NASA Technical Memorandum 208545

Research and Technology

1998 Annual Report

John F. Kennedy Space Center
About the Cover

The three technology links to access space are the Launch and Launch

Vehicle Processing Systems, the Payload and Payload Carrier Processing

Systems, and the Landing and Recovery Systems. These technology links

support KSC's Strategic Roadmap to the Future. The center illustration

depicts KSC as the future Spaceport Technology Center.

Cover art: by Caroline Zaffent

Dynacs Engineering Co., Inc.

Engineering Development Contract
NASATechnical Memorandum 208545

Research and Technology

1998 Annual Report

John F. Kennedy Space Center

Research and Technology 1998

Foreword

As the NASA Center responsible for preparing and launching space missions, the

John E Kennedy Space Center (KSC) is

placing increasing emphasis on its advanced technology development program.

KSC is transitioning from an operations to

a spaceport technology development

center. Our technology development

encompasses the efforts of the entire KSC

team, consisting of Government and contractor personnel, working in partnership

with academic institutions and commercial

industry. This edition of the KSC Research

and Technology 1998 Annual Report covers the efforts of these contributors

to the KSC advanced technology development program, as well as our technology transfer activities.

Gale Allen, Associate Director of KSC's Technology Programs and Commercialization organization, (407) 867-6226, is responsible for publication of this

report and should be contacted for any desired information regarding the

advanced technology program.

Roy D. Bridges, Jr.

Director

///'/'

CONTENTS

LIFE SCIENCES ................................................................................................................................................................................. 1

Candidate Crop Evaluation for Advanced Life Support and Gravitational Biology and Ecology ...................................................

Plant Nutrient Delivery Systems .................................................................................................................................................... 4

Plant Lighting Systems ....................................................................................................................................................................... 5

Microbial Ecology of Bioregenerative Life Support Systems for Space Exploration .......................................................................... 6

MECHANICAL ENGINEERING ..................................................................................................................................................... 9

Insulation Testing Using a C_ostat Apparatus With Sh'eve ......................................................................................................... 10

Development of a Multipurpose Cryostat for Insulation Testing ................................................................................................... 12

Cryogenics Test Laboratory ............................................................................................................................................................. 13

Verification Test Article Pn_ject ...................................................................................................................................................... 14

Liquid Nitrogen Feed System and Subcooler for the Cryostat ........................................................................................................ 16

Liquid Nitrogen Flow Test Area ...................................................................................................................................................... 17

Analysis of Nonstationary Signals Using Wavelets for Extracting Resonances ........................................................................... 18

ENVIRONMENTAL ENGINEERING .......................................................................................................................................... 21

Habitat Management and Ecological Risk Assessment Modeling ................................................................................................. 22

Threatened and Endangered Species Monitoring ........................................................................................................................... 24

Pilot-Scale Evaluation of a New Technology To Control NO_ Emissions From Stationary Combustion Sources ......................... 26

Development of an In Situ Technique for Electrokinetic Remedh_tion of Soils Contaminated With Heavy Metals ...................... 28

Enhanced In Situ Zero-Valent Metal Permeable Treatment Walls ................................................................................................. 30

Installation of a New Scrubber Liquor for the Nitrogen Tetroxide Scrubbers That Produces a Comnu'rchTl Fertilizer. ................ 32

Less Toxic Orbiter TPS Rewaterproofing Agent Study .................................................................................................................. 34

Supercritical Air-Powered Environmental Control Unit for SCAPE ............................................................................................ 36

ADVANCED SOFTWARE ............................................................................................................................................................... 37

Mars ISPP Autonomous Controller ................................................................................................................................................ 38

JView Internet Display of Shuttle Real-Time Data Using Java ....................................................................................................... 40

Automation of OMI $9002 for Orbiter Processing ......................................................................................................................... 42

Web-Based Work Tracking Systems ................................................................................................................................................. 44

ATMOSPHERIC SCIENCE ............................................................................................................................................................. 47

Hurricane Wind Sensor ................................................................................................................................................................... 48

Single-Station Accurate Location of Lightning Strikes ................................................................................................................... 50
CONTENTS(cont)

MATERIALS SCIENCE ................................................................................................................................................................... 5.3

Study of Electrostatic Charging and Discharging of Materials in a Simulated Martian Environment .......................................... 54

Investigation of Water Soluble Polyaniline as a Replaceme_# for Chromate Coatings on Alumim_m Alloys ................................ 56

Qual![ied Materials Listings for Plastic Fihns and Adhesive Tapes ................................................................................................. 57

Determination of Sodium in Colloidal Silica .................................................................................................................................... 58

Radiant Heating Facility ................................................................................................................................................................... 60

X-33 Rocket System Fuel Tank Electrostatic Coating ..................................................................................................................... 61

Analysis of Chloropel by Direct Pyrolysis/FTIR ............................................................................................................................. 62

Hydrolytic Degradation of Polyimide Wire hzsulation .................................................................................................................... 64

Epoxy Bonding Agents .................................................................................................................................................................. 66

C_ogenic Insulation Systems for Soft Vacuum .............................................................................................................................. 68

Permanent Antistatic SCAPE Suit Coating .................................................................................................................................... 70

NONDESTRUCTIVE EVALUATION .......................................................................................................................................... 71

Condition Monitoring and Fault Identification in Rotating Machinery (CONFIRM) .................................................................... 72

Evolved Expendable Launch Vehicle (EELV) Hydrogen Testing ....................................................................................................... 74

Thermography for Nondestructive Evaluation and Laser Shearography .......................................................................................... 76

PROCESS/INDUSTRIAL ENGINEERING .............................................................................................................................. 77

Management Support Systems: Goal Performance Evaluation System ....................................................................................... 78

Management Support Systems: Organizational Change Models for Strategic Management ..................................................... 80

Management Support Systems: Methodology To Harvest Intellectual Property at KSC ............................................................ 82

Management Support Systems: KSC Customer Focus Process Development ............................................................................... 84

Management Support Systems: Balanced Scorecard Metrics ......................................................................................................... 86

Management Support Systems: Program Corporate Memory -- a Knowledge Repository for KSC ........................................... 88

Human Factors Engineering: Root-Cause Analysis System .......................................................................................................... 90

Human Factors Engineering: Applications in the Checkout and Launch Contnd System ............................................................ 92

Human Factors Engineering: Human Error Research in Shuttle Processing and Aircraft Maintenance Operations .................. 94

Work Methods and Measurement: Expert System To Generate lob Standards .............................................................................. 96

Work Methods and Measurement: Electronic Portable Information Collection .............................................................................. 98

Work Methods and Measurement: Work Instruction Task Team ................................................................................................. 100

Work Methods and Measurement: Industrial Engineering Decision Support Tool ..................................................................... I02

Generah Center for Applied Research in Industrial and Systems Engineering ........................................................................... I04

Generah K_ Characteristics in Manufacturing and Maintenance .............................................................................................. I06

IV
CONTEHTS(cont)

General: Searchable Answer Generating Environment -- A Knowledge Management System To

Seek Experts in the Florida State University System .................................................................................................... 1_)8

Process Analysis and Modeling: Statistical Process Control Techniques for VarhTble Shuttle System Pc_formaHce Data .......... I10

Process Analysis and Modelinx: Intelligent Assistant for Optimization Modelin X .................................................................... 112

Process Analysis and Modeling: Vish_n Spaceport Model Developme_t ..................................................................................... 114

