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

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

+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **In-Flight   | **C       | **      | *    |        |
| Record \#**\ | Anomaly       | ontractor | JSC#**\ | *KSC |        |
| A10659       | Number**\     | Report    | \--     | #**\ |        |
|              | \--           | Number**\ |         | \--  |        |
|              |               | E-93-1    |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| LOX LEVEL    |               |           |         |      |        |
| SENSOR (S/N  |               |           |         |      |        |
| 391) FAILED  |               |           |         |      |        |
| ELECT        |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| TEST         |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **EICN#**\   | **ELEMENT**\  | **Cont    | **F     | **   |        |
| \--          | ET            | ractor**\ | SCM#**\ | FCRI |        |
|              |               | MMMSS     | \--     | T**\ |        |
|              |               |           |         | 1R   |        |
+--------------+---------------+-----------+---------+------+--------+
| **HCRIT**\   | **Sys_Lvl**\  | **Misc    |         |      |        |
| \--          | N             | Codes**\  |         |      |        |
|              |               | A 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 28  | 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          | LOX LEVEL     | 74L4-1    | 391     | UFAC |        |
|              | SENSOR        |           |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | SIMM |        |
|              |               |           |         | ONDS |        |
+--------------+---------------+-----------+---------+------+--------+
| **Test/      | **Prevailing  | **F /     | **Fail  | **   |        |
| Operation**\ | Condtion**\   | U**\      | Mode**\ | Caus |        |
| L - FLD      | E -           | F         | EE -    | e**\ |        |
|              | ENVIRONMENT   |           | RANDOM  | E    |        |
|              |               |           |         | TP - |        |
|              |               |           |         | EI-T |        |
|              |               |           |         | EST- |        |
|              |               |           |         | INST |        |
+--------------+---------------+-----------+---------+------+--------+
| **System**\  | **Defect**\   | **Ma      | **Work  | **   |        |
| ELECTRICAL   | CN - CONTAM   | terial**\ | Con     | Fail |        |
|              |               | C - EEE   | tact**\ | Dat  |        |
|              |               |           | J.      | e**\ |        |
|              |               |           | ADAMS   | 08   |        |
|              |               |           |         | /23/ |        |
|              |               |           |         | 1985 |        |
+--------------+---------------+-----------+---------+------+--------+
| **Received   | **Date        | **FMEA    | **IFA:  | *    |        |
| at MSFC**\   | Isolated**\   | Ref       | Mission | *Mis |        |
| 04/01/1987   | \--           | erence**\ | P       | sion |        |
|              |               | 3.1.1.4   | hase**\ | Ela  |        |
|              |               |           | \--     | psed |        |
|              |               |           |         | Tim  |        |
|              |               |           |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               | **S       |         | **   |        |
| *Location**\ |               | ymptom**\ |         | Time |        |
| MAF          |               | EVM -     |         | Cycl |        |
|              |               | CON/MEG   |         | e**\ |        |
|              |               | FAIL      |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               |           |         |      |        |
| *Effectivity |               |           |         |      |        |
| Text**\      |               |           |         |      |        |
| LWTS 15 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   | *       |      |        |
| Approved     | Req Defer     | Close**\  | *Remark |      |        |
| Defer Until  | Until Date**\ | \--       | /       |      |        |
| Date**\      | \--           |           | Ac      |      |        |
| \--          |               |           | tion**\ |      |        |
|              |               |           | \--     |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **I          |               |           |         |      |        |
| nvestigation |               |           |         |      |        |
| / Resolution |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Last MSFC  | **CN RSLV     | **Defer   | **Add   | *    |        |
| Update**\    | SBMT**\       | Date**\   | Date**\ | *R/C |        |
| 01/10/1995   | 04/01/1987    | \--       | \--     | Code |        |
|              |               |           |         | s**\ |        |
|              |               |           |         | 4 -  |        |
|              |               |           |         | TEST |        |
|              |               |           |         | \--  |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Assignee** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| P. MULLER    | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | J. NICHOLS    | R.        | M.      | ject |        |
|              |               | JACKSON   | PESSIN  | MG   |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Approval** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| P. MULLER    | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | J. NICHOLS    | R.        | M.      | ject |        |
|              |               | JACKSON   | PESSIN  | MG   |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **PAC        | **PAC Review  | **MSFC    | **St    | *    |        |
| Assignee**\  | Complete**\   | Closure   | atus**\ | *F/A |        |
| J.EL-IBRAHIM | \--           | Date**\   | C -     | C    |        |
|              |               | 0         | CLOSED  | ompl |        |
|              |               | 8/06/1987 |         | etio |        |
|              |               |           |         | n**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    | **SEV**\      | **Program | **      | **O  |        |
| Type**\      | \--           | Name**\   | REVL**\ | PRIN |        |
| \--          |               | \--       | \--     | C**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **FUNC       | **Software    | *         |         | **SU | **So   |
| MOD**\       | E             | *Software |         | BTYP | ftware |
| \--          | ffectivity**\ | Fail      |         | E**\ | C      |
|              | \-- \-- \--   | CD**\     |         | \--  | losure |
|              | \-- \--       | \--       |         |      | CD**\  |
|              |               |           |         |      | \--    |
+--------------+---------------+-----------+---------+------+--------+
| **RES PERSON | **Approval    |           |         |      |        |
| L2**\        | Signature     |           |         |      |        |
| \--          | L3**\         |           |         |      |        |
|              | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| Status       |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Reliabi    |               |           |         |      |        |
| lity/Quality |               |           |         |      |        |
| Assurance    |               |           |         |      |        |
| Concerns,    |               |           |         |      |        |
| Recomm       |               |           |         |      |        |
| endations:** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| D            |               |           |         |      |        |
| escription** |               |           |         |      |        |
|              |               |           |         |      |        |
| LOX LEVEL    |               |           |         |      |        |
| SENSOR (S/N  |               |           |         |      |        |
| 391) ON      |               |           |         |      |        |
| FORWARD MAST |               |           |         |      |        |
| OF LWT-28    |               |           |         |      |        |
| FAILED THE   |               |           |         |      |        |
|              |               |           |         |      |        |
| ELECTRICAL   |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| TEST         |               |           |         |      |        |
| PERFORMED IN |               |           |         |      |        |
| THE MAF      |               |           |         |      |        |
| FINAL ASSY   |               |           |         |      |        |
|              |               |           |         |      |        |
| AREA. THE    |               |           |         |      |        |
| MEASURED     |               |           |         |      |        |
| VALUE OF     |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| WAS LESS     |               |           |         |      |        |
| THAN 5       |               |           |         |      |        |
| MEGOHMS.     |               |           |         |      |        |
| MINIMUM      |               |           |         |      |        |
|              |               |           |         |      |        |
| ACCEPTABLE   |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| VALVE IS 5   |               |           |         |      |        |
| MEGOHMS.     |               |           |         |      |        |
| REF: MARS    |               |           |         |      |        |
| T-83880,     |               |           |         |      |        |
