-----------------------------------------------------------------------
  **MSFC PRACA : 2003-02-12 08:41**

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

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

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

+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **In-Flight   | **C       | **      | *    |        |
| Record \#**\ | Anomaly       | ontractor | JSC#**\ | *KSC |        |
| A17402       | Number**\     | Report    | \--     | #**\ |        |
|              | \--           | Number**\ |         | \--  |        |
|              |               | P-088     |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| VENT VALVE   |               |           |         |      |        |
| SENSE PORT   |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **EICN#**\   | **ELEMENT**\  | **Cont    | **F     | **   |        |
| \--          | ET            | ractor**\ | SCM#**\ | FCRI |        |
|              |               | LMMSS     | 06887   | T**\ |        |
|              |               |           |         | 1R   |        |
+--------------+---------------+-----------+---------+------+--------+
| **HCRIT**\   | **Sys_Lvl**\  | **Misc    |         |      |        |
| \--          | \--           | Codes**\  |         |      |        |
|              |               | A B C D E |         |      |        |
|              |               | F G H I J |         |      |        |
|              |               | K L M N O |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| EIM          | \--           | \--       | \--     | UFAC |        |
|              |               |           |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| LRU          | \--           | \--       | \--     | UFAC |        |
|              |               |           |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| NCA          | LH2 VENT      | M         | ET-104  | UFAC |        |
|              | VALVE EXTER   | S24394-J4 |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | L    |        |
|              |               |           |         | MMSS |        |
+--------------+---------------+-----------+---------+------+--------+
| **Test/      | **Prevailing  | **F /     | **Fail  | **   |        |
| Operation**\ | Condtion**\   | U**\      | Mode**\ | Caus |        |
| AS - ATS     | F -           | F         | UC -    | e**\ |        |
|              | FUNCTIONAL    |           | UNSAT   | M    |        |
|              |               |           |         | PP - |        |
|              |               |           |         | MFG- |        |
|              |               |           |         | PRC- |        |
|              |               |           |         | INST |        |
+--------------+---------------+-----------+---------+------+--------+
| **System**\  | **Defect**\   | **Ma      | **Work  | **   |        |
| PROPULSION   | \--           | terial**\ | Con     | Fail |        |
|              |               | \--       | tact**\ | Dat  |        |
|              |               |           | E.      | e**\ |        |
|              |               |           | ALDAHIR | 05   |        |
|              |               |           |         | /06/ |        |
|              |               |           |         | 1999 |        |
+--------------+---------------+-----------+---------+------+--------+
| **Received   | **Date        | **FMEA    | **IFA:  | *    |        |
| at MSFC**\   | Isolated**\   | Ref       | Mission | *Mis |        |
| 05/11/1999   | 05/06/1999    | erence**\ | P       | sion |        |
|              |               | 2.1.1.7   | hase**\ | Ela  |        |
|              |               |           | \--     | psed |        |
|              |               |           |         | Tim  |        |
|              |               |           |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               | **S       |         | **   |        |
| *Location**\ |               | ymptom**\ |         | Time |        |
| MAF          |               | UC -      |         | Cycl |        |
|              |               | UNSAT     |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               |           |         |      |        |
| *Effectivity |               |           |         |      |        |
| Text**\      |               |           |         |      |        |
| ET 104       |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    |               |           |         |      |        |
| Effectivity  |               |           |         |      |        |
| Codes**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    | **Vehicle     | **Vehicle | **      | *    |        |
| 1**\         | 2**\          | 3**\      | Vehicle | *Veh |        |
| \--          | \--           | \--       | 4**\    | icle |        |
|              |               |           | \--     | 5**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Mission    |               |           |         |      |        |
| Effectivity  |               |           |         |      |        |
| Codes**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Mssn 1**\  | **Mssn 2**\   | **Mssn    | **Mssn  | **   |        |
| \--          | \--           | 3**\      | 4**\    | Mssn |        |
|              |               | \--       | \--     | 5**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Estimated  |               |           |         |      |        |
| Completion   |               |           |         |      |        |
| Dates**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **Contractor  | **LVL 3   | *       |      |        |
| Approved     | Req Defer     | Close**\  | *Remark |      |        |
| Defer Until  | Until Date**\ | \--       | /       |      |        |
| Date**\      | 05/26/1999    |           | Ac      |      |        |
| 09/07/1999   |               |           | tion**\ |      |        |
|              |               |           | 05/     |      |        |
|              |               |           | 26/1999 |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **I          |               |           |         |      |        |
| nvestigation |               |           |         |      |        |
| / Resolution |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Last MSFC  | **CN RSLV     | **Defer   | **Add   | *    |        |
| Update**\    | SBMT**\       | Date**\   | Date**\ | *R/C |        |
| 02/02/2001   | 05/29/1999    | 0         | 05/     | Code |        |
|              |               | 5/19/1999 | 12/1999 | s**\ |        |
|              |               |           |         | \--  |        |
|              |               |           |         | \--  |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Assignee** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| M. BUTLER    | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | J. LUSK       | A. ADAMS  | \--     | ject |        |