Process Analysis and Modeling: Intelligent Synthesis Environment .......................................................................................... 1 lo

Process Analysis and Modeling: Virtual Shuttle Processing Model ............................................................................................ 118

AUTOMATION AND ROBOTICS .............................................................................................................................................. I19

Advanced Life Support Automated Remote Manipulator (ALSARM) ......................................................................................... 120

Advanced Payload Transfer Measurement System (APTMS) ...................................................................................................... 122

Automated Umbilical Matin_ Technology ..................................................................................................................................... 124

Payload Ground Handling Mechanism (PGHM) Automath_n ..................................................................................................... 126

Cable and Line Inspection Mechanism (CLIM) ............................................................................................................................. 128

OmniBot Mobile Base .................................................................................................................................................................... 130

Electro-Mechanical Actuator ......................................................................................................................................................... 131

Solid Rocket Motor (SRM) Stacking Enhancement Tool (SSET) .................................................................................................. 132

ELECTRONICS AND INSTRUMENTATION ....................................................................................................................... 135

Space Shuttle Integrated Vehicle Health Management (IVHM) Flight Experiment ..................................................................... 13_

Orbiter Jack and Leveling Operations ............................................................................................................................................. 138

Leak Detection and Visualization Using Laser Sl_earography ........................................................................................................ 140

Support of the Linear Aerospike SR-71 Experiment (LASRE) ........................................................................................................ 142

Ferroelectric Camera for Infrared Fire Imaging ............................................................................................................................... 144

6U VME Universal Signal Conditioning Amplifier (USCA) Interface Module ........................................................................... 14o

Medical Aerot_autical Communications System ............................................................................................................................. 147

Portable Magnetic Field Sensor for Measuring Lightning Effects ................................................................................................. 148

hdine Gas Analyzer for Cryogenic Hydrogen ................................................................................................................................ 15(1

Space Shuttle Orbiter to External Tank Mating Tool ..................................................................................................................... 152

Main Three Contamination Monitoring Cart ................................................................................................................................ 154

Thermographic Inspection of Subsurface Voids in Composite Structures ...................................................................................... /5o

Automatic Calibration Station &r the Universal Signal Conditioning Amplifier (USCA) .......................................................... I58

v/vi

Technology Programs

and Commercialization

introduction John E Kennedy Space Center (KSC) maintains a

vigorous applied development program in support of

its designation as the NASA Center of Excellence for

Launch and Payload Processing. In accordance with

this mission, KSC is establishing its Spaceport Technology Center (STC) that supports the development and

utilization of technologies required to access space.

The STC is composed of three pillars, Launch and

Launch Vehicle Processing Systems, Payload and

Payload Carrier Processing Systems, and Landing and

Recovery Systems. The STC forms the foundation for

KSC's growth into its future role as a development

center for support of the Nation's increasingly commercial space initiatives. Having focused historically

on applied development programs supporting industrial-level operations and processes, KSC technology

and expertise are uniquely suited to support the development of commercial products and services. Both

rapid-turnaround problemsolving and design techniques and long-term investment in critical operations

technology form the core of KSC's research and development programs.

KSC aggressively seeks industry participation in

its research initiatives and proactively seeks to transfer

its innovative expertise and technology to commercial

space initiatives and the nonaerospace commercial

sector. Programs and commercialization opportunities

available to American industry and other institutional

organizations are described in the Technology Programs and Commercialization Office Internet Web site

at http://technology.ksc.nasa.gov.

viiviii

Life

Sciences

he Life Sciences research and technology program at the John

F. Kennedy Space Center (KSC)

primarily supports the development of

advanced technologies for application

in life support for long-term human

habitation in space. The near-term

focus of the Advanced Life Support

(ALS) project is biomass production

improvement, resource recovery development, and system engineering.

Plant Gravitational Biology is investigating lighting and nutrient-delivery

hardware systems, the effects of environmental conditions (i.e., carbon

dioxide and temperature) on plants

growing in flight-type chambers, and

microgravity effects on plant growth

and development. These efforts are

directed toward evaluating and integrating components of bioregenerative

life support systems and investigating

the effects of a space environment on

photosynthesis and carbon metabolism

in higher plants.
Candidate Crop Evaluation for

Advanced Life Support and

Gravitational Biology and Ecology

Rice cv. Ai Nan Tsio (grown in the BPC to determine the effect

of atmospheric contaminants on productivity and suitability

for advanced life support applications)

he primary objective of this task is to define

environmental conditions and horticultural

methodologies to optimize edible biomass production in candidate crop species. This task includes

coordination of NASA-supported tasks at the New

Jersey NASA Specialized Center of Research and

Training (NJNSCORT) for tomato and salad crops,

at the Tuskegee Institute for peanut and sweet

potato, at Utah State University for wheat and

soybean, and at NASA Research Announcement

(NRA) grant recipients for other candidate crops.

This task involves the screening of different cultivars and the compilation of all crop growth data for

inclusion in a crop handbook. This effort will use a

standardized testing procedure for all candidate

crop species that were selected from the Crop

Selection Meeting held at KSC in May 1997. This

task will develop crop management strategies for

reuse of nutrient solutions with a special emphasis

on biologically active organic materials that may

accumulate in the nutrient solution.

The development of a bioregenerative life

support system requires that the horticultural

methodologies and the range of suitable environmental conditions for various candidate crops be

well understood. This is an integrated activity

requiring coordination with several research organizations and ongoing Advanced Life Support (ALS)

tasks in order to maximize the benefit to the ALS

program.

The candidate crop research and technology

development conducted at KSC during 1998 included:

2
Research and Technology 1998

Rice: A large-scale test of rice,

cultivar Ai Nan Tsio, obtained

from Utah State University,

was evaluated in the Biomass

Production Chamber (BPC)

under filtered and unfiltered

atmospheres (see the figure).

Dry Bean: Tests to determine

the suitability of a dry bean

(Etna) and snap bean (Hystyle)

for hydroponic production

under elevated carbon dioxide

conditions were initiated in

collaboration with Cornell

University.

Radish: Tests to determine the

effect of narrow-band spectral

radiation delivered through

light-emitting diodes (LED's)

were initiated in collaboration

with the ALS lighting task.

Chard: Tests were conducted

in collaboration with the

nutrient delivery task to compare the results of the nutrient

film technique to solid substrates, including various

zeolite formulations.

Table Beet: Tests were conducted in collaboration with

the National Research Council

(NRC) on the ability of table

beet to accumulate sodium

(Na) in the leaf tissue.

Spinach: Tests to determine the

effect of narrow-band spectral

radiation delivered through

LED's were initiated in collaboration with the ALS lighting

task.

Sweetpotato: A comparison of

the nutrient management

system developed at KSC was

compared with that of

Tuskegee Institute.

White Potato: Tests were

conducted in collaboration

with the ALS lighting task to

determine the maximum

amount of light that can be

perceived by potatoes during

the dark cycle without inhibiting tuber formation.

Wheat: Tests were conducted

in collaboration with the

resource recovery-water recovery task to determine the effect

of gray water additions to the

nutrient solution on growth

and development of wheat.

Lettuce: Tests were conducted

in collaboration with the

resource recovery-water recovery task, to determine the effect

of gray water additions to the

nutrient solution on growth

and development of lettuce.

Key accomplishments:

• 1997: ALS program Crop

Selection Meeting hosted by

KSC in May. Candidate crop

testing in the BPC test bed of

the Breadboard Project was

completed in December.