|              |               |           |         |      |        |
| T-83884,     |               |           |         |      |        |
| T-83888,     |               |           |         |      |        |
| CAPS E-093,  |               |           |         |      |        |
| E-092, AND   |               |           |         |      |        |
| E-093-3      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| In           |               |           |         |      |        |
| vestigation/ |               |           |         |      |        |
| Resolution** |               |           |         |      |        |
|              |               |           |         |      |        |
| R/A -        |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| INSTRUCTION  |               |           |         |      |        |
| 5008 WAS     |               |           |         |      |        |
| REVISED TO   |               |           |         |      |        |
| PROVIDE      |               |           |         |      |        |
| FORCED,      |               |           |         |      |        |
| HEATED,      |               |           |         |      |        |
|              |               |           |         |      |        |
| NITROGEN     |               |           |         |      |        |
| DRYING OF    |               |           |         |      |        |
| BOTH THE LOX |               |           |         |      |        |
| AND LH2      |               |           |         |      |        |
| INTERNAL     |               |           |         |      |        |
| WIRE         |               |           |         |      |        |
| HAR          |               |           |         |      |        |
| NESSES/MASTS |               |           |         |      |        |
|              |               |           |         |      |        |
| THIS L02     |               |           |         |      |        |
| LEVEL SENSOR |               |           |         |      |        |
| FAILURE DOES |               |           |         |      |        |
| NOT          |               |           |         |      |        |
| CONSTRAIN    |               |           |         |      |        |
| FUTURE       |               |           |         |      |        |
| LAUNCHES FOR |               |           |         |      |        |
|              |               |           |         |      |        |
| THE          |               |           |         |      |        |
| FOLLOWING    |               |           |         |      |        |
| REASONS: IN  |               |           |         |      |        |
| ADDITION TO  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| ACCEPTANCE   |               |           |         |      |        |
| TEST AT THE  |               |           |         |      |        |
|              |               |           |         |      |        |
| VENDOR\'S    |               |           |         |      |        |
| FACILITY,    |               |           |         |      |        |
| ALL L02      |               |           |         |      |        |
| LEVEL        |               |           |         |      |        |
| SENSORS MUST |               |           |         |      |        |
| PASS AN      |               |           |         |      |        |
| ELEC- TRICAL |               |           |         |      |        |
|              |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| TEST DURING  |               |           |         |      |        |
| FINAL        |               |           |         |      |        |
| ASSEMBLY     |               |           |         |      |        |
| CHECKOUT AT  |               |           |         |      |        |
| MAF          |               |           |         |      |        |
|              |               |           |         |      |        |
| EXPERIENCE   |               |           |         |      |        |
| HAS          |               |           |         |      |        |
| DEMONSTRA-   |               |           |         |      |        |
| TED THAT THE |               |           |         |      |        |
| CHECKOUT     |               |           |         |      |        |
| PROCEDURES   |               |           |         |      |        |
| AT MAF IS    |               |           |         |      |        |
|              |               |           |         |      |        |
| ADEQUATE TO  |               |           |         |      |        |
| IDENTIFY ANY |               |           |         |      |        |
| DEFECTIVE    |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| INSTALLED    |               |           |         |      |        |
| INTO THE     |               |           |         |      |        |
| SYSTEM       |               |           |         |      |        |
|              |               |           |         |      |        |
| THIS         |               |           |         |      |        |
| STATEMENT    |               |           |         |      |        |
| HAS BEEN     |               |           |         |      |        |
| APPROVED BY  |               |           |         |      |        |
| ET PROJECT   |               |           |         |      |        |
| MANAGER, G.  |               |           |         |      |        |
| P. BRIDWELL, |               |           |         |      |        |
|              |               |           |         |      |        |
| REF. PROBLEM |               |           |         |      |        |
| A09653.      |               |           |         |      |        |
| GENERAL A.   |               |           |         |      |        |
| BACKGROUND   |               |           |         |      |        |
| INFORMATION  |               |           |         |      |        |
| THE LOX AND  |               |           |         |      |        |
| LH2          |               |           |         |      |        |
|              |               |           |         |      |        |
| LIQUID LEVEL |               |           |         |      |        |
| SENSORS ARE  |               |           |         |      |        |
| IDENTICAL    |               |           |         |      |        |
| EXCEPT FOR   |               |           |         |      |        |
| THE TYPE OF  |               |           |         |      |        |
| FLUOROCARBON |               |           |         |      |        |
|              |               |           |         |      |        |
| INSULATION   |               |           |         |      |        |
| USED ON THE  |               |           |         |      |        |
| WIRE LEADS.  |               |           |         |      |        |
| EACH SENSOR  |               |           |         |      |        |
| IS CONNECTED |               |           |         |      |        |
| TO A SIGNAL  |               |           |         |      |        |
|              |               |           |         |      |        |
| CONDITIONER  |               |           |         |      |        |
| IN THE       |               |           |         |      |        |
| ORBITER.     |               |           |         |      |        |
| EACH SENSOR  |               |           |         |      |        |
| CIRCUIT IS   |               |           |         |      |        |
| CAPABLE OF   |               |           |         |      |        |
|              |               |           |         |      |        |
| GENERATING   |               |           |         |      |        |
| ONLY A       |               |           |         |      |        |
| \"WET\" OR   |               |           |         |      |        |
| \"DRY\"      |               |           |         |      |        |
| OUTPUT       |               |           |         |      |        |
| SIGNAL. AN   |               |           |         |      |        |
| ARRAY OF     |               |           |         |      |        |
| THESE POINT  |               |           |         |      |        |
|              |               |           |         |      |        |
| LEVEL        |               |           |         |      |        |
| SENSORS IS   |               |           |         |      |        |
| INSTALLED IN |               |           |         |      |        |
| BOTH THE LOX |               |           |         |      |        |
| AND LH2      |               |           |         |      |        |
| TANKS TO     |               |           |         |      |        |
| MONITOR THE  |               |           |         |      |        |
|              |               |           |         |      |        |
| FLUID        |               |           |         |      |        |
| LEVELS. EACH |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| CONTAINS A   |               |           |         |      |        |
| FINE WIRE    |               |           |         |      |        |
| RESISTIVE    |               |           |         |      |        |
| ELEMENT. THE |               |           |         |      |        |
|              |               |           |         |      |        |
| ORBITER      |               |           |         |      |        |
| SIGNAL       |               |           |         |      |        |
| CONDITIONER  |               |           |         |      |        |
| PROVIDES     |               |           |         |      |        |
| CURRENTTO    |               |           |         |      |        |
| HEAT THE     |               |           |         |      |        |
| ELEMENT.     |               |           |         |      |        |
| WHEN A       |               |           |         |      |        |
|              |               |           |         |      |        |