|              |               |           |         | MG   |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | P.   |        |
|              |               |           |         | CO   |        |
|              |               |           |         | UNTS |        |
+--------------+---------------+-----------+---------+------+--------+
| **Approval** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| M. BUTLER    | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | J. LUSK       | A. ADAMS  | \--     | ject |        |
|              |               |           |         | MG   |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | P.   |        |
|              |               |           |         | CO   |        |
|              |               |           |         | UNTS |        |
+--------------+---------------+-----------+---------+------+--------+
| **PAC        | **PAC Review  | **MSFC    | **St    | *    |        |
| Assignee**\  | Complete**\   | Closure   | atus**\ | *F/A |        |
| R. TUCKER    | RT            | Date**\   | C -     | C    |        |
|              |               | 0         | CLOSED  | ompl |        |
|              |               | 6/28/1999 |         | etio |        |
|              |               |           |         | n**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    | **SEV**\      | **Program | **      | **O  |        |
| Type**\      | \--           | Name**\   | REVL**\ | PRIN |        |
| \--          |               | \--       | \--     | C**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **FUNC       | **Software    | *         |         | **SU | **So   |
| MOD**\       | E             | *Software |         | BTYP | ftware |
| \--          | ffectivity**\ | Fail      |         | E**\ | C      |
|              | \-- \-- \--   | CD**\     |         | \--  | losure |
|              | \-- \--       | \--       |         |      | CD**\  |
|              |               |           |         |      | \--    |
+--------------+---------------+-----------+---------+------+--------+
| **RES PERSON | **Approval    |           |         |      |        |
| L2**\        | Signature     |           |         |      |        |
| \--          | L3**\         |           |         |      |        |
|              | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | N043150       |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| Status       |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Reliabi    |               |           |         |      |        |
| lity/Quality |               |           |         |      |        |
| Assurance    |               |           |         |      |        |
| Concerns,    |               |           |         |      |        |
| Recomm       |               |           |         |      |        |
| endations:** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| D            |               |           |         |      |        |
| escription** |               |           |         |      |        |
|              |               |           |         |      |        |
| PROBLEM      |               |           |         |      |        |
|              |               |           |         |      |        |
| THERE WAS NO |               |           |         |      |        |
| GAS FLOW     |               |           |         |      |        |
| FROM THE     |               |           |         |      |        |
| SENSE PORT,  |               |           |         |      |        |
| WHICH IS     |               |           |         |      |        |
| LOCATED ON   |               |           |         |      |        |
|              |               |           |         |      |        |
| THE MINUS    |               |           |         |      |        |
| Z-AXIS AT    |               |           |         |      |        |
| STATION 1075 |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| INTERTANK.   |               |           |         |      |        |
| THIS IS IN   |               |           |         |      |        |
|              |               |           |         |      |        |
| VIOLATION OF |               |           |         |      |        |
| FINAL        |               |           |         |      |        |
| ACCEPTANCE   |               |           |         |      |        |
| TESTING PER  |               |           |         |      |        |
| MMC-ET-TM04K |               |           |         |      |        |
|              |               |           |         |      |        |
| PARAGRAPH    |               |           |         |      |        |
| 2.1.1.7      |               |           |         |      |        |
|              |               |           |         |      |        |
| CRITICALITY: |               |           |         |      |        |
| THE EXTERNAL |               |           |         |      |        |
| VENT SENSE   |               |           |         |      |        |
| PORT IS A    |               |           |         |      |        |
| CRITICALITY  |               |           |         |      |        |
|              |               |           |         |      |        |
| 1R; FMEA     |               |           |         |      |        |
| 2.8.12.1;    |               |           |         |      |        |
| \"BLOCKAGE\" |               |           |         |      |        |
|              |               |           |         |      |        |
| REVISION     |               |           |         |      |        |
| \"B\" -      |               |           |         |      |        |
| DATED        |               |           |         |      |        |
| 5-26-99 -    |               |           |         |      |        |
| SEE          |               |           |         |      |        |
| ASTERISKS    |               |           |         |      |        |
| (\*)         |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| In           |               |           |         |      |        |
| vestigation/ |               |           |         |      |        |
| Resolution** |               |           |         |      |        |
|              |               |           |         |      |        |
| GENERAL      |               |           |         |      |        |
|              |               |           |         |      |        |
| THE GH2 VENT |               |           |         |      |        |
| VALVE RELIEF |               |           |         |      |        |
| SETTING IS   |               |           |         |      |        |
| REFERENCED   |               |           |         |      |        |
| TO AMBIENT   |               |           |         |      |        |
|              |               |           |         |      |        |
| PRESSURE     |               |           |         |      |        |
| THROUGH A    |               |           |         |      |        |
