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

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

+-------------+---------------+-----------+----------+------+--------+
| **MSFC      | **In-Flight   | **C       | *        | *    |        |
| Record      | Anomaly       | ontractor | *JSC#**\ | *KSC |        |
| \#**\       | Number**\     | Report    | \--      | #**\ |        |
| A07581      | \--           | Number**\ |          | \--  |        |
|             |               | T-038     |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Problem   |               |           |          |      |        |
| Title**\    |               |           |          |      |        |
| LH2 AFT     |               |           |          |      |        |
| DOME VOIDS  |               |           |          |      |        |
| IN PLUG     |               |           |          |      |        |
| PULL        |               |           |          |      |        |
| REPAIRS     |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **EICN#**\  | **ELEMENT**\  | **Cont    | **       | **   |        |
| \--         | ET            | ractor**\ | FSCM#**\ | FCRI |        |
|             |               | MMMSS     | \--      | T**\ |        |
|             |               |           |          | 3    |        |
+-------------+---------------+-----------+----------+------+--------+
| **HCRIT**\  | **Sys_Lvl**\  | **Misc    |          |      |        |
| \--         | N             | Codes**\  |          |      |        |
|             |               | A **(2)** |          |      |        |
|             |               | B C D E F |          |      |        |
|             |               | G H I J K |          |      |        |
|             |               | L M N O   |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **          | **NO          | *         | **SER    | *    |        |
| HARDWARE**\ | MENCLATURE**\ | *PART#**\ | /LOT#**\ | *MAN |        |
| EIM         | EXTERNAL TANK | 82        | LWT-10   | UFAC |        |
|             |               | 601000000 |          | TURE |        |
|             |               |           |          | R**\ |        |
|             |               |           |          | MMC  |        |
+-------------+---------------+-----------+----------+------+--------+
| **          | **NO          | *         | **SER    | *    |        |
| HARDWARE**\ | MENCLATURE**\ | *PART#**\ | /LOT#**\ | *MAN |        |
| LRU         | N/A           | N/A       | N/A      | UFAC |        |
|             |               |           |          | TURE |        |
|             |               |           |          | R**\ |        |
|             |               |           |          | N/A  |        |
+-------------+---------------+-----------+----------+------+--------+
| **          | **NO          | *         | **SER    | *    |        |
| HARDWARE**\ | MENCLATURE**\ | *PART#**\ | /LOT#**\ | *MAN |        |
| NCA         | LH2 TANK      | 80        | LWT-10   | UFAC |        |
|             |               | 974048409 |          | TURE |        |
|             |               |           |          | R**\ |        |
|             |               |           |          | MMC  |        |
+-------------+---------------+-----------+----------+------+--------+
| **Test/O    | **Prevailing  | **F /     | **Fail   | **   |        |
| peration**\ | Condtion**\   | U**\      | Mode**\  | Caus |        |
| M - MFG     | N -           | UC        | MSI -    | e**\ |        |
|             | INSPECTION    |           | IN       | M    |        |
|             |               |           | SULATION | AP - |        |
|             |               |           |          | MFG- |        |
|             |               |           |          | ASY- |        |
|             |               |           |          | INST |        |
+-------------+---------------+-----------+----------+------+--------+
| **System**\ | **Defect**\   | **Ma      | **Work   | **   |        |
| TPS         | CX - VOID     | terial**\ | Co       | Fail |        |
|             |               | F - INSUL | ntact**\ | Dat  |        |
|             |               |           | C.       | e**\ |        |
|             |               |           | WILLIAMS | 10   |        |
|             |               |           |          | /27/ |        |
|             |               |           |          | 1983 |        |
+-------------+---------------+-----------+----------+------+--------+
| **Received  | **Date        | **FMEA    | **IFA:   | *    |        |
| at MSFC**\  | Isolated**\   | Ref       | Mission  | *Mis |        |
| 11/17/1983  | \--           | erence**\ | Phase**\ | sion |        |
|             |               | 1.2.1     | \--      | Ela  |        |
|             |               |           |          | psed |        |
|             |               |           |          | Tim  |        |
|             |               |           |          | e**\ |        |
|             |               |           |          | \--  |        |
+-------------+---------------+-----------+----------+------+--------+
| **          |               | **S       |          | **   |        |
| Location**\ |               | ymptom**\ |          | Time |        |
| MAF         |               | UC -      |          | Cycl |        |
|             |               | UNSAT     |          | e**\ |        |
|             |               |           |          | \--  |        |
+-------------+---------------+-----------+----------+------+--------+
| **          |               |           |          |      |        |
| Effectivity |               |           |          |      |        |
| Text**\     |               |           |          |      |        |
| LWT-4 AND   |               |           |          |      |        |
| SUBS        |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **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   | **Remark |      |        |
| Approved    | Req Defer     | Close**\  | /        |      |        |
| Defer Until | Until Date**\ | \--       | A        |      |        |
| Date**\     | \--           |           | ction**\ |      |        |
| \--         |               |           | \--      |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **In        |               |           |          |      |        |
| vestigation |               |           |          |      |        |
| /           |               |           |          |      |        |
| Resolution  |               |           |          |      |        |
| Summary**   |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Last MSFC | **CN RSLV     | **Defer   | **Add    | *    |        |