| SENSOR IS    |               |           |         |      |        |
| IMMERSED IN  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| CRYOGENIC    |               |           |         |      |        |
| LIQUID       |               |           |         |      |        |
| PROPELLENT,  |               |           |         |      |        |
| THE COOLING  |               |           |         |      |        |
| OF           |               |           |         |      |        |
|              |               |           |         |      |        |
| THE ELEMENT  |               |           |         |      |        |
| IS DETECTED  |               |           |         |      |        |
| BY THE       |               |           |         |      |        |
| SIGNAL       |               |           |         |      |        |
| CONDITIONER  |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
| PROVIDES A   |               |           |         |      |        |
|              |               |           |         |      |        |
| \"WET\"      |               |           |         |      |        |
| OUTPUT       |               |           |         |      |        |
| SIGNAL TO    |               |           |         |      |        |
| THE ORBITER. |               |           |         |      |        |
| IN THE ET    |               |           |         |      |        |
| LOX TANK     |               |           |         |      |        |
| THERE IS ONE |               |           |         |      |        |
|              |               |           |         |      |        |
| SENSOR AT    |               |           |         |      |        |
| THE 5% LEVEL |               |           |         |      |        |
| AND SEVEN    |               |           |         |      |        |
| SENSORS      |               |           |         |      |        |
| BETWEEN THE  |               |           |         |      |        |
| 98% AND      |               |           |         |      |        |
|              |               |           |         |      |        |
| 3 LEVELS.    |               |           |         |      |        |
| ALL SEVEN OF |               |           |         |      |        |
| THE SENSORS  |               |           |         |      |        |
| AT THE       |               |           |         |      |        |
| TOP/FORWARD  |               |           |         |      |        |
| END OF THE   |               |           |         |      |        |
| LOX          |               |           |         |      |        |
|              |               |           |         |      |        |
| TANK ARE     |               |           |         |      |        |
| MOUNTED ON A |               |           |         |      |        |
| ALUMINUM     |               |           |         |      |        |
| TUBE KNOWN   |               |           |         |      |        |
| AS THE       |               |           |         |      |        |
| \"FORWARD    |               |           |         |      |        |
| LOX MAST\"   |               |           |         |      |        |
|              |               |           |         |      |        |
| THE MAST IS  |               |           |         |      |        |
| INSTALLED AS |               |           |         |      |        |
| A COMPLETED  |               |           |         |      |        |
| SUBASSEMBLY  |               |           |         |      |        |
| DURING WORK  |               |           |         |      |        |
| PERFORMED    |               |           |         |      |        |
|              |               |           |         |      |        |
| IN THE MAF   |               |           |         |      |        |
| FINAL        |               |           |         |      |        |
| ASSEMBLY     |               |           |         |      |        |
| AREA. TASK I |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
| I            |               |           |         |      |        |
| NVESTIGATION |               |           |         |      |        |
| A. 1         |               |           |         |      |        |
|              |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| IN-PROCESS   |               |           |         |      |        |
| ELECTRICAL   |               |           |         |      |        |
| TESTING OF   |               |           |         |      |        |
| THE FORWARD  |               |           |         |      |        |
| LOX LEVEL    |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
|              |               |           |         |      |        |
| MAST ON      |               |           |         |      |        |
| LWT-27, THE  |               |           |         |      |        |
| \"100% MINUS |               |           |         |      |        |
| LIQUID       |               |           |         |      |        |
| LEVEL\"      |               |           |         |      |        |
| CIRCUIT HAD  |               |           |         |      |        |
| AN ISOLATION |               |           |         |      |        |
|              |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| OF LESS THAN |               |           |         |      |        |
| THE REQUIRED |               |           |         |      |        |
| FIVE         |               |           |         |      |        |
| MEGOHMS.     |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
| ANALYSIS     |               |           |         |      |        |
|              |               |           |         |      |        |
| FOUND THE    |               |           |         |      |        |
| PROBABLE     |               |           |         |      |        |
| CAUSE TO BE  |               |           |         |      |        |
| COLD FLOW OF |               |           |         |      |        |
| THE TEFLON   |               |           |         |      |        |
| HEAT SHRINK  |               |           |         |      |        |
|              |               |           |         |      |        |
| TUBING       |               |           |         |      |        |
| INTERNAL TO  |               |           |         |      |        |
| THE SENSOR.  |               |           |         |      |        |
| THE INTERNAL |               |           |         |      |        |
| STEEL        |               |           |         |      |        |
| TERMINALS    |               |           |         |      |        |
| HAD BEEN     |               |           |         |      |        |
|              |               |           |         |      |        |
| IMPROPERLY   |               |           |         |      |        |
| FORMED       |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| ASSEMBLY AT  |               |           |         |      |        |
| THE VENDOR.  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| TERMINALS    |               |           |         |      |        |
| FORCED       |               |           |         |      |        |
|              |               |           |         |      |        |
| THE OUTPUT   |               |           |         |      |        |
| LEAD WIRES   |               |           |         |      |        |
| AGAINST AN   |               |           |         |      |        |
| INTER- NAL   |               |           |         |      |        |
| LIP IN THE   |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| HOUSING      |               |           |         |      |        |
|              |               |           |         |      |        |
| AND DAMAGED  |               |           |         |      |        |
| THE SHRINK   |               |           |         |      |        |
| TUBING       |               |           |         |      |        |
| INSULATION   |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| MARS T-85671 |               |           |         |      |        |
| AND          |               |           |         |      |        |
|              |               |           |         |      |        |
| T-82975).    |               |           |         |      |        |
| B. 1. THE    |               |           |         |      |        |
| LOX LEVEL    |               |           |         |      |        |
| SENSOR MAST  |               |           |         |      |        |
| WHICH HAD    |               |           |         |      |        |
| BEEN REMOVED |               |           |         |      |        |
| FROM         |               |           |         |      |        |
|              |               |           |         |      |        |
| LWT-27, DUE  |               |           |         |      |        |
| TO FAILURE   |               |           |         |      |        |
| LISTED IN    |               |           |         |      |        |
| TASK I.A.1,  |               |           |         |      |        |
| WAS REPAIRED |               |           |         |      |        |
| AND          |               |           |         |      |        |
| INSTALLED    |               |           |         |      |        |
|              |               |           |         |      |        |
| IN LWT-28.   |               |           |         |      |        |
| AFTER        |               |           |         |      |        |
| I            |               |           |         |      |        |
| NSTALLATION, |               |           |         |      |        |
| A LEVEL      |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| MEASUREMENT  |               |           |         |      |        |
| CIRCUIT      |               |           |         |      |        |
|              |               |           |         |      |        |