• 1998: Nine peer-reviewed

articles were either published

or accepted for publication.

Key milestones:

• 1999: First edition of the

handbook for ALS candidate

crops.

• 2000: 100-percent improvement in productivity of soybean and peanut.

Contact: Dr. J.C. Sager (]ohn.Sagerl@ksc.nasa.gov), J]-G, (407) 853-5142

Participating Organizations: Dymm,w

Corporation (Dr. G.W. St_ttel, Utah

State University (Dr. B, BaugbeeL

Cornell University (D. DeVilh'rs), NRC

(Dr. G. Subbarao), and Tuske_ee

University

8
Plant Nutrient Delivery Systems

uring long-term space missions, a reliable

nutrient delivery system (NDS) is required to

cultivate plants that yield a satisfactory quantity of

edible biomass. Many plant nutrient delivery

systems used on Earth will not function effectively

in space. An effective plant nutrient delivery

system for spaceflight must provide adequate

amounts and uniform distribution of water, nutrient, and oxygen in the root zone, while at the same

time, prevent release of free nutrient solution to the

atmosphere. The ultimate goal is to design a nutrient delivery system that is capable of sustaining

plants for long periods under spaceflight conditions

yet requires minimal system maintenance and

limited demands on crew time. For extended plant

cultivation in space, root-zone media will require

more than just an initial loading of water and

nutrients due to losses from plant evapotranspiration and nutrient uptake. Recent plant testing for

spaceflight has begun to explore active nutrient

delivery concepts in which water and nutrients are

replenished on a continuous basis for long-term

plant growth. At KSC, a series of ground-based

tests are being conducted on various recirculating

nutrient delivery systems that are proposed for

extended space expeditions. The merits of each

nutrient delivery system are largely based upon the

performance of different shoot and root-zone crops

in terms of edible biomass yield from complete

growth cycles. To date for several crop species,

these nutrient delivery systems were characterized

with respect to plant water use, ion uptake, and

nutrient solution pH changes over time.

Key accomplishments:

Developed and tested recirculating nutrient

delivery systems that accommodate a range of

shoot and root-zone crops.

Explored nutrient buffered concepts to simplify

system management, particularly for spaceflight.

Developed a protocol for continuous salad crop

production for the Lunar-Mars Life Support Test

Project Phase III at Johnson Space Center and

conducted comparative studies with salad crops

with zeoponic media, porous tubes, and nutrient

thin-film hydroponic nutrient delivery systems.

Contacts: Dr. W.M. Knott (William.Knott-l@ksc.nasa.gov),

Dr. J.C. Sager, and Dr. R.M. Wheeler; J]-G; (407) 853-5142

Participating Organization: Dynamac Corporation

(Dr. G.D. Goins)

ASTROCULTURE TM (Subirrigated Porous Tube System) Root

Tray With Lettuce Plants at 8, 15, and 22 Days After Seeding in

ARABASKETS Filled With Zeoponic Growing Media

4
Plant Lighting Systems

A major challenge to growing

plants in space will be controlling and supplying sufficient

quantity and quality of light. The

primary objective of this task is to

significantly improve the efficiency of converting electrical

energy into edible plant biomass.

Technology development efforts

are focusing on obtaining light

sources to increase electrical

conversion efficiency of lighting

systems and methods of collecting, transporting, and distribution of photosynthetically active

radiation (PAR) to the crop

canopy. Current research includes investigations of light

sources and methods that deliver

PAR to crop plants that will

produce food for the space inhabitants. Two new sources that

show great promise in delivering

PAR to the plant canopy include

microwave lamps and lightemitting diodes (LED's). Microwave lamps are a new technology

that use microwave energy to

energize an electrode-less sulfurfilled element. It has a spectral

Mature USU-SuperDwarf Wheat Plants Growing Under an Array of

600-Nanometer Red Aluminum-Gallium-Arsenide (GaAIAs) LED's

output similar to other high-intensity discharge sources but uses 20 to

30 percent less energy for comparable output. LED's are a promising

electric light source for space-based plant growth chambers and

bioregenerative advanced life support because of their small mass and

volume, solid state construction, safety, and longevity.

Key accomplishments:

* Completed LED experiments with different food crops to investigate carbon exchange and stomatal conductance differences between light treatments and species.

• Determined low-level irradiance requirements during the dark

period for photoperiodic-induced tuberization of potato.

• Evaluated solid-state magnetron microwave lamp systems.

Contacts: Dr. W.M. Knott (William.Knott-l@ksc.nasa.gov), Dr. J.C. Sager, and Dr.

R.M. Wheeler; J]-G; (407) 853-5142

Participating Organization: Dynamac Corporation (Dr. G.D. Goins, N.C. Yorio,

and G. Koerner)
Microbial Ecology of Bioregenerative

Life Support Systems for Space Exploration

he stability of microbial communities within closed bioregenerative systems is an important

component of overall system

stability due to the risk of human

or plant disease and the reliance on

microbially based reactors for waste

processing. Effective management

of microbial communities requires

an improved understanding of the

complex interactions among microorganisms within Advanced Life

Support (ALS) systems that, in turn,

depend on advancements in rapid

and reliable monitoring techniques.

The purposes of this work are to

develop monitoring tools that allow

for a better understanding of the

microbial risks associated with

bioregenerative life support systems

and to evaluate the suitability of

these tools for use in Moon or Mars

bases. Experiments with prototype

ALS subsystems under development at KSC (e.g., plant production

systems and bioreactors) will assess

the ability of different techniques to

identify changes in the overall

stability of microbial communities

and detect the presence of specific

human or plant pathogens before

the health of the system is adversely

affected. These efforts will help

identify the best approaches for

managing microbial risks within the

systems in addition to evaluating

specific sensor technology.

The primary effort this year

involved the development of

advanced analytical software for a

rapid, simple monitoring method

based on functional profiling of

microbial communities. This

approach, which was developed by

the Dynamac staff, detects respiration of 95 separate carbon sources

using a redox sensitive dye. Initial

testing indicated that the community-level physiological profiles

(CLPP's) can detect small changes

in microbial communities associated

with prototype ALS systems. The

new software enables automated

analysis of the kinetic profile of dye

reduction for each of the 95 separate

carbon sources based on nonlinear

regression. The parameters of the

nonlinear curve (lag, maximum

rate, asymptote, and integral) can be

automatically exported into the

statistical software for subsequent

multivariate analysis.

Another major effort this year

involved assessment of the effects of

bacterial diversity (the number and

relative abundance of bacterial

types) in prototype ALS systems on

the survival of introduced opportunistic human pathogens. Ecological

theory suggests that greater diversity may decrease the likelihood of

potentially deleterious organisms,

such as opportunistic human

pathogens, from growing in microbial habitats within ALS systems. In

collaboration with scientists from

the University of South Florida, the

University of Virginia, and Michigan State University, the relative

survival of opportunistic human

pathogens in systems with different

levels of diversity was evaluated.

Such studies will be important in

defining effective approaches for

inoculating bioregenerative life

support systems.

A third focal area involved the

development of molecular tools for

assessing microbial communities in

bioregenerative ALS. Several

profiling techniques based on the

detection of genetic variation within

bacterial communities were used to

characterize ALS systems, including

Terminal Restriction Fragment

Length Polymorphisms (T-RFLP's),

Randomly Amplified Polymorphic

DNA (RAPD), and Amplified

Fragment Length Polymorphism

(AFLP). All of these methods

involve amplification of genes using

the polymerase chain reaction

(PCR). T-RFLP analyses were

performed at Rutgers University

while the other approaches were

performed at KSC in collaboration

with the University of Virginia.