| Update**\   | SBMT**\       | Date**\   | Date**\  | *R/C |        |
| 03/17/1992  | 12/11/1984    | \--       | \--      | Code |        |
|             |               |           |          | s**\ |        |
|             |               |           |          | 2 -  |        |
|             |               |           |          | MFG  |        |
|             |               |           |          | \--  |        |
|             |               |           |          | \--  |        |
+-------------+---------------+-----------+----------+------+--------+
| *           |               |           |          |      |        |
| *Assignee** |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Design**\ | **Chief       | **S &     | **Pr     | *    |        |
| B. DAVIS    | Engineer**\   | MA**\     | oject**\ | *Pro |        |
|             | \--           | D. NEWMAN | G.       | ject |        |
|             |               |           | C        | MG   |        |
|             |               |           | AVALARIS | R**\ |        |
|             |               |           |          | \--  |        |
+-------------+---------------+-----------+----------+------+--------+
| *           |               |           |          |      |        |
| *Approval** |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Design**\ | **Chief       | **S &     | **Pr     | *    |        |
| B. DAVIS    | Engineer**\   | MA**\     | oject**\ | *Pro |        |
|             | \--           | D. NEWMAN | E. BRYAN | ject |        |
|             |               |           |          | MG   |        |
|             |               |           |          | R**\ |        |
|             |               |           |          | \--  |        |
+-------------+---------------+-----------+----------+------+--------+
| **PAC       | **PAC Review  | **MSFC    | **S      | *    |        |
| Assignee**\ | Complete**\   | Closure   | tatus**\ | *F/A |        |
| G. MILLER   | GM            | Date**\   | C -      | C    |        |
|             |               | 0         | CLOSED   | ompl |        |
|             |               | 1/11/1985 |          | etio |        |
|             |               |           |          | n**\ |        |
|             |               |           |          | \--  |        |
+-------------+---------------+-----------+----------+------+--------+
| **Problem   | **SEV**\      | **Program | *        | **O  |        |
| Type**\     | \--           | Name**\   | *REVL**\ | PRIN |        |
| \--         |               | \--       | \--      | C**\ |        |
|             |               |           |          | \--  |        |
+-------------+---------------+-----------+----------+------+--------+
| **FUNC      | **Software    | *         |          | **SU | **So   |
| MOD**\      | E             | *Software |          | BTYP | ftware |
| \--         | ffectivity**\ | Fail      |          | E**\ | C      |
|             | \-- \-- \--   | CD**\     |          | \--  | losure |
|             | \-- \--       | \--       |          |      | CD**\  |
|             |               |           |          |      | \--    |
+-------------+---------------+-----------+----------+------+--------+
| **RES       | **Approval    |           |          |      |        |
| PERSON      | Signature     |           |          |      |        |
| L2**\       | L3**\         |           |          |      |        |
| \--         | \--           |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Related   | **Related     |           |          |      |        |
| Document    | Document      |           |          |      |        |
| Type**\     | ID**\         |           |          |      |        |
| \--         | \--           |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Related   |               |           |          |      |        |
| Document    |               |           |          |      |        |
| Title**\    |               |           |          |      |        |
| \--         |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Related   | **Related     |           |          |      |        |
| Document    | Document      |           |          |      |        |
| Type**\     | ID**\         |           |          |      |        |
| \--         | \--           |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Related   |               |           |          |      |        |
| Document    |               |           |          |      |        |
| Title**\    |               |           |          |      |        |
| \--         |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Related   | **Related     |           |          |      |        |
| Document    | Document      |           |          |      |        |
| Type**\     | ID**\         |           |          |      |        |
| \--         | \--           |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Related   |               |           |          |      |        |
| Document    |               |           |          |      |        |
| Title**\    |               |           |          |      |        |
| \--         |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| *           |               |           |          |      |        |
| *Contractor |               |           |          |      |        |
| Status      |               |           |          |      |        |
| Summary**   |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Reliabil  |               |           |          |      |        |
| ity/Quality |               |           |          |      |        |
| Assurance   |               |           |          |      |        |
| Concerns,   |               |           |          |      |        |
| Recomme     |               |           |          |      |        |
| ndations:** |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **Problem   |               |           |          |      |        |
| De          |               |           |          |      |        |
| scription** |               |           |          |      |        |
|             |               |           |          |      |        |
| REF: DURING |               |           |          |      |        |
| REMOVAL OF  |               |           |          |      |        |
| DISCREPANT  |               |           |          |      |        |
| NCFI FOAM   |               |           |          |      |        |
| FROM LWT-10 |               |           |          |      |        |
| DISCOVERED  |               |           |          |      |        |