| FAILED TO    |               |           |         |      |        |
| MEET THE     |               |           |         |      |        |
| FIVE MEGOHM  |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| REQUIREMENT. |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| MAST WAS RE- |               |           |         |      |        |
| MOVED, THE   |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
| TRACED TO A  |               |           |         |      |        |
| LEVEL        |               |           |         |      |        |
| SENSOR, THE  |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
|              |               |           |         |      |        |
| WAS REPLACED |               |           |         |      |        |
| AND THE MAST |               |           |         |      |        |
| WAS REIN-    |               |           |         |      |        |
| STALLED IN   |               |           |         |      |        |
| LWT-28. THE  |               |           |         |      |        |
| CYCLE WAS    |               |           |         |      |        |
|              |               |           |         |      |        |
| REPEATED     |               |           |         |      |        |
| TWICE FOR A  |               |           |         |      |        |
| TOTAL OF     |               |           |         |      |        |
| THREE FAILED |               |           |         |      |        |
| LEVEL        |               |           |         |      |        |
| SENSORS.     |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
|              |               |           |         |      |        |
| ANALYSES     |               |           |         |      |        |
| T-83880,     |               |           |         |      |        |
| T-83884, AND |               |           |         |      |        |
| T-83888      |               |           |         |      |        |
| FOUND THE    |               |           |         |      |        |
| PROBABLE     |               |           |         |      |        |
| CAUSE OF THE |               |           |         |      |        |
|              |               |           |         |      |        |
| FAILURES TO  |               |           |         |      |        |
| BE THAT      |               |           |         |      |        |
| MOISTURE     |               |           |         |      |        |
| CONDENSED ON |               |           |         |      |        |
| THE SENSORS  |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| CLEANING     |               |           |         |      |        |
|              |               |           |         |      |        |
| THE LEVEL    |               |           |         |      |        |
| SENSOR MAST  |               |           |         |      |        |
| ASSEMBLY IS  |               |           |         |      |        |
| CLEANED WITH |               |           |         |      |        |
| FREON TMC    |               |           |         |      |        |
| AND FREON    |               |           |         |      |        |
| PCA          |               |           |         |      |        |
|              |               |           |         |      |        |
| IN ORDER TO  |               |           |         |      |        |
| MEET THE     |               |           |         |      |        |
| CLEANLINESS  |               |           |         |      |        |
| REQUIREMENTS |               |           |         |      |        |
| FOR USE IN A |               |           |         |      |        |
| LOX          |               |           |         |      |        |
|              |               |           |         |      |        |
| ENVIRONMENT. |               |           |         |      |        |
| EVAPORATION  |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| CLEANING     |               |           |         |      |        |
| SOLVENT      |               |           |         |      |        |
| CHILLS THE   |               |           |         |      |        |
| MAST BELOW   |               |           |         |      |        |
|              |               |           |         |      |        |
| THE DEW      |               |           |         |      |        |
| POINT AND    |               |           |         |      |        |
| MOISTURE     |               |           |         |      |        |
| CONDENSES ON |               |           |         |      |        |
| IT. THE      |               |           |         |      |        |
| FIBERGLASS   |               |           |         |      |        |
| BRAID USED   |               |           |         |      |        |
|              |               |           |         |      |        |
| ON LOX TANK  |               |           |         |      |        |
| WIRE         |               |           |         |      |        |
| HARNESSES    |               |           |         |      |        |
| ACTS AS A    |               |           |         |      |        |
| WICK. THE    |               |           |         |      |        |
| BRAID CAN    |               |           |         |      |        |
| BECOME WET   |               |           |         |      |        |
|              |               |           |         |      |        |
| WITH WATER   |               |           |         |      |        |
| CONDENSED    |               |           |         |      |        |
| FROM THE     |               |           |         |      |        |
| AIR. 2.      |               |           |         |      |        |
| LWT-28 MET   |               |           |         |      |        |
| THE          |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
|              |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| REQUIREMENTS |               |           |         |      |        |
| AFTER        |               |           |         |      |        |
| REPAIRS TO   |               |           |         |      |        |
| THE MAST,    |               |           |         |      |        |
| LISTED IN    |               |           |         |      |        |
| TASK         |               |           |         |      |        |
|              |               |           |         |      |        |
| I.B.1, WERE  |               |           |         |      |        |
| COMPLETED    |               |           |         |      |        |
| AND THE ET   |               |           |         |      |        |
| WAS MOVED TO |               |           |         |      |        |
| BUILDING 420 |               |           |         |      |        |
| FOR FINAL    |               |           |         |      |        |
|              |               |           |         |      |        |
| ACCEPTANCE   |               |           |         |      |        |
| TESTING. TWO |               |           |         |      |        |
| LOX LEVEL    |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| CIRCUITS     |               |           |         |      |        |
| FAILED TO    |               |           |         |      |        |
| MEET THE     |               |           |         |      |        |
|              |               |           |         |      |        |
| FIVE MEGOHMS |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| ACCEP- TANCE |               |           |         |      |        |
| TESTING. THE |               |           |         |      |        |
| LOX          |               |           |         |      |        |
|              |               |           |         |      |        |
| TANK WAS     |               |           |         |      |        |
| CONNECTED TO |               |           |         |      |        |
| A HEATED     |               |           |         |      |        |
| VENTILATION  |               |           |         |      |        |
| AIR PACK FOR |               |           |         |      |        |
| FOUR DAYS.   |               |           |         |      |        |
| AT           |               |           |         |      |        |
|              |               |           |         |      |        |
| THE END OF   |               |           |         |      |        |
| THIS TIME,   |               |           |         |      |        |
| THE TWO      |               |           |         |      |        |
| DEFECTIVE    |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| READINGS     |               |           |         |      |        |
|              |               |           |         |      |        |
| HAD          |               |           |         |      |        |
| INCREASED    |               |           |         |      |        |
| FROM         |               |           |         |      |        |
| A            |               |           |         |      |        |
| PPROXIMATELY |               |           |         |      |        |
| TWO MEGOHMS  |               |           |         |      |        |
| TO           |               |           |         |      |        |
| A            |               |           |         |      |        |
| PPROXIMATELY |               |           |         |      |        |
| EIGHTY       |               |           |         |      |        |
|              |               |           |         |      |        |
| MEGOHMS      |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| MARS         |               |           |         |      |        |
| T-76354). 3. |               |           |         |      |        |
| A LOX LEVEL  |               |           |         |      |        |
| SENSOR MAST  |               |           |         |      |        |
| FAILED AN    |               |           |         |      |        |
