator heat pipes will utilize two fault tolerance in the
implementation of thermostatic control of the heaters. To preclude these
heaters from failing on, there are three thermostatic control devices
controlling the operation of the heaters (one in return leg of heaters)
in addition to a computer control of the heater’s operations through
heater power application and thermal feedback from temperature sensors.
Each string of the heaters on the radiators is controlled in this two
fault tolerance manner. The thermostatic threshold for the heaters is
set to -35ºC to -25 ºC.</p>
<p>8.3.1 SVM: Review of Design for inclusion of heater thermostatic
control and thermal threshold values</p>
<p>8.3.2 SVM: Thermal Analysis to Establish MDP</p>
<p>8.3.3 SVM: Functional testing/Acceptance Testing of thermostatic
switches.</p>
<p>8.3.4 SVM: Inspection of flight hardware for proper installation of
thermostatic switches.</p>
<p>8.3.1 STATUS: Open</p>
<p>8.3.2 STATUS: Open</p>
<p>8.3.3 STATUS: Open</p>
<p>8.3.4 STATUS: Open</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="odd">
<td colspan="10"><p>8.4 CONTROL: TTCS TWO PHASE LOOP. The Tracker
Thermal Controls System utilizes heaters on the two phase loop that are
not controlled in a two-fault tolerant means to prevent continuous
heater operation. Thermal analysis of the two phase loop indicates that
only the temperature of the accumulator is capable of driving the
pressure of the system to MDP. Failed on heaters on the “loop” will only
force the liquid phase of the working fluid to an alternate location.
Only single thermostatic control is implemented at these line heaters.
The accumulator heater system implements a two-fault tolerant heater
control circuitry as described in Control 8.5. Note: Controls 8.5 and
8.11 document heater elements that are capable of driving the pressure
of the TTCS Two Phase Loop.</p>
<p>8.4.1 SVM: Analysis of TTCS Two Phase Loop thermal response to failed
heater operations.</p>
<p>8.4.1 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>8.5 CONTROL: TTCS ACCUMULATOR HEAT PIPE/TTCS
ACCUMULATOR. The TTCS Accumulator is heated by the TTCS accumulator heat
pipe that is situated down the center of the accumulator and possibly by
Peltier Devices attached to the Accumulator shell. The accumulator heat
pipe extends out of the accumulator and is fitted with heaters and
thermostatic switches. These heaters/Peltier devices will be controlled
by thermostatic control devices that are attached to the heat pipe and
accumulator by way of thermally conductive fixtures. The thermostatic
control for the heaters/Peltier devices is two fault tolerant, with one
thermostatic control device implemented in the return leg of the
heaters. NOTE: In addition to heater control by thermostatic devices,
the pressure of the TTCS is monitored and a computer system is capable
of shutting down the heater sources if the pressure is too high for
efficient operations, this value is lower than the MDP.</p>
<p>8.5.1 SVM: Review of Design for inclusion of heater thermostatic
control and thermal threshold values</p>
<p>8.5.2 SVM: Thermal Analysis to Establish MDP</p>
<p>8.5.3 SVM: Functional testing/Acceptance Testing of thermostatic
switches.</p>
<p>8.5.4 SVM: Inspection of flight hardware for proper installation of
thermostatic switches.</p>
<p>8.5.1 STATUS: Open</p>
<p>8.5.2 STATUS: Open</p>
<p>8.5.3 STATUS: Open</p>
<p>8.3.4 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>8.6 CONTROL: HEAT PIPES. The worst case thermal
conditioning for heat pipes consider the heaters that have been provided
on the Tracker Radiator – RAM, Main Radiator – RAM, Tracker Radiator –
Wake, Main Radiator – Wake, CAB heat pipe and the PDS heat pipes. Each
of these heater systems has implemented a two fault tolerant system for
inhibiting heater operations over the thermal threshold that could
induce pressures over the MDP. (Set points for some thermostats are
lower than the thermal environments that actually drive the MDP.) All
heater systems utilize one thermostatic switch in the power leg, one in
the return leg that are set to lower, health maintenance temperatures
below the safety limit and a third “safety” thermostat that is dedicated
to precluding exceeding the safety threshold for temperature (60°C, main
radiators) under worst case conditions and faults. Note: Independent of
the safety controls there is a computer based, thermal sensor driven
control of the entire heater circuitry power supply that will activate
if temperature gets too high to protect the electronics.</p>
<p>8.6.1 SVM: Heater Fault Tolerance Thermal Analysis</p>
<p>8.6.2 SVM: Review of design for inclusion of heater thermostatic
control and thermal threshold values</p>
<p>8.6.3 SVM: Inspection of Flight Hardware to assure proper
thermostatic control placement and parts used.</p>
<p>8.6.4 SVM: Functional testing of thermostatic switches/Acceptance
testing.</p>
<p>8.6.1 STATUS: Open. Christian Vettore has completed the essential
work and will be producing the final report. (11/18/2005)</p>
<p>8.6.2 STATUS: Open</p>
<p>8.6.3 STATUS: Open</p>
<p>8.6.4 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>8.7 CONTROL: CAB LOOP HEAT PIPE. The CAB Loop Heat
Pipe is indirectly heated by heaters within the CAB box used to keep the
avionics within an operating temperature range. These heaters are
limited by thermostatic control (single fault tolerant) and computer
based control from exceeding the CAB operating threshold temperatures.
The upper thermal limit of the CAB Loop Heat Pipe is established by this
temperature and hence the MDP for the heat pipes. At least one
thermostatic control devices will be located in the return leg of the
heater circuit.</p>
<p>8.7.1 SVM: Review of Design for inclusion of heater thermostatic
control and thermal threshold values</p>
<p>8.7.2 SVM: Thermal Analysis to Establish MDP</p>
<p>8.7.3 SVM: Functional testing/Acceptance Testing of thermostatic
switches and computer control</p>
<p>8.7.4 SVM: Inspection of flight hardware for proper installation of
thermostatic switches.</p>
<p>8.7.1 STATUS: Open</p>
<p>8.7.2 STATUS: Open</p>
<p>8.7.3 STATUS: Open</p>
<p>8.7.4 STATUS: Open</p></td>
<td colspan="2"><mark></mark></td>
</tr>
<tr class="odd">
<td colspan="10"><p>8.8 CONTROL: CRYOCOOLER LOOP HEAT PIPE. The
Cryocooler Loop Heat Pipe and the extension of those heat pipes into the
Zenith Radiators (four heat pipes) utilize a heater attached to the
individual Cryocoolers attached thermally to the loop heat pipes
evaporators. The thermal load of the Cryocoolers under worst case
conditions, fault and environmental conditions has been used to
establish the MDP for the loop heat pipes. This fault condition is
controlled by a single thermostat dedicated to the heater (68.5 W)
itself, and as the Cryocooler provides the actual driving heat source,
two independent thermocontrol devices will shut down the Cryocooler
operations (150W max) when the thermal threshold is met. The MDP of the
Cryocooler Loop Heat Pipe is established under this fault condition.</p>
<p>8.8.1 SVM: Review of design to assure single thermostatic control of
heater and Cryocooler thermal cut off devices and control.</p>
<p>8.8.2 SVM: Inspection of the flight hardware for inclusion of
thermostatic control for heater and Cryocooler cut off devices.</p>
<p>8.8.3 SVM: Thermal Analysis of Cryocooler Loop Heat Pipe to establish
MDP.</p>
<p>8.8.1 STATUS: Open</p>
<p>8.8.2 STATUS: Open</p>
<p>8.8.3 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>8.9 CONTROL: CRYOCOOLERS. The each Cryocooler is
equipped with a 68.5 watt heater with a single thermostatic control and
the heat load of the Cryocooler operating at it’s maximum capability is
150W. This heater has been assessed for failed on conditions and with
the operating thermal load of the Cryocooler. MDPs of the Cryocooler and
the Cryocooler Loop Heat Pipe/Zenith Radiator have been established
based on this analysis.</p>
<p>8.9.1 SVM: Review of design to assure single thermostatic control of
heater and cryocooler thermal cut off devices and control.</p>
<p>8.9.2 SVM: Inspection of the flight hardware for inclusion of
thermostatic control for heater and cryocooler cut off devices.</p>
<p>8.9.3 SVM: Thermal Analysis of Cryocooler to establish MDP.</p>
<p>8.9.1 STATUS: Open</p>
<p>8.9.2 STATUS: Open</p>
<p>8.9.3 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>8.10 CONTROL: &lt;OHP Removed from AMS-02, Control
number retained as deleted entry to maintain accountability&gt;</p>
<p>8.10.1 SVM: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p>
<p>8.10.2 STATUS: &lt;OHP Removed from AMS-02, SVM number retained as
deleted entry to maintain accountability&gt;</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>8.11 CONTROL: TTCS Start Up Heaters. The TTCS Start
Up Heaters have been assessed as being capable of driving the pressure
of the TTCS CO2 loops sufficiently to warrant two fault tolerant
thermostatic control devices to be implemented on each of the TTCS Start
Up Heater loops. These thermostatic switches have been set to thermal
threshold values that will preclude the TTCS Start Up Heaters from
driving the pressure of the TTCS two phase loop beyond the established
MDP. Two thermostatic control devices are in the source (power) to the
heater elements and a single thermostatic control device in the return
leg from the heater elements.</p>
<p>8.11.1 SVM: Review of Design for inclusion of heater thermostatic
control and thermal threshold values</p>
<p>8.11.2 SVM: Thermal Analysis to Establish MDP</p>
<p>8.11.3 SVM: Functional testing/Acceptance Testing of thermostatic
switches.</p>
<p>8.11.4 SVM: Inspection of flight hardware for proper installation of
thermostatic switches.</p>
<p>8.11.1 STATUS: Open</p>
<p>8.11.2 STATUS: Open</p>
<p>8.11.3 STATUS: Open</p>
<p>8.11.4 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">9. CAUSE: Meteoroid and Orbital Debris (M/OD)
impact.</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>9.1 CONTROL: All pressurized tanks will be protected
by M/OD shields. The shields are designed to meet the Probability of
Non-Penetration (PNP) requirement of SSP 52005. While the AMS-02 will
have an extended on-orbit life, the pressurized tanks will only
represent a hazardous condition for a limited period of time before the
pressure reserves are spent. Each tank will be assessed for PNP for the
duration of operational life.</p>
<p>9.1.1 SVM: AMS-02 M/OD Risk Analysis</p>
<p>9.1.2 SVM: Analysis of AMS-02 pressurized system utilization to
establish on-orbit penetration threat life duration (period during which
M/OD represents a hazard to the pressure vessel.)</p>
<p>9.1.1 STATUS: Open</p>
<p>9.1.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>9.2 CONTROL: The Warm Helium Tank will release any
residual helium gas through cycling of pilot valves at the end of the
Cryomagnet’s life (loss of superfluid helium after approximately 5
years).</p>
<p>9.2.1 SVM: Review of design/Analysis to confirm ability to empty
residual gas from Warm Helium Supply Tank.</p>
<p>9.2.2 SVM: Review of Procedures for inclusion of Warm Helium Supply
Residual Release (AMS Project Procedure)</p>
<p>9.2.1 STATUS: Closed. Scientific Magnetics Memorandum 2903, Phase 2
Safety: System for Dumping of Warm Helium Supply at Mission End, from
Mark Gallilee, dated February 14, 2007</p>
<p>9.2.2 STATUS: Open</p></td>
<td colspan="2">I(A)</td>
</tr>
<tr class="even">
<td colspan="10"><p>9.3 CONTROL: The TRD Xenon and Carbon Dioxide Tanks
will continue to be utilized after the end of life of the
superconducting magnet taking scientific data. Upon depletion of one
supply, the other supply will be slowly released through the TRD purging
system until the tank is also depleted.</p>
<p>9.3.1 SVM: Review of design/Analysis to confirm ability to empty
residual gas from TRD Pressurized Tanks.</p>
<p>9.3.2 SVM: Review of Procedures for inclusion of TRD Pressurized Tank
Residual Release (AMS Project Procedure)</p>
<p>9.3.1 STATUS: Open</p>
<p>9.3.2 STATUS: Open</p></td>
<td colspan="2">I(A)</td>
</tr>
<tr class="odd">
<td colspan="10">10.0 CAUSE: Damage to Composite Overwrapped Pressure
Vessel</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>10.1 CONTROL: All Composite Overwrapped Pressure
Vessels will implement the ground handling damage control requirements
of ANSI/AIAA S-081 for the protection and inspection of COPV.</p>
<p>10.1.1 SVM: Review of TRD COPV Protection Protocols</p>
<p>10.1.2 SVM: Review of Warm Helium Gas Supply COPV Protection
Protocols</p>
<p>10.1.3 SVM: Inspection of TRD COPVs (at late in process as possible
prior to flight)</p>
<p>10.1.4 SVM: Inspection of Warm Helium Gas Supply COPV (at late in
process as possible prior to flight)</p>
<p>10.1.1 STATUS: Open</p>
<p>10.1.2STATUS: Open</p>
<p>10.1.3STATUS: Open</p>
<p>10.1.4STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>10.2 CONTROL: Thermostatic control of the heaters
mounted to the exterior of the TRD Composite Overwrapped Pressure
Vessels have four thermostatic control devices that are set to a thermal
limit below the temperature that could possibly induce
delaminations.</p>
<p>10.2.1 SVM: Arde Certification of thermostatic control
acceptability.</p>
<p>10.2.2 SVM: Inspection of as built hardware for proper thermostat
installation.</p>
<p>10.2.1 STATUS: Open</p>
<p>10.2.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10">NOTES:</td>
<td colspan="2"></td>
</tr>
</tbody>
</table>