Key accomplishments (1998):

• Submitted a new technology

report for the CLPP technique.

• Developed the CLPP analysis

software.

• Completed the report comparing

the effectiveness of the different

analytical approaches on classifying microbial communities from

plant production systems and

bioreactors.

• Completed studies evaluating the

effect of community diversity on

the survival of human pathogens

in plant production systems and

bioreactors.

• Completed the analysis and

preliminary report on T-RFLP

analysis of samples from ALS

biomass production systems.

• Established molecular microbial

ecology facilities at KSC and

completed the preliminary

analysis of ALS samples using

RAPD and AFLP.

Key milestones (1999):

• Complete the testing of the CLPP

software, including the publication of the results and the distribution of the product to interested research organizations.

• Expand the molecular microbial

ecology infrastructure at KSC,

including the purchase of a DNA

sequencer.
• Developandtestminiaturizedbiosensorsbased

onbioluminescentbioreporterintegratedcircuit

(BBIC)technologyincollaborationwith the

UniversityofTennessee.

• Completetheinitialassessment of theeffectsof

diversityonthemicrobialrisksassociatedwith

thegrowthof opportunistichumanpathogens.

Contact: Dr. J.C. Sager (lohn.Sager-I@ksc.nasa.gov), /l-G, (407)

853-5142

Participating Organizations: Rutgers University (Dr. L. Kerkhof),

University of Virginia (Dr. A. Mills), University of Temressee

(Dr. G. Saylor), University of South Florida, Michigan State

University, and Dynamac Corporation (Dr. ]. Garland)

Nonlinear

Regression

(x 95)

A

1.6 . _

1.4 |

b

1.2

1

P

0.8

0.6 _o

0.4 "_

1

0,2

0 20 40 60 80 100 120

Monitoring/Control

Rapid

Metabolic

Profiling

Microbial Systems

(Bioreactors, Plants)

Microbial Monitoring for the ALS

7/8

Research and Technology 1998

Mechanical

Engineering

he Mechanical Engineering program

at the John F. Kennedy Space Center

(KSC) supports the development of

technology with analysis, design, and

operation of launch and ground support

equipment for space flight vehicles.

Technology is advanced by a broad

variety of analysis including structural

deflection, dynamic response, stress,

dynamic data requirements, reduction,

and processing. Also included are single

and multiphase flow, cryogenic fluid

flow and storage, thermal insulation

development, and fracture mechanics.

Launch-induced environments are predicted and evaluated with test spectra,

modal testing, portable dynamic data

acquisition, and analysis. Mechanical

Engineering also covers system and

mechanism troubleshooting, component

testing, and development of tools, devices, and systems for fabricating systems and obtaining required cleanliness.
Mechanical Engineering

insulation Testing Using a Cryostat Apparatus With Sleeve

he method and equipment of

testing continuously rolled

insulation materials was developed at the KSC Cryogenics Test

Laboratory in 1998. The testing of

blanket and molded products is

facilitated by the technology.

Materials are installed around a

cylindrical copper sleeve using a

wrapping machine. Large size

insulation test articles that are

6.69 inches inside diameter by 36

inches long by up to 2 inches in

thickness can be fabricated and

tested. The sleeve is slid onto the

vertical cold mass of the cryostat.

The gap between the cold mass

and the sleeve measures 0.035

inch. The cryostat apparatus (see

figure 1) is a liquid nitrogen

boiloff calorimeter system that

.E

E

350 t

300 1

250

i

200 t150 t

100

50i

0 :

CVP=O. 13

CVP=IO

CVP=IO0

CVP= 1000

! "_" CVP=IO000

L,........

Cold Mass Sleeve Layer 2 Layer 4 Layer 8

(0.106") (0.212") (0.424")

Layers

Layer 18

(0.953")

Shroud

Figure 2. Layer Temperature Profiles for Different Vacuum Levels

(Cryostat 1, Test Series Cl14)

enables direct measurement of the apparent thermal

conductivity (k-value) of the insulation system at any

vacuum level between 5x10 -5and 760 torr.

Figure 1. Cryostat Apparatus -- Liquid Nitrogen

Boiloff Colorimeter System

Sensors are placed between layers of the insulation to

provide complete temperature-thickness profiles. The

temperatures of the cold mass [maintained at 77.8 kelvin

(K)], the sleeve [cold boundary temperature (CBT)], the

insulation outer surface [warm boundary temperature

(WBT)], and the vacuum chamber (maintained at 315 K by

the thermal shroud) are measured. Layer temperature

profiles as a function of the vacuum level, as shown in

figure 2, indicate the three ranges (radiation, gas conduction, and convection) of dominant heat transfer modes.

Heat leak through to the ends of the cryostat is reduced to

a negligible amount by the use of liquid nitrogen filled

chambers on the top and bottom. The cryostat apparatus

is supplied with liquid nitrogen subcooled to approximately 77.8 K. The upper guard chamber is kept at a

slightly higher pressure (0.150 +0.050 pound per square

inch differential) than the test chamber to preclude the

condensation of any boiloff gas as it is exiting through the

center of the guard. During the boiloff replenish phase,

10
E

Q.

E

o

r_

8

eL.J_

8OO

700

600

500

400

the guard chambers must be maintained at 0.6 +0.1 pound per square

inch gage for minimum heat leak. Steady-state boiloff conditions are

achieved in 6 to 12 hours after an initial chilldown and thermal stabilization period of at least 24 hours. Typical plots of flow rate and

k-value are shown in figure 3. (Note that the end of the first plateau is

the point at which the replenish of the guard chambers is terminated.)

The vacuum pumping system consists of a combination of

turbopumps and mechanical pumps plus a finely metered gaseous

nitrogen supply for controlling the pumping speed. All measurements are recorded on a National Instrument Field Point data acquisition system using LabView software.

I

---k 1

5 6 7 8 9 10

Time (hours)

Figure 3. Liquid Nitrogen Boiloff Test Perfomance

[Cryostat 1, Test Series Cl14, Run 10 (0.1 micron)]

1t

c

>

(D

-$

E

o._

,

G

O

o

E

12

For this cryostat apparatus, the measurable heat gain

is from 0.2 to 20 watts (which

corresponds to a boiloff flow

rate of 50 to 5,000 standard

cubic centimeters per

minute). The surface area for

a typical 1-inch-thick insulation test article is 969 square

inches. The steady-state

measurement of the insulation performance is made

when all temperatures and

the boiloff flow are stable.

The k-value of the insulation

is directly computed from the

boiloff rate, the cold mass

geometry, and the delta

temperature (WBT-CBT).

Contact: I.E. Fesmire (lames.

Fesmire- 7@ksc.nasa. _ov), MM-]2,

(407) 867-7969

Participatin_ O_anization:

Dynacs Engineerin_ Co., Inc.

(S. Augustynowicz)

11
Development of a Multipurpose Cryostat

for Insulation Testing

A multipurpose cryostat apparatus (Cryostat-2) was

designed and fabricated at the

KSC Cryogenics Test Laboratory.

The apparatus can be used for

testing insulation materials or

cryogenic couplings and seals.