| PLUG        |               |           |          |      |        |
|             |               |           |          |      |        |
| PULL        |               |           |          |      |        |
| REPAIRS HAD |               |           |          |      |        |
| CORE HOLE   |               |           |          |      |        |
| VOIDS       |               |           |          |      |        |
| APPROX 1    |               |           |          |      |        |
| IN. DEEP BY |               |           |          |      |        |
| 1.3 IN. DIA |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| *           |               |           |          |      |        |
| *Contractor |               |           |          |      |        |
| Inve        |               |           |          |      |        |
| stigation/R |               |           |          |      |        |
| esolution** |               |           |          |      |        |
|             |               |           |          |      |        |
| CAUSE -     |               |           |          |      |        |
| CORE PULL   |               |           |          |      |        |
| PLUG HOLES  |               |           |          |      |        |
| IMPROPERLY  |               |           |          |      |        |
| FILLED      |               |           |          |      |        |
| DURING      |               |           |          |      |        |
| PREVIOUS    |               |           |          |      |        |
| REPAIR      |               |           |          |      |        |
|             |               |           |          |      |        |
| OPERATIONS. |               |           |          |      |        |
| HOLES WERE  |               |           |          |      |        |
| FILLEDWITH  |               |           |          |      |        |
| SINGLE POUR |               |           |          |      |        |
| PDL         |               |           |          |      |        |
| APPLICATION |               |           |          |      |        |
| RATHER      |               |           |          |      |        |
|             |               |           |          |      |        |
| THAN        |               |           |          |      |        |
| MULTIPLE    |               |           |          |      |        |
| POURS AS    |               |           |          |      |        |
| REQ\'D BY   |               |           |          |      |        |
| STP-1518.   |               |           |          |      |        |
| 11/21/83    |               |           |          |      |        |
| PRB         |               |           |          |      |        |
| STATUS -    |               |           |          |      |        |
| CAPS AS     |               |           |          |      |        |
|             |               |           |          |      |        |
| WRITTEN     |               |           |          |      |        |
| CONFUSES    |               |           |          |      |        |
| PROB OF     |               |           |          |      |        |
| VOIDS FOUND |               |           |          |      |        |
| IN PLUG     |               |           |          |      |        |
| PULL        |               |           |          |      |        |
| REPAIRS     |               |           |          |      |        |
| WITH NCFI   |               |           |          |      |        |
|             |               |           |          |      |        |
| FOAM        |               |           |          |      |        |
| THICKNESS   |               |           |          |      |        |
| PROB. MR.   |               |           |          |      |        |
| D. NEWMAN   |               |           |          |      |        |
| REQUESTED   |               |           |          |      |        |
| MMC CLARIFY |               |           |          |      |        |
| CAPS. ALSO  |               |           |          |      |        |
| MR          |               |           |          |      |        |
|             |               |           |          |      |        |
| D. NEWMAN   |               |           |          |      |        |
| QUESTIONED  |               |           |          |      |        |
| WHY CAPS    |               |           |          |      |        |
| NOT WRITTEN |               |           |          |      |        |
| ON THIN     |               |           |          |      |        |
| FOAM.       |               |           |          |      |        |
| 3/8/84 PRB  |               |           |          |      |        |
|             |               |           |          |      |        |
| STATUS -    |               |           |          |      |        |
| OCCURRED ON |               |           |          |      |        |
| LWT-10.     |               |           |          |      |        |
| SINGLE POUR |               |           |          |      |        |
| PDL         |               |           |          |      |        |
| APPLICATION |               |           |          |      |        |
| WAS         |               |           |          |      |        |
| PERFORMED   |               |           |          |      |        |
|             |               |           |          |      |        |
| RATHER THAN |               |           |          |      |        |
| A MULTIPLE  |               |           |          |      |        |
| POUR. RC    |               |           |          |      |        |
| INVOLVED    |               |           |          |      |        |
| REVISION OF |               |           |          |      |        |
| STP-1518    |               |           |          |      |        |
| (WHICH      |               |           |          |      |        |
|             |               |           |          |      |        |
| WAS OPEN TO |               |           |          |      |        |
| INTE        |               |           |          |      |        |
| RPRETATION) |               |           |          |      |        |
| TO REQ. A 2 |               |           |          |      |        |
| STEP POUR   |               |           |          |      |        |
| FOR AFT     |               |           |          |      |        |
| DOME PLUG   |               |           |          |      |        |
|             |               |           |          |      |        |
| PULL        |               |           |          |      |        |
| REPAIRS.    |               |           |          |      |        |