| 1/4 INCH     |               |           |         |      |        |
| TUBE RUN     |               |           |         |      |        |
| THAT         |               |           |         |      |        |
| PENETRATES   |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| INTERTANK AT |               |           |         |      |        |
| STATION 1075 |               |           |         |      |        |
| ON THE MINUS |               |           |         |      |        |
| Z-AXIS. THE  |               |           |         |      |        |
| SYSTEM       |               |           |         |      |        |
|              |               |           |         |      |        |
| TERMINATES   |               |           |         |      |        |
| WITH AN      |               |           |         |      |        |
| ELBOW, THE   |               |           |         |      |        |
| OPEN END OF  |               |           |         |      |        |
| WHICH IS THE |               |           |         |      |        |
| PRIMARY      |               |           |         |      |        |
|              |               |           |         |      |        |
| SENSE PORT.  |               |           |         |      |        |
| A SECONDARY  |               |           |         |      |        |
| ORIFICE IS   |               |           |         |      |        |
| INSTALLED IN |               |           |         |      |        |
| THE LINE     |               |           |         |      |        |
|              |               |           |         |      |        |
| WITHIN THE   |               |           |         |      |        |
| INTERTANK.   |               |           |         |      |        |
| DURING THE   |               |           |         |      |        |
| GAS FLOW     |               |           |         |      |        |
| VERIFICATION |               |           |         |      |        |
| TEST         |               |           |         |      |        |
|              |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| VENT SENSE   |               |           |         |      |        |
| PORT         |               |           |         |      |        |
| (            |               |           |         |      |        |
| TP-8C101-AT; |               |           |         |      |        |
| STEP 12.11), |               |           |         |      |        |
|              |               |           |         |      |        |
| THERE WAS NO |               |           |         |      |        |
| GAS FLOW AT  |               |           |         |      |        |
| THE EXTERNAL |               |           |         |      |        |
| PORT OF      |               |           |         |      |        |
| STATION 1075 |               |           |         |      |        |
|              |               |           |         |      |        |
| \*TASK I.    |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
| I            |               |           |         |      |        |
| NVESTIGATION |               |           |         |      |        |
|              |               |           |         |      |        |
| A. OBTAIN    |               |           |         |      |        |
| PART REMOVED |               |           |         |      |        |
| FROM VENT    |               |           |         |      |        |
| LINE         |               |           |         |      |        |
| ASSEMBLY PER |               |           |         |      |        |
| N043150      |               |           |         |      |        |
|              |               |           |         |      |        |
| AND          |               |           |         |      |        |
| DETERMINE    |               |           |         |      |        |
| CONTAMINANT  |               |           |         |      |        |
|              |               |           |         |      |        |
| RES          |               |           |         |      |        |
| PONSIBILITY: |               |           |         |      |        |
| E.           |               |           |         |      |        |
| AL           |               |           |         |      |        |
| DAHIR/3741 - |               |           |         |      |        |
| D.           |               |           |         |      |        |
| W            |               |           |         |      |        |
| ESTPHAL/3740 |               |           |         |      |        |
|              |               |           |         |      |        |
| L.           |               |           |         |      |        |
| RANDO/4643 - |               |           |         |      |        |
| R.           |               |           |         |      |        |
| MEYER/4640   |               |           |         |      |        |
|              |               |           |         |      |        |
| ECD:         |               |           |         |      |        |
| 5/14/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| COMPLETE:    |               |           |         |      |        |
| 5/13/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| \*CLOSURE    |               |           |         |      |        |
| STATEMENT:   |               |           |         |      |        |
|              |               |           |         |      |        |
| THE EXTERNAL |               |           |         |      |        |
| SENSE PORT   |               |           |         |      |        |
| (MS24394-J4) |               |           |         |      |        |
| WAS REMOVED  |               |           |         |      |        |
| PER N043150  |               |           |         |      |        |
|              |               |           |         |      |        |
| AND          |               |           |         |      |        |
| SUBMITTED TO |               |           |         |      |        |
| TECHNICAL    |               |           |         |      |        |
| OPERATIONS   |               |           |         |      |        |
| LABORATORY   |               |           |         |      |        |
| FOR          |               |           |         |      |        |
|              |               |           |         |      |        |
| ANALYSIS OF  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| CONTAMINANT  |               |           |         |      |        |
| THAT WAS     |               |           |         |      |        |
| INTERNAL TO  |               |           |         |      |        |
| THE REMOVED  |               |           |         |      |        |
|              |               |           |         |      |        |
| PART. BASED  |               |           |         |      |        |
| ON THE X-RAY |               |           |         |      |        |
| FLUORESCENT  |               |           |         |      |        |