  -----------------------------------------------------------------------
  ACRONYMS                           
  ---------------------------------- ------------------------------------
  °C -- degrees Centigrade (Celsius) mm -- millimeter

  AIAA -- American Institute         MUAs -- Material Usage Agreements
  Aeronautics and Astronautics       

  AMS-02 -- Alpha Magnetic           OHP -- Oscillating Heat Pipe
  Spectrometer - 02                  (experiment)

  ANSI -- American National          PNP -- Probability of No Penetration
  Standards Institute                

  CAB -- Cryomagnet Avionics Box     psi -- Pounds per square inch

  CO~2~ -- Carbon Dioxide            psia -- Pounds per square inch
                                     absolute

  COPV -- Composite Overwrapped      SVM -- Safety Verification Method
  Pressure Vessel                    

  He -- Helium                       SVP -- Structural Verification Plan

  HP -- Heat Pipe                    TRD -- Transition Radiation Detector

  M/OD -- Meteoroid/Orbital Debris   TTCS -- Tracker Thermal Control
                                     System

  MDP -- Maximum Design Pressure     USS-02 -- Unique Support Structure
                                     02

  MLI -- Multilayer insulation       Xe -- Xenon

  C of C -- Certificate of           ksi -- kilo pounds per square inch
  Compliance                         

  lbf -- pound force                 mbar -- millibar

  MUA -- Material Usage Agreements   Ops -- Operations

  QA -- Quality Assurance            Ult - Ultimate
  -----------------------------------------------------------------------

**A. TRD Gas Supply**

<table>
<colgroup>
<col style="width: 9%" />
<col style="width: 8%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 6%" />
<col style="width: 9%" />
</colgroup>
<thead>
<tr class="header">
<th colspan="17"><strong>TRD Pressure System Components</strong></th>
</tr>
<tr class="odd">
<th rowspan="3"><p> </p>
<p>Description</p>
<p> </p></th>
<th rowspan="3">Material Of Construction</th>
<th colspan="2" rowspan="2"><p>Mass</p>
<p>Of Fluid </p></th>
<th colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure (max)</p></th>
<th colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></th>
<th colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></th>
<th colspan="2">Burst SF</th>
<th colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></th>
<th rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></th>
<th rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></th>
<th rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></th>
</tr>
<tr class="header">
<th rowspan="2">Req</th>
<th rowspan="2">Actual</th>
</tr>
<tr class="odd">
<th>kg</th>
<th>lbm</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
</tr>
</thead>
<tbody>
<tr class="odd">
<td>Xe Storage Vessel, ARDE D4815 (similarity: D4636) <sup>2</sup></td>
<td>Carbon Fiber Overwrapped Stainless Steel Liner</td>
<td>49.4</td>
<td>109</td>
<td>173</td>
<td>2500</td>
<td>206.8</td>
<td>3,000</td>
<td>641.2</td>
<td>9,300</td>
<td>2</td>
<td>3.1</td>
<td>310.3</td>
<td>4500</td>
<td>1.5</td>
<td>Similarity &amp; Test</td>
<td>MIL-STD-1522A<br />
SSP 30559C</td>
</tr>
<tr class="even">
<td>CO<sub>2</sub> Storage Vessel, ARDE D4816 (similarity: D4683)
<sup>2</sup></td>
<td>Carbon Fiber Overwrapped Stainless Steel Liner</td>
<td>5.0</td>
<td>11.0</td>
<td>100</td>
<td>1440</td>
<td>206.8</td>
<td>3,000</td>
<td>441.3</td>
<td>6,400</td>
<td>2</td>
<td>2.1</td>
<td>330.9</td>
<td>4800</td>
<td>1.6</td>
<td>Similarity &amp; Test</td>
<td>SSP 30559C</td>
</tr>
<tr class="odd">
<td>Mixing Vessel, ARDE C4810 <sup>2</sup></td>
<td>Stainless Steel</td>
<td>0.1</td>
<td>0.22</td>
<td>13.8</td>
<td>200</td>
<td>20.7</td>
<td>300</td>
<td>82.7</td>
<td>1,200</td>
<td>2</td>
<td>4.0</td>
<td>41.4</td>
<td>600</td>
<td>2</td>
<td>Test</td>
<td>SSP 30559C</td>
</tr>
<tr class="even">
<td>TRD "Straw" Tubes</td>
<td>Wrapped Carbon-Kapton-Aluminum Composite</td>
<td>1.17 </td>
<td>2.58 </td>
<td>1.2</td>
<td>17..4</td>
<td>2.0</td>
<td>29.4</td>
<td>&gt;5</td>
<td>&gt;72.5</td>
<td>2</td>
<td>2.5</td>
<td>3.0</td>
<td>44.1</td>
<td>1.5</td>
<td>Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Plumbing Line 1/8"</td>
<td>Stainless Steel</td>
<td>0.003</td>
<td>0.01</td>
<td>120.0</td>
<td>1,740</td>
<td>206.8</td>
<td>3,000</td>
<td>882.5</td>
<td>12,800</td>
<td>4</td>
<td>4.3</td>
<td>413.7</td>
<td>6,000</td>
<td>2</td>
<td>Test</td>
<td> </td>
</tr>
<tr class="even">
<td>Plumbing Line 1/4"</td>
<td>Stainless Steel</td>
<td>0.005</td>
<td>0.01</td>
<td>120.0</td>
<td>1,740</td>
<td>206.8</td>
<td>3,000</td>
<td>882.5</td>
<td>12,800</td>
<td>4</td>
<td>4.3</td>
<td>413.7</td>
<td>6,000</td>
<td>2</td>
<td>Test</td>
<td>NSTS 17007B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Plumbing Line 1/16"</td>
<td>Stainless Steel</td>
<td>&lt;0.001</td>
<td>&lt;0.002</td>
<td>1.2</td>
<td>17.4</td>
<td>2.0</td>
<td>29.4</td>
<td>&gt;11.0</td>
<td>160</td>
<td>4</td>
<td>5.44</td>
<td>3</td>
<td>44.1</td>
<td>1.5</td>
<td>Test</td>
<td>NSTA 17007B SSP 30559 C</td>
</tr>
<tr class="even">
<td>TRD segment metal fitting</td>
<td>Stainless steel aluminum Viton</td>
<td>&lt;0.001</td>
<td>&lt;0.002</td>
<td>1.2</td>
<td>17.4</td>
<td>2.0</td>
<td>29.4</td>
<td>&gt;11.0</td>
<td>160</td>
<td>4</td>
<td>5.44</td>
<td>3</td>
<td>44.1</td>
<td>1.5</td>
<td>Test</td>
<td>NSTA 17007B SSP 30559 C</td>
</tr>
<tr class="odd">
<td>Marotta MV 100 Valves <sup>2</sup></td>
<td>See Data Sheet</td>
<td>&lt;0.002</td>
<td>0.004</td>
<td>2.0</td>
<td>29.4</td>
<td>20.7</td>
<td>300</td>
<td>517.1</td>
<td>7,500</td>
<td>2.5</td>
<td>25</td>
<td>310.3</td>
<td>4,500</td>
<td>15</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B Marotta Spec SP 1200</td>
</tr>
<tr class="even">
<td>Marotta MV 197 Valves <sup>2</sup></td>
<td>See Data Sheet</td>
<td>&lt;0.002</td>
<td>0.004</td>
<td>106.9</td>
<td>1,550</td>
<td>206.8</td>
<td>3,000</td>
<td>1,723.7</td>
<td>25,000</td>
<td>2.5</td>
<td>8.3</td>
<td>868.7</td>
<td>12,600</td>
<td>4.2</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B Marotta Spec SP 1200</td>
</tr>
<tr class="odd">
<td>Bürkert Type 6124 Flipper Valves Manifold: VA, B, C,
D)<sup>9</sup></td>
<td>See Data Sheet</td>
<td>N/A</td>
<td>N/A</td>
<td>1.2</td>
<td>17.4</td>
<td>2.0</td>
<td>29.4</td>
<td>8.6</td>
<td>125</td>
<td>2.5</td>
<td>4.3</td>
<td>3.0</td>
<td>44.1</td>
<td>1.5</td>
<td>Similarity &amp; Test</td>
<td> </td>
</tr>
<tr class="even">
<td>GP-50 Pressure Sensors <sup>3</sup></td>
<td>See Data Sheet</td>
<td>&lt;0.002</td>
<td>0.004</td>
<td>1.4</td>
<td>20.4</td>
<td>2.0</td>
<td>29.4</td>
<td>41.4</td>
<td>600</td>
<td>2.5</td>
<td>20.4</td>
<td>13.8</td>
<td>200.0</td>
<td>6.8</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>GP-50 Pressure Sensors <sup>3</sup></td>
<td>See Data Sheet</td>
<td>&lt;0.002</td>
<td>&lt;0.004</td>
<td>13.8</td>
<td>200</td>
<td>20.7</td>
<td>300</td>
<td>62.1</td>
<td>900</td>
<td>2.5</td>
<td>3.0</td>
<td>41.4</td>
<td>600</td>
<td>2</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>GP-50 Pressure Sensors <sup>3</sup></td>
<td>See Data Sheet</td>
<td>&lt;0.002</td>
<td>&lt;0.004</td>
<td>106.9</td>
<td>1,550</td>
<td>206.8</td>
<td>3,000</td>
<td>620.5</td>
<td>9,000</td>
<td>2.5</td>
<td>3.0</td>
<td>413.7</td>
<td>6,000</td>
<td>2</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Kulite Pressure Senosrs <sup>3</sup></td>
<td>Stainless Steel</td>
<td>&lt;0.002</td>
<td>&lt;0.004</td>
<td>13.8</td>
<td>200</td>
<td>20.7</td>
<td>300</td>
<td>62.1</td>
<td>900</td>
<td>2.5</td>
<td>3.0</td>
<td>41.4</td>
<td>600</td>
<td>2</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Kulite Pressure Senosrs <sup>3</sup></td>
<td>Stainless Steel</td>
<td>&lt;0.002</td>
<td>&lt;0.004</td>
<td>106.9</td>
<td>1,550</td>
<td>206.8</td>
<td>3,000</td>
<td>620.5</td>
<td>9,000</td>
<td>2.5</td>
<td>3.0</td>
<td>310.3</td>
<td>4,500</td>
<td>1.5</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>TheLeeCo restictors</td>
<td>Stainless Steel, 304L</td>
<td>N/A</td>
<td>N/A</td>
<td>20.7</td>
<td>300</td>
<td>206.8</td>
<td>3,000</td>
<td>413.7</td>
<td>6,000</td>
<td>2.5</td>
<td>2.0</td>
<td>TBD</td>
<td>TBD</td>
<td>TBD</td>
<td>Test</td>
<td> </td>
</tr>
<tr class="even">
<td>7 micron Inline Filters</td>
<td>See Data Sheet</td>
<td>N/A</td>
<td>N/A</td>
<td>106.9</td>
<td>1,550</td>
<td>206.8</td>
<td>3,000</td>
<td>827.4</td>
<td>12,000</td>
<td>2.5</td>
<td>4.0</td>
<td>TBD</td>
<td>TBD</td>
<td>TBD</td>
<td>Similarity &amp; Test</td>
<td> </td>
</tr>
<tr class="odd">
<td>Pressure Container for CO<sub>2</sub> sensor, Box C <sup>4,
5</sup></td>
<td>Stainless Steel</td>
<td>&lt;0.01</td>
<td>&lt;0.02</td>
<td>1.2</td>
<td>17.4</td>
<td>2.0</td>
<td>29.4</td>
<td>4.1</td>
<td>58.8</td>
<td>2</td>
<td>2.0</td>
<td>3.0</td>
<td>44.1</td>
<td>1.5</td>
<td>Test</td>
<td>MIL-STD-1522A<br />
SSP 30559C</td>
</tr>
<tr class="even">
<td>Monitor Tubes</td>
<td>Stainless Steel CrNi 18.10</td>
<td>&lt;0.002</td>
<td>&lt;0.004</td>
<td>1.2</td>
<td>17.4</td>
<td>2.0</td>
<td>29.4</td>
<td>8.1</td>
<td>117.6</td>
<td>4</td>
<td>4.0</td>
<td>3.0</td>
<td>44.1</td>
<td>1.5</td>
<td>Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Pumps</td>
<td>See Data Sheet</td>
<td>&lt;0.002</td>
<td>&lt;0.004</td>
<td>1.2</td>
<td>17.4</td>
<td>1.7</td>
<td>25.0</td>
<td>2.4</td>
<td>35.0</td>
<td>N/A </td>
<td>N/A</td>
<td>N/A</td>
<td>N/A</td>
<td>N/A</td>
<td>Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Marotta Pressure Relief Valves <sup>2</sup></td>
<td>See Data Sheet</td>
<td>&lt;.002</td>
<td>&lt;0.004</td>
<td>13.8</td>
<td>200</td>
<td>20.7</td>
<td>300</td>
<td>61.0</td>
<td>885</td>
<td>2.5</td>
<td>3.0</td>
<td>32.8</td>
<td>475</td>
<td>1.6</td>
<td>Similarity &amp; Test</td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Pressure Relief Valve Box C</td>
<td>See Data Sheet</td>
<td>&lt;.002</td>
<td>&lt;0.004</td>
<td>1.2</td>
<td>17.4</td>
<td>2.0</td>
<td>29.4</td>
<td>20.7</td>
<td>300.0</td>
<td>2.5</td>
<td>10.2</td>
<td>3.0</td>
<td>44.1</td>
<td>1.5</td>
<td>Test</td>
<td>MIL-STD-1522A<br />
SSP 30559C</td>
</tr>
<tr class="even">
<td>Burst Disks Box S <sup>2 ,6</sup></td>
<td>Stainless Steel</td>
<td>&lt;.002</td>
<td>&lt;0.004</td>
<td>13.8</td>
<td>200</td>
<td>20.3</td>
<td>295</td>
<td>20.3</td>
<td>295</td>
<td>N/A</td>
<td>N/A</td>
<td>N/A</td>
<td>N/A</td>
<td>N/A</td>
<td>Similarity &amp; Test</td>
<td>BS &amp; B, M.S. 18</td>
</tr>
<tr class="odd">
<td>Xe Fill Port Valves</td>
<td>Stainless Steel</td>
<td> </td>
<td> </td>
<td>106.9</td>
<td>1550</td>
<td>206.8</td>
<td>3,000</td>
<td>TBD</td>
<td>TBD</td>
<td>2.5</td>
<td>TBD</td>
<td> </td>
<td>TBD</td>
<td>TBD</td>
<td> </td>
<td> </td>
</tr>
<tr class="even">
<td>CO<sub>2</sub> Fill Port Valves <sup>4</sup></td>
<td>Stainless Steel</td>
<td> </td>
<td> </td>
<td>64.8</td>
<td>940</td>
<td>206.8</td>
<td>3,000</td>
<td>TBD</td>
<td>TBD</td>
<td>2.5</td>
<td>TBD</td>
<td> </td>
<td>TBD</td>
<td>TBD</td>
<td> </td>
<td> </td>
</tr>
<tr class="odd">
<td>Xe Fill Port Caps <sup>4</sup></td>
<td>Stainless Steel</td>
<td> </td>
<td> </td>
<td>106.9</td>
<td>1550</td>
<td>206.8</td>
<td>3,000</td>
<td>TBD</td>
<td>TBD</td>
<td>2.5</td>
<td>TBD</td>
<td> </td>
<td>TBD</td>
<td>TBD</td>
<td> </td>
<td> </td>
</tr>
<tr class="even">
<td>CO<sub>2</sub> Fill Port Caps <sup>4</sup></td>
<td>Stainless Steel</td>
<td> </td>
<td> </td>
<td>64.8</td>
<td>940</td>
<td>206.8</td>
<td>3,000</td>
<td>TBD</td>
<td>TBD</td>
<td>2.5</td>
<td>TBD</td>
<td> </td>
<td>TBD</td>
<td>TBD</td>
<td> </td>
<td> </td>
</tr>
<tr class="odd">
<td colspan="17"><p>Notes:</p>
<p><sup>1</sup> MDP has been established based on worst case thermal
profile and where applicable (with mechanisms to fail) worst case two
fault condition.</p>
<p><sup>2</sup> Pressure is in psig.</p>
<p><sup>3</sup> Pressure is in psia</p>
<p><sup>4</sup> Manufactured at CERN and pressure is in psia</p>
<p><sup>5</sup> As per data approved by Peter Fisher, file:
TRD_gas-press.doc, 06/23/2004</p>
<p><sup>6</sup> Burst pressure equals 5% to the stamped burst pressure
of 295 psig; proof SF is 80% of stamped burst pressure.</p>
<p>7) All 328 Straw modules have been tested to 1.8 bar (26.1 psid)</p>
<p>8) Maximum applied test pressure</p>
<p>9) The valves are completely contained inside potted magnetic
shielding</p></td>
</tr>
</tbody>
</table>