| LWT-5 HAS   |               |           |          |      |        |
| BEEN        |               |           |          |      |        |
| CLEARED BY  |               |           |          |      |        |
| ENGR\'G     |               |           |          |      |        |
| RATIONALE   |               |           |          |      |        |
| FOR         |               |           |          |      |        |
|             |               |           |          |      |        |
| 0023 OF     |               |           |          |      |        |
| POSSIBLE    |               |           |          |      |        |
| VOIDS       |               |           |          |      |        |
| (DOCUMENTED |               |           |          |      |        |
| IN MEMO     |               |           |          |      |        |
| 3           |               |           |          |      |        |
| 570-83-60). |               |           |          |      |        |
| MCC EXPECTS |               |           |          |      |        |
| TO          |               |           |          |      |        |
|             |               |           |          |      |        |
| HAVE CAPS   |               |           |          |      |        |
| CLOSURE BY  |               |           |          |      |        |
| 3-12-84.    |               |           |          |      |        |
| 9/6/84 PRB  |               |           |          |      |        |
| STATUS -    |               |           |          |      |        |
| PROBLEM IN  |               |           |          |      |        |
| REWORK AT   |               |           |          |      |        |
|             |               |           |          |      |        |
| KSC CAUSED  |               |           |          |      |        |
| BY          |               |           |          |      |        |
| IMPROPERLY  |               |           |          |      |        |
| MODIFIED    |               |           |          |      |        |
| TOOLS - MMC |               |           |          |      |        |
| ENGR\'G TO  |               |           |          |      |        |
| MONITOR KSC |               |           |          |      |        |
|             |               |           |          |      |        |
| REPAIRS.    |               |           |          |      |        |
| ECD         |               |           |          |      |        |
| EXTENDED TO |               |           |          |      |        |
| 2-15-85.    |               |           |          |      |        |
| 12/12/84    |               |           |          |      |        |
| CAUSE OF    |               |           |          |      |        |
| PROBLEM - A |               |           |          |      |        |
| SINGLE      |               |           |          |      |        |
|             |               |           |          |      |        |
| POUR PDL    |               |           |          |      |        |
| APPLICATION |               |           |          |      |        |
| WAS USED TO |               |           |          |      |        |
| REPAIR THE  |               |           |          |      |        |
| PLUG PULL   |               |           |          |      |        |
| HOLES. THIS |               |           |          |      |        |
|             |               |           |          |      |        |
| METHOD WAS  |               |           |          |      |        |
| FOUND TO BE |               |           |          |      |        |
| INADEQUATE  |               |           |          |      |        |
| TO PROPERLY |               |           |          |      |        |
| FILL PLUG   |               |           |          |      |        |
| PULLS       |               |           |          |      |        |
| REPAIRED    |               |           |          |      |        |
|             |               |           |          |      |        |
| IN THE      |               |           |          |      |        |
| OVERHEAD    |               |           |          |      |        |
| POSITION.   |               |           |          |      |        |
| R           |               |           |          |      |        |
| ESOLUTION - |               |           |          |      |        |
| AFTER       |               |           |          |      |        |
| DISCOVERY   |               |           |          |      |        |
| OF THE      |               |           |          |      |        |
| UNFILLED    |               |           |          |      |        |
|             |               |           |          |      |        |
| CAVITIES ON |               |           |          |      |        |
| LWT-10 AFT  |               |           |          |      |        |
| DOME, WHICH |               |           |          |      |        |
| WERE THE    |               |           |          |      |        |
| RESULT OF   |               |           |          |      |        |
| THE         |               |           |          |      |        |
| I           |               |           |          |      |        |
| NADEQUACIES |               |           |          |      |        |
|             |               |           |          |      |        |
| OF THE      |               |           |          |      |        |
| SINGLE STEP |               |           |          |      |        |
| OVERHEAD    |               |           |          |      |        |
| PDL         |               |           |          |      |        |
| CLOSE-OUT,  |               |           |          |      |        |
| ENGR\'G     |               |           |          |      |        |
| REVISED DWG |               |           |          |      |        |
|             |               |           |          |      |        |
| 80974048409 |               |           |          |      |        |
| TO REQUIRE  |               |           |          |      |        |
| A 2 STEP    |               |           |          |      |        |
| PDL         |               |           |          |      |        |
| CLOSE-OUT.  |               |           |          |      |        |
| THIS REPAIR |               |           |          |      |        |
| METHOD WAS  |               |           |          |      |        |
|             |               |           |          |      |        |
| IMPLEMENTED |               |           |          |      |        |
| FOR LWT-7 & |               |           |          |      |        |
| UP.         |               |           |          |      |        |