| (XRF)        |               |           |         |      |        |
| ANALYSIS,    |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| CONTAMINANT  |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| IDENTIFIED   |               |           |         |      |        |
| AS PDL FOAM  |               |           |         |      |        |
| (REF. LAB    |               |           |         |      |        |
| REPORT       |               |           |         |      |        |
|              |               |           |         |      |        |
| 99A061)      |               |           |         |      |        |
|              |               |           |         |      |        |
| B. PENDING   |               |           |         |      |        |
| RESULTS OF   |               |           |         |      |        |
| 1A, IDENTIFY |               |           |         |      |        |
| ALL PROCESS  |               |           |         |      |        |
| OPERATIONS   |               |           |         |      |        |
|              |               |           |         |      |        |
| PERFORMED IN |               |           |         |      |        |
| THE          |               |           |         |      |        |
| IMMEDIATE    |               |           |         |      |        |
| AREA OF THE  |               |           |         |      |        |
| INSTALLED    |               |           |         |      |        |
| SENSE        |               |           |         |      |        |
|              |               |           |         |      |        |
| PORT         |               |           |         |      |        |
|              |               |           |         |      |        |
| RES          |               |           |         |      |        |
| PONSIBILITY: |               |           |         |      |        |
| E.           |               |           |         |      |        |
| AL           |               |           |         |      |        |
| DAHIR/3741 - |               |           |         |      |        |
| D.           |               |           |         |      |        |
| W            |               |           |         |      |        |
| ESTPHAL/3740 |               |           |         |      |        |
|              |               |           |         |      |        |
| ECD:         |               |           |         |      |        |
| 5/21/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| COMPLETE:    |               |           |         |      |        |
| 5/18/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| \* CLOSURE   |               |           |         |      |        |
| STATEMENT:   |               |           |         |      |        |
|              |               |           |         |      |        |
| PDL          |               |           |         |      |        |
| APPLICATION  |               |           |         |      |        |
| IN THIS AREA |               |           |         |      |        |
| ON ET-104    |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| PERFORMED    |               |           |         |      |        |
| PER          |               |           |         |      |        |
|              |               |           |         |      |        |
| MPP          |               |           |         |      |        |
| 809710       |               |           |         |      |        |
| 68422-500OP2 |               |           |         |      |        |
| (TPS CLOSE   |               |           |         |      |        |
| OUT ET       |               |           |         |      |        |
| COMPLETE) IN |               |           |         |      |        |
| FINAL        |               |           |         |      |        |
|              |               |           |         |      |        |
| ASSEMBLY.    |               |           |         |      |        |
| THE          |               |           |         |      |        |
| FOLLOWING IS |               |           |         |      |        |
| THE PROCESS  |               |           |         |      |        |
| FLOW FOR THE |               |           |         |      |        |
| PDL          |               |           |         |      |        |
|              |               |           |         |      |        |
| CLOSE OUT IN |               |           |         |      |        |
| THIS         |               |           |         |      |        |
| IMMEDIATE    |               |           |         |      |        |
| AREA:        |               |           |         |      |        |
|              |               |           |         |      |        |
| 1\) THE      |               |           |         |      |        |
| ADHESIVE     |               |           |         |      |        |
| MATERIAL WAS |               |           |         |      |        |
| APPLIED,     |               |           |         |      |        |
|              |               |           |         |      |        |
| 2\) GENERAL  |               |           |         |      |        |
| PREPARATION  |               |           |         |      |        |
| FOR FOAM     |               |           |         |      |        |
| APPLICATION, |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
|              |               |           |         |      |        |
| INCLUDED     |               |           |         |      |        |
| MASKING OFF  |               |           |         |      |        |
| ALL ADJACENT |               |           |         |      |        |
| SURFACES AND |               |           |         |      |        |
|              |               |           |         |      |        |
| INSTALLING A |               |           |         |      |        |
| TEFLON PLUG  |               |           |         |      |        |
| (            |               |           |         |      |        |
| TL-0931-040) |               |           |         |      |        |
| INTO THE     |               |           |         |      |        |
| PORT         |               |           |         |      |        |
|              |               |           |         |      |        |
| OPENING, AND |               |           |         |      |        |
|              |               |           |         |      |        |
| 3\) THE PDL  |               |           |         |      |        |
| FOAM         |               |           |         |      |        |
| MATERIAL WAS |               |           |         |      |        |
| PREPARED AND |               |           |         |      |        |
| APPLIED      |               |           |         |      |        |
|              |               |           |         |      |        |
| ACCORDINGLY  |               |           |         |      |        |