  -----------------------------------------------------------------------
  ![](media/image1.jpeg){width="8.736805555555556in" height="5.95in"}

  **TRD Box S**

  ![](media/image2.png){width="7.7652777777777775in"
  height="5.9215277777777775in"}

  **TRD Box C**

  ![](media/image3.jpeg){width="8.986805555555556in"
  height="2.066666666666667in"}

  **TRD Manifold-Straw Representation**

  ![](media/image4.jpeg){width="8.970833333333333in"
  height="1.1333333333333333in"}

  **Legend for TRD Schematics**

  ![](media/image5.png){width="8.34375in" height="4.59375in"}

  **TRD Tank Heaters**

  ![](media/image6.jpeg){width="6.466666666666667in" height="4.85in"}

  **TRD GAS Tanks With Installed Heaters**

  ![](media/image7.png){width="6.677083333333333in"
  height="4.166666666666667in"}

  **TRD Gas Valve Block Heater**
  -----------------------------------------------------------------------

+-----------------------------------------------------------------------+
| **Location**                                                          |
|                                                                       |
|   --------------- ------                                              |
| --------- ---------- --------- --------------- ------------ --------- |
|   **Temperature                                                       |
|    **Average       **T Open** **T       **Tolerance**   **Number**    |
|   Range**                                                             |
|    Temperature**              Close**                                 |
|                                                                       |
|   Xe Tank                                                             |
|   20°C-65°C       42.5°C     49°C      38°C            ±2.8°C       8 |
|                                                                       |
|   CO2 Tank                                                            |
|   34°C-65°C       48.5°C     54        43              ±2.8°C       8 |
|                                                                       |
|   Tower                                                               |
|   24°C-41°C       32.5°C     38        27              ±2.8°C       2 |
|                                                                       |
|   2 Valve                                                             |
|   5°C-39°C        22°C       27        16              ±2.8°C       4 |
|   Filters, 2                                                          |
|                                                                       |
|   Valve GP50                                                          |
|                                                                       |
|                                                                       |
|   4 Valve, Vent                                                       |
| 5°C-39°C        22°C       27        16              ±2.8°C       4+1 |
|   Valve                                                               |
|                                                                       |
|                                                                       |
|   Box C                                                               |
| 7°C-24°C        15.5°C     21        10              ±2.8°C       2+1 |
|                                                                       |
|   Preheater                                                           |
|   34°C -65°C      48.5°C     54        43              ±2.8°C       8 |
|   --------------- ------                                              |
| --------- ---------- --------- --------------- ------------ --------- |
+-----------------------------------------------------------------------+
| **TRD Gas Supply Thermostat List**                                    |
+-----------------------------------------------------------------------+
| ![](media/image8.png){width="7.507638888888889in"                     |
| height="5.845833333333333in"}                                         |
+-----------------------------------------------------------------------+
| TRD coldest thermal conditions assuming greater than 200 hours in     |
| coldest attitude and power off.                                       |
+-----------------------------------------------------------------------+