|              |               |           |         |      |        |
| IN-PROCESS   |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| TEST IN      |               |           |         |      |        |
| FINAL        |               |           |         |      |        |
| ASSEMBLY     |               |           |         |      |        |
| PRIOR TO     |               |           |         |      |        |
|              |               |           |         |      |        |
| INSTALLATION |               |           |         |      |        |
| IN LWT-30.   |               |           |         |      |        |
| FIVE OF THE  |               |           |         |      |        |
| SEVEN        |               |           |         |      |        |
| CIRCUITS HAD |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
|              |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| VALUES BELOW |               |           |         |      |        |
| FIVE         |               |           |         |      |        |
| MEGOHMS.     |               |           |         |      |        |
| AFTER FORCED |               |           |         |      |        |
| AIR, HEATED  |               |           |         |      |        |
| TO           |               |           |         |      |        |
|              |               |           |         |      |        |
| A            |               |           |         |      |        |
| PPROXIMATELY |               |           |         |      |        |
| 100          |               |           |         |      |        |
| DEGREES-F,   |               |           |         |      |        |
| WAS BLOWN    |               |           |         |      |        |
| OVER THE     |               |           |         |      |        |
| MAST FOR     |               |           |         |      |        |
| FOUR HOURS,  |               |           |         |      |        |
|              |               |           |         |      |        |
| ALL CIRCUITS |               |           |         |      |        |
| WERE ABOVE   |               |           |         |      |        |
| 100 MEGOHMS  |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| MARS         |               |           |         |      |        |
| T-86702). 4. |               |           |         |      |        |
| A            |               |           |         |      |        |
|              |               |           |         |      |        |
| REVEIW OF    |               |           |         |      |        |
| PREVIOUS     |               |           |         |      |        |
| MOISTURE     |               |           |         |      |        |
| CAUSED       |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| FAILURES OF  |               |           |         |      |        |
|              |               |           |         |      |        |
| LEVEL SENSOR |               |           |         |      |        |
| CIRCUITS     |               |           |         |      |        |
| FOUND A      |               |           |         |      |        |
| SINGLE       |               |           |         |      |        |
| PREVIOUS     |               |           |         |      |        |
| OCCURRENCE   |               |           |         |      |        |
| THAT WAS     |               |           |         |      |        |
|              |               |           |         |      |        |
| SIMILAR TO   |               |           |         |      |        |
| THE FAILURES |               |           |         |      |        |
| OF LWTS 27,  |               |           |         |      |        |
| 28, AND 30.  |               |           |         |      |        |
| AN AFT LOX   |               |           |         |      |        |
| LEVEL SENSOR |               |           |         |      |        |
|              |               |           |         |      |        |
| MAST FAILED  |               |           |         |      |        |
| AN ISOLATION |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| TEST WHEN    |               |           |         |      |        |
| BEING        |               |           |         |      |        |
| INSTALLED ON |               |           |         |      |        |
|              |               |           |         |      |        |
| LWT-11. WHEN |               |           |         |      |        |
| TESTED AFTER |               |           |         |      |        |
| EIGHT HOURS  |               |           |         |      |        |
| IN THE OPEN  |               |           |         |      |        |
| AIR, THE     |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
|              |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| WAS ACCEP-   |               |           |         |      |        |
| TABLE. THE   |               |           |         |      |        |
| ENGINEERING  |               |           |         |      |        |
| ANALYSIS     |               |           |         |      |        |
| FOUND THAT   |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| PROBABLE     |               |           |         |      |        |
| CAUSE WAS    |               |           |         |      |        |
| MOISTURE ON  |               |           |         |      |        |
| THE WIRING/  |               |           |         |      |        |
| CONNECTOR    |               |           |         |      |        |
| FROM THE     |               |           |         |      |        |
| CLEANING     |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| MARS         |               |           |         |      |        |
| T-49783). 5. |               |           |         |      |        |
| A REVIEW OF  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| PROCEDURES   |               |           |         |      |        |
| AND          |               |           |         |      |        |
|              |               |           |         |      |        |
| EQUIPMENT    |               |           |         |      |        |
| USED TO      |               |           |         |      |        |
| PROVIDE DRY  |               |           |         |      |        |
| AIR TO THE   |               |           |         |      |        |
| INTERIOR OF  |               |           |         |      |        |
| THE PRO-     |               |           |         |      |        |
| PELLANT      |               |           |         |      |        |
|              |               |           |         |      |        |
| TANKS DURING |               |           |         |      |        |
| ASSEMBLY OF  |               |           |         |      |        |
| THE ET FOUND |               |           |         |      |        |
| NO           |               |           |         |      |        |
| D            |               |           |         |      |        |
| EFICIENCIES. |               |           |         |      |        |
| THE \"PURGE  |               |           |         |      |        |
|              |               |           |         |      |        |
| CARTS\" ARE  |               |           |         |      |        |
| CERTI- FIED  |               |           |         |      |        |
| FOR HUMIDITY |               |           |         |      |        |
| AND          |               |           |         |      |        |
| P            |               |           |         |      |        |
| ARTICULATES. |               |           |         |      |        |
| WHEN THE     |               |           |         |      |        |
| PURGE        |               |           |         |      |        |
|              |               |           |         |      |        |
| CARTS ARE    |               |           |         |      |        |
| NOT IN USE,  |               |           |         |      |        |
| DESICCANT    |               |           |         |      |        |
| BREATHERS    |               |           |         |      |        |
| ARE          |               |           |         |      |        |
| INSTALLED.   |               |           |         |      |        |
| THE          |               |           |         |      |        |
| BREATHERS    |               |           |         |      |        |
|              |               |           |         |      |        |
| HAVE         |               |           |         |      |        |
| HUMIDITY     |               |           |         |      |        |
| INDICATORS   |               |           |         |      |        |
| WHICH ARE    |               |           |         |      |        |
| CHECKED      |               |           |         |      |        |
| REGULARLY    |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
|              |               |           |         |      |        |
| INTEROFFICE  |               |           |         |      |        |
| MEMORANDUM   |               |           |         |      |        |
| 3            |               |           |         |      |        |
| 743-85-231). |               |           |         |      |        |
| TASK II      |               |           |         |      |        |
| CORRECTIVE   |               |           |         |      |        |
| ACTION 1     |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| INSTRUCTION  |               |           |         |      |        |
| 5008 WAS     |               |           |         |      |        |
| REVISED TO   |               |           |         |      |        |
| PROVIDE      |               |           |         |      |        |
| FORCED,      |               |           |         |      |        |
| HEATED,      |               |           |         |      |        |