| SUBSEQUENT  |               |           |          |      |        |
| EVALUATION  |               |           |          |      |        |
| DIRECTED BY |               |           |          |      |        |
| CAPS        |               |           |          |      |        |
|             |               |           |          |      |        |
| TASKS III & |               |           |          |      |        |
| IV SHOWED   |               |           |          |      |        |
| THAT THE 2  |               |           |          |      |        |
| STEP REPAIR |               |           |          |      |        |
| WAS ALSO    |               |           |          |      |        |
| INADEQUATE. |               |           |          |      |        |
| AN          |               |           |          |      |        |
|             |               |           |          |      |        |
| ACCEPTABLE  |               |           |          |      |        |
| REPAIR      |               |           |          |      |        |
| METHOD      |               |           |          |      |        |
| (PLUG       |               |           |          |      |        |
| DI          |               |           |          |      |        |
| SPLACEMENT) |               |           |          |      |        |
| WAS         |               |           |          |      |        |
| DEVELOPED,  |               |           |          |      |        |
| THOROUGHLY  |               |           |          |      |        |
|             |               |           |          |      |        |
| EVALUATED,  |               |           |          |      |        |
| &           |               |           |          |      |        |
| S           |               |           |          |      |        |
| UBSEQUENTLY |               |           |          |      |        |
| VALIDATED   |               |           |          |      |        |
| FOR         |               |           |          |      |        |
| PRODUCTION  |               |           |          |      |        |
| USE. THE    |               |           |          |      |        |
| TECHNIQUE   |               |           |          |      |        |
|             |               |           |          |      |        |
| ESTABLISHED |               |           |          |      |        |
| WAS TO MAKE |               |           |          |      |        |
| A           |               |           |          |      |        |
| POLYSTYRENE |               |           |          |      |        |
| PLUG 2 IN.  |               |           |          |      |        |
| THICK BY    |               |           |          |      |        |
| THE DIA. OF |               |           |          |      |        |
|             |               |           |          |      |        |
| THE HOLE &  |               |           |          |      |        |
| USE IT LIKE |               |           |          |      |        |
| A HYD       |               |           |          |      |        |
| PISTON.     |               |           |          |      |        |
| WHEN USED   |               |           |          |      |        |
| TO FILL A   |               |           |          |      |        |
| STRAIGHT 3  |               |           |          |      |        |
| IN          |               |           |          |      |        |
|             |               |           |          |      |        |
| HOLE THE    |               |           |          |      |        |
| TECHNIQUE   |               |           |          |      |        |
| IS          |               |           |          |      |        |
| SIMPLICITY  |               |           |          |      |        |
| IN ITSELF.  |               |           |          |      |        |
| THE 1ST     |               |           |          |      |        |
| STEP IS TO  |               |           |          |      |        |
| TAKE A      |               |           |          |      |        |
|             |               |           |          |      |        |
| STYRENE     |               |           |          |      |        |
| PLUG OF A   |               |           |          |      |        |
| DIA.        |               |           |          |      |        |
| SLIGHTLY    |               |           |          |      |        |
| SMALLER     |               |           |          |      |        |
| THEN THE    |               |           |          |      |        |
| HOLE & BORE |               |           |          |      |        |
| A HOLE      |               |           |          |      |        |
|             |               |           |          |      |        |
| THRU THE    |               |           |          |      |        |
| CENTER FOR  |               |           |          |      |        |
| THE SEMKIT  |               |           |          |      |        |
| NOZZLE.     |               |           |          |      |        |
| THIS PLUG,  |               |           |          |      |        |
| WITH THE    |               |           |          |      |        |
| NOZZLE IN   |               |           |          |      |        |
|             |               |           |          |      |        |
| PLACE IS    |               |           |          |      |        |
| THEN        |               |           |          |      |        |
| INSERTED    |               |           |          |      |        |
| INTO THE    |               |           |          |      |        |
| HOLE UNTIL  |               |           |          |      |        |
| IT BOTTOMS  |               |           |          |      |        |
| OUT. THE    |               |           |          |      |        |
| PLUG IS     |               |           |          |      |        |
|             |               |           |          |      |        |
| THEN TAPED  |               |           |          |      |        |
| TO THE FOAM |               |           |          |      |        |
| SO THAT IT  |               |           |          |      |        |
| MAY FREELY  |               |           |          |      |        |
| MOVE OUT    |               |           |          |      |        |
| UNTIL IT    |               |           |          |      |        |
| BECOMES     |               |           |          |      |        |
|             |               |           |          |      |        |
| FLUSH WITH  |               |           |          |      |        |
| THE         |               |           |          |      |        |