**B. Warm Helium Gas Supply**

**Warm Helium Gas Supply Pressure System Components**

<table style="width:100%;">
<colgroup>
<col style="width: 7%" />
<col style="width: 8%" />
<col style="width: 8%" />
<col style="width: 7%" />
<col style="width: 5%" />
<col style="width: 6%" />
<col style="width: 6%" />
<col style="width: 9%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 8%" />
<col style="width: 5%" />
<col style="width: 6%" />
<col style="width: 10%" />
</colgroup>
<thead>
<tr class="header">
<th><strong>Description</strong></th>
<th><strong>Volume</strong></th>
<th><p><strong>Operating</strong></p>
<p><strong>Pressure</strong></p></th>
<th><p><strong>Material</strong></p>
<p><strong>(See Note 2)</strong></p></th>
<th><strong>Temp</strong></th>
<th><strong>MDP</strong></th>
<th><p><strong>MDP</strong></p>
<p><strong>Determin-ation</strong></p></th>
<th><p><strong>Burst</strong></p>
<p><strong>Pressure</strong></p></th>
<th colspan="2"><p><strong>Burst</strong></p>
<p><strong>Safety Factor</strong></p></th>
<th><p><strong>Proof</strong></p>
<p><strong>Pressure</strong></p></th>
<th><p><strong>Proof</strong></p>
<p><strong>SF</strong></p></th>
<th><p><strong>Basis</strong></p>
<p><strong>(See</strong></p>
<p><strong>Note 3)</strong></p></th>
<th><p><strong>Reference</strong></p>
<p><strong>Document</strong></p></th>
</tr>
<tr class="odd">
<th><strong>Units</strong></th>
<th><p><strong>Liter</strong></p>
<p><strong>(in^3)</strong></p></th>
<th><p><strong>Bar</strong></p>
<p><strong>(psid)</strong></p></th>
<th></th>
<th><strong>(K)</strong></th>
<th><p><strong>Bar</strong></p>
<p><strong>(psid)</strong></p></th>
<th></th>
<th><p><strong>Bar</strong></p>
<p><strong>(psid)</strong></p></th>
<th><strong>Reqd</strong></th>
<th><strong>Actual</strong></th>
<th><p><strong>Bar</strong></p>
<p><strong>(psid)</strong></p></th>
<th></th>
<th><p><strong>A:Analysis</strong></p>
<p><strong>T:Test</strong></p></th>
<th></th>
</tr>
</thead>
<tbody>
<tr class="odd">
<td><p>Burst Disc</p>
<p>BD17A</p>
<p>BD17B</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>-1 (-14.5)</td>
<td><p>Stainless steel</p>
<p>316L</p>
<p>Nickel 200</p></td>
<td>300</td>
<td><p>11 (159.5)</p>
<p>See</p>
<p>Note 6</p></td>
<td>-</td>
<td>-</td>
<td><h1 id="section">-</h1></td>
<td>-</td>
<td>-</td>
<td>-</td>
<td><p>T</p>
<p>(TBD)</p></td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td><h1 id="section-1"></h1></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
<tr class="odd">
<td><p>Warm valves</p>
<p>DV20A-D</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>-1 (-14.5)</td>
<td>CRES</td>
<td>300</td>
<td>10 (145)</td>
<td>See Note 1</td>
<td>689.7 (10000)</td>
<td><h1 id="section-2">2.5</h1></td>
<td>45</td>
<td>413.8(6000)</td>
<td>41.4</td>
<td>-</td>
<td>See Manufacturers Qualification Docs (TBD)</td>
</tr>
<tr class="even">
<td><p>Warm valves</p>
<p>DV22A-D</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>CRES</td>
<td>300</td>
<td>244(3538)</td>
<td>See Note 13</td>
<td>689.7 (10000)</td>
<td><h1 id="section-3">2.5</h1></td>
<td>2.83</td>
<td>413.8(6000)</td>
<td>1.7</td>
<td>-</td>
<td>See Manufacturers Qualification Docs (TBD)</td>
</tr>
<tr class="odd">
<td><p>Warm valves</p>
<p>DV21A-D</p>
<p>DV52</p>
<p>DV53</p>
<p>DV55</p>
<p>DV56A-B</p>
<p>DV57</p>
<p>DV60</p>
<p>DV62</p>
<p>DV64</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>PAA GF60, Brass, Spring Steel, Steel, Nitric Rubber, POM,
Aluminium</td>
<td>300</td>
<td>8 (116)</td>
<td>See Note 1</td>
<td><p>&gt;20</p>
<p>(&gt;290)</p></td>
<td><h1 id="section-4">2.5</h1></td>
<td>&gt;2.5</td>
<td>&gt;12 (&gt;174)</td>
<td>&gt;1.5</td>
<td><p>T</p>
<p>(TBD)</p></td>
<td></td>
</tr>
<tr class="even">
<td><p>Warm Valves</p>
<p>MV40</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td><p>Outlet:</p>
<p>6 (87)</p>
<p>Inlet:</p>
<p>200 (2900)</p></td>
<td>Al. Aly., CRES 17-4PH, CRES 300 SER, Nylon</td>
<td>300</td>
<td><p>Outlet:</p>
<p>8 (116)</p>
<p>Inlet:</p>
<p>244(3538))</p></td>
<td>See Note 1</td>
<td><p>&gt;20</p>
<p>(&gt;290)</p>
<p>800(11760)</p></td>
<td><h1 id="section-5">2.5</h1></td>
<td>3.28</td>
<td><p>Outlet:</p>
<p>15.6 (226.2)</p>
<p>See Note 8</p>
<p>Inlet:</p>
<p>480 (6960)</p></td>
<td><p>Inlet:</p>
<p>1.95</p>
<p>Outlet:</p>
<p>1.97</p></td>
<td><p>T</p>
<p>(TBD)</p></td>
<td>Manufacturers data – Stanford Mu</td>
</tr>
<tr class="odd">
<td><p>Warm Helium Fill and Drain Port</p>
<p>MV42</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>200 (2900)</td>
<td>6Al4V Titanium</td>
<td>300</td>
<td>244(3538)</td>
<td>See Note 1</td>
<td><p>800</p>
<p>(11600)</p></td>
<td><h1 id="section-6">2.5</h1></td>
<td>3.28</td>
<td>480 (6960)</td>
<td>1.97</td>
<td><p>T</p>
<p>(TBD)</p></td>
<td>Manufacturers data - Marotta</td>
</tr>
<tr class="even">
<td>Warm Helium Supply COPV</td>
<td><p>8.3</p>
<p>(506)</p></td>
<td><p>200</p>
<p>(2900)</p></td>
<td>Al 2219, Carbon Fibre</td>
<td>300</td>
<td>244(3538)</td>
<td>See Note 1</td>
<td>610(8845)</td>
<td><h1 id="section-7">2.5</h1></td>
<td>2.5</td>
<td><p>500</p>
<p>(7250)</p></td>
<td>2.05</td>
<td><p>T</p>
<p>(TBD</p></td>
<td>Manufacturers drawing / data</td>
</tr>
<tr class="odd">
<td>Warm pilot valve tubing. See Note 11 for all fittings</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>316 SS Grade A</td>
<td>300</td>
<td>10 (145)</td>
<td>See Note 1</td>
<td>1485 (21532)</td>
<td><h1 id="section-8">4</h1></td>
<td>185</td>
<td>16.5 (239.3)</td>
<td>1.5</td>
<td>A</td>
<td>SCL – AMS-02 Pressure system parts.xls</td>
</tr>
<tr class="even">
<td>Tube from COPV to DV22 and MV42. See Note 11 for fittings</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>200 (2900)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>244(3538)</td>
<td>See Note 13</td>
<td><p>1739</p>
<p>(25215)</p></td>
<td><h1 id="section-9">4</h1></td>
<td>7.13</td>
<td>480 (6960)</td>
<td>1.97</td>
<td>A</td>
<td>SCL – AMS-02 Pressure system parts.xls</td>
</tr>
<tr class="odd">
<td>Tube from DV22 to MV40valve</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>200 (2900)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>244(3538)</td>
<td>See Note 13</td>
<td><p>1739</p>
<p>(25215)</p></td>
<td><h1 id="section-10">4</h1></td>
<td>7.13</td>
<td>480(6960)</td>
<td>1.97</td>
<td>A</td>
<td>SCL – AMS-02 Pressure system parts.xls</td>
</tr>
<tr class="even">
<td>Tube from DV22 valves to PS01 and PS02</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>8 (116)</td>
<td>See Note 1</td>
<td><p>1739</p>
<p>(25215)</p></td>
<td><h1 id="section-11">4</h1></td>
<td>217</td>
<td>12 (174)</td>
<td>1.5</td>
<td>A</td>
<td>SCL – AMS-02 Pressure system parts.xls</td>
</tr>
<tr class="odd">
<td>PS01 and PS02</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>8 (116)</td>
<td>See Note 1</td>
<td><p>&gt;20</p>
<p>(&gt;290)</p></td>
<td><h1 id="section-12">2.5</h1></td>
<td>&gt;2.5</td>
<td>20 (290)</td>
<td>2.5</td>
<td>T (TBD manufacturer)</td>
<td>United Electronic Controls Drawing E17W-H97</td>
</tr>
<tr class="even">
<td>Tube from PS01 and PS02 to warm pilot valves</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>8 (116)</td>
<td>See Note 1</td>
<td><p>693</p>
<p>(10048.5)</p></td>
<td><h1 id="section-13">2.5</h1></td>
<td>86</td>
<td>12 (174)</td>
<td>1.5</td>
<td>T (TBD)</td>
<td>SCL – AMS-02 Pressure system parts.xls</td>
</tr>
<tr class="odd">
<td>Tube from PS01 and PS02 to cold pilot valves</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>8 (116)</td>
<td>See Note 1</td>
<td><p>1485</p>
<p>(21532.5)</p></td>
<td><h1 id="section-14">2.5</h1></td>
<td>185</td>
<td>12 (174)</td>
<td>1.5</td>
<td>T (TBD)</td>
<td>SCL – AMS-02 Pressure system parts.xls</td>
</tr>
<tr class="even">
<td><p>Warm Weka valves actuation bellows for</p>
<p>DV09A – B</p>
<p>DV11A – B</p>
<p>DV15A – D</p>
<p>DV16A – B</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>St St 316Ti/ EN1.4571</td>
<td>300</td>
<td>8 (116)</td>
<td>See Note 1</td>
<td><p>&gt;20</p>
<p>(&gt;290)</p></td>
<td><h1 id="section-15">2.5</h1></td>
<td>&gt;2.5</td>
<td>8.8 (127.6)</td>
<td>1.1</td>
<td>T (Weka)</td>
<td>Weka qualification and acceptance tests of warm valves</td>
</tr>
<tr class="odd">
<td>Pilot valve vacuum vessel (PVVV)</td>
<td>4.0</td>
<td>-1 (-14.5)</td>
<td><p>Stainless Steel</p>
<p>304-S12</p></td>
<td>300</td>
<td>10 (145)</td>
<td>See Note 1</td>
<td>91.5 (1326.7)</td>
<td><h1 id="section-16">2.5</h1></td>
<td>9</td>
<td><p>15</p>
<p>(217.5)</p></td>
<td>1.5</td>
<td><p>A</p>
<p>See Note 9</p>
<p>T(TBD)</p></td>
<td>SCL – AMS-02 Pressure system parts.xls</td>
</tr>
<tr class="even">
<td>Tube from PVVV to DV20 Valves</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>-1 (-14.5)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>10 (145)</td>
<td>See Note 1</td>
<td>1739 (25215)</td>
<td><h1 id="section-17">2.5</h1></td>
<td>174</td>
<td><p>15</p>
<p>(217.5)</p></td>
<td>1.5</td>
<td>T (TBD)</td>
<td></td>
</tr>
<tr class="odd">
<td>Tube from MV43 to PVVV</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>-1 (-14.5)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>10 (145)</td>
<td>See Note 1</td>
<td>2080 (30160)</td>
<td><h1 id="section-18">2.5</h1></td>
<td>208</td>
<td><p>15</p>
<p>(217.5)</p></td>
<td>1.5</td>
<td>T (TBD)</td>
<td></td>
</tr>
<tr class="even">
<td>Tube from PVVV to MV44</td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>-1 (-14.5)</td>
<td>AISI 316 L</td>
<td>300</td>
<td>10 (145)</td>
<td>See Note 1</td>
<td>2080 (30160)</td>
<td><h1 id="section-19">2.5</h1></td>
<td>208</td>
<td><p>15</p>
<p>(217.5)</p></td>
<td>1.5</td>
<td>T (TBD)</td>
<td></td>
</tr>
<tr class="odd">
<td><p>Warm valve pilot valves</p>
<p>DV61AS-BS</p>
<p>DV61AO-BO</p>
<p>DV66AS-BS</p>
<p>DV66AO-BO</p>
<p>DV59AS-BS</p>
<p>DV59AS-BO</p>
<p>DV65AS-DS</p>
<p>DV65AO-DO</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>PAA GF60, Brass, Spring Steel, Steel, Nitric Rubber, POM,
Aluminium</td>
<td>300</td>
<td>8 (116)</td>
<td>See Note 1</td>
<td><p>&gt;20</p>
<p>(&gt;290)</p></td>
<td><h1 id="section-20">2.5</h1></td>
<td>&gt;2.5</td>
<td>12 (174)</td>
<td>&gt;1.5</td>
<td><p>T</p>
<p>(TBD)</p></td>
<td></td>
</tr>
<tr class="even">
<td><p>Relief valve</p>
<p>RV03</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>6061 T6 Al. Aly., 316 SST, VESPEL SP1, 320 SST, TEFLON</td>
<td>300</td>
<td><p>Fault:</p>
<p>8 (116)</p></td>
<td>See Note 1</td>
<td>24.8 (365)</td>
<td><h1 id="section-21">2.5</h1></td>
<td>3.1</td>
<td>15 (217.5)</td>
<td>1.8</td>
<td>-</td>
<td>See Manufacturers Qualification Docs (TBD)</td>
</tr>
<tr class="odd">
<td><p>Relief valve</p>
<p>RV04</p></td>
<td><p>&lt;10</p>
<p>(&lt;610)</p></td>
<td>6 (87)</td>
<td>6061 T6 Al. Aly., 316 SST, VESPEL SP1, 320 SST, TEFLON</td>
<td>300</td>
<td><p>Fault:</p>
<p>8 (116)</p></td>
<td>See Note 1</td>
<td>24.8 (359.6)</td>
<td><h1 id="section-22">2.5</h1></td>
<td>3.1</td>
<td>15 (217.5)</td>
<td>1.8</td>
<td>-</td>
<td>See Manufacturers Qualification Docs (TBD)</td>
</tr>
</tbody>
</table>

### Note 1: Derivation of MDP values per NSTS 1700.7B and ISS Addendum, section 208.4

The maximum design pressure (MDP) for all systems considered in this
report is set by the upper defined limit of the relevant pressure relief
device which is a space-qualified bursting disc or relief valve or by
the highest pressure attainable based on fill and thermal environments.

The bursting disc systems have been extensively assessed by LM/NASA and
SCL and accepted.

a.  [3 bar Pressure Relief]{.underline}

> The pressure is set by the upper limit on the differential pressure,
> when cold, necessary to rupture bursting disc BD03, shown on SCL
> Cryogenic System Schematic Drawing SCD 1000.
>
> In service and in test, the downstream pressure on this disc is kept
> at zero bar absolute.
>
> In the warm state, the bursting disc will rupture at less than 3 bar.

b.  [20 bar Pressure Relief]{.underline}

> The pressure is set by the upper limit on the differential pressure,
> when cold, necessary to rupture bursting disc BD02, shown on SCL
> Cryogenic System Schematic Drawing SCD 1000.
>
> Although in service the downstream pressure is \~ 10 mbar (fill
> vacuum), the design allows for the downstream pressure being 3 bar
> abs. The superfluid cooling loop SCL is thus designed for 20 bar abs
> (and differential), whereas the bursting disc BD02 is set for a
> maximum differential of 20 bar, in the cold state.
>
> In the warm state, the bursting disc BD02 will rupture at less than 22
> bar differential.

c.  [10 bar Pressure Relief]{.underline}

> The pressure is set by the upper limit on the burst disc differential
> pressure and vacuum case vacuum, when cold, necessary to rupture
> bursting discs BD05A, BD05B, BD10A, BD11A,BD11B, BD12A, BD12B, BD13
> shown on SCL Cryogenic System Schematic Drawing SCD 1000.
>
> Although in service the pipework pressure is \< 1.0 bar, the design
> allows for the trapped volume pressures being up to 11 bar abs. (10
> bar differential of the bursting disc failing to atmosphere + 1 bar
> vacuum in the Vacuum Case) The general pipework is thus designed for
> 11 bar abs (and differential), whereas the bursting discs listed are
> set for a maximum differential of 10 bar.

d.  [RV03 / RV04]{.underline}

> RV03 and RV04 relief valves operate in parallel and pressure is set by
> the upper limit of the relief valve cracking pressures.

Note 2: Materials of pressure-containing part.

Note 3: Basis for verification of Burst Safety Factor.

Note 4: This is a vacuum vessel and the MDP only applies in the event of
contingency case.

Note 5: Ground Case - Worst case thermal pressure environment caused by
rupture of the Super Fluid He Tank into the Vacuum Case.

Note 6: Pressure on upstream side of disc, absolute.

Note 7: For all items in this table, the designed on-orbit life is: 3
years + 2 contingency years. Expected life is TBD as the AMS-02 does not
have an independent means of end of life disposal from the ISS.

Note 8: Proof pressure is based upon current specification for valve
fittings and will be updated when valves are ordered to meet
requirements of 1.5 times MDP.

Note 9: Current pilot valve vacuum vessel design based upon calculations
in BS 5500. Vessel will be proof tested to 16.5 bar once manufactured.

Note 10: Actuation, hence pressurisation can only occur when DV22A -- D
are open; therefore MDP determination set by RV04 due to two relief
valves being present in the system.

Note 11: Any fittings are designed to have a minimum wall thickness
equivalent to the pipework they are connecting.

Note 12: A proof pressure of 1.1 MDP is applicable to all bi-metallic
feedthroughs as they will be pressure tested with the helium vessel and
not prior to this. Analysis shows that factors of safety against burst
are tens of times greater than MDP therefore a 1.1 proof test is deemed
acceptable.

Note 13: MDP Determined by controlling the fill of warm helium gas as
per SCL memo 2906 Control of Warm Helium Gas System Fill_Rev04.pdf dated
4^th^ April 2007.

  -----------------------------------------------------------------------
  ![](media/image10.jpeg){width="8.980555555555556in"
  height="5.268055555555556in"}

  **Cryogenic Superfluid Helium System (With Warm Helium Gas Supply)**
  -----------------------------------------------------------------------

  -----------------------------------------------------------------------
  ![](media/image12.jpeg){width="7.441666666666666in"
  height="6.091666666666667in"}

  **Warm Helium Gas Supply (See Legend on Cryosystem Diagram)**
  -----------------------------------------------------------------------

+-----------------------------------+-----------------------------------+
| ![](media/image13.                | ![](media/image14.                |
| jpeg){width="2.984027777777778in" | jpeg){width="4.405555555555556in" |
| height="                          | height="2.3833333333333333in"}    |
| 4.214583333333334in"}Functionally |                                   |
| the Weka Heliomatic Valves use    |                                   |
| helium pressurant to activate a   |                                   |
| bellows that will either open or  |                                   |
| close a latching valve.           |                                   |
| Pressurizing the opposing bellows |                                   |
| is required to reposition the     |                                   |
| valve.                            |                                   |
|                                   |                                   |
| This function is consistent with  |                                   |
| both the cryogenic and warm       |                                   |
| valves.                           |                                   |
+-----------------------------------+-----------------------------------+
| **Weka Heliomatic Warm Valve**    |                                   |
+-----------------------------------+-----------------------------------+
| ![](media/image15.                | Valve Off                         |
| jpeg){width="4.416666666666667in" |                                   |
| height="5.679861111111111in"}     | ![](media/image18                 |
|                                   | .png){width="4.410416666666666in" |
|                                   | height="1.7979166666666666in"}    |
+-----------------------------------+-----------------------------------+
|                                   | Valve On                          |
|                                   |                                   |
|                                   | ![](media/image19                 |
|                                   | .png){width="4.418055555555555in" |
|                                   | height="1.7243055555555555in"}    |
+-----------------------------------+-----------------------------------+
| **Weka Warm Valves**              |                                   |
+-----------------------------------+-----------------------------------+
| ![](media/image17.j               | ![](m                             |
| peg){width="4.4118055555555555in" | edia/image16.jpeg){width="2.75in" |
| height="5.7340277777777775in"}    | height="4.9222222222222225in"}    |
+-----------------------------------+-----------------------------------+
| **Weka Heliomatic Cryogenic       |                                   |
| Valve**                           |                                   |
+-----------------------------------+-----------------------------------+