Using custom handling fixtures,

the inner assembly is easily and

quickly removable for installation

on an 18-inch-wide insulationwrapping machine. Alternatively,

the lower thermal guard can be

removed for the testing of flatplate configurations. The stainless-steel inner vessel is a cylinder

5.2 inches in diameter by 10.5

inches in length. The overall

dimensions of the vacuum chamber are 12 inches in diameter and

26 inches in length. The figure

shows the inner assembly on its

work stand adjacent to the

vacuum chamber assembly.

Thermal guarding of each end is

provided by a 5-inch-diameter by

5-inch-long stack of aerogel

composite disks with silvered

film layers between each disk. A

single 1/2-inch diameter by 19-

inch-long fluid feed-through

constructed from thin-wall

bellows and a VCR coupling

allow for liquid nitrogen filling,

venting, and boiloff. The entire

inner assembly is suspended by

three Kevlar threads that are

attached to the flange of the

vacuum chamber. The design

maximum heat leak for the

system is 0.025 watt at a high

vacuum level to 0.050 watt at a

soft vacuum level. The surface

area for a typical 1-inch-thick

insulation test article is 969

square inches. The measurable

heat gain is estimated to be from

0.100 to 40 watts (which corresponds to a boiloff flow rate of 25

to 9,666 standard cubic centimeters per minute). The operating

temperature range is 77 to 373

kelvin while the operating pressure range is lx10 -_torr to 1,000

torr. Cryostat-2 is currently being

used for testing continuously

rolled insulation materials.

Contact: J.E. Fesmire (]ames.Fesmirel@ksc.nasa.gov), MM-J2, (407) 867-

7969

Participating Ore,anization: Dynacs Engineerin_ Co., Inc. (S. Au_ustynowicz)

12
Rosearch and Technology 1998

Cryogenics Test

Laboratory

he KSC Cryogenics Test

Laboratory is located at the

NASA Development Testing

Laboratory (Building M7-581). A

variety of industry, aerospace,

and research activities in the area

of cryogenics and propellant

systems is supported. These

activities include design, fabrication, testing, analysis, field testing, and engineering evaluation.

The laboratory facilities include a

liquid nitrogen flow test area, a

valve test cell, a high-vacuum

workstation, and a liquid nitrogen boiloff calorimeter (Cryostat1). Cryogenic insulation system

development is the main line of

work at this time. The areas of

expertise include:

• Cryogenic insulation systems

• Cryogenic valves and devices

• Connectors, seals, and seal

materials

• High vacuum and leakage

• Design concepts and prototype

fabrication

• Flow testing and analysis

Plans for 1999 include:

• Activation of a multipurpose

cryostat apparatus (Cryostat-2)

Conversion to National Instruments FieldPoint data acquisition systems

Addition of instrumentation

and controls to the flow test

area

• Enhancement of valve test cell

The renovation of a 5,000-

square-foot facility to house test,

checkout, and research activities

is also being planned for completion in late 1999.

Contact: J.E. Fesmire (]ames.Fesmirel@ksc.nasa.gov), MM-J2, (407) 867-

7969

Participating Organization: Dynacs

Engineering Co., Inc. (S. Au_ustynowicz)

13
Mechanical Engineering

Verification Test

Article Project

uring a Shuttle launch, ground support equipment

and structures in the proximity of

the launch pad are subjected to

intense vibration due to acoustic

pressure generated by rocket

exhausts. Continuous monitoring

of launch-critical loads (acoustics)

and simultaneous structural

response (vibration and strain) is

vital for design of new and

proactive maintenance of existing

structures. By the end of 1996,

the collection of acoustic, vibration, and strain data from seven

launches from Launch Pad 39A

was completed on a cantilever

beam, called the Verification Test

Article (VETA). Analyzed data

from these launches was crucial

for validating a random vibration

response model based on the

deterministic approach developed at KSC. A detailed report

outlining the validation methodology was released in 1997.

VETA measurements proved

extremely valuable in characterizing two separate zones of acoustic

loading on the ground support

equipment. Tests showed the

liftoff peak acoustics (between

T+2 to T+7 seconds) are often

overshadowed by a significant

secondary peak (between T+10

and T+17 seconds). This second

peak, the "plume impingement"

peak, is directly attributable to

the Shuttle roll maneuver. ]he

liftoff peak is composed primarily

of high-frequency components

above 50 hertz. The secondary

plume impingement effect contributes significantly to the

structural resonances because of

its low-frequency composition.

Limited launches and failed

sensors restricted analysis efforts

to evaluate effects of launch

trajectory, multimodal contribution, and effects of higher modes

on the overall response and

prediction confidence intervals.

Key accomplishments:

1998: Several lectures on

rocket noise and vibration were

presented at the Universities of

Perth and Adelaide in Australia. The acoustibox concept

was tested on several launches

and results were positive. To

record launch-induced acoustics, a totally self-contained

acoustibox (operates on batteries) was installed on the launch

pad and has (1) the capability

to "wake up" prior to launch

and to store the recorded data

and (2) postlaunch retrieval

software.

Key milestone:

1999: Efforts will be aimed

toward developing a totally

indigenous unit for use by KS(

operations, in line with NASA

policy of "better, faster,

cheaper."

Contact: R.E. Caimi (Raoul.Caimil@ksc.nasa.gov), MM-]2, (407) 867-

3748

Participating Organizations: Dynacs

Engineering Co., Inc. (R.N. Maq_asahayam), United Space Alliance

(E Walker), and Information Dynamics

Inc. (0. Varosi and L. Albri&,ht)

14
Research end Technology 1998

Self-Contained Acoustibox on the Launch Pad

15
Mechanical Engineering

Liquid Nitrogen Feed System and Subcooler for the Cryostat

A special liquid nitrogen feed

system for the insulation test

cryostat (Cryostat-1) was designed and constructed at the

KSC Cryogenics Test Laboratory.

The cryostat requires a stable

supply of liquid nitrogen near the

normal boiling point (77.36 kelvin

at atmospheric pressure) for run

times of up to 12 hours. The feed

system consists of an adjustable

pressure phase separator (APPS)

unit, a 1/2-inch vacuum-jacketed

pipeline with cryo-vent devices,

and a subcooler unit. The APPS

unit maintains a supply of liquid

nitrogen saturated at 19 +1 pound

per square inch gage and allows

insulation testing to be performed

independent of other tests using

the main supply dewar. The

subcooler unit provides 11 +0.5

pound per square inch gage

liquid nitrogen conditioned at

approximately 77.8 kelvin to the

cryostat inlet manifold. The

liquid reservoir of the subcooler

consists of a stainless-steel vessel

10.75 inches in diameter by 24

inches tall that is enclosed by an

outer shell. The annular space is

filled with excess liquid from the

inner vessel and vented to the

atmosphere. The levels in the

liquid reservoir and outer shell

are maintained by an adjustment

of a control valve from the main

supply line. Tube fittings on the

top allow for simple installation

or removal. The exposed fittings

are quenched in the liquid nitrogen overflow from the outer shell

to eliminate a heat leak. An

overall view of the subcooler unit

is shown in the figure.

Contact: J.E. Fesmire (]ames.Fesmire1@ksc.nasa.gov), MM-J2, (407) 867-

7969

16
Liquid Hitrogen Flow

Test Area

he liquid nitrogen flow test

area was activated at the KSC

Cryogenics Test Laboratory. The

area includes a 6,000-gallon

dewar that supplies liquid to lowflow and high-flow test sections.

