# Presentation: 122347

## Section 15

_***Section 15***_
***Reaction Control System***

*** ******. . . Mike McCullough***
*Swales Aerospace *

## Reaction Control System - Agenda

***Reaction Control System - Agenda***

***System Overview***
***Test Verification Matrix***
***Component and Subsystem Level Testing***
***System Level Testing***
***Thermal Balance***
***Internal Leak Checks***
***Status of Launch Site Procedures***
***Status of Launch Site GSE***
***System Readiness***

## Reaction Control System

***Reaction Control System***

## RCS Verification Matrix Items

***RCS Verification Matrix Items***

***Alignment - by analysis***
***Thruster alignment maintained by control of manufacturing tolerances***
***Static Load - Qualification by similarity***
***Proof Pressure - Test***
***Proof Pressure Tests conducted at component and subsystem level***
***Mass Properties - Weighed***
***Weighed at the subsystem level including Zenith Deck***
***Interface Verification - Test***
***Interfaces tested during Spacecraft I&T Process***
***Functional - Test***
***Tested at the component and subsystem level***

## RCS Component Verification

***RCS Component Verification***

***Propellant Tank***
***Determination of Volume***
***Proof Pressure Test***
***Internal and External Leakage Test***
***Radiographic/Penetrant Inspection***
***Visual Inspection and Cleanliness***
***Fill/Drain Valves***
***Inspection and Cleanliness***
***Proof Pressure***
***Internal and External Leakage***
***Operational Cycles***
***Filter***
***Proof Pressure Test***
***External Leakage***
***Bubble Point and D-P ***
***Visual Inspection and Cleanliness***

***Latch Valve***
***Internal and External Leakage Test***
***Operating Cycles***
***Visual Inspection and Cleanliness***
***Vibration***
***Thrusters***
***Hot Fire Performance***
***Proof Pressure, Vibration***
***Internal and External Leakage***
***Pull-In and Drop-Out Voltage***
***Visual Inspection and Cleanliness***
***Pressure Transducer***
***Vibration and Proof Pressure Test***
***Calibration***
***Electrical Characteristics***

## RCS Verification at Primex

***RCS Verification at Primex***

***System Welds***
***Leak Checked, Dye Penetrant and Radiographic Inspection***
***Proof Pressure Checks***
***High Pressure Proof Pressure Test (820 psig) excluding Tank***
***Complete System Proof Pressure Test (480 psig) ***
***Internal Valve Leak Checks***
***Thruster and Latch Valve Seats checked individually***
***Electrical Component Resistance and Isolation Checks***
***System Level Functional Checks***
***Thrusters, Latch Valve, Pressure Transducer and Thermostats***

## RCS Verification

## RCS Checks at Swales

***RCS Checks at Swales***

***Electrical Component Resistance and Isolation Checks***
***System Integration with Spacecraft***
***System Level Functional Checks***
***Pre and Post Integration***
***Thrusters, Latch Valve, Pressure Transducer, Thermostats and Thermistors***
***Thruster Phasing with Gas Flow at 15 psig***

## RCS Environmental Test Program

***RCS Environmental Test Program***

***The EO-1 RCS was fully integrated with the spacecraft for Shock, Vibration and Acoustic Testing***
***RCS Functionality verified during CPT 5***
*Exercised thruster valves*
*Powered catalyst bed heaters*
*Exercised the latch valve*
***RCS Integrity verified during Pressure Transducer Calibration and Valve Leak Checks***
***Thermal Vacuum / Thermal Balance Testing Verified Proper Operation of the RCS Thermal Control System.***
***Temperatures maintained between 18°C - 24°C during cold case tests***
***No heater activity during hot case testing***

## RCS Thermal Control (1)

## RCS Thermal Control (2)

## RCS Pressure Transducer Calibration

***RCS Pressure Transducer Calibration***

***End-to-end Test Performed, Propellant Tank to Ground System Display***
***No Change in Scale Factor ***
***100 psi/volt***
***Offset Adjusted by 1.3 psi***
***No Hysteresis***
***2 Counts Maximum Error ***
***0.2% FS***

## RCS Internal Leak Check

***RCS Internal Leak Check***

***Performed Internal Leak Check on All RCS Valves***
***Series Redundant Valve Seats checked individually***
***Checked At MEOP (320 psig)***
***Total of 9 Valve Seats checked***
***One Failed to Meet ATP Level Performance ***
***Leakage Rate of 13 scc/h GN******2****** will still not permit liquid to pass***
***System Level Leak Rate Criteria Developed - 100 scc/h per valve seat, no more than 130 scc/h combined leakage per thruster***
***System Level Performance is Acceptable***

- All Thrusters Pass revised Leak rate criteria

## RCS Pressure Cycle Log

## RCS Launch Site Procedure Status

***RCS Launch Site Procedure Status***

***Two procedures considered hazardous by NASA/KSC and Air Force 30SW - Review and Approval Required***
***RCS Checkout and Leak Test Procedure SAI-PROC-309***
***Hazardous due to pressures involved***
***Submitted to Range for comment***
***Comments incorporated***
***Ready for Final Range Review & Approval***
***EO-1/SAC-C Propellant Loading Procedure PAC IP-0645***
***Hazardous due to propellants and pressures involved***
***Submitted to Range for comment***
***Comments incorporated - TIM held to discuss details***
***Submitted to the Range for final approval***

## RCS Ground Support Equipment Status

***RCS Ground Support Equipment Status***

***Propellant Loading Cart has been demonstrated using PAC procedure IP-0645***
***Pressure Test Console and all associated equipment has been calibrated and / or proof tested and will remain valid throughout the launch campaign***
***Portable Pressure Monitor Unit (PPMU) has been functionally demonstrated***
***All Export / ITAR issues associated with SAC-C propellant loading have been resolved***
***SCAPE / PHE and Interscan Training will be accomplished shortly after arrival at the launch site***
***Range Safety has reviewed GSE Design documented in the EO-1 MSPSP: SAI-SFTY-019 submitted to the Range 26 Oct 99***
***Previewed by Range Safety Prior to Official Submittal***

## RCS Statement of Readiness

***RCS Statement of Readiness***

***The EO-1 Reaction Control System is Ready for Launch Site Processing ***
***System Integrity, Performance and Functionality has been demonstrated***
***The EO-1 RCS Launch Site Procedures are Ready for Launch Site Operations***
***Procedures have been demonstrated using GSE***
***There are no obstacles to procedure approval by the Western Range***
***The EO-1 RCS GSE is Ready to Support Launch Site Processing***
***Primex is Ready to Support EO-1 / SAC-C Propellant Loading***
_***No Residual Risk for RCS ***_
_***No Red Book Items***_