|              |               |           |         |      |        |
| NITROGEN     |               |           |         |      |        |
| DRYING OF    |               |           |         |      |        |
| BOTH THE LOX |               |           |         |      |        |
| AND LH2      |               |           |         |      |        |
| INTERNAL     |               |           |         |      |        |
| WIRE         |               |           |         |      |        |
| HAR          |               |           |         |      |        |
| NESSES/MASTS |               |           |         |      |        |
|              |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| INTEROFFICE  |               |           |         |      |        |
| MEMORANDUM   |               |           |         |      |        |
| 3693         |               |           |         |      |        |
| -87-HP-080). |               |           |         |      |        |
| 2. THE       |               |           |         |      |        |
| CHANGES TO   |               |           |         |      |        |
|              |               |           |         |      |        |
| PI-5008 FOR  |               |           |         |      |        |
| THE LOX WIRE |               |           |         |      |        |
| HAR          |               |           |         |      |        |
| NESSES/MASTS |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| INCORPORATED |               |           |         |      |        |
| INTO THE     |               |           |         |      |        |
|              |               |           |         |      |        |
| M            |               |           |         |      |        |
| ANUFACTURING |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| PLANS        |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| MPP          |               |           |         |      |        |
| 8093         |               |           |         |      |        |
| 2003709-029, |               |           |         |      |        |
| PLANNING     |               |           |         |      |        |
|              |               |           |         |      |        |
| CHANGE       |               |           |         |      |        |
| LEVEL: NEW,  |               |           |         |      |        |
| 3/25/87; AND |               |           |         |      |        |
| MPP          |               |           |         |      |        |
| 8093         |               |           |         |      |        |
| 1003769-059, |               |           |         |      |        |
| PLANNING     |               |           |         |      |        |
| CHANGE       |               |           |         |      |        |
|              |               |           |         |      |        |
| LEVEL; NEW,  |               |           |         |      |        |
| 3/25/87.     |               |           |         |      |        |
| TASK III     |               |           |         |      |        |
| CLEARANCE OF |               |           |         |      |        |
| E            |               |           |         |      |        |
| FFECTIVITIES |               |           |         |      |        |
| THERE ARE NO |               |           |         |      |        |
|              |               |           |         |      |        |
| CONSTRAINTS. |               |           |         |      |        |
| THE FAILURES |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| DETECTED     |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| TESTING AT   |               |           |         |      |        |
| MAF. THERE   |               |           |         |      |        |
|              |               |           |         |      |        |
| HAVE BEEN NO |               |           |         |      |        |
| FAILURES AT  |               |           |         |      |        |
| KSC. ALL ETS |               |           |         |      |        |
| ARE PURGED   |               |           |         |      |        |
| WITH DRY     |               |           |         |      |        |
| NITROGEN     |               |           |         |      |        |
|              |               |           |         |      |        |
| PRIOR TO     |               |           |         |      |        |
| SHIPMENT,    |               |           |         |      |        |
| WHICH        |               |           |         |      |        |
| PREVENTS     |               |           |         |      |        |
| MOISTURE     |               |           |         |      |        |
| RELATED      |               |           |         |      |        |
| FAILURES     |               |           |         |      |        |
| WITH THE     |               |           |         |      |        |
|              |               |           |         |      |        |
| PROPELLANT   |               |           |         |      |        |
| TANKS AT     |               |           |         |      |        |
| KSC. TASK IV |               |           |         |      |        |
| CAPS CLOSURE |               |           |         |      |        |
| SUMMARY      |               |           |         |      |        |
| SEVERAL LOX  |               |           |         |      |        |
| LEVEL        |               |           |         |      |        |
|              |               |           |         |      |        |
| SENSORS IN   |               |           |         |      |        |
| USE ON ETS   |               |           |         |      |        |
| AT MAF HAD A |               |           |         |      |        |
| LOWER        |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| THAN         |               |           |         |      |        |
|              |               |           |         |      |        |
| ACCEPTABLE.  |               |           |         |      |        |
| THE SECOND   |               |           |         |      |        |
| PROBLEM WAS  |               |           |         |      |        |
| THE RESULT   |               |           |         |      |        |
| OF           |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
| DRYING OF    |               |           |         |      |        |
|              |               |           |         |      |        |
| THE          |               |           |         |      |        |
| MAST/HARNESS |               |           |         |      |        |
| ASSEMBLIES   |               |           |         |      |        |
| FOLLOWING    |               |           |         |      |        |
| CLEANING     |               |           |         |      |        |
| WITH FREON   |               |           |         |      |        |
| SOLVENTS.    |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| INSTRUCTION  |               |           |         |      |        |
| FOR DRYING   |               |           |         |      |        |
| THE          |               |           |         |      |        |
| ASSEMBLIES   |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| IMPROVED.    |               |           |         |      |        |
| 7/31/87      |               |           |         |      |        |
|              |               |           |         |      |        |
| UPDATE       |               |           |         |      |        |
| STATUS - THE |               |           |         |      |        |
| SENSOR S/N   |               |           |         |      |        |
| 361 WAS      |               |           |         |      |        |
| BUILT USING  |               |           |         |      |        |
| THE OLD      |               |           |         |      |        |
| TOOLING      |               |           |         |      |        |
|              |               |           |         |      |        |
| WHICH IN     |               |           |         |      |        |
| SOME         |               |           |         |      |        |
| ISOLATED     |               |           |         |      |        |
| CASES COULD  |               |           |         |      |        |
| ALLOW        |               |           |         |      |        |
| IMPROPERLY   |               |           |         |      |        |
| FORMED       |               |           |         |      |        |
| TERMINALS    |               |           |         |      |        |
|              |               |           |         |      |        |
| RESULTING IN |               |           |         |      |        |
| THE LOW 1R   |               |           |         |      |        |
| READINGS AS  |               |           |         |      |        |
| NOTED IN     |               |           |         |      |        |
| CAPS E-093.  |               |           |         |      |        |
| PER TELECON  |               |           |         |      |        |
|              |               |           |         |      |        |
| WITH MR.     |               |           |         |      |        |
| ADAMS OF     |               |           |         |      |        |
| MMC, CN      |               |           |         |      |        |
| 5/27/87, HE  |               |           |         |      |        |
| STATED THE   |               |           |         |      |        |
| SENSOR S/N   |               |           |         |      |        |
| 391 WAS NOT  |               |           |         |      |        |
|              |               |           |         |      |        |
| IN- SPECTED  |               |           |         |      |        |
| FOR          |               |           |         |      |        |
| IMPROPERLY   |               |           |         |      |        |
| FORMED       |               |           |         |      |        |