**C. Tracker Thermal Control System**

<table style="width:100%;">
<colgroup>
<col style="width: 0%" />
<col style="width: 9%" />
<col style="width: 0%" />
<col style="width: 7%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 4%" />
<col style="width: 0%" />
<col style="width: 4%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 4%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 3%" />
<col style="width: 0%" />
<col style="width: 4%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 7%" />
<col style="width: 0%" />
<col style="width: 9%" />
<col style="width: 0%" />
<col style="width: 0%" />
</colgroup>
<thead>
<tr class="header">
<th colspan="34"><strong>Tracker Thermal Control System Pressure System
Components (Primary Loop)</strong></th>
<th colspan="2"></th>
</tr>
<tr class="odd">
<th colspan="3" rowspan="3"><p> </p>
<p>Description</p>
<p> </p></th>
<th rowspan="3">Material Of Construction</th>
<th colspan="4" rowspan="2"><p>Mass</p>
<p>Of fluid </p></th>
<th colspan="4" rowspan="2"><p>Max. Operating</p>
<p>Pressure</p></th>
<th colspan="4" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></th>
<th colspan="4" rowspan="2"><p>Burst</p>
<p>Pressure</p></th>
<th colspan="4">Burst SF</th>
<th colspan="4" rowspan="2"><p>Proof</p>
<p>Pressure</p></th>
<th colspan="2" rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></th>
<th colspan="3" rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></th>
<th colspan="3" rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></th>
</tr>
<tr class="header">
<th colspan="2" rowspan="2">Req<sup>3</sup></th>
<th colspan="2" rowspan="2">Actual</th>
</tr>
<tr class="odd">
<th colspan="2">kg</th>
<th colspan="2">lbm</th>
<th colspan="2">bar</th>
<th colspan="2">psid</th>
<th colspan="2">bar</th>
<th colspan="2">psid</th>
<th colspan="2">bar</th>
<th colspan="2">psid</th>
<th colspan="2">bar</th>
<th colspan="2">psid</th>
</tr>
</thead>
<tbody>
<tr class="odd">
<td colspan="2">RAM feed line</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0251</td>
<td colspan="2">0.0553</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="2">RAM return line</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0251</td>
<td colspan="2">0.0553</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td colspan="2">RAM capillary condenser lines</td>
<td colspan="3">Inconel 718</td>
<td colspan="2">0.0328</td>
<td colspan="2">0.0723</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">3009.0</td>
<td colspan="2">43641.9</td>
<td colspan="2">13962.0</td>
<td colspan="2">202501.7</td>
<td colspan="2">2.5</td>
<td colspan="2">4.6<sup>14</sup></td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="even">
<td colspan="2">WAKE feed line</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0251</td>
<td colspan="2">0.0553</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td colspan="2">WAKE return line</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0251</td>
<td colspan="2">0.0553</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="2">WAKE capillary condenser lines</td>
<td colspan="3">Inconel 718</td>
<td colspan="2">0.0328</td>
<td colspan="2">0.0723</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">3009.0</td>
<td colspan="2">43641.9</td>
<td colspan="2">13962.0</td>
<td colspan="2">202501.7</td>
<td colspan="2">2.5</td>
<td colspan="2">4.6<sup>14</sup></td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="odd">
<td colspan="2">Top Evaporator</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0535</td>
<td colspan="2">0.1180</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">927.7</td>
<td colspan="2">13455.0</td>
<td colspan="2">4.0</td>
<td colspan="2">5.8</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="2">Top Evaporator feed</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0093</td>
<td colspan="2">0.0205</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td colspan="2">Top Evaporator return</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0093</td>
<td colspan="2">0.0205</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="2">Lower Evaporator</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0535</td>
<td colspan="2">0.1180</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">927.7</td>
<td colspan="2">13455.0</td>
<td colspan="2">4.0</td>
<td colspan="2">5.8</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td colspan="2">Lower Evaporator feed</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0048</td>
<td colspan="2">0.0106</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="2">Lower Evaporator return</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0048</td>
<td colspan="2">0.0106</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td colspan="2"></td>
<td colspan="3"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td></td>
<td colspan="4"></td>
</tr>
<tr class="even">
<td colspan="2">Common Evaporator out</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0028</td>
<td colspan="2">0.0062</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">1888.2</td>
<td colspan="2">27386.0</td>
<td colspan="2">4.0</td>
<td colspan="2">11.8</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td colspan="2">Pump_inlet tube</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0070</td>
<td colspan="2">0.0155</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">1888.2</td>
<td colspan="2">27386.0</td>
<td colspan="2">4.0</td>
<td colspan="2">11.8</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="2">Pressure sensor connecting tubes</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0021</td>
<td colspan="2">0.0047</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td colspan="2">Box tubing</td>
<td colspan="3">ANSI 316L Stainless Steel</td>
<td colspan="2">0.0131</td>
<td colspan="2">0.0288</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">2569.7</td>
<td colspan="2">37270.0</td>
<td colspan="2">4.0</td>
<td colspan="2">16.1</td>
<td colspan="2">239.9</td>
<td colspan="2">3480.0</td>
<td colspan="2">1.5</td>
<td>Analysis<sup>2</sup></td>
<td colspan="4">NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="2">Pressure sensors</td>
<td colspan="3">PT sensor housing Stainless steel 316 L</td>
<td colspan="2">0.0020</td>
<td colspan="2">0.0044</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">400.0</td>
<td colspan="2">5800.0</td>
<td colspan="2">2.5</td>
<td colspan="2">TBD</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Similarity or Test</td>
<td colspan="4"></td>
</tr>
<tr class="odd">
<td colspan="2">Pump</td>
<td colspan="3">304L CRES per SAE AMS-QQ-S-763</td>
<td colspan="2">0.0735</td>
<td colspan="2">0.1620</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">400.0</td>
<td colspan="2">5800.0</td>
<td colspan="2">2.5</td>
<td colspan="2">TBD</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="even">
<td colspan="2">Heat Exchanger</td>
<td colspan="3">Inconel 625</td>
<td colspan="2">0.0560</td>
<td colspan="2">0.1235</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">400.0</td>
<td colspan="2">5800.0</td>
<td colspan="2">2.5</td>
<td colspan="2">TBD</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="odd">
<td colspan="2">Hydraulic connectors</td>
<td colspan="3">RES 386 (15--5PH)</td>
<td colspan="2">0.0050</td>
<td colspan="2">0.0111</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">827.4</td>
<td colspan="2">12000.0</td>
<td colspan="2">2.5</td>
<td colspan="2">5.2</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>by Specification</td>
<td colspan="4"></td>
</tr>
<tr class="even">
<td colspan="2">Condenser Manifolds</td>
<td colspan="3">ANSI 316 Stainless Steel</td>
<td colspan="2">0.0045</td>
<td colspan="2">0.0099</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.0</td>
<td colspan="2">400.0</td>
<td colspan="2">5800.0</td>
<td colspan="2">2.5</td>
<td colspan="2">TBD</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="odd">
<td colspan="2"></td>
<td colspan="3"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td colspan="2"></td>
<td></td>
<td colspan="4"></td>
</tr>
<tr class="even">
<td colspan="2">TTCS Accumulator</td>
<td colspan="3">A316LN CRES</td>
<td colspan="2">0.7000</td>
<td colspan="2">1.5432</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2320.6</td>
<td colspan="2">614.6</td>
<td colspan="2">8914.0</td>
<td colspan="2">2.5</td>
<td colspan="2">3.8</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="odd">
<td colspan="2">TTCS Accumulator Heat Pipe outside Accumulator</td>
<td colspan="3">A316LN CRES</td>
<td colspan="2">0.0030</td>
<td colspan="2">0.0066</td>
<td colspan="2">10.1</td>
<td colspan="2">146.5</td>
<td colspan="2">50.2.</td>
<td colspan="2">728.1</td>
<td colspan="2">962.0</td>
<td colspan="2">13952.6</td>
<td colspan="2">4.0</td>
<td colspan="2">19.2</td>
<td colspan="2">76.0</td>
<td colspan="2">1102.3</td>
<td colspan="2">1.6</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="even">
<td colspan="2">TTCS Accumulator Heat Pipe inside Accumulator</td>
<td colspan="3">A316LN CRES</td>
<td colspan="2">0.0030</td>
<td colspan="2">0.0066</td>
<td colspan="2">64.0</td>
<td colspan="2">928.2</td>
<td colspan="2">160.0</td>
<td colspan="2">2319.0</td>
<td colspan="2">24125.0</td>
<td colspan="2">349903.5</td>
<td colspan="2">2.5</td>
<td colspan="2">150.8</td>
<td colspan="2">240.0</td>
<td colspan="2">3480.9</td>
<td colspan="2">1.5</td>
<td>Analysis and Test</td>
<td colspan="4"></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">Notes:</td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td colspan="34">1) MDP has been established based on worst case thermal
profile and where applicable (with mechanisms to fail) worst case two
fault condition.</td>
<td></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">2) Burst Safety Factor is calculated from the material
allowable stress and pipe geometry</td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td colspan="34">3) Heat pipes are part of a pressurized system and are
not isolated. Burst Factor of 4.0 is used.</td>
<td></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">4) Ref TCS Hardware Design Report AMS-OHB-DER-001 issue
2, March 1, 2005</td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td colspan="34">5) Condenser MDP is based on more detailed CO2 melting
line data (NIST) at -5 C (3009 bar). The burst pressure is calculated
with</td>
<td></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">6) HP MDP pressure based on 110 C maximum HP
temperature (see see AMS02-CAST-TTCS-HP-SF-03 page 6)</td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td colspan="34">7) The burst pressures of the Pumps valves, Pressure
sensors and HX are design values. Pump design and HX designers have
performed preliminary FEM analyses. Documents need to be written and
delivered.</td>
<td></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">8) The TTCS Accumulator heat pipe inside the
accumulator numbers extracted from AMS-02-CAST-TTCS-HP-SF-001 Issue 2,
14-03-2007 p8.</td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td colspan="34">9) The maximum NH3 heat pipe working pressure is based
on a maximum HP operating Temperature of 25 C</td>
<td></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">10) The MDP inside the accumulator and onto the outside
accu heat pipe is 160 bar. For burst analyses (see
AMS-02-CAST-TTCS-HP-SF-001 Issue 2, 14-03-2007 p8)</td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td colspan="34">11) The liquid mass is the mass of pure liquid in the
component (this implies the overall mass of this table is larger then
the CO2 mass in the loop)</td>
<td></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">12) The liquid mass presented is the sum of liquid at
-40 C in the components</td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td colspan="34">13) The mass of the accumulator is based on a 969.5 ml
volume (see AMS02-CAST-TTCS-ACC-DR-002draft page 28) and is calculated
below</td>
<td></td>
</tr>
<tr class="odd">
<td></td>
<td colspan="34">14) The Burst SF of the Inconel 718 condenser tubes is
based on calculated strain hardening of the tubing during the pressure
cycle (See Equation). Hydraulic testing of representative bent tube
parts to the condenser will be done to a pressure of 1.5x 3009 = 45135
bar as a “proof” and up to a maximum of 10,000 bar to validate a burst
limit. The QM and FM condenser assemblies will be tested up to a
pressure of 240 bar because of the connected manifolds (MDP = 160 bar)
during the condenser proof pressure tests.</td>
<td></td>
</tr>
</tbody>
</table>

  ------------- ---------- ------------- ---------- ---------- ------------------------------------------ ----------
  Rho           1.12E+03   Density at                          ![](media/image20.png){width="2.59375in"   
                           lowest                              height="1.0013888888888889in"}             
                           temperature                                                                    
                           (-40 C)                                                                        

  Rho_liq       551.771    Liquid                                                                         
                           density at                                                                     
                           highest                                                                        
                           liquid level                                                                   
                           30 C                                                                           

  Rho_vap       352.983    Vapour                                                                         
                           density at                                                                     
                           highes liquid                                                                  
                           level 30 C                                                                     

  Highest       80%        Highest                                                                        
  liquid level             liquid level                                                                   
                           in the loop                                                                    
                           is at BOL, 30                                                                  
                           C, low                                                                         
                           subcooling                                                                     

                                                                                                          

                Volume     Number \[-\]  Liquid     Vapor mass Total \[kg\]                               
                \[ml\]                   mass       \[kg\]                                                
                                         \[kg\]                                                           

  Accumulator   969.5      1             0.43       0.27       0.70                                       
  ------------- ---------- ------------- ---------- ---------- ------------------------------------------ ----------

