<table>
<colgroup>
<col style="width: 7%" />
<col style="width: 5%" />
<col style="width: 13%" />
<col style="width: 4%" />
<col style="width: 5%" />
<col style="width: 13%" />
<col style="width: 13%" />
<col style="width: 8%" />
<col style="width: 9%" />
<col style="width: 10%" />
<col style="width: 5%" />
<col style="width: 2%" />
</colgroup>
<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-F10</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">Materials, Thermal Control System</td>
<td>e. HAZARD GROUP:</td>
<td colspan="2">Fire/Flammability</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">Flammable Materials in the Payload Bay</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 209.2</td>
</tr>
<tr class="odd">
<td colspan="4">j. DESCRIPTION OF HAZARD:</td>
<td colspan="8"><p>Use of flammable materials, solid or gaseous, in the
Orbiter Payload Bay can present an uncontrolled fire hazard to the
Orbiter and other payloads.</p>
<p>Note: Shuttle Cabin flammability issues are addressed in
STD-AMS-02-F02.</p></td>
</tr>
<tr class="even">
<td>k. CAUSES</td>
<td colspan="11" rowspan="2"><blockquote>
<p>1. Use of flammable materials in the construction of the AMS-02</p>
<p>2. Use of flammable fluids/gases in the AMS-02 Thermal Control
System</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: Use of flammable materials in the
construction of the AMS-02</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>1.1 CONTROL: Materials used in the construction of
the AMS-02 hardware to be locate in the shuttle payload bay will be “A”
rated for flammability as rated in the MAPTIS database or will be
included in a flammability assessment per NSTS 22648.</p>
<p>1.1.1 SVM: Review of design.</p>
<p>1.1.2 SVM: Inspection of as built hardware.</p>
<p>1.1.3 SVM: Material Certification by JSC ES4.</p>
<p>1.1.1 STATUS: Open</p>
<p>1.1.2 STATUS: Open</p>
<p>1.1.3 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10">2. CAUSE: Use of flammable fluids/gases in the AMS-02
Thermal Control System</td>
<td colspan="2"></td>
</tr>
<tr class="even">
<td colspan="10"><p>2.1 CONTROL: The Tracker radiators/thermal control
system radiators incorporate heat pipes that utilize ammonia as a
working fluid. There are 7 individual heat pipes in each of the Tracker
radiators each containing 22.3 to 26.3 grams of ammonia. Ram and Wake
Tracker radiators heat pipes are identical with regards to ammonia and
heat pipe use. All of these heat pipes are qualified under NSTS 1700.7B
208.4C Pressurized Lines, Fittings and Components. Reference
AMS-02-F05.</p>
<p>2.1.1 SVM: Review of design to establish flammable material
quantity.</p>
<p>2.1.2 SVM: Flammability assessment on the use of ammonia in the
payload bay.</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: The Electronics Crate thermal control
system radiators (Ram and Wake) incorporate heat pipes that utilize
ammonia as a working fluid. There are 24 individual heat pipes in the
Wake Radiator with a maximum ammonia quantity of 30.2 grams and 16
individual heat pipes with the maximum ammonia quantity of 40.7 grams in
the Ram Radiator. All of these heat pipes are qualified under NSTS
1700.7B 208.4C Pressurized Lines, Fittings and Components. Reference
AMS-02-F05.</p>
<p>2.2.1 SVM: Review of design to establish flammable material
quantity.</p>
<p>2.2.2 SVM: Flammability assessment on the use of ammonia in the
payload bay.</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 CONTROL: The Cryocooler Loop Heat Pipe Radiators
incorporate heat pipes that utilize propylene as a working fluid to
transport heat to the Zenith Radiators. There are four sets of dual
parallel (2) loop heat pipes in the Zenith radiators each loop
containing 42 grams of propylene. All of the heat pipes are qualified
under NSTS 1700.7B 208.4C Pressurized Lines, Fittings and Components.
Reference AMS-02-F05.</p>
<p>2.3.1 SVM: Review of design to establish flammable material
quantity.</p>
<p>2.3.2 SVM: Flammability assessment on the use of propylene in the
payload bay.</p>
<p>2.3.1 STATUS: Open</p>
<p>2.3.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>2.4 CONTROL: The CAB Loop Heat Pipe utilizes 55
grams of ammonia as a working fluid. The CAB Loop Heat Pipe is a closed
loop that does not incorporate vents or valves that may released the
ammonia. The CAB Loop Heat Pipe is qualified as a pressure system under
NSTS 1700.7B 208.4 Pressure Systems. Reference AMS-02-F05.</p>
<p>2.4.1 SVM: Review of design to establish flammable material
quantity.</p>
<p>2.4.2 SVM: Flammability assessment of the use of ammonia in the
payload bay.</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"><p>2.5 CONTROL: The USS heat pipes utilize 7 grams of
ammonia as a working fluid. The USS heat pipes are a closed system that
does not incorporate any nominal venting means. The USS heat pipes are
qualified under NSTS 1700.7B, 208.4C Pressurize Lines, Fittings and
Components. Reference AMS-02-F05.</p>
<p>2.5.1 SVM: Review of design to establish flammable material
quantity.</p>
<p>2.5.2 SVM: Flammability assessment on the use of ammonia in the
payload bay.</p>
<p>2.5.1 STATUS: Open</p>
<p>2.5.2 STATUS: Open</p></td>
<td colspan="2"></td>
</tr>
<tr class="odd">
<td colspan="10"><p>2.6 CONTROL: The TTCS Accumulator Heat Pipes utilize
3 grams of ammonia as a working fluid. The TTCS Accumulator Heat Pipe is
a closed system that does not incorporate any nominal venting means. The
TTCS Accumulator Heat Pipe is qualified under NSTS 1700.7B, 208.4C
Pressurized Lines Fittings and Components. Reference AMS-02-F05.</p>
<p>2.6.1 SVM: Review of design to establish flammable material
quantity.</p>
<p>2.6.2 SVM: Flammability assessment on the use of ammonia in the
payload bay.</p>
<p>2.6.1 STATUS: Open</p>
<p>2.6.2 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                           
  ---------------------------------- ------------------------------------
  ACOP -- AMS Crew Operations Post   MAPTIS - Materials and Processes
                                     Technical Information System

