# Presentation: 157389

## STS OperationsRoot Cause Analysis

- STS-81 Orbiter Processing Facility (OPF)
***SESSION #4 PACKAGE:***
***UNPLANNED TROUBLESHOOTING & REPAIR***
*Carey M. McCleskey/YA-D4*
- June 25, 2002

## Schedule

- Carey M. McCleskey/YA-C

## OPF Cycle Time--Ops & Design Insight

_**OPF Cycle Time--Ops & Design Insight**_

**GENERIC OPERATIONS**

**DESIGN DISCIPLINES**

*Preliminary*

- STS81 Orbiter Processing Facility (OPF)
- Based on cumulative task durations

_**Data File Hyperlink**_

- Carey M. McCleskey/YA-C

## Turnaround Functions Breakdown of Work Content (Based on Cumulative Task Durations Only)

- Carey M. McCleskey/YA-C

## Where is the Time Going in the OPF?(2 of 2)

**Where is the Time Going in the OPF?****(2 of 2)**

- (Based on STS-81 Cumulative Task Durations)

- Carey M. McCleskey/YA-C

## Unplanned Troubleshooting & Repair Breakdownby Design Discipline(Based on Cumulative Task Durations Only)

- Carey M. McCleskey/YA-C

## 6.0 Unplanned Troubleshooting and RepairDetailed Causal Analysis Charts

## 6.0 Unplanned Troubleshooting & Repair 

**6.0 Unplanned Troubleshooting & Repair**** **

**Typical Work Content:**
- 6.1—(PH-M2)Troubleshooting and replacement or acceptance of failed/suspect LRUs
- 6.2—(PH-G)Troubleshooting and repair of leaks
- 6.3—(PH-G) Fluid/pneumatic system decontamination/cleaning
- 6.4—(PH-F/K) Troubleshooting an d repair of electrical shorts/opens
- 6.5—(PH-H) In-place repair/refurbishment of TPS
- 6.6—(PH-H) Structural repair/refurbishment (stop-drilling, doubler installation, mold-impressions and subsequent grinding/polishing, corrosion repair and re-application of protective material, loose bolts
- 6.7—(PH-H/G) Repair of damaged ducts, tubes, hoses
- 6.8—(PH-H) Troubleshooting and repair of mechanical binding, interferences, thermal and pressure seal defects
- Items failed or discovered to have failed during flight
- Items failed due to collateral damage during ground operations
- Items discovered during routine inspections and checkout
- Items discovered during other routine turnaround operations

**Work Content Summary By Design Discipline**

**Definition:**
- Non-routine activity required to recover from discovery of out-of spec conditions. Initial actions include problem isolation and troubleshooting, which may or may not lead to non-routine gaining of access, component repair, component removal and replacement, closeout, and retest

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.1 – Troubleshooting and Replacement or Acceptance of Failed/Suspect LRUs

**6.1 – Troubleshooting and Replacement or Acceptance of Failed/Suspect LRUs**

**Requirements**
- Fluid Requirements
- Fluid samplings required for all fluid integrity breaks
- Leak checks
- Electrical Requirements
- Functional path re-verification
- SCAN Retest required for all electrical integrity breaks

**Contributing & Root Causes**
- Items failed or discovered to have failed during flight
- Items failed due to collateral damage during ground operations
- Items discovered during routine inspections and checkout
- Items discovered during other routine turnaround operations
- Design life requirements inadequate
- Excessive ground power on time due to other turnaround functions
- Excessive and intrusive personnel traffic required for vehicle turnaround—a second order processing effect
- Reliability requirements inadequate
- Seal materials inadequate
- Electrical insulation materials and connector designs inadequate