|              |               |           |         |      |        |
| C. REVIEW    |               |           |         |      |        |
| THE          |               |           |         |      |        |
| PROCESSES /  |               |           |         |      |        |
| TECHNIQUE    |               |           |         |      |        |
| ASSOCIATED   |               |           |         |      |        |
| WITH THE     |               |           |         |      |        |
|              |               |           |         |      |        |
| MASKING      |               |           |         |      |        |
| OPERATION OF |               |           |         |      |        |
| THE PORT     |               |           |         |      |        |
| OPENING      |               |           |         |      |        |
| DURING THE   |               |           |         |      |        |
| PDL FOAM     |               |           |         |      |        |
|              |               |           |         |      |        |
| APPLICATION  |               |           |         |      |        |
|              |               |           |         |      |        |
| RES          |               |           |         |      |        |
| PONSIBILITY: |               |           |         |      |        |
| E.           |               |           |         |      |        |
| AL           |               |           |         |      |        |
| DAHIR/3741 - |               |           |         |      |        |
| D.           |               |           |         |      |        |
| W            |               |           |         |      |        |
| ESTPHAL/3740 |               |           |         |      |        |
|              |               |           |         |      |        |
| ECD:         |               |           |         |      |        |
| 5/21/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| COMPLETE:    |               |           |         |      |        |
| 5/21/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| \* CLOSURE   |               |           |         |      |        |
| STATEMENT:   |               |           |         |      |        |
|              |               |           |         |      |        |
| THE REVIEW   |               |           |         |      |        |
| RESULTED IN  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| FOLLOWING:   |               |           |         |      |        |
|              |               |           |         |      |        |
| 1\) THE      |               |           |         |      |        |
| TEFLON PLUG  |               |           |         |      |        |
| TOOL USED TO |               |           |         |      |        |
| MASK THE     |               |           |         |      |        |
| PORT OPENING |               |           |         |      |        |
| HAS AN       |               |           |         |      |        |
|              |               |           |         |      |        |
| OD OF        |               |           |         |      |        |
| 0.156\"      |               |           |         |      |        |
| WHICH IS     |               |           |         |      |        |
| LESS THAN    |               |           |         |      |        |
| THE .172\"   |               |           |         |      |        |
| ID OF THE    |               |           |         |      |        |
|              |               |           |         |      |        |
| PORT OPENING |               |           |         |      |        |
|              |               |           |         |      |        |
| 2\) THE      |               |           |         |      |        |
| OPERATION IS |               |           |         |      |        |
| PERFORMED ON |               |           |         |      |        |
| THE MINUS    |               |           |         |      |        |
| Z-AXIS OF    |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| INTERTANK    |               |           |         |      |        |
| WHEN THE     |               |           |         |      |        |
| VEHICLE IS   |               |           |         |      |        |
| IN THE       |               |           |         |      |        |
| HORIZONTAL   |               |           |         |      |        |
| POSITION     |               |           |         |      |        |
|              |               |           |         |      |        |
| AS A RESULT, |               |           |         |      |        |
| WHEN THE     |               |           |         |      |        |
| FOAM RISES   |               |           |         |      |        |
| IT EXTRACTS  |               |           |         |      |        |
| THE TEFLON   |               |           |         |      |        |
|              |               |           |         |      |        |
| PLUG         |               |           |         |      |        |
| (            |               |           |         |      |        |
| TL-0931-040) |               |           |         |      |        |
| FROM THE     |               |           |         |      |        |
| PORT         |               |           |         |      |        |
| OPENING,     |               |           |         |      |        |
| WHICH ALLOWS |               |           |         |      |        |
|              |               |           |         |      |        |
| THE FOAM TO  |               |           |         |      |        |
| MIGRATE INTO |               |           |         |      |        |
| THE ORIFICE  |               |           |         |      |        |
|              |               |           |         |      |        |
| D. REVIEW    |               |           |         |      |        |
| AND REVISE   |               |           |         |      |        |
| THE PROCESS  |               |           |         |      |        |
| PLAN TO      |               |           |         |      |        |
| PRECLUDE     |               |           |         |      |        |
| THIS         |               |           |         |      |        |
|              |               |           |         |      |        |
| ANOMALY      |               |           |         |      |        |
|              |               |           |         |      |        |
| RES          |               |           |         |      |        |
| PONSIBILITY: |               |           |         |      |        |
| E.           |               |           |         |      |        |
| AL           |               |           |         |      |        |
| DAHIR/3741 - |               |           |         |      |        |
| D.           |               |           |         |      |        |
| W            |               |           |         |      |        |
| ESTPHAL/3740 |               |           |         |      |        |