The low-flow section, fed by an

adjustable pressure phase separator and a 1/2-inch vacuumjacketed pipeline, can provide 0

to 100 pounds per square inch

gage at up to15 gallons per

minute. An inline density meter

built by Dynacs Engineering Co.,

Inc., is included to monitor flow

conditions and transients during

a test. The high-flow section

includes run piping with 3-inch

and 6-inch diameter test sections

that are adaptable to any size

component up to a 12-inch nocninal pipe size. The high-flow

section provides flow rates of up

to 1,000 gallons per minute at 250

pounds per square inch gage.

Instrumentation and controls are

tailored to the requirements for a

given test using the new National

Instruments FieldPoint equipment and LabView software for

the data acquisition system. An

overall view of tile test area is

shown in the figure.

Contact: I.E. Fcsmirc (]ames.Fcsmirc1@ksc.nasa._ov), MM-J2, (407) 867-

7969

Participating Orga,ization: D}/,acs

En,_,,incerinv Co., Inc. (Z. NaVy)

17
Mechanical Engineering

Analysis of Nonstationary Signals Using

Wavelets for Extracting Resonances

o determine the frequency

composition of a signal for

mechanical analysis, signal

processing tools such as the Fast

Fourier Transform (FFT) and the

Short Time Fourier Transform

(STFT) are used. However, the

use of Fourier analysis for frequency component extraction is

restricted to band-limited stationary signals. Thus, small transients may not be detected due to

a smoothing effect of the FFT, or

the FFT spectrum may be

smeared due to frequency ramping or discontinuities in the

signal. Space Shuttle launchinduced acoustic and vibration

signals can be classified as

nonstationary random and

exhibit features of a very short

duration transient. Various

techniques have been employed

to overcome the limitations of the

FFT for nonstationary data.

These techniques include windowed Fourier Transform (Gabor

or STFT), synchronous sampling

to remove revolutions-per-minute

ramp effects, Wigner-Ville analysis, and wavelet analysis.

Wavelet analysis is based on a

fundamentally different approach

in which the signal is decomposed on a series of special-basis

functions called wavelets, which

are localized in time and have an

integral value of zero. Wavelet

analysis can pinpoint local phenomena in nonstationary signals

and provide the capability to

compress or de-noise a signal

without appreciable degradation,

while preserving both highfrequency and low-frequency

components. Wavelet techniques

can be extended to detect and

analyze impending bearing

failure in rotating machinery (see

the graphs). Planned developments will use the MATLAB

platform, a commercially available software.

Key accomplishments:

1998: The wavelet analysis

methods were applied to Space

Shuttle launch-induced acoustic and vibration signals to

highlight key low-frequency

components affecting structural resonance. The wavelet

analysis methods were applied

to liquid oxygen pump rotating

machinery analysis for condition monitoring, machine

diagnostics, and bearing fault

detection and prediction.

Key milestones:

A comparative evaluation of

the FFT and wavelets is

planned. Effectiveness of

different wavelet techniques

will be studied.

Contact: R.E. Caimi (RaouI.Caimil@ksc.nasa.gov), MM-J2, (407) 867-

3748

Participating Organizations: Dynacs

Engineering Co., Inc. (R.N. Margasahayam) and Information Dynamics,

Inc. (0.1. Varosi)

18
Rosearch and Technology 1998

!

-- Stationary Failure

Onset of

Nonstationary

Failure

, _ Steady State

Before Failure

Time Domain Signal for hnpending Bearing Failure

Malvar DW-IUseful During

Nonstationary

Interval

LKL;

hub.-.--

FFT Not

Useful During

Nonstationary

Interval

Comparison of D WT and FFT

_K.&.,,

_a...k_ _

19/20

Research and Technology 1998

Environmental

Engineering

he John F. Kennedy Space Center (KSC) is located on the Merritt

Island National Wildlife Refuge. Therefore, KSC has always approached its mission with an awareness

of the impact on the environment. As a

society, Americans have become increasingly concerned about the effect their actions have on the environment. With this

awareness, KSC has increased its efforts to develop technologies

that are environmentally oriented and proactive.

The projects presented this year cover a wide range of environmental technologies. An innovative method of scrubbing emissions from boilers is being developed that will reduce the amount

of pollutants produced by power plants that burn fossil fuels. Also

under development are methods to clean solvent-contaminated

groundwater using in situ techniques that could reduce cleanup

costs significantly.

Another area of interest is the geographical information required

to make environmental decisions. A development is continuing

to integrate geographical databases that provide easy access to the

data used for planning purposes.

A project to plan controlled burns is also underway. The burns are

an important tool for restoration of endangered species habitat and

reduction of the danger of wildfire in operational areas.

21
Environmental Engineering

Habitat Management and Ecological Risk

Assessment Modeling

Provide information and

methods to reduce the potential for wildfires at KSC.

onitoring and definition of habitat quality for

biodiversity, threatened and

endangered species, and environmental risk assessment require

state-of-the-art information

collection and analysis capabilities to minimize costs. Land

management practices in many

ecosystems, including KSC, are

based on controlled burning for

habitat enhancement and reduction of wildfire fuels. Available

ecosystem models and fire and

smoke models provide some

guidance; however, no system

currently exists that incorporates

these tools with operational

schedules such as a payload or

vehicle processing system, realtime meteorological data, and

remote sensing data for use in

environmental decision support

and risk assessment.

The approach to this project

involves development of a diverse set of information tools

including rule-based expert

systems, numerical models, time

series analysis, and fusion of a

variety of data collection systems

and databases to enhance the

decision process. The project

will:

Provide data and information

to optimize the management of

resources at KSC and the

Merritt Island National Wildlife Refuge.

Incorporate NASA remote

sensing and advanced GIS

technology into local-scale,

decisionmaking processes.

Enhance NASA's capabilities to

comply with Federal and State

environmental laws such as the

Endangered Species Act.

Key accomplishments:

• 1996: Obtained a high spectral

resolution image of the KSC

area using the NASA AVIRIS

sensor. Initiated development

of a deterministic model for

estimating plant canopy biochemical and biophysical

characteristics.

• 1997: Conducted an experimental control burn at KSC in

association with the U.S. Fish

and Wildlife Service, Los

Alamos National Laboratory,

United States Air Force, and

Los Angeles County Fire

Department to develop data on

fire spread, intensity, and

smoke production. Obtained

high spatial resolution images

(1 to 2 meters) of KSC. Obtained field measurements of

plant canopy biophysical and

biochemical features and plant

canopy and leaf spectral

characteristics for model

development and parameterization.

• 1998: Developed a Web-based

decision support tool that

integrates payload schedules,

Shuttle operations schedules,

facility locations, and controlled burn prescriptions to

minimize conflicts and maximize management of wildfire

fuels and endangered wildlife

habitat. Integrated plant

biophysical features such as

leaf area, leaf angle distribu22
tion, canopy closure, canopy height,

and bottom reflectance into a two-flow

irradiance model for radiative transfer

in plant canopies.

Key milestones:

• 1996: Initiated GIS database integration in Oracle and development of

image processing methods for use of

high spectral resolution data in wildlife

habitat mapping. Presented two

papers at the Eco-Informa Conference

in Orlando, Florida, on remote sensing

modeling in plant canopies.

• 1997: Coordinated a multiagency

experimental controlled burn to obtain

data on fire and smoke behavior in

coastal environments.