| SURFACE.    |               |           |          |      |        |
| WHEN THE    |               |           |          |      |        |
| PLUG        |               |           |          |      |        |
| REACHES THE |               |           |          |      |        |
| SURFACE IT  |               |           |          |      |        |
| IS HELD BY  |               |           |          |      |        |
|             |               |           |          |      |        |
| THE TAPE    |               |           |          |      |        |
| FROM        |               |           |          |      |        |
| FALLING     |               |           |          |      |        |
| TOTAL-LY    |               |           |          |      |        |
| OUT OF THE  |               |           |          |      |        |
| WAY. IN     |               |           |          |      |        |
| THIS        |               |           |          |      |        |
| FASHION THE |               |           |          |      |        |
| PLUG        |               |           |          |      |        |
|             |               |           |          |      |        |
| ALLOWS FOR  |               |           |          |      |        |
| FOAM RELIEF |               |           |          |      |        |
| AROUND      |               |           |          |      |        |
| CI          |               |           |          |      |        |
| RCUMFERENCE |               |           |          |      |        |
| BUT STILL   |               |           |          |      |        |
| ACTS AS A   |               |           |          |      |        |
| CLOSED      |               |           |          |      |        |
|             |               |           |          |      |        |
| MOLD. ONCE  |               |           |          |      |        |
| THE PLUG IS |               |           |          |      |        |
| IN PLACE A  |               |           |          |      |        |
| SEMKIT IS   |               |           |          |      |        |
| ACTIVATED & |               |           |          |      |        |
| SCREWED     |               |           |          |      |        |
| INTO        |               |           |          |      |        |
|             |               |           |          |      |        |
| THE NOZZLE. |               |           |          |      |        |
| THE         |               |           |          |      |        |
| PLUG/SEMKIT |               |           |          |      |        |
| COMBINATION |               |           |          |      |        |
| IS HELD     |               |           |          |      |        |
| WITH SLIGHT |               |           |          |      |        |
| PRESSURE    |               |           |          |      |        |
|             |               |           |          |      |        |
| FROM MOVING |               |           |          |      |        |
| FREELY OUT  |               |           |          |      |        |
| OF THE      |               |           |          |      |        |
| HOLE. AFTER |               |           |          |      |        |
| SUFFICIENT  |               |           |          |      |        |
| PRESSURE    |               |           |          |      |        |
| HAS BUILT   |               |           |          |      |        |
|             |               |           |          |      |        |
| UP & PUSHED |               |           |          |      |        |
| THE PLUG    |               |           |          |      |        |
| HALF THE    |               |           |          |      |        |
| WAY OUT OF  |               |           |          |      |        |
| THE HOLE,   |               |           |          |      |        |
| THE SEMKIT  |               |           |          |      |        |
| IS RE-      |               |           |          |      |        |
|             |               |           |          |      |        |
| MOVED & THE |               |           |          |      |        |
| FOAM IS     |               |           |          |      |        |
| ALLOWED TO  |               |           |          |      |        |
| FINISH ITS  |               |           |          |      |        |
| RISE        |               |           |          |      |        |
| UNIMPEDED   |               |           |          |      |        |
| TO THE      |               |           |          |      |        |
| LIMITS      |               |           |          |      |        |
|             |               |           |          |      |        |
| OF THE      |               |           |          |      |        |
| TAPE. WHEN  |               |           |          |      |        |
| THE PLUG    |               |           |          |      |        |
| HAS CLEARED |               |           |          |      |        |
| THE HOLE IT |               |           |          |      |        |
| ALLOWS THE  |               |           |          |      |        |
| EXCESS      |               |           |          |      |        |
|             |               |           |          |      |        |
| FOAM TO     |               |           |          |      |        |
| VENT. ONCE  |               |           |          |      |        |
| THE FOAM    |               |           |          |      |        |
| HAS CURED 1 |               |           |          |      |        |
| HR., THE    |               |           |          |      |        |
| TAPE IS     |               |           |          |      |        |
| REMOVED &   |               |           |          |      |        |
| THE         |               |           |          |      |        |
|             |               |           |          |      |        |
| PLUG CUT    |               |           |          |      |        |
| OFF. WHAT   |               |           |          |      |        |
| IS LEFT IS  |               |           |          |      |        |
| A FOAM      |               |           |          |      |        |
| CLOSEOUT    |               |           |          |      |        |
| WHICH CAN   |               |           |          |      |        |
| EASILY BE   |               |           |          |      |        |
|             |               |           |          |      |        |
| MACHINED TO |               |           |          |      |        |
| THE         |               |           |          |      |        |
| SURFACE.    |               |           |          |      |        |