<table>
<colgroup>
<col style="width: 9%" />
<col style="width: 7%" />
<col style="width: 5%" />
<col style="width: 0%" />
<col style="width: 4%" />
<col style="width: 3%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 6%" />
<col style="width: 3%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 3%" />
<col style="width: 6%" />
<col style="width: 9%" />
</colgroup>
<thead>
<tr class="header">
<th colspan="18"><strong>Tracker Thermal Control System Pressure System
Components (Secondary Loop)</strong></th>
</tr>
<tr class="odd">
<th rowspan="3"><p> </p>
<p>Description</p>
<p> </p></th>
<th rowspan="3">Material Of Construction</th>
<th colspan="3" rowspan="2"><p>Mass</p>
<p>Of fluid </p></th>
<th colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure</p></th>
<th colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></th>
<th colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></th>
<th colspan="2">Burst SF</th>
<th colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></th>
<th rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></th>
<th rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></th>
<th rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></th>
</tr>
<tr class="header">
<th rowspan="2">Req</th>
<th rowspan="2">Actual</th>
</tr>
<tr class="odd">
<th colspan="2">kg</th>
<th>lbm</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
</tr>
</thead>
<tbody>
<tr class="odd">
<td>RAM feed line</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0251</td>
<td colspan="2">0.0553</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>RAM return line</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0251</td>
<td colspan="2">0.0553</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>RAM capillary condenser lines</td>
<td>Inconel 718</td>
<td>0.0328</td>
<td colspan="2">0.0723</td>
<td>64.0</td>
<td>928.2</td>
<td>3009.0</td>
<td>43641.9</td>
<td>13962.0</td>
<td>202501.7</td>
<td>2.5</td>
<td>4.6<sup>14</sup></td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
<tr class="even">
<td>WAKE feed line</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0251</td>
<td colspan="2">0.0553</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>WAKE return line</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0251</td>
<td colspan="2">0.0553</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>WAKE capillary condenser lines</td>
<td>Inconel 718</td>
<td>0.0328</td>
<td colspan="2">0.0723</td>
<td>64.0</td>
<td>928.2</td>
<td>3009.0</td>
<td>43641.9</td>
<td>13962.0</td>
<td>202501.7</td>
<td>2.5</td>
<td>4.6<sup>14</sup></td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
<tr class="odd">
<td>Top Evaporator</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0535</td>
<td colspan="2">0.1180</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>927.7</td>
<td>13455.0</td>
<td>4.0</td>
<td>5.8</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Top Evaporator feed</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0156</td>
<td colspan="2">0.0343</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Top Evaporator return</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0369</td>
<td colspan="2">0.0813</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Lower Evaporator</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0535</td>
<td colspan="2">0.1180</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>927.7</td>
<td>13455.0</td>
<td>4.0</td>
<td>5.8</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Lower Evaporator feed</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0117</td>
<td colspan="2">0.0258</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Lower Evaporator return</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0277</td>
<td colspan="2">0.0611</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td></td>
<td></td>
<td></td>
<td colspan="2"></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
<tr class="even">
<td>Common Evaporator out</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0028</td>
<td colspan="2">0.0062</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>1888.2</td>
<td>27386.0</td>
<td>4.0</td>
<td>11.8</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Pump_inlet tube</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0070</td>
<td colspan="2">0.0155</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>1888.2</td>
<td>27386.0</td>
<td>4.0</td>
<td>11.8</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Pressure sensor connecting tubes</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0014</td>
<td colspan="2">0.0031</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Box tubing</td>
<td>ANSI 316L Stainless Steel</td>
<td>0.0131</td>
<td colspan="2">0.0288</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>2569.7</td>
<td>37270.0</td>
<td>4.0</td>
<td>16.1</td>
<td>239.9</td>
<td>3480.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Pressure sensors</td>
<td>PT sensor housing Stainless steel 316 L</td>
<td>0.0020</td>
<td colspan="2">0.0044</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>400.0</td>
<td>5800.0</td>
<td>2.5</td>
<td>TBD</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Similarity or Test</td>
<td></td>
</tr>
<tr class="odd">
<td>Pump</td>
<td>304L CRES per SAE AMS-QQ-S-763</td>
<td>0.0735</td>
<td colspan="2">0.1620</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>400.0</td>
<td>5800.0</td>
<td>2.5</td>
<td>TBD</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
<tr class="even">
<td>Heat Exchanger</td>
<td>Inconel 625</td>
<td>0.0560</td>
<td colspan="2">0.1235</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>400.0</td>
<td>5800.0</td>
<td>2.5</td>
<td>TBD</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
<tr class="odd">
<td>Hydraulic connectors</td>
<td>RES 386 (15--5PH)</td>
<td>0.0050</td>
<td colspan="2">0.0111</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>827.4</td>
<td>12000.0</td>
<td>2.5</td>
<td>5.2</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>by Specification</td>
<td></td>
</tr>
<tr class="even">
<td>Condenser Manifolds</td>
<td>ANSI 316 Stainless Steel</td>
<td>0.0045</td>
<td colspan="2">0.0099</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.0</td>
<td>400.0</td>
<td>5800.0</td>
<td>2.5</td>
<td>TBD</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
<tr class="odd">
<td>TTCS Accumulator</td>
<td>A316LN CRES</td>
<td>0.7000</td>
<td colspan="2">1.5432</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2320.6</td>
<td>614.6</td>
<td>8914.0</td>
<td>2.5</td>
<td>3.8</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
<tr class="even">
<td>TTCS Accumulator Heat Pipe outside Accumulator</td>
<td>A316LN CRES</td>
<td>0.0030</td>
<td colspan="2">0.0066</td>
<td>10.1</td>
<td>146.5</td>
<td>50.2</td>
<td>728.1</td>
<td>962.0</td>
<td>13952.6</td>
<td>4.0</td>
<td>19.2</td>
<td>76.0</td>
<td>1102.3</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
<tr class="odd">
<td>TTCS Accumulator Heat Pipe inside Accumulator</td>
<td>A316LN CRES</td>
<td>0.0030</td>
<td colspan="2">0.0066</td>
<td>64.0</td>
<td>928.2</td>
<td>160.0</td>
<td>2319.0</td>
<td>24125.0</td>
<td>349903.6</td>
<td>2.5</td>
<td>150.8</td>
<td>240.0</td>
<td>3480.9</td>
<td>1.5</td>
<td>Analysis and Test</td>
<td></td>
</tr>
</tbody>
</table>

  -----------------------------------------------------------------------
  Notes:

  1\) MDP has been established based on worst case thermal profile and
  where applicable (with mechanisms to fail) worst case two fault
  condition.

  2\) Burst Safety Factor is calculated from the material allowable
  stress and pipe geometry

  3\) Heat pipes are part of a pressurized system and are not isolated.
  Burst Factor of 4.0 is used.

  4\) Ref TCS Hardware Design Report AMS-OHB-DER-001 issue 2, March 1,
  2005

  5\) Condenser MDP is based on more detailed CO2 melting line data
  (NIST) at -5 C (3009 bar). The burst pressure is calculated with

  6\) HP MDP pressure based on 110 C maximum HP temperature (see see
  AMS02-CAST-TTCS-HP-SF-03 page 6)

  7\) The burst pressures of the Pumps valves, Pressure sensors and HX
  are design values. Pump design and HX designers have performed
  preliminary FEM analyses. Documents need to be written and delivered.

  8\) The TTCS Accumulator heat pipe inside the accumulator numbers
  extracted from AMS-02-CAST-TTCS-HP-SF-001 Issue 2, 14-03-2007 p8.

  9\) The maximum NH3 heat pipe working pressure is based on a maximum HP
  operating Temperature of 25 C

  10\) The MDP inside the accumulator and onto the outside accu heat pipe
  is 160 bar. For burst analyses (see AMS-02-CAST-TTCS-HP-SF-001 Issue 2,
  14-03-2007 p8)

  11\) The liquid mass is the mass of pure liquid in the component (this
  implies the overall mass of this table is larger then the CO2 mass in
  the loop)

  12\) The liquid mass presented is the sum of liquid at -40 C in the
  components

  13\) The mass of the accumulator is based on a 969.5 ml volume (see
  AMS02-CAST-TTCS-ACC-DR-002draft page 28) and is calculated below

  14\) The Burst SF of the Inconel 718 condenser tubes is based on
  calculated strain hardening of the tubing during the pressure cycle
  (see Equation). Hydraulic testing of representative ent tube bards to
  the condenser will be done to a pressure of 1.5 x 3009 = 45135 bar as a
  "proof" and up to a maximum 10,000 bar to validate the burst limit. The
  QM and FM condenser assemblies will be tested up to a pressure of 240
  bar because of the connected manifold (MDP = 160 bar) during condenser
  proof pressure tests.
  -----------------------------------------------------------------------

  ------------- ---------- ------------- ---------- ---------- ------------------------------------------ ----------
  Rho           1.12E+03   Density at                          ![](media/image20.png){width="2.59375in"   
                           lowest                              height="1.0013888888888889in"}             
                           temperature                                                                    
                           (-40 C)                                                                        

  Rho_liq       551.771    Liquid                                                                         
                           density at                                                                     
                           highest                                                                        
                           liquid level                                                                   
                           30 C                                                                           

  Rho_vap       352.983    Vapour                                                                         
                           density at                                                                     
                           highes liquid                                                                  
                           level 30 C                                                                     

  Highest       80%        Highest                                                                        
  liquid level             liquid level                                                                   
                           in the loop                                                                    
                           is at BOL, 30                                                                  
                           C, low                                                                         
                           subcooling                                                                     

                                                                                                          

                Volume     Number \[-\]  Liquid     Vapor mass Total \[kg\]                               
                \[ml\]                   mass       \[kg\]                                                
                                         \[kg\]                                                           

  Accumulator   969.5      1             0.43       0.27       0.70                                       
  ------------- ---------- ------------- ---------- ---------- ------------------------------------------ ----------

<table>
<colgroup>
<col style="width: 9%" />
<col style="width: 8%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 9%" />
</colgroup>
<tbody>
<tr class="odd">
<td colspan="17"><strong>Tracker Radiator Heat Pipes Pressure System
Components</strong></td>
</tr>
<tr class="even">
<td rowspan="3"><p> </p>
<p>Description</p>
<p> </p></td>
<td rowspan="3">Material Of Construction</td>
<td colspan="2" rowspan="2"><p>Mass</p>
<p>Of fluid </p></td>
<td colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure<sup>6</sup>)</p></td>
<td colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></td>
<td colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></td>
<td colspan="2">Burst SF</td>
<td colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></td>
<td rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></td>
<td rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></td>
<td rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></td>
</tr>
<tr class="odd">
<td rowspan="2">Req <sup>3</sup></td>
<td rowspan="2">Actual</td>
</tr>
<tr class="even">
<td>kg</td>
<td>lbm</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
</tr>
<tr class="odd">
<td>Embedded Heat Pipes</td>
<td>AL 6063</td>
<td>Note 5</td>
<td> </td>
<td>4.0</td>
<td>58.0</td>
<td>20.0</td>
<td>290.0</td>
<td>174.7</td>
<td>2534.0</td>
<td>4.0</td>
<td>8.7</td>
<td>30.0</td>
<td>435.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="17"><p> Notes:</p>
<p>1) MDP has been established based on worst case thermal profile
(50°C) and where applicable (with mechanisms to fail) worst case two
fault condition.</p>
<p>2) Burst Safety Factor is calculated from the material allowable
stress and pipe geometry</p>
<p>3) Heat pipes single components and not a part of a greater pressure
system. Burst Factor of 4.0 is used (2.5 could be used for heat pipes as
components.).</p>
<p>4) Ref TCS Hardware Design Report AMS-OHB-DER-001 Issue 2, Revision
A, May 5, 2005</p>
<p>5) There are 7 embedded heat pipes with different lengths, mass of
fluid (ammonia) ranges from 44.6 grams for the shortest to 52.6 grams
for the longest</p>
<p>6) Calculated at 0°C, typical working temperature of the tracker
cooling loop</p></td>
</tr>
</tbody>
</table>

  ------ ------ --- --- --- --- --- --- --- ---- -- --- --- --- --- ----- -----------
                                                                          

                                                                          

                                                                          

                                                                          

                                                                          []{.mark}

                                                                          
  ------ ------ --- --- --- --- --- --- --- ---- -- --- --- --- --- ----- -----------

+-----------------------------------------------------------------------+
| ![](media/image21.png){width="6.615277777777778in"                    |
| height="4.165277777777778in"}                                         |
+-----------------------------------------------------------------------+
| **Components of the Tracker Thermal Control System (new Condenser     |
| configurations not shown)**                                           |
+-----------------------------------------------------------------------+
|                                                                       |
+-----------------------------------------------------------------------+
| ![](media/image23.jpeg){width="8.4375in"                              |
| height="5.977777777777778in"}                                         |
|                                                                       |
| **TTCS Primary Loop**                                                 |
+-----------------------------------------------------------------------+
| ![](media/image25.jpeg){width="8.559027777777779in"                   |
| height="6.070833333333334in"}                                         |
+-----------------------------------------------------------------------+
| **TTCS Secondary Loop**                                               |
+-----------------------------------------------------------------------+