• 1998: Enhanced communications

between the U.S. Fish and Wildlife

Service and NASA Shuttle and Payloads Operations through development

of a Web-based Schedule Analysis

System for controlled burns at KSC.

Contact: Dr. W.M. Knott (William.Knottl@ksc.nasa._ov), ]J-G, (407) 867-7411

Participating O_xanization: Dynamac

Corporation (R. Schaub and C. Hall)

Controlled Burn

I_ C-21/36

li_k F

VAB

OPF

Pad B

Pad A

SSPF

O&C

PSB

TCF

MPPF

SAEF-2

MOSB

PHSF

VPF

RTGF

Hgr AE

Buffe r- 1/2 mile

SLF

VAB

Pad B

Pad A

KSCIA

CCASIA

V Smoke Management

Area

Example Output From the Web-Based Decision Support Tool Showinf

lnt¢_,ration of Fire Management amt KSC Operational Areas

• Individual controlled burn events are plotted on separate maps.

• Only facilities with potentially critical smoke-sensitive operations are plotted.

• Half-mile buffer zones are plotted aroumt each potentially

critical smoke-sensitive operation to facilitate viewin_ _fithe

large-scale map.

• Shuttle operations occur within the Shuttle Landing Facility,

Vehicle Assembly Buihting, and launch pad regions.

• Payload operations occur within the KSC Industrial Area and

Cape Canaveral Air Station Industrial Area.

• The smoke management area defines the region in which smoke

may occur based on desired wimts (smoke may also occur

downwind of this area).

23
Threatened and Endangered Species Monitoring

he habitats on KSC represent

an area of biological diversity

unsurpassed among Federal

facilities. Under the Endangered

Species Act and the National

Environmental Policy Act, all

operations require evaluation and

impact minimization. Approximately 100 wildlife species on the

Merritt Island National Wildlife

Refuge are vulnerable to extinction. Monitoring focuses on

combining field and remote

sensing data with predictive/

interpretive models on marine

turtles, gopher tortoises, indigo

snakes, wading birds, shorebirds,

scrub jays, beach mice, and

manatees. These studies contributed to more than 20 scientific

journal articles and were used to

develop rangewide species

recovery efforts.

The influence of habitat on

habitat use and demographic

success is quantified at different

spatial scales. Monte Carlo

simulation models are used to

quantify the influence of habitat

quality, population size, and

catastrophes on populations.

Declining habitat quality was

found to be a critical factor

influencing extinction risk, so

more frequently prescribed fires

are needed.

Key accomplishments:

1991: Developed habitat maps

of the most important areas at

KSC for scrub jays, wading

birds, and other species.

• 1992: Developed a scrub

restoration and monitoring

program.

• 1993: Developed a wetlands

restoration program plan.

• 1994: Developed a KSC biological diversity evaluation

summary.

• 1995: Developed techniques to

map habitat suitability.

• 1996: Developed models to

predict demographic success

using maps.

• 1997: Tested the ability of

maps and models to predict

populations.

• 1998: Developed rapid assessment tools for environmental

managers.

Key milestones:

• 1995: Population and habitat

status trends summarized for

gopher tortoise, wading birds,

and scrub jays.

• 1996: Development of scrub

jay population recovery strategy.

• 1997: Biological diversity

prioritization analyses published.

• 1998: Habitat analysis procedures published.

Contact: Dr. W.M. Knott (William.

Knott-1 @ksc.nasa._ovL JJ-G, (407) 867-

7411

Participating Organizatio,: Dynamac

Corporation (D.R. Brei,i,ger)

24
Research and Technology 1998

Height Classes of Florida Scrub Jay Territories at KSC From 1988 to 1997

(Habitat classes are used for rapid assessment of scrub habitat quality.)

Height Class Description Minimum Mapping Units

Short Entire territory was <120 centime- No patch taller than 120 cm was

ters (cm) tall >0.4 hectare (ha) (1 acre)

Short/optimal mix

Tall mix

Territory was a mix of short (<120

cm) and optimal scrub (120 to 170

cm tall) and had no tall scrub

(>170 cm tall)

Territory was a mix of tall scrub

(>170 cm) and short and/or

optimal scrub

At least 1 patch of optimal scrub

was >0.4 ha and at least 1 patch of

short scrub was _>0.4 ha; no patch

of tall scrub was _>0.4 ha

At least I patch of tall scrub was

_>0.4 ha; at least 1 patch of short or

optimal scrub was _>0.4 ha

Tall Entire territory was >170 cm tall No scrub <170 cm tall was ->0.4 ha

Florida Scrub Jay Demography and Densities Among Scrub Height Classes

Fledglings/pairs

Juveniles/pair

Yearlings/pair

Breeder survival

Fledgling survival

Demographic

perfoffnahce**

Family size

Territory size (ha)

Density (jays/ha)

That Resulted From Fire Patterns at KSC From 1988 to 1997

(Values in parentheses are the mean and sample sizes.)

All Short

(<120 cm tall)

1.05 (63)

0.46 (65)

0.23 (65)

0.76 (131)

0.20 (66)

-0.28 (65)

2.66 (65)

7.37 (65)

0.51 (65)

Short/Optimal

Mix

1.41 (101)

0.88 (103)

0.61 (103)

0.81 (212)

0.43 (143)

0.21 (103)

3.05 (103)

9.15 (103)

0.45 (103)

Tall Mix

0.99 (178)

0.41 (181)

0.28 (181)

0.80 (366)

0.28 (178)

-0.16 (181)

2.86 (181)

6.25 (181)

0.62 (181)

All Tall

(>170 cm tall)

0.25 (36)

0.08 (37)

0.08 (37)

0.77 (77)

0.33 (9)

-0.41 (37)

2.40 (37)

4.69 (37)

0.78 (37)

Unburned

Archbold*

1.58

0.8

0.36

0.72

0.23

Optimal

Archbold*

1.97

1.23

0.68

0.79

0.31

3.00

9.00

* Woolfenden and Fitzpatrick (1984 1991)

** Yearling production; breeder mortality

25
Environmental Engineering

Pilot-Scale Evaluationof a Hew TechnologyTo Control HOx

Emissions From Stationary Combustion Sources

Injection

Reaction Zone

I Samp=es I

Figure 1. Conceptua/

s a result of the implementation of the Clean Air Act

Amendments of 1990, parties

responsible for stationary combustion sources emitting nitrogen

oxides (NOx) are looking for

methods to meet regulatory

requirements. NASA entered into

a 3-year cooperative agreement

with the University of Central

Florida (UCF) to perform a pilotscale study of a new control

technology for NO× emissions

from industrial-sized boilers (see

figure 1). Hydrogen peroxide is

injected into the flue gas stream

to oxidize the NO× to nitrogen

acids. This step is followed by

liquid scrubbing, which produces

a nitrogen-rich, water-based

waste stream. This study was a

scale-up on the order of 1,000

times from lab-scale studies

previously conducted at UCE A

scale-up from this pilot plant to a

m

Exhaust I

Design of the System

power plant would be on the

same order of magnitude. NASA

and UCF are joined by industry

partner EKA Chemicals, Inc., on

this research and development

project. EKA Chemicals brings to

the project extensive engineering

expertise on various hydrogen

peroxide applications.