  AMS-02 -- Alpha Magnetic           SVM -- Safety Verification Method
  Spectrometer -02                   

  CAB -- Cryomagnet Avionics Box     TCS -- Thermal Control System

  DFMR -- Design for Minimum Risk    USS -- Unique Support Structure
  -----------------------------------------------------------------------

**Summary of Flammable Gas/Fluid use in AMS-02 Heat Pipes**

+-------------+-------------+-----------+-----------------------------+
| System      | Number of   | Quantity  | Construction                |
|             | Heat Pipes  | per HP    |                             |
+-------------+-------------+-----------+-----------------------------+
| CAB Loop    | 2           | 55 grams  | Stainless Steel (AISI 321)  |
| Heat Pipe   |             | of        | tubes for vapor and liquid  |
|             |             | ammonia   | lines, Stainless Steel      |
|             |             | each      | (AISI 321 reservoir and     |
|             |             |           | evaporator and AL 6063      |
|             |             |           | condenser.                  |
+-------------+-------------+-----------+-----------------------------+
| Cryocooler  | Four        | 42 grams  | Four: Aluminum (6063) of    |
| Thermal     | redundant   | pure      | 4mm OD, 3mm ID soldered to  |
| Control     | systems,    | propylene | the underside of radiator   |
| Sy          | each system | per loop  | sandwich material (1.6 mm   |
| stem/Zenith | with dual   | (8 total) | aluminum sheet/10mm         |
| Radiators   | loops (8    |           | ROHACELL core/0.3mm         |
|             | total)      |           | aluminum lower sheet)       |
|             |             |           | connected through stainless |
|             |             |           | steel tubes to evaporators  |
|             |             |           | connected thermally to the  |
|             |             |           | sterling engines            |
|             |             |           | (Cryocoolers). Stainless    |
|             |             |           | steel tube with internal    |
|             |             |           | wick evaporators are used.  |
+-------------+-------------+-----------+-----------------------------+
| Wake Crate  | Twenty heat | Total:    | Aluminum alloy face sheets  |
| Radiator    | pipes of    | 331.3     | of each 0.5 mm thickness,   |
|             | various     | grams     | ROHACELL 51 core of 25 mm   |
|             | lengths and |           | height (density 51 kg/m3)   |
|             | bends       | Largest   | with embedded heat pipes,   |
|             | fitted to   | single    | aluminum tubes with         |
|             | radiator    | ammonia   | internal capillary          |
|             |             | quantity: | structure                   |
|             |             | 30.2      |                             |
|             |             | grams     | Identical internal heat     |
|             |             |           | pipe profile                |
+-------------+-------------+-----------+-----------------------------+
| Ram Crate   | Sixteen     | Total:    | Aluminum alloy face sheets  |
| Radiator    | heat pipes  | 292.4     | of each 0.5 mm thickness,   |
|             | of various  | grams     | ROHACELL 51 core of 25 mm   |
|             | lengths and |           | height (density 51 kg/m3)   |
|             | bends       | Largest   | with embedded heat pipes,   |
|             | fitted to   | single    | aluminum tubes with         |
|             | radiator    | ammonia   | internal capillary          |
|             |             | quan      | structure                   |
|             |             | tity:40.7 |                             |
|             |             | grams     | Identical internal heat     |
|             |             |           | pipe profile                |
+-------------+-------------+-----------+-----------------------------+
| Tracker     | Seven heat  | Total     | Aluminum alloy face sheets  |
| Radiator    | pipes       | quantity: | of 0.8 mm thickness on      |
| Wake        | varying in  | 170.05    | radiating side and 0,2 mm   |
|             | length from | grams     | on opposite side. ROHACELL  |
|             | 2125 mm to  |           | 51 core of 15 mm height     |
|             | 2505 mm     | I         | (density 51 kg/m3) with 7   |
|             |             | ndividual | embedded heat pipes.        |
|             |             | heat      | Extruded aluminum with      |
|             |             | pipes     | internal capillary          |
|             |             | range     | structure heat pipes        |
|             |             | from 22.3 |                             |
|             |             | to 26.3   |                             |
|             |             | grams     |                             |
|             |             | ammonia   |                             |
+-------------+-------------+-----------+-----------------------------+
| Tracker     | Seven heat  | Total     | Aluminum alloy face sheets  |
| Radiator    | pipes       | quantity: | of 0.8 mm thickness on      |
| Ram         | varying in  | 170.05    | radiating side and 0,2 mm   |
|             | length from | grams     | on opposite side. ROHACELL  |
|             | 2125 mm to  |           | 51 core of 15 mm height     |
|             | 2505 mm     | I         | (density 51 kg/m3) with 7   |
|             |             | ndividual | embedded heat pipes.        |
|             |             | heat      | Extruded aluminum with      |
|             |             | pipes     | internal capillary          |
|             |             | range     | structure heat pipes        |
|             |             | from 22.3 |                             |
|             |             | to 26.3   |                             |
|             |             | grams     |                             |
|             |             | ammonia   |                             |
+-------------+-------------+-----------+-----------------------------+
| USS Heat    | Three heat  | 7 grams   | Axial groove heat pipes     |
| Pipes       | pipes       | of        | constructed of Al 6063      |
|             |             | Ammonia   |                             |
|             |             | per pipe. |                             |
+-------------+-------------+-----------+-----------------------------+
| TTCS        | Two heat    | 3 grams   | Stainless 316L tube with    |
| Accumulator | pipes, one  | of        | internal wicking materials. |
| Heat Pipe   | per         | Ammonia   | 232 mm long, OD 10.06 mm,   |
|             | accumulator |           | ID 7.6 mm                   |
+-------------+-------------+-----------+-----------------------------+
| CAB Heat    | Two Heat    | 5 grams   | Axial groove heat pipes     |
| Pipe        | Pipes       | of        | constructed of Al 6063      |
|             |             | Ammonia   |                             |
|             |             |           |                             |
|             |             | 7 grams   |                             |
|             |             | of        |                             |
|             |             | Ammonia   |                             |
+-------------+-------------+-----------+-----------------------------+