|              |               |           |         |      |        |
| C.           |               |           |         |      |        |
| C            |               |           |         |      |        |
| ULVER/3743 - |               |           |         |      |        |
| D.           |               |           |         |      |        |
| W            |               |           |         |      |        |
| ESTPHAL/3740 |               |           |         |      |        |
|              |               |           |         |      |        |
| W.           |               |           |         |      |        |
| M            |               |           |         |      |        |
| EYERS/3614 - |               |           |         |      |        |
| R.           |               |           |         |      |        |
| WEAVER/3614  |               |           |         |      |        |
|              |               |           |         |      |        |
| ECD:         |               |           |         |      |        |
| 5/25/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| COMPLETE:    |               |           |         |      |        |
| 5/24/1999    |               |           |         |      |        |
|              |               |           |         |      |        |
| \* CLOSURE   |               |           |         |      |        |
| STATEMENT:   |               |           |         |      |        |
|              |               |           |         |      |        |
| MPP          |               |           |         |      |        |
| 809710       |               |           |         |      |        |
| 68422-500OP2 |               |           |         |      |        |
| AND MPP      |               |           |         |      |        |
| 809710       |               |           |         |      |        |
| 68422-019OP2 |               |           |         |      |        |
| HAVE BEEN    |               |           |         |      |        |
|              |               |           |         |      |        |
| REVISED TO   |               |           |         |      |        |
| READ AS      |               |           |         |      |        |
| FOLLOWS: USE |               |           |         |      |        |
| TL-0931-040  |               |           |         |      |        |
| TEFLON PLUG  |               |           |         |      |        |
| TO           |               |           |         |      |        |
|              |               |           |         |      |        |
| MASK PORT    |               |           |         |      |        |
| OPENING.     |               |           |         |      |        |
| APPLY HAND   |               |           |         |      |        |
| PRESSURE TO  |               |           |         |      |        |
| TEFLON PLUG, |               |           |         |      |        |
|              |               |           |         |      |        |
| UNTIL FOAM   |               |           |         |      |        |
| QUITS        |               |           |         |      |        |
| RISING, TO   |               |           |         |      |        |
| ENSURE       |               |           |         |      |        |
| TEFLON PLUG  |               |           |         |      |        |
| REMAINS IN   |               |           |         |      |        |
|              |               |           |         |      |        |
| OPENING      |               |           |         |      |        |
| DURING PDL   |               |           |         |      |        |
| POUR. (REF.  |               |           |         |      |        |
| M            |               |           |         |      |        |
| ANUFACTURING |               |           |         |      |        |
| ENGINEERING  |               |           |         |      |        |
|              |               |           |         |      |        |
| CHANGE DATED |               |           |         |      |        |
| 5/24/1999)   |               |           |         |      |        |
|              |               |           |         |      |        |
| TASK CLOSED  |               |           |         |      |        |
|              |               |           |         |      |        |
| \* CAUSE     |               |           |         |      |        |
|              |               |           |         |      |        |
| THE TEFLON   |               |           |         |      |        |
| PLUG         |               |           |         |      |        |
| (            |               |           |         |      |        |
| TL-0931-040) |               |           |         |      |        |
| REQUIRED TO  |               |           |         |      |        |
| MASK THE     |               |           |         |      |        |
| PORT         |               |           |         |      |        |
|              |               |           |         |      |        |
| OPENING      |               |           |         |      |        |
| DISPLACED    |               |           |         |      |        |
| DURING PDL   |               |           |         |      |        |
| FOAM RISING, |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
| RESULTED IN  |               |           |         |      |        |
|              |               |           |         |      |        |
| FOAM         |               |           |         |      |        |
| MIGRATION    |               |           |         |      |        |
| INTO THE     |               |           |         |      |        |
| PORTHOLE     |               |           |         |      |        |
|              |               |           |         |      |        |
| \* ROOT      |               |           |         |      |        |
| CAUSE        |               |           |         |      |        |
|              |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
| INSTRUCTION  |               |           |         |      |        |
| OF TOOL      |               |           |         |      |        |
| USAGE        |               |           |         |      |        |
|              |               |           |         |      |        |
| \* TASK II.  |               |           |         |      |        |
| CORRECTIVE   |               |           |         |      |        |
| ACTION       |               |           |         |      |        |
|              |               |           |         |      |        |
| SPECIFIC     |               |           |         |      |        |
| INSTRUCTIONS |               |           |         |      |        |
| FOR PROPER   |               |           |         |      |        |
| USE OF THE   |               |           |         |      |        |
| MASKING TOOL |               |           |         |      |        |