| THE         |               |           |          |      |        |
| ADVANTAGES  |               |           |          |      |        |
| TO THIS     |               |           |          |      |        |
| TECHNIQUE   |               |           |          |      |        |
| ARE MAINLY  |               |           |          |      |        |
|             |               |           |          |      |        |
| THE         |               |           |          |      |        |
| OPERATION   |               |           |          |      |        |
| IS ONE      |               |           |          |      |        |
| STEP, WHICH |               |           |          |      |        |
| MAKES IT    |               |           |          |      |        |
| FAST. IT IS |               |           |          |      |        |
| FOOLPROOF   |               |           |          |      |        |
| SINCE       |               |           |          |      |        |
|             |               |           |          |      |        |
| THE         |               |           |          |      |        |
| EXPANSION   |               |           |          |      |        |
| OF THE FOAM |               |           |          |      |        |
| IS WHAT     |               |           |          |      |        |
| MOVES THE   |               |           |          |      |        |
| PLUG AS     |               |           |          |      |        |
| WELL AS THE |               |           |          |      |        |
| AIR OUT     |               |           |          |      |        |
|             |               |           |          |      |        |
| OF THE HOLE |               |           |          |      |        |
| & IT IS     |               |           |          |      |        |
| CLEAR SINCE |               |           |          |      |        |
| NO          |               |           |          |      |        |
| EXCESSIVE   |               |           |          |      |        |
| MASKING IS  |               |           |          |      |        |
| NEEDED TO   |               |           |          |      |        |
| KEEP        |               |           |          |      |        |
|             |               |           |          |      |        |
| THE FOAM    |               |           |          |      |        |
| BLEEDOUT    |               |           |          |      |        |
| OFF THE     |               |           |          |      |        |
| SURFACE.    |               |           |          |      |        |
| WHEN        |               |           |          |      |        |
| FILLING A 2 |               |           |          |      |        |
| STEP HOLE,  |               |           |          |      |        |
| LIKE        |               |           |          |      |        |
|             |               |           |          |      |        |
| THAT FOUND  |               |           |          |      |        |
| ON A STD    |               |           |          |      |        |
| PORTAPULL   |               |           |          |      |        |
| HOLE, YOU   |               |           |          |      |        |
| SIMPLY USE  |               |           |          |      |        |
| A DIFFERENT |               |           |          |      |        |
| TYPE        |               |           |          |      |        |
|             |               |           |          |      |        |
| PLUG. THE   |               |           |          |      |        |
| PLUG USED   |               |           |          |      |        |
| FOR THIS    |               |           |          |      |        |
| REPAIR IS   |               |           |          |      |        |
| BUILT LIKE  |               |           |          |      |        |
| A           |               |           |          |      |        |
| COLLAPSIBLE |               |           |          |      |        |
| TWO         |               |           |          |      |        |
|             |               |           |          |      |        |
| STAGE       |               |           |          |      |        |
| PISTON. THE |               |           |          |      |        |
| OUTER       |               |           |          |      |        |
| PISTON IS   |               |           |          |      |        |
| INSERTED    |               |           |          |      |        |
| FLUSH WITH  |               |           |          |      |        |
| THE 3 IN.   |               |           |          |      |        |
| BASE        |               |           |          |      |        |
|             |               |           |          |      |        |
| THE INNER   |               |           |          |      |        |
| PISTON IS   |               |           |          |      |        |
| PUSHED      |               |           |          |      |        |
| FLUSH TO    |               |           |          |      |        |
| THE TANK    |               |           |          |      |        |
| SKIN. ALL   |               |           |          |      |        |
| OTHER STEPS |               |           |          |      |        |
| ARE         |               |           |          |      |        |
|             |               |           |          |      |        |
| THE SAME    |               |           |          |      |        |
| EXCEPT WHEN |               |           |          |      |        |
| IT COMES TO |               |           |          |      |        |
| RESTRICTING |               |           |          |      |        |
| THE         |               |           |          |      |        |
| MOVEMENT OF |               |           |          |      |        |
| THE PISTON  |               |           |          |      |        |
|             |               |           |          |      |        |
| OUT OF THE  |               |           |          |      |        |
| HOLE. ONCE  |               |           |          |      |        |
| THE SEMKIT  |               |           |          |      |        |
| IS          |               |           |          |      |        |
| INSERTED,   |               |           |          |      |        |
| THE FOAM    |               |           |          |      |        |
| RISING 1ST  |               |           |          |      |        |
| MOVES       |               |           |          |      |        |
|             |               |           |          |      |        |
| THE INNER   |               |           |          |      |        |