| TERMINALS TO |               |           |         |      |        |
| THE          |               |           |         |      |        |
| STANDARDS    |               |           |         |      |        |
| NOW IN USE   |               |           |         |      |        |
|              |               |           |         |      |        |
| SINCE THE    |               |           |         |      |        |
| FAILURE WAS  |               |           |         |      |        |
| CAUSED BY    |               |           |         |      |        |
| MOISTURE     |               |           |         |      |        |
| (REF FAILURE |               |           |         |      |        |
| ANALYSIS     |               |           |         |      |        |
| T83888)      |               |           |         |      |        |
|              |               |           |         |      |        |
| THE SENSOR   |               |           |         |      |        |
| S/N 391 WILL |               |           |         |      |        |
| BE           |               |           |         |      |        |
| SCRAPPED/    |               |           |         |      |        |
| REFURBISHED. |               |           |         |      |        |
| ALL NEW      |               |           |         |      |        |
| SENSORS WILL |               |           |         |      |        |
|              |               |           |         |      |        |
| BE           |               |           |         |      |        |
| MANUFACTURED |               |           |         |      |        |
| UTILIZING    |               |           |         |      |        |
| THE NEW      |               |           |         |      |        |
| TOOL. ALL    |               |           |         |      |        |
| SENSORS ARE  |               |           |         |      |        |
| TESTED AT    |               |           |         |      |        |
| LEAST        |               |           |         |      |        |
|              |               |           |         |      |        |
| TWICE AFTER  |               |           |         |      |        |
| INSTALLATION |               |           |         |      |        |
| AT MAF WHICH |               |           |         |      |        |
| PROVIDES     |               |           |         |      |        |
| PROOF OF     |               |           |         |      |        |
| INSTALLATION |               |           |         |      |        |
|              |               |           |         |      |        |
| RESISTANCE.  |               |           |         |      |        |
| MSFC         |               |           |         |      |        |
| STATEMENT:   |               |           |         |      |        |
| 8/7/87 - THE |               |           |         |      |        |
| SENSORS NOW  |               |           |         |      |        |
| ON LWT-28    |               |           |         |      |        |
| AND          |               |           |         |      |        |
|              |               |           |         |      |        |
| LWT-30 WERE  |               |           |         |      |        |
| FABRICATED   |               |           |         |      |        |
| WITHOUT A    |               |           |         |      |        |
| SPECIAL TOOL |               |           |         |      |        |
| TO CONTROL   |               |           |         |      |        |
| THE FORMING  |               |           |         |      |        |
| OF           |               |           |         |      |        |
|              |               |           |         |      |        |
| THE          |               |           |         |      |        |
| TERMINALS AS |               |           |         |      |        |
| DONE ON      |               |           |         |      |        |
| CURRENT      |               |           |         |      |        |
| BUILDS.      |               |           |         |      |        |
| THEREFORE,   |               |           |         |      |        |
| THE EXACT    |               |           |         |      |        |
| CAUSE OF     |               |           |         |      |        |
|              |               |           |         |      |        |
| THE FAILURES |               |           |         |      |        |
| NOTED AFTER  |               |           |         |      |        |
| INSTALLATION |               |           |         |      |        |
| IS NOT KNOWN |               |           |         |      |        |
| AND COULD    |               |           |         |      |        |
| HAVE BEEN    |               |           |         |      |        |
|              |               |           |         |      |        |
| DUE TO       |               |           |         |      |        |
| MOISTURE, AS |               |           |         |      |        |
| ASSESSED     |               |           |         |      |        |
| ABOVE, OR A  |               |           |         |      |        |
| COMBINATION  |               |           |         |      |        |
| OF TEFLON    |               |           |         |      |        |
| COLD         |               |           |         |      |        |
|              |               |           |         |      |        |
| FLOW AND     |               |           |         |      |        |
| MOISTURE.    |               |           |         |      |        |
| THE          |               |           |         |      |        |
| ADDITIONAL   |               |           |         |      |        |
| TESTS        |               |           |         |      |        |
| REQUIRED AT  |               |           |         |      |        |
| KSC, ALONG   |               |           |         |      |        |
| WITH THE     |               |           |         |      |        |
|              |               |           |         |      |        |
| BUILT-IN     |               |           |         |      |        |
| SYSTEM       |               |           |         |      |        |
| REDUNDANCY,  |               |           |         |      |        |
| SHOULD       |               |           |         |      |        |
| PREVENT ANY  |               |           |         |      |        |
| LAUNCH       |               |           |         |      |        |
| PROBLEMS.    |               |           |         |      |        |
| 8/17/87      |               |           |         |      |        |
|              |               |           |         |      |        |
| \- MMC       |               |           |         |      |        |
| CLOSURE      |               |           |         |      |        |
| SUMMARY      |               |           |         |      |        |
| SEVERL LOX   |               |           |         |      |        |
| LEVEL        |               |           |         |      |        |
| SENSORS IN   |               |           |         |      |        |
| USE ON ETS   |               |           |         |      |        |
| AT MAF HAD   |               |           |         |      |        |
|              |               |           |         |      |        |
| A LOWER      |               |           |         |      |        |
| ISOLATION    |               |           |         |      |        |
| RESISTANCE   |               |           |         |      |        |
| THAN IS      |               |           |         |      |        |
| ACCEPTABLE.  |               |           |         |      |        |
| THE PROBLEMS |               |           |         |      |        |
| WERE THE     |               |           |         |      |        |
|              |               |           |         |      |        |
| RESULT OF    |               |           |         |      |        |
| TWO SEPARATE |               |           |         |      |        |
| D            |               |           |         |      |        |
| EFICIENCIES. |               |           |         |      |        |
| THE FIRST    |               |           |         |      |        |
| PROBLEM WAS  |               |           |         |      |        |
| CAUSED BY    |               |           |         |      |        |
|              |               |           |         |      |        |
| COLD FLOWING |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| TEFLON       |               |           |         |      |        |
| SHRINK       |               |           |         |      |        |
| TUBING       |               |           |         |      |        |
| INSULATION   |               |           |         |      |        |
| ON THE       |               |           |         |      |        |
| INTERNAL     |               |           |         |      |        |
|              |               |           |         |      |        |
| WIRES OF THE |               |           |         |      |        |
| SENSOR DUE   |               |           |         |      |        |
| TO IMPROPER  |               |           |         |      |        |
| ASSEMBLY AT  |               |           |         |      |        |
| THE VENDOR.  |               |           |         |      |        |
| THE VENDOR   |               |           |         |      |        |
|              |               |           |         |      |        |
| DEVELOPED A  |               |           |         |      |        |
| TOOL TO      |               |           |         |      |        |
| CORRECT THE  |               |           |         |      |        |
| ASSEMBLY     |               |           |         |      |        |
| OPERATION    |               |           |         |      |        |