| HAS          |               |           |         |      |        |
|              |               |           |         |      |        |
| BEEN ADDED   |               |           |         |      |        |
| TO THE MPPS  |               |           |         |      |        |
| (809710      |               |           |         |      |        |
| 68422-500OP2 |               |           |         |      |        |
| AND MPP      |               |           |         |      |        |
|              |               |           |         |      |        |
| 80971068     |               |           |         |      |        |
| 422-019OP2), |               |           |         |      |        |
| WHICH READS  |               |           |         |      |        |
| AS FOLLOWS:  |               |           |         |      |        |
| \"USE        |               |           |         |      |        |
| TL-0931-     |               |           |         |      |        |
|              |               |           |         |      |        |
| 040 TEFLON   |               |           |         |      |        |
| PLUG TO MASK |               |           |         |      |        |
| PORT         |               |           |         |      |        |
| OPENING.     |               |           |         |      |        |
| APPLY HAND   |               |           |         |      |        |
| PRESSURE     |               |           |         |      |        |
|              |               |           |         |      |        |
| TO TEFLON    |               |           |         |      |        |
| PLUG, UNTIL  |               |           |         |      |        |
| FOAM QUITS   |               |           |         |      |        |
| RISING, TO   |               |           |         |      |        |
| ENSURE       |               |           |         |      |        |
| TEFLON       |               |           |         |      |        |
|              |               |           |         |      |        |
| PLUG REMAINS |               |           |         |      |        |
| IN OPENING   |               |           |         |      |        |
| DURING PDL   |               |           |         |      |        |
| POUR.\"      |               |           |         |      |        |
|              |               |           |         |      |        |
| TASK CLOSED  |               |           |         |      |        |
|              |               |           |         |      |        |
| TASK III.    |               |           |         |      |        |
| CLEARANCE OF |               |           |         |      |        |
| E            |               |           |         |      |        |
| FFECTIVITIES |               |           |         |      |        |
|              |               |           |         |      |        |
| ALL ETS      |               |           |         |      |        |
| CLEARED.     |               |           |         |      |        |
| TM04K FINAL  |               |           |         |      |        |
| ACCEPTANCE   |               |           |         |      |        |
| TEST AT MAF  |               |           |         |      |        |
| REQUIRES     |               |           |         |      |        |
|              |               |           |         |      |        |
| THAT A       |               |           |         |      |        |
| POSITIVE GAS |               |           |         |      |        |
| FLOW TEST BE |               |           |         |      |        |
| PERFORMED,   |               |           |         |      |        |
| WHICH WOULD  |               |           |         |      |        |
| DETECT       |               |           |         |      |        |
|              |               |           |         |      |        |
| THIS         |               |           |         |      |        |
| ANOMALY. ALL |               |           |         |      |        |
| PRIOR BUILT  |               |           |         |      |        |
| VEHICLES     |               |           |         |      |        |
| HAVE         |               |           |         |      |        |
| SUCCESSFULLY |               |           |         |      |        |
|              |               |           |         |      |        |
| PASSED THIS  |               |           |         |      |        |
| TM04K        |               |           |         |      |        |
| REQUIREMENT  |               |           |         |      |        |
|              |               |           |         |      |        |
| TASK CLOSED  |               |           |         |      |        |
|              |               |           |         |      |        |
| \* TASK IV.  |               |           |         |      |        |
| CAPS CLOSURE |               |           |         |      |        |
| SUMMARY      |               |           |         |      |        |
|              |               |           |         |      |        |
| DURING THE   |               |           |         |      |        |
| GAS FLOW     |               |           |         |      |        |
| VERIFICATION |               |           |         |      |        |
| TEST OF THE  |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| VENT         |               |           |         |      |        |
|              |               |           |         |      |        |
| SENSE PORT   |               |           |         |      |        |
| (            |               |           |         |      |        |
| TP-8C101-AT; |               |           |         |      |        |
| STEP 12.11)  |               |           |         |      |        |
| LOCATED ON   |               |           |         |      |        |
| THE MINUS    |               |           |         |      |        |
|              |               |           |         |      |        |
| Z-AXIS AT    |               |           |         |      |        |
| STATION 1075 |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| INTERTANK,   |               |           |         |      |        |
| THERE WAS NO |               |           |         |      |        |
| GAS          |               |           |         |      |        |
|              |               |           |         |      |        |
| FLOW         |               |           |         |      |        |
| DETECTED.    |               |           |         |      |        |
| THIS IS IN   |               |           |         |      |        |
| VIOLATION OF |               |           |         |      |        |
| FINAL        |               |           |         |      |        |
| ACCEPTANCE   |               |           |         |      |        |
|              |               |           |         |      |        |
| TESTING      |               |           |         |      |        |
| MMC-ET-TM04K |               |           |         |      |        |