| PISTON      |               |           |          |      |        |
| FLUSH WITH  |               |           |          |      |        |
| THE OUTER   |               |           |          |      |        |
| PISTON      |               |           |          |      |        |
| WHICH THEN  |               |           |          |      |        |
| MOVES OUT   |               |           |          |      |        |
| AS A        |               |           |          |      |        |
|             |               |           |          |      |        |
| UNIT UNTIL  |               |           |          |      |        |
| IT REACHES  |               |           |          |      |        |
| THE TAPE    |               |           |          |      |        |
| LIMIT.      |               |           |          |      |        |
| EXISTING    |               |           |          |      |        |
| AFT DOME    |               |           |          |      |        |
| PLUG PULL   |               |           |          |      |        |
|             |               |           |          |      |        |
| REPAIRS ON  |               |           |          |      |        |
| ALL         |               |           |          |      |        |
| VEHICLES    |               |           |          |      |        |
| WERE        |               |           |          |      |        |
| EVALUATED   |               |           |          |      |        |
| BY ENGR\'G. |               |           |          |      |        |
| AFTER       |               |           |          |      |        |
| EVALUATION  |               |           |          |      |        |
| OF          |               |           |          |      |        |
|             |               |           |          |      |        |
| THE REPAIR  |               |           |          |      |        |
| LOCATION &  |               |           |          |      |        |
| THE         |               |           |          |      |        |
| REMAINING   |               |           |          |      |        |
| NCFI UNDER  |               |           |          |      |        |
| THE         |               |           |          |      |        |
| SPOT-FACE,  |               |           |          |      |        |
| ALL         |               |           |          |      |        |
|             |               |           |          |      |        |
| U           |               |           |          |      |        |
| NACCEPTABLE |               |           |          |      |        |
| AREAS WERE  |               |           |          |      |        |
| REPAIRED    |               |           |          |      |        |
| USING AN    |               |           |          |      |        |
| ACCEPTABLE  |               |           |          |      |        |
| METHOD      |               |           |          |      |        |
| (EITHER     |               |           |          |      |        |
|             |               |           |          |      |        |
| HAND-PACKED |               |           |          |      |        |
| SLA         |               |           |          |      |        |
| FOLLOWED BY |               |           |          |      |        |
| PDL, OR BY  |               |           |          |      |        |
| PLUG        |               |           |          |      |        |
| D           |               |           |          |      |        |
| ISPLACEMENT |               |           |          |      |        |
| PDL POUR).  |               |           |          |      |        |
| ALL         |               |           |          |      |        |
|             |               |           |          |      |        |
| VEHICLES    |               |           |          |      |        |
| (LWT-4 &    |               |           |          |      |        |
| SUBS) HAVE  |               |           |          |      |        |
| BEEN        |               |           |          |      |        |
| CLEARED FOR |               |           |          |      |        |
| USE.        |               |           |          |      |        |
| RECOMMEND   |               |           |          |      |        |
| THAT THIS   |               |           |          |      |        |
|             |               |           |          |      |        |
| PROBLEM     |               |           |          |      |        |
| REPORT BE   |               |           |          |      |        |
| CLOSED      |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+
| **MSFC      |               |           |          |      |        |
| Response/Co |               |           |          |      |        |
| ncurrence** |               |           |          |      |        |
+-------------+---------------+-----------+----------+------+--------+

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

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

  -------------- ------------------- ------------------- ------------ ----------- ------------
  **MSFC         **IFA#**\           **Contractor        **JSC#**\    **KSC#**\   **EICN#**\
  Report#**\     \--                 RPT#**\             \--          \--         \--
  A07581                             T-038                                        

  **Asmnt        **Asmnt Part        **Asmnt                                      
  Part#**\       Name**\             Serial/Lot#**\                               
  80974048409    LH2 AFT DOME FOAM   LWT-10                                       

  **HCRIT CD**\  **FCRIT CD**\       **CAUSE CD**\       **FAIL                   
  \--            1                   MAP - MFG-ASY-INST  MODE**\                  
                                                         MI -                     
                                                         INSULATION               

  **Asmnt        **Asmnt FM**\       **FMEA CSE**\       **FMEA                   
  FMEA**\        1                   B                   SCSE**\                  
  5.1.1.1                                                3                        

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

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

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

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

  **MAJOR DESIGN                                                                  
  CHANGES**                                                                       

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

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