- Div: PH-M2

**Description**
- Troubleshooting includes isolating problem to source. May include hooking up reg panels, breakout boxes, cross-strapping techniques, special test equipment such as time delay reflectometers (TDR), meggars, mass spectrometers, x-ray devices or other special non-destructive test equipment (NDE). Replacement may include teardown of flight certified vehicle configuration to gain access, special access and handling equipment and hardware such as platforms and device installers. Functional retest operations are required and re-servicing of the affecting system may also be required

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.2 – Troubleshooting and Repair of Leaks

**6.2 – Troubleshooting and Repair of Leaks**

**Requirements**
- TBD

**Contributing & Root Causes**
- TBD

- Div: PH-G

**Description**
- TBD

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.3 – Fluid/Pneumatic System Decontamination/Cleaning

**6.3 – ****Fluid/Pneumatic System Decontamination/Cleaning**

**Requirements**
- TBD

**Contributing & Root Causes**
- TBD

- Div: PH-G

**Description**
- TBD

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.4 – Troubleshooting and Repair of Electrical Shorts & Opens

**6.4 – Troubleshooting and Repair of Electrical Shorts & Opens**

**Requirements**
- Access Requirements for wires and cables throughout the forward compartment’s flight deck, mid deck, airlocks, forward RCS module, mid-body fuselage, wings, gear wells, payload bay, aft propulsion compartment, and OMS pods.
- Most-often requires removal of avionics bay panels, installation of breakout boxes with adequately sized fuses for motor controllers and other high current sources and loads.
- All connector integrity breaks are tracked and functional re-verification required of all electrical paths

**Contributing & Root Causes**
- Excessive number of wire and cable paths
- Excessive number of connectors
- Lack of electrical equipment integration into minimum number of LRUs with minimum number of electrical paths
- Inadequate location of avionics equipment
- Electrical wiring material and connector designs inadequate

- Div: PH-F/K

**Description**
- This process involves locating wire or connector damage or an electrical connection problem. This may involve added operations for system power on, vehicle access to wire and cable trays, installation of breakout or breakthrough boxes (with appropriate fuse configurations, and location/installation of clamp-on ammeters. Also examination of connectors for recessed pins or foreign contamination includes cable splicing repairs, and replacement of wire segments, cable segments and/or connectors and feedthroughs. May also involve inspection of wiring insulation for wear and tear due to brittleness/vibration causing cracks and other failures of the insulation material. Operations may also include relocating cables away from nearby sharp or abrasive frqying sources.

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.5 – In-Place Repair of Thermal Protection Systems (TPS) Hardware

**6.5 – In-Place Repair of Thermal Protection Systems (TPS) Hardware**

**Requirements**
- TBD

**Contributing & Root Causes**
- TBD

- Div: PH-H

**Description**
- TBD

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.6 –  Structural Repair/Refurbishment

**6.6 –  Structural Repair/Refurbishment**

**Requirements**
- TBD

**Contributing & Root Causes**
- TBD

- Div: PH-H

**Description**
- TBD

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.7 –  Repair of Damaged Ducts, Tubes & Hoses 

**6.7 –  Repair of Damaged Ducts, Tubes & Hoses **

**Requirements**
- TBD

**Contributing & Root Causes**
- TBD

- Div: PH-H/G

**Description**
- TBD

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.). 

## 6.8 –  Troubleshooting & Repair of Mechanisms and Thermal/Pressure Seals

**6.8 –  Troubleshooting & Repair of Mechanisms and Thermal/Pressure Seals**

**Requirements**
- TBD

**Contributing & Root Causes**
- TBD

- Div: PH-H

**Description**
- TBD

- Carey M. McCleskey/YA-C

**Notes:**
Definition:
Functions required to receive and prepare reusable space vehicle element(s) for assembly/launch ops

Includes any necessary vehicle “safing”, inspections, troubleshooting/repair, checkout, and servicing (e.g., fluid replenishment, mechanical adjustments, software updates).
Functions also include support operations resulting from the foregoing functions (e.g., gaining access, applying power, controlling temperatures, supplying purge gases, etc.).