| PARAGRAPH    |               |           |         |      |        |
| 2.1.1.7      |               |           |         |      |        |
|              |               |           |         |      |        |
| AFTER        |               |           |         |      |        |
| I            |               |           |         |      |        |
| NVESTIGATION |               |           |         |      |        |
| IT WAS       |               |           |         |      |        |
| DETERMINED   |               |           |         |      |        |
| THAT THE     |               |           |         |      |        |
| CAUSE OF THE |               |           |         |      |        |
|              |               |           |         |      |        |
| FAILURE WAS  |               |           |         |      |        |
| THAT THE     |               |           |         |      |        |
| TEFLON PLUG  |               |           |         |      |        |
| (            |               |           |         |      |        |
| TL-0931-040) |               |           |         |      |        |
| REQUIRED TO  |               |           |         |      |        |
|              |               |           |         |      |        |
| MASK THE     |               |           |         |      |        |
| PORT OPENING |               |           |         |      |        |
| DISPLACED    |               |           |         |      |        |
| DURING PDL   |               |           |         |      |        |
| FOAM RISING, |               |           |         |      |        |
|              |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
| RESULTED IN  |               |           |         |      |        |
| FOAM         |               |           |         |      |        |
| MIGRATION    |               |           |         |      |        |
| INTO THE     |               |           |         |      |        |
| PORTHOLE.    |               |           |         |      |        |
| THE MPPS     |               |           |         |      |        |
|              |               |           |         |      |        |
| HAVE BEEN    |               |           |         |      |        |
| REVISED TO   |               |           |         |      |        |
| PROVIDE      |               |           |         |      |        |
| SPECIFIC     |               |           |         |      |        |
| INSTRUCTIONS |               |           |         |      |        |
| BY           |               |           |         |      |        |
|              |               |           |         |      |        |
| APPLYING     |               |           |         |      |        |
| HAND         |               |           |         |      |        |
| PRESSURE TO  |               |           |         |      |        |
| THE TEFLON   |               |           |         |      |        |
| PLUG UNTIL   |               |           |         |      |        |
| FOAM RISING  |               |           |         |      |        |
|              |               |           |         |      |        |
| HAS CEASED   |               |           |         |      |        |
|              |               |           |         |      |        |
| TASK CLOSED  |               |           |         |      |        |
|              |               |           |         |      |        |
| THIS CAPS IS |               |           |         |      |        |
| CLOSED. NO   |               |           |         |      |        |
| FURTHER      |               |           |         |      |        |
| ACTION       |               |           |         |      |        |
| REQUIRD      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       |               |           |         |      |        |
| Response/C   |               |           |         |      |        |
| oncurrence** |               |           |         |      |        |
|              |               |           |         |      |        |
| 05/19/99 -   |               |           |         |      |        |
| MSFC         |               |           |         |      |        |
| APPROVES     |               |           |         |      |        |
| CLOSED-P     |               |           |         |      |        |
| STATUS. THIS |               |           |         |      |        |
| STATUS IS    |               |           |         |      |        |
| EFFECTIVE    |               |           |         |      |        |
|              |               |           |         |      |        |
| THROUGH      |               |           |         |      |        |
| 09/07/99     |               |           |         |      |        |
|              |               |           |         |      |        |
| 06/28/99 -   |               |           |         |      |        |
| MSFC CONCURS |               |           |         |      |        |
| WITH CLOSURE |               |           |         |      |        |
| RATIONALE.   |               |           |         |      |        |
| THIS PR IS   |               |           |         |      |        |
| CLOSED       |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+

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

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

  -------------- --------------------- ------------------ ----------- ----------- ------------
  **MSFC         **IFA#**\             **Contractor       **JSC#**\   **KSC#**\   **EICN#**\
  Report#**\     \--                   RPT#**\            \--         \--         \--
  A17402                               P-088                                      

  **Asmnt        **Asmnt Part Name**\  **Asmnt                                    
  Part#**\       EXTRNL VNT SNS PORT   Serial/Lot#**\                             
  MS24394-J4                           \--                                        

  **HCRIT CD**\  **FCRIT CD**\         **CAUSE CD**\      **FAIL                  
  \--            1R                    MPP - MFG-PRC-INST MODE**\                 
                                                          UC - UNSAT              

  **Asmnt        **Asmnt FM**\         **FMEA CSE**\      **FMEA                  
  FMEA**\        1                     \--                SCSE**\                 
  2.8.12                                                  \--                     

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

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

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

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

  **MAJOR DESIGN                                                                  
  CHANGES**                                                                       

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

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