+--------------------+-------------+-----------------------------------+
| ![](media/imag     |             |                                   |
| e26.png){width="8. |             |                                   |
| 972916666666666in" |             |                                   |
| height="3.78       |             |                                   |
| 47222222222223in"} |             |                                   |
+--------------------+-------------+-----------------------------------+
| **TTCS Accumulator |             |                                   |
| Cross Section with |             |                                   |
| Accumulator Heat   |             |                                   |
| Pipe.**            |             |                                   |
+--------------------+-------------+-----------------------------------+
| ![](media/ima      |             |                                   |
| ge27.png){width="8 |             |                                   |
| .98263888888889in" |             |                                   |
| height="4.3        |             |                                   |
| 56944444444444in"} |             |                                   |
+--------------------+-------------+-----------------------------------+
| **TTCE Accumulator |             |                                   |
| Heat Pipe Design** |             |                                   |
+--------------------+-------------+-----------------------------------+
| ![](media/imag     | ![](me      |                                   |
| e28.png){width="2. | dia/image29 |                                   |
| 259027777777778in" | .png){width |                                   |
| height="3.7        | ="5.9625in" |                                   |
| 32638888888889in"} | height="    |                                   |
|                    | 3.528472222 |                                   |
|                    | 2222222in"} |                                   |
+--------------------+-------------+-----------------------------------+
| **Tracker TTCS     |             |                                   |
| Radiators**        |             |                                   |
|                    |             |                                   |
| **Heat Pipe        |             |                                   |
| AGHP-14 (13mm      |             |                                   |
| outer, 7 mm inner, |             |                                   |
| 1.25 mm flange)**  |             |                                   |
+--------------------+-------------+-----------------------------------+
|                    |             |                                   |
+--------------------+-------------+-----------------------------------+
|                    |             |                                   |
+--------------------+-------------+-----------------------------------+
| ![](media/image31. |             |                                   |
| png){width="9.0in" |             |                                   |
| height="3.0        |             |                                   |
| 33333333333333in"} |             |                                   |
+--------------------+-------------+-----------------------------------+
| **Tracker Radiator |             |                                   |
| Heater Locations** |             |                                   |
+--------------------+-------------+-----------------------------------+
| ![](media/imag     |             |                                   |
| e32.wmf){width="7. |             |                                   |
| 944444444444445in" |             |                                   |
| height="5.8        |             |                                   |
| 60416666666667in"} |             |                                   |
+--------------------+-------------+-----------------------------------+
| **Tracker Radiator |             |                                   |
| Heater Circuits    |             |                                   |
| with Thermal       |             |                                   |
| Switches.**        |             |                                   |
+--------------------+-------------+-----------------------------------+
| ![](media/imag     |             | ![](media/image34                 |
| e33.wmf){width="4. |             | .wmf){width="4.272916666666666in" |
| 240972222222222in" |             | height="5.999305555555556in"}     |
| height="5.9        |             |                                   |
| 65972222222222in"} |             |                                   |
+--------------------+-------------+-----------------------------------+
| **Tracker Radiator |             | **Tracker Radiator Heater         |
| Heater Schematic   |             | Schematic (Wake)**                |
| (RAM)**            |             |                                   |
+--------------------+-------------+-----------------------------------+
| ![](media/imag     |             |                                   |
| e35.png){width="7. |             |                                   |
| 716666666666667in" |             |                                   |
| height="3.8        |             |                                   |
| 28472222222222in"} |             |                                   |
+--------------------+-------------+-----------------------------------+
| **TTCS Accumulator |             |                                   |
| Location of        |             |                                   |
| Thermoswitches**   |             |                                   |
+--------------------+-------------+-----------------------------------+

  -----------------------------------------------------------------------
  ![](media/image36.png){width="4.352777777777778in"
  height="6.031944444444444in"}

  **Overview of Thermal Testing of Capillary Tubing for Freeze/Thaw
  Testing**

  ![](media/image37.png){width="8.98611111111111in"
  height="5.281944444444444in"}

  **Carbon Dioxide Temperature-Pressure Diagram**

  ![](media/image38.png){width="6.449305555555555in"
  height="6.048611111111111in"}

  **Capillary Tube Mounting Plate for Condenser**
  -----------------------------------------------------------------------

  -----------------------------------------------------------------------
  ![](media/image39.wmf){width="8.478472222222223in"
  height="4.954166666666667in"}

  **TTCS Freeze/Thaw Test Configuration (Extracted from NLR Memorandum
  AMSTR-NLR-TN-039 Issue 02)**

  ![](media/image40.wmf){width="7.222222222222222in"
  height="5.916666666666667in"}

  **Physical Test Setup for TTCS CO~2~ Freeze/Thaw Testing**
  -----------------------------------------------------------------------

  -----------------------------------------------------------------------

  -----------------------------------------------------------------------

D. Thermal Control System

<table>
<colgroup>
<col style="width: 9%" />
<col style="width: 8%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 6%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 9%" />
</colgroup>
<tbody>
<tr class="odd">
<td colspan="17"><strong>Cryomagnet Avionics Box Loop Heat Pipe Pressure
System Components</strong></td>
</tr>
<tr class="even">
<td rowspan="3"><p> </p>
<p>Description</p>
<p> </p></td>
<td rowspan="3">Material Of Construction</td>
<td colspan="2" rowspan="2"><p>Mass</p>
<p>Of fluid </p></td>
<td colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure<sup>6</sup>)</p></td>
<td colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></td>
<td colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></td>
<td colspan="2">Burst SF</td>
<td colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></td>
<td rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></td>
<td rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></td>
<td rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></td>
</tr>
<tr class="odd">
<td rowspan="2">Req <sup>3</sup></td>
<td rowspan="2">Actual</td>
</tr>
<tr class="even">
<td>kg</td>
<td>lbm</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
</tr>
<tr class="odd">
<td>Loop heat pipe evaporator</td>
<td>AISI 321 stainless steel</td>
<td></td>
<td></td>
<td>15.0</td>
<td>217.6</td>
<td>20.3</td>
<td>294.0</td>
<td>208.5</td>
<td>3024.0</td>
<td>4.0</td>
<td>10.3</td>
<td>30.4</td>
<td>441.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Loop heat pipe reservoir<sup>5</sup></td>
<td>AISI 321 stainless steel</td>
<td>0.055</td>
<td>0.121</td>
<td>15.0</td>
<td>217.6</td>
<td>20.3</td>
<td>294.0</td>
<td>165.5</td>
<td>2400.0</td>
<td>4.0</td>
<td>8.2</td>
<td>30.4</td>
<td>441.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Loop Heat pipe vapor tubes</td>
<td>AISI 321 stainless steel</td>
<td> </td>
<td> </td>
<td>15.0</td>
<td>217.6</td>
<td>20.3</td>
<td>294.0</td>
<td>672.4</td>
<td>9753.0</td>
<td>4.0</td>
<td>33.2</td>
<td>30.4</td>
<td>441.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Loop Heat pipe liquid tubes</td>
<td>AISI 321 stainless steel</td>
<td> </td>
<td> </td>
<td>15.0</td>
<td>217.6</td>
<td>20.3</td>
<td>294.0</td>
<td>924.0</td>
<td>13401.0</td>
<td>4.0</td>
<td>45.6</td>
<td>30.4</td>
<td>441.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Loop Heat pipe condenser tubes</td>
<td>Al 6063</td>
<td> </td>
<td> </td>
<td>15.0</td>
<td>217.6</td>
<td>20.3</td>
<td>294.0</td>
<td>450.5</td>
<td>6534.0</td>
<td>4.0</td>
<td>22.2</td>
<td>30.4</td>
<td>441.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Bypass valve gas bellow – Argon<sup>7</sup></td>
<td>AISI 321 stainless steel</td>
<td></td>
<td></td>
<td>6.0</td>
<td>87.0</td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
<tr class="odd">
<td>Bypass valve liquid side – Ammonia</td>
<td>AISI 321 stainless steel</td>
<td></td>
<td></td>
<td>6.0</td>
<td>87.0</td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
<tr class="even">
<td colspan="17"><p>Notes:</p>
<p>1) MDP has been established based on worst case thermal profile and
where applicable (with mechanisms to fail) worst case two fault
condition.</p>
<p>2) Burst Safety Factor is calculated from the material allowable
stress and pipe geometry</p>
<p>3) Heat pipes are part of a pressurized system and are not isolated.
Burst Factor of 4.0 is used (2.5 could be used for heat pipes as
components.)</p>
<p>4) Ref TCS Hardware Design Report AMS-OHB-DER-001 Issue 2, Revision
A, May 5, 2005</p>
<p>5) Mass of working fluid is allocated to reservoir for accounting
purposes.</p>
<p>6) Calculated at 40°C; maximum operating temperature of CAB</p>
<p>7) Operating Pressure calculated at 20°C</p></td>
</tr>
</tbody>
</table>

<table>
<colgroup>
<col style="width: 9%" />
<col style="width: 8%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 9%" />
</colgroup>
<tbody>
<tr class="odd">
<td colspan="17"><strong>Cryomagnet Avionics Box Heat Pipes Pressure
System Components</strong></td>
</tr>
<tr class="even">
<td rowspan="3"><p> </p>
<p>Description</p>
<p> </p></td>
<td rowspan="3">Material Of Construction</td>
<td colspan="2" rowspan="2"><p>Mass</p>
<p>Of fluid </p></td>
<td colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure<sup>6</sup>)</p></td>
<td colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></td>
<td colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></td>
<td colspan="2">Burst SF</td>
<td colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></td>
<td rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></td>
<td rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></td>
<td rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></td>
</tr>
<tr class="odd">
<td rowspan="2">Req <sup>3</sup></td>
<td rowspan="2">Actual</td>
</tr>
<tr class="even">
<td>kg</td>
<td>lbm</td>
<td>Bar</td>
<td>psid</td>
<td>Bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
</tr>
<tr class="odd">
<td>Body mounted Heat Pipes</td>
<td>AL 6063</td>
<td>Note 5</td>
<td> </td>
<td>15.0</td>
<td>217.6</td>
<td>20.0</td>
<td>290.0</td>
<td>174.7</td>
<td>2534.0</td>
<td>4.0</td>
<td>8.7</td>
<td>30.0</td>
<td>435.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="17"><p> Notes:</p>
<p>1) MDP has been established based on worst case thermal profile and
where applicable (with mechanisms to fail) worst case two fault
condition.</p>
<p>2) Burst Safety Factor is calculated from the material allowable
stress and pipe geometry</p>
<p>3) Heat pipes single components and not a part of a greater pressure
system. Burst Factor of 4.0 is used (2.5 could be used for heat pipes as
components.)</p>
<p>4) Ref TCS Hardware Design Report AMS-OHB-DER-001 Issue 2, Revision
A, May 5, 2005</p>
<p>5) There are 2 heat pipes with different lengths, mass of fluid
(ammonia) is 5 grams for the shortest and 7 grams for the longest</p>
<p>6) Calculated at 40°C; maximum operating temperature of CAB</p></td>
</tr>
</tbody>
</table>

  ----------------------------------------------------- -----------------------------------
  ![](media/image43.png){width="3.1305555555555555in"   CAB Heat Pipe Specifications
  height="4.000694444444444in"}                         

  ----------------------------------------------------- -----------------------------------

<table>
<colgroup>
<col style="width: 9%" />
<col style="width: 8%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 6%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 9%" />
</colgroup>
<tbody>
<tr class="odd">
<td colspan="17"><strong>USS-02 Structure Heat Pipes Pressure System
Components</strong></td>
</tr>
<tr class="even">
<td rowspan="3"><p> </p>
<p>Description</p>
<p> </p></td>
<td rowspan="3">Material Of Construction</td>
<td colspan="2" rowspan="2"><p>Mass</p>
<p>Of fluid </p></td>
<td colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure<sup>6</sup>)</p></td>
<td colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></td>
<td colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></td>
<td colspan="2">Burst SF</td>
<td colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></td>
<td rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></td>
<td rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></td>
<td rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></td>
</tr>
<tr class="odd">
<td rowspan="2">Req <sup>3</sup></td>
<td rowspan="2">Actual</td>
</tr>
<tr class="even">
<td>kg</td>
<td>lbm</td>
<td>Bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
</tr>
<tr class="odd">
<td>USS Mounted HP</td>
<td>Al 6063</td>
<td>Note 5</td>
<td> </td>
<td>15.0</td>
<td>217.6</td>
<td>20.3</td>
<td>294.0</td>
<td>174.7</td>
<td>2534.0</td>
<td>4.0</td>
<td>8.6</td>
<td>30.4</td>
<td>441.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="17"><p>Notes:</p>
<p>1) MDP has been established based on worst case thermal profile and
where applicable (with mechanisms to fail) worst case two fault
conditions.</p>
<p>2) Burst Safety Factor is calculated from the material allowable
stress and pipe geometry</p>
<p>3) Heat pipes single components and not a part of a greater pressure
system. Burst Factor of 4.0 is used (2.5 could be used for heat pipes as
components.)</p>
<p>4) Ref TCS Hardware Design Report AMS-OHB-DER-001 Issue 2, Revision
A, May 5, 2005</p>
<p>5) The USS-02 Structure Heat Pipes consist of three non-embedded heat
pipes that each contains 6.8 grams of ammonia.</p>
<p>6) Calculated at 40°C; maximum operating temperature of CAB</p></td>
</tr>
</tbody>
</table>

  -----------------------------------------------------------------------
  ![](media/image44.png){width="6.375in" height="3.15625in"}

  CAB Loop Heat Pipe

  ![](media/image45.wmf){width="5.464583333333334in" height="5.7in"}

  **CAB (Avionics Box) Heater Layout, Computer Control of Heaters Not
  Shown.**
  -----------------------------------------------------------------------

  ----------------------------------------------------- -----------------------------------------------------
  ![](media/image46.png){width="2.7472222222222222in"   ![](media/image47.png){width="5.5465277777777775in"
  height="2.0409722222222224in"}                        height="2.111111111111111in"}

  ![](media/image48.png){width="4.055555555555555in"    
  height="2.9555555555555557in"}                        

  USS Heat Pipes (a.k.a CAB-USS Heat Pipes)             
  ----------------------------------------------------- -----------------------------------------------------