| WHICH HAD    |               |           |         |      |        |
| CAUSED THE   |               |           |         |      |        |
|              |               |           |         |      |        |
| FAILURE. ALL |               |           |         |      |        |
| SENSORS      |               |           |         |      |        |
| BUILT BEFORE |               |           |         |      |        |
| THE USE OF   |               |           |         |      |        |
| THE FORMING  |               |           |         |      |        |
| TOOL FOR THE |               |           |         |      |        |
|              |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| INTERNAL     |               |           |         |      |        |
| TERMINALS    |               |           |         |      |        |
| PASSED       |               |           |         |      |        |
| ACCEPTANCE   |               |           |         |      |        |
| TESTS. THE   |               |           |         |      |        |
| CONDITION OF |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| TEFLON       |               |           |         |      |        |
| TUBING IN    |               |           |         |      |        |
| THESE        |               |           |         |      |        |
| SENSORS,     |               |           |         |      |        |
| WHILE NOT    |               |           |         |      |        |
| KNOWN, IS    |               |           |         |      |        |
| ADEQUATE TO  |               |           |         |      |        |
| ASSURE       |               |           |         |      |        |
|              |               |           |         |      |        |
| OPERATION.   |               |           |         |      |        |
| THE SECOND   |               |           |         |      |        |
| PROBLEM WAS  |               |           |         |      |        |
| THE RESULT   |               |           |         |      |        |
| OF           |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
| DRYING OF    |               |           |         |      |        |
|              |               |           |         |      |        |
| THE          |               |           |         |      |        |
| MAST/HARNESS |               |           |         |      |        |
| ASSEMBLIES   |               |           |         |      |        |
| FOLLOWING    |               |           |         |      |        |
| CLEANING     |               |           |         |      |        |
| WITH FREON   |               |           |         |      |        |
| SOLVENTS.    |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| INSTRUCTION  |               |           |         |      |        |
| FOR DRYING   |               |           |         |      |        |
| THE          |               |           |         |      |        |
| ASSEMBLIES   |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| IMPROVED.    |               |           |         |      |        |
| THERE ARE    |               |           |         |      |        |
|              |               |           |         |      |        |
| SUFFICIENT   |               |           |         |      |        |
| TESTS AT THE |               |           |         |      |        |
| VENDOR, MAF, |               |           |         |      |        |
| AND THE      |               |           |         |      |        |
| LAUNCH SITES |               |           |         |      |        |
| TO DETECT    |               |           |         |      |        |
|              |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| FAILURES.    |               |           |         |      |        |
| WHILE THE    |               |           |         |      |        |
| CAUSE OF THE |               |           |         |      |        |
| ORIGINAL     |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
| FAILURES ON  |               |           |         |      |        |
|              |               |           |         |      |        |
| LWT-28 WAS   |               |           |         |      |        |
| CLEARLY      |               |           |         |      |        |
| IDENTIFIED   |               |           |         |      |        |
| AS MOISTURE  |               |           |         |      |        |
| AND THE      |               |           |         |      |        |
| LATER        |               |           |         |      |        |
| FAILURES ON  |               |           |         |      |        |
|              |               |           |         |      |        |
| LWTS 28 AND  |               |           |         |      |        |
| 30 INDICATED |               |           |         |      |        |
| MOISTURE     |               |           |         |      |        |
| RELATED      |               |           |         |      |        |
| PROBLEMS, NO |               |           |         |      |        |
| RESEARCH WAS |               |           |         |      |        |
|              |               |           |         |      |        |
| PERFORMED TO |               |           |         |      |        |
| CHARACTERIZE |               |           |         |      |        |
| THE          |               |           |         |      |        |
| CONDITION OF |               |           |         |      |        |
| THE SENSOR   |               |           |         |      |        |
| INTERNAL     |               |           |         |      |        |
|              |               |           |         |      |        |
| COMPONENTS,  |               |           |         |      |        |
| INCLUDING    |               |           |         |      |        |
| THE          |               |           |         |      |        |
| TERMINALS,   |               |           |         |      |        |
| AS THEY HAD  |               |           |         |      |        |
| NOT AFFECTED |               |           |         |      |        |
| SENSOR       |               |           |         |      |        |
|              |               |           |         |      |        |
| AC           |               |           |         |      |        |
| CEPTABILITY. |               |           |         |      |        |
| THE CAUSE OF |               |           |         |      |        |
| FAILURES     |               |           |         |      |        |
| WERE         |               |           |         |      |        |
| IDENTIFIED   |               |           |         |      |        |
| AS (1)       |               |           |         |      |        |
| IMPROPERLY   |               |           |         |      |        |
|              |               |           |         |      |        |
| FORMED       |               |           |         |      |        |
| TERMINALS    |               |           |         |      |        |
| AND (2)      |               |           |         |      |        |
| MOISTURE IN  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| MAST/HARNESS |               |           |         |      |        |
| DUE TO       |               |           |         |      |        |
| CLEANING     |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESS. THE |               |           |         |      |        |
| FIRST CAUSE  |               |           |         |      |        |
| IS ADDRESSED |               |           |         |      |        |
| IN PROBLEM   |               |           |         |      |        |
| A09653. THE  |               |           |         |      |        |
| ABOVE IS A   |               |           |         |      |        |
|              |               |           |         |      |        |
| VERBATIM OF  |               |           |         |      |        |
| MMC CAPS     |               |           |         |      |        |
| E-093 A      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       |               |           |         |      |        |
| Response/C   |               |           |         |      |        |
| oncurrence** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+

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

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

  --------------- ------------------- ----------------- ----------- ----------- ------------
  **MSFC          **IFA#**\           **Contractor      **JSC#**\   **KSC#**\   **EICN#**\
  Report#**\      \--                 RPT#**\           \--         \--         \--
  A10659                              E-93-1                                    

  **Asmnt         **Asmnt Part        **Asmnt                                   
  Part#**\        Name**\             Serial/Lot#**\                            
  74L4-1          LOX LEVEL SENSOR    391                                       

  **HCRIT CD**\   **FCRIT CD**\       **CAUSE CD**\     **FAIL                  
  \--             1R                  ETP -             MODE**\                 
                                      EI-TEST-INST      UC - UNSAT              

  **Asmnt FMEA**\ **Asmnt FM**\       **FMEA CSE**\     **FMEA                  
  3.1.2.2         2                   A                 SCSE**\                 
                                                        4                       

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

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

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

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

  **MAJOR DESIGN                                                                
  CHANGES**                                                                     

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

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