![](media/image1.png){width="8.67986111111111in"
height="6.490972222222222in"}

![](media/image2.png){width="7.580555555555556in"
height="5.6930555555555555in"}

**Worst case analysis of total release of flammable gasses indicates
that the quantities of flammable gases used in the design of the AMS-02
are significantly below any flammability threshold.**

![](media/image3.png){width="4.7972222222222225in"
height="5.090277777777778in"}

**TCS -- Wake Side Radiator for Avionics Crates**

![](media/image4.png){width="4.685416666666667in"
height="4.4215277777777775in"}

**TCS -- Ram Side Radiator for Avionics Crates**

![](media/image5.png){width="8.126388888888888in"
height="5.541666666666667in"}

TCS Heat Pipe Profile -- Axial Grooved

![](media/image6.png){width="8.997916666666667in"
height="5.735416666666667in"}

**Tracker TCS Radiator**

![](media/image7.png){width="2.638888888888889in"
height="4.360416666666667in"}![](media/image8.png){width="5.50625in"
height="3.2506944444444446in"}

> Tracker TCS Layout

![](media/image9.png){width="4.936111111111111in"
height="5.50625in"}![](media/image10.png){width="2.1333333333333333in"
height="6.0881944444444445in"}

> **Cryocooler Zenith Radiator Sub Panel Cryocooler Plumbing Layout**

![](media/image11.png){width="8.739583333333334in" height="4.0in"}

**Cryocooler Zenith Radiator -- Four Sub-Panel Layout**

  ----------------------------------------------------- ----------------------------------------------------
  ![](media/image12.png){width="3.140277777777778in"    ![](media/image13.png){width="5.371527777777778in"
  height="2.2805555555555554in"}                        height="2.2131944444444445in"}

  USS Heat Pipes on USS-02                              USS Heat Pipe Construction (mm)

  ![](media/image14.png){width="2.7868055555555555in"   
  height="2.0701388888888888in"}                        

  USS Heat Pipe Cross section, (mm)                     
  ----------------------------------------------------- ----------------------------------------------------

  ------------------------------- ---------------------------------------
  ![](media/image15.wmf)          

  **CAB Loop Heat Pipe and Heat   **CAB Wake Heat Pipe**
  Pipes**                         
  ------------------------------- ---------------------------------------

  -----------------------------------------------------------------------
  ![](media/image16.png){width="8.35in" height="2.7375in"}

  **TTCS Accumulator Heat Pipe Cross Section**

  ![](media/image17.png){width="8.636805555555556in"
  height="5.144444444444445in"}

  **TTCS Accumulator Heat Pipe Cross Section**
  -----------------------------------------------------------------------

  -----------------------------------------------------------------------
  ![](media/image18.png){width="8.592361111111112in"
  height="6.247222222222222in"}

  ![](media/image19.png){width="8.24375in" height="6.158333333333333in"}
  -----------------------------------------------------------------------