<table>
<colgroup>
<col style="width: 9%" />
<col style="width: 8%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 9%" />
</colgroup>
<thead>
<tr class="header">
<th colspan="17"><strong>Cryocooler Loop Heat Pipe/Zenith Radiators
Pressure System Components</strong></th>
</tr>
<tr class="odd">
<th rowspan="3"><p> </p>
<p>Description</p>
<p> </p></th>
<th rowspan="3">Material Of Construction</th>
<th colspan="2" rowspan="2"><p>Mass</p>
<p>Of Fluid </p></th>
<th colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure<sup>7</sup></p></th>
<th colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></th>
<th colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></th>
<th colspan="2">Burst SF</th>
<th colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></th>
<th rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></th>
<th rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></th>
<th rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></th>
</tr>
<tr class="header">
<th rowspan="2">Req <sup>3</sup></th>
<th rowspan="2">Actual</th>
</tr>
<tr class="odd">
<th>kg</th>
<th>lbm</th>
<th>Bar</th>
<th>Psid</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
<th>bar</th>
<th>psid</th>
</tr>
</thead>
<tbody>
<tr class="odd">
<td>Loop Heat Pipe Evaporator</td>
<td>AISI 321 stainless steel</td>
<td> </td>
<td> </td>
<td>4.0</td>
<td>58.0</td>
<td>18.0</td>
<td>261.0</td>
<td>165.4</td>
<td>2399.0</td>
<td>4.0</td>
<td>9.2</td>
<td>27.0</td>
<td>392.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Loop Heat Pipe Reservoir<sup>5</sup></td>
<td>AISI 321 stainless steel</td>
<td>0.042</td>
<td>0.093</td>
<td>4.0</td>
<td>58.0</td>
<td>18.0</td>
<td>261.0</td>
<td>123.1</td>
<td>1785.0</td>
<td>4.0</td>
<td>6.8</td>
<td>27.0</td>
<td>392.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Loop Heat Pipe Liquid Tubes</td>
<td>AISI 321 stainless steel</td>
<td> </td>
<td> </td>
<td>4.0</td>
<td>58.0</td>
<td>18.0</td>
<td>261.0</td>
<td>924.0</td>
<td>13401.0</td>
<td>4.0</td>
<td>51.3</td>
<td>27.0</td>
<td>392.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Loop Heat Pipe Vapor Tubes</td>
<td>AISI 321 stainless steel</td>
<td> </td>
<td> </td>
<td>4.0</td>
<td>58.0</td>
<td>18.0</td>
<td>261.0</td>
<td>672.4</td>
<td>9753.0</td>
<td>4.0</td>
<td>37.4</td>
<td>27.0</td>
<td>392.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Loop Heat Pipe Valve</td>
<td>AISI 321 stainless steel</td>
<td> </td>
<td> </td>
<td>4.0</td>
<td>58.0</td>
<td>18.0</td>
<td>261.0</td>
<td>266.1</td>
<td>3859.0</td>
<td>4.0</td>
<td>14.8</td>
<td>27.0</td>
<td>392.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td>Loop Heat Pipe Condensor Tubes</td>
<td>AL 6063</td>
<td> </td>
<td> </td>
<td>&lt;4.0</td>
<td>&lt;58.0</td>
<td>18.0</td>
<td>261.0</td>
<td>252.2</td>
<td>3658.0</td>
<td>4.0</td>
<td>14.0</td>
<td>27.0</td>
<td>392.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="odd">
<td>Bypass valve gas bellow – ARGON (6)</td>
<td>AISI 321 stainless steel</td>
<td></td>
<td></td>
<td>6.0</td>
<td>87.0</td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
<tr class="even">
<td>Bypass valve liquid side – Propylene</td>
<td>AISI 321 stainless steel</td>
<td></td>
<td></td>
<td>6.0</td>
<td>87.0</td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
<tr class="odd">
<td colspan="17"><p>Notes:</p>
<p>1) MDP has been established based on worst case thermal profile and
where applicable (with mechanisms to fail) worst case two fault
condition.</p>
<p>2) Burst Safety Factor is calculated from the material allowable
stress and pipe geometry</p>
<p>3) Listed Components are part of a pressurized system and are not
isolated. Burst Factor of 4.0 is used (2.5 could be used for heat pipes
as components.)</p>
<p>5) Mass of working fluid is allocated to reservoir for accounting
purposes.</p>
<p>6) Operating Pressure calculated at 20°C</p>
<p>7) Calculated at 0°C, typical working temperature of the
cryocoolers</p></td>
</tr>
</tbody>
</table>

  ---------------------------------------------------- -----------------------------------------------------
  ![](media/image49.png){width="6.007638888888889in"   ![](media/image50.png){width="2.8465277777777778in"
  height="2.104861111111111in"}                        height="3.036111111111111in"}

  ![](media/image51.png){width="5.007638888888889in"   
  height="2.2916666666666665in"}                       

  Cryocooler Loop Heat Pipe System                     

  ![](media/image52.png){width="6.125in"               
  height="5.50625in"}                                  

  **Four Radiators of the Zenith Radiators/Cryocooler  
  Loop Heat Pipe System**                              
  ---------------------------------------------------- -----------------------------------------------------

<table>
<colgroup>
<col style="width: 10%" />
<col style="width: 8%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 3%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 11%" />
</colgroup>
<tbody>
<tr class="odd">
<td colspan="17"><strong>Wake and Ram Radiator (Crates) Heat Pipes
Pressure System Components</strong></td>
</tr>
<tr class="even">
<td rowspan="3"><p> </p>
<p>Description</p>
<p> </p></td>
<td rowspan="3">Material Of Construction</td>
<td colspan="2" rowspan="2"><p>Mass</p>
<p>Of fluid </p></td>
<td colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure<sup>6</sup>)</p></td>
<td colspan="2" rowspan="2"><p>MDP<sup>1</sup></p>
<p> </p></td>
<td colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></td>
<td colspan="2">Burst SF</td>
<td colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></td>
<td rowspan="3"><p>Proof</p>
<p>SF</p>
<p> </p></td>
<td rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></td>
<td rowspan="3"><p>Reference</p>
<p>Document</p>
<p> </p></td>
</tr>
<tr class="odd">
<td rowspan="2">Req <sup>3</sup></td>
<td rowspan="2">Actual</td>
</tr>
<tr class="even">
<td>kg</td>
<td>lbm</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
</tr>
<tr class="odd">
<td>Embedded Heat Pipes</td>
<td>AL 6063</td>
<td>Note 5</td>
<td> </td>
<td>15.0</td>
<td>217.6</td>
<td>25.0</td>
<td>362.5</td>
<td>155.4</td>
<td>2254.0</td>
<td>4.0</td>
<td>6.2</td>
<td>30.0</td>
<td>435.0</td>
<td>1.5</td>
<td>Analysis<sup>2</sup></td>
<td>NSTS 1700.7B SSP 30559C</td>
</tr>
<tr class="even">
<td colspan="17"><p>Notes:</p>
<p>1) MDP has been established based on worst case thermal profile and
where applicable (with mechanisms to fail) worst case two fault
conditions with a relevant MDT of 60°C.</p>
<p>2) Burst Safety Factor is calculated from the material allowable
stress and pipe geometry</p>
<p>3) Heat pipes single components and not a part of a greater pressure
system. Burst Factor of 4.0 is used (2.5 could be used for heat pipes as
components.)</p>
<p>4) Ref TCS Hardware Design Report AMS-OHB-DER-001 Issue 2, Revision
A, May 5, 2005</p>
<p>5) There are 20 embedded heat pipes with different lengths on the
Wake Radiator, 16 heat pipes on the Ram Radiator, mass of fluid
(ammonia) ranges from 7.6 grams for the shortest to 29.6 grams for the
longest</p>
<p>6) Calculated at 40°C, maximum working temperature of the
electronic</p></td>
</tr>
</tbody>
</table>

  -----------------------------------------------------------------------
  ![](media/image53.png){width="5.199305555555555in"
  height="3.5340277777777778in"}

  **AMS-02 Wake and Ram Radiators**
  -----------------------------------------------------------------------

  ----------------------------------------------------- ----------------------------------------- ---------------------------------------------------- ----------------------------------------------------
  ![](media/image54.wmf){width="2.85in"                 ![](media/image55.wmf){width="5.2625in"                                                        
  height="5.7131944444444445in"}                        height="5.0256944444444445in"}                                                                 

  **RAM Radiator Heater Set 1 Schematic**               **RAM Radiator Heater and Thermostatic                                                         
                                                        Switch Locations (Set 1)**                                                                     

  ![](media/image56.wmf){width="5.270833333333333in"                                                                                                   
  height="5.576388888888889in"}                                                                                                                        

  **Ram Heater Set 1 Control Zone Layout with Heater                                                                                                   
  Locations**                                                                                                                                          

  ![](media/image57.wmf){width="3.6756944444444444in"                                                                                                  ![](media/image58.wmf){width="4.911111111111111in"
  height="5.186805555555556in"}                                                                                                                        height="4.98125in"}

  **Ram Radiator Heater Set 2 Schematic**                                                                                                              **Ram Radiator Heater and Thermostatic Switch
                                                                                                                                                       Locations (Set 2)**

  ![](media/image59.wmf){width="5.728472222222222in"                                                                                                   
  height="5.963888888888889in"}                                                                                                                        

  **Ram Heater Set 2 Control Zone Layout with Heater                                                                                                   
  Locations**                                                                                                                                          

  ![](media/image60.wmf){width="3.7569444444444446in"                                             ![](media/image61.wmf){width="4.990277777777778in"   
  height="5.0881944444444445in"}                                                                  height="4.863888888888889in"}                        

  Wake Radiator Schematic                                                                         **Wake Radiator Heater and Thermostatic Switch       
                                                                                                  Locations**                                          
  ----------------------------------------------------- ----------------------------------------- ---------------------------------------------------- ----------------------------------------------------

  ---------------------------------------------------- ----------------------------------------------------
  ![](media/image62.wmf){width="3.796527777777778in"   ![](media/image63.wmf){width="5.029861111111111in"
  height="5.727777777777778in"}                        height="5.263888888888889in"}

  **PDS Heaters Schematics**                           **PDS Heaters Location with Thermostats**
  ---------------------------------------------------- ----------------------------------------------------

  ---------------------------------------------------- ----------------------------------------------------
  ![](media/image64.png){width="3.1in"                 ![](media/image65.png){width="4.415277777777778in"
  height="2.870138888888889in"}                        height="3.75in"}

  TCS Main Radiator Heat Pipe                          

  ![](media/image66.png){width="5.206944444444445in"   
  height="3.5694444444444446in"}                       

  Mounting Options for Main Radiator Heat Pipes        
  ---------------------------------------------------- ----------------------------------------------------

E. Cryocoolers

<table style="width:100%;">
<colgroup>
<col style="width: 9%" />
<col style="width: 8%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 4%" />
<col style="width: 4%" />
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<col style="width: 4%" />
<col style="width: 5%" />
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<col style="width: 4%" />
<col style="width: 8%" />
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</colgroup>
<tbody>
<tr class="odd">
<td colspan="17"><strong>Cryocoolers</strong></td>
</tr>
<tr class="even">
<td rowspan="3">Description</td>
<td rowspan="3">Material Of Construction</td>
<td colspan="2" rowspan="2"><p>Mass</p>
<p>Of fluid</p></td>
<td colspan="2" rowspan="2"><p>Operating</p>
<p>Pressure</p></td>
<td colspan="2" rowspan="2">MDP</td>
<td colspan="2" rowspan="2"><p>Burst</p>
<p>Pressure</p></td>
<td colspan="2">Burst SF</td>
<td colspan="2" rowspan="2"><p>Proof</p>
<p>Pressure</p></td>
<td rowspan="3"><p>Proof</p>
<p>SF</p></td>
<td rowspan="3"><p>Analysis</p>
<p>Test or</p>
<p>Similarity</p></td>
<td rowspan="3"><p>Reference</p>
<p>Document</p></td>
</tr>
<tr class="odd">
<td rowspan="2">Req</td>
<td rowspan="2">Actual</td>
</tr>
<tr class="even">
<td>kg</td>
<td>lbm</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
<td>bar</td>
<td>psid</td>
</tr>
<tr class="odd">
<td>Sunpower Stirling cycle mechanical cryocoolers</td>
<td>Stainless Steel</td>
<td>7.20E-04</td>
<td>1.60E-03</td>
<td>Note 1</td>
<td>Note 1</td>
<td>20.3</td>
<td>294</td>
<td>124</td>
<td>1800</td>
<td>Note 2</td>
<td>6.1</td>
<td>Note 2</td>
<td>Note 2</td>
<td>Note 2</td>
<td>Leak Test</td>
<td>Note 3</td>
</tr>
<tr class="even">
<td colspan="17"><p>Notes:</p>
<p>Note 1: The cryocoolers are filled with 275 cm^3 of helium gas at a
pressure of 16 bar (232 psid) and ambient temperature. When operating,
the helium in the compression space can reach a pressure as high as 20
bar (290 psid) at the maximum operating temperature of the cooler. This
is very nearly the same as the MDP, which occurs with a non-operating
cryocooler exposed to an 80°C environment. The MDP is derived from the
increased pressure when raising 16 bar of helium at ambient temperature
to a temperature of 80°C at constant volume.</p>
<p>Note 2: The measured burst pressure is 124 bar (1800 psid) in the
compressor body and 152 bar (2200 psid) in the cold finger so the
minimum Burst SF is 6.1. The cryocooler has been classified as a
pressurized device by personnel on the Fracture Control Panel at JSC
(see e-mail from N. Martinez to C. Balas, Subject: AMS Cryocoolers -
Fracture Control), and we were not given a required Burst Safety Factor.
Also, no proof pressure test is required, only a leak test to verify
workmanship.</p>
<p>Note 3: We consulted NSTS 1700.7B, MIL STD 1522A, ANSI/AIAA S-080,
and NPD 8710.5A (Draft) and did not find Pressurized Device
listed.</p></td>
</tr>
</tbody>
</table>

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  ![](media/image67.png){width="9.071527777777778in"
  height="5.511111111111111in"}

  **CRYOCOOLER Functional Cross Section of Sunpower M87N cryocoolers**
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