A data acquisition system

using a personal computer and

LabView software (see figure 2) is

tied into the entire system to

allow for control, automatic

emergency shutdown, and recording of 21 points at a rate of 1

sample per second. Over 100

tests were conducted during the

past year resulting in over 6

million data points.

The primary result from the

first phase of this study is shown

in figure 3. A feasibility study

conducted by UCF researchers

indicated this technology would

be competitive with technology

(selective catalytic reduction)

currently available to power

plants if nitric oxide (NO) conversion efficiencies above 90 percent

could be achieved at a hydrogen

peroxide feed rate of 1.37 moles

of hydrogen peroxide per mole of

NO converted (to acid). The

Phase I results of this technology

show 96 percent NO conversions

were achieved at a molar ratio of

1.0.

Key accomplishments:

1997: Phase I design, installation, and preliminary testing

complete.

1998: Phase I testing, data

analysis, and reports complete.

Presentations at the Air and

Waste Management

Association's Pacific Northwest and Southern States

section meetings.

Key milestones:

• 1999: Present Phase I results at

the Air and Waste Management Association's annual

conference. Phase II design,

testing, data analysis, and

reports to be completed.

Contact: M.M. Collins (Michelle.

Collins@ksc.nasa.gov), J]-D, (407) 867-

4270

Participating Organizations: University

of Central Florida (Dr. C.D. Cooper; Dr.

C.A. Clausen, 111;and Dr. I.D. Dietz)

and EKA Chemicals, Inc. (J. Temtey and

D. Bonis/awski)

26
NOXEmissionReduction EventTest Counter _ Vd¢ (5=On, 0=Ofl IDatanl..... ip,...m. I I Record I

A The event indicator

has been depressed I°B times during this run. i |

I I I sT°P I

I I Control Panel FC-1 FC-2 FC-3 FC-4 FC-5 FC-6

I I _ _ Input0400 :oL_.llO0.O0 i;iooo Iflooo plooo i:-ioooo plooo I

_ v for percentage 'V I ..... *

[ I ave Act NOX Flow SO2 Ftow Not Used Fan Speed Natural ALARMS

I I . ' % of FS. %olFS %ofFS Gas

I t:l _ DegF _) T5 De F F a .....

'_L L_ ] _ y 4 5 6 G _ _ _ _ "Fll_lc_ SFDM

_1 _iL'Ni_ " 6 1 ;'1_12_),_ _ T_8" _ [_ ? FAN Vent tA OutSide

I I/ i

NOX Flow

Wl _ Ibs

BOILER

_gpm

Y

L

Fig.re 2. Front Pane/of the PC Software Used To Collect Data From Points in the S_,stem

100%

g

g

o

o

Z

oe

80%

60%

400,%

20%

0°,%

A , , • ....

• •

4, %NO Conversion

0.0 0.5 1.0 1.5 2.0 2.5

H202:NO

Figure 3. Percent NO Conversions,for Inlet NOx of 400 plmt and

Tests ('omhtcted Within the Teml_erature Range q/'912 to 939°F

27
J

Ev

C

.o_

C

0

C

o

0

Development of an In Situ Technique for Electr0kinetic

Remediati0n of Soils Contaminated With Heavy Metals

ecause of the costs and limita- tions of the current remediation methods, considerable effort

is being directed toward the

development of in situ treatment

methods. An innovative method,

electrokinetic remediation, offers

a way for soils with a variety of

hydraulic conductivities to be

remediated in situ. Electrokinetics has been used for decades to

remove water from soils and in

the oil recovery industry, but in

situ applications to remediate

contaminated soils is new. Electrokinetics is a process that

separates and extracts certain

heavy metals, radionuclides, and

organic contaminants from

saturated or unsaturated soils,

sludges, and sediments. A lowintensity direct current is applied

across electrode pairs that have

been implanted in the ground on

each side of the contaminated soil

mass. The electrical current

120

Effect of Potential Effluent Concentrate

(01/26/98 to 01/29/98, 20 V, 55 mA)

---- lead _ zinc I

i "I

0 20 40 60 80

lOO

8o

60

40

20

0

Time (hours)

Lead and Zinc Concentrations in Effluent With Applied Voltage

causes electroosmosis, ion migration, and electrophoresis, which

removes bound ions from solid

particles and moves the aqueous

phase contaminants in the subsurface from one electrode to the

other.

Laboratory studies at the

University of Central Florida

have been used to evaluate the

efficiency of this process and its

likelihood of success at KSC.

Initially, studies were carried out

in a 12-inch-long, 4-inch-diameter

Plexiglas cell that was loaded

with 2,000 grams (dry weight) of

a synthetic soil mixture. The soil

was spiked with lead (Pb) and

zinc (Zn) to concentrations up to

2,000 milligrams per kilogram of

soil, then the metals were immobilized using a sodium hydroxide

rinse. Graphite electrodes (placed

either perpendicular or parallel to

the flow) were used with applied

voltages ranging from 15 to 48

volts and a constant current of

100 milliamperes. A conditioning

solution of dilute lactic (0.1 to 0.5

percent) acid was introduced at

the anode and removed at the

cathode. This conditioning fluid

served as an additional liquid for

current flow and to keep the pH

in an acceptable operating range

near the cathode region.

It was shown from these

experiments that both Pb and Zn

were quickly removed to 10

percent of their original concentrations (within 7 days). A comparison of the ion removal effi28
ciency with and without an

applied voltage is shown in the

figure. As voltage was applied,

the concentrations of Pb and Zn

in the effluent solution increased.

In another experiment, removal

efficiency was shown to be

dependent on the addition of

lactic acid. With only water as a

conditioning fluid, extraction

efficiency was low but, with the

introduction of a very low concentration of lactic acid (as low as

0.1 percent), the ion concentrations in the effluent solution

began to increase dramatically.

The effects of electrode position were studied by constructing

a rectangular cell and positioning

two pairs of electrodes at different distances. Experiments have

shown that electrodes positioned

18 to 22 inches apart provided

effective movement of ions in

various soil types. This information was used to develop the

most efficient electrode arrangement for a field application. A

hexagonal array of anodes with a

single cathode placed directly in

the center was found to yield

efficient removal of metal ions

while reducing the number of

pumping stations (cathodes)

required.

Additionally, a telephone line,

an extension cord, and various

types of weathered pipe were

buried in the soil for a period of 3

weeks to determine if the process

would interfere with communications or other subsurface electrical conduits. During this time,

there was no disruption of communication or electrical use and

the pipes showed no pitting.

Key accomplishments:

• June 1998: Laboratory studies

were completed.

• August 1998: Field demonstration site was selected at KSC.

• September 1998: Field design

was completed.

Key milestone:

Laboratory data used to design

the field demonstration was

completed, with field implementation to begin in January

1999.

Contact: ].w. Quinn (lacqueline.

Quinn-1 @ksc.nasa.y, ov), JI-D, (407)

867-4265

Participating Or wnization: University

of Central Florida (Departmc_lt q(

Chemistry and Departments of Civil amt

Environmental Engineering)

29
Enhanced In Situ Zero-Valent Metal

Permeable Treatment Walls

hlorinated solvents have been

widely used by NASA and

others in the aerospace industry

for over three decades. They

have primarily been used as

nonflammable degreasers and

dryers for electronic parts. Historically, the disposal practices for

spent chlorinated solvents included discharges to surface

water and groundwater. It is,

therefore, not surprising to find

groundwater solvent contamination at 791 of the 1,300 National

Priority List sites.

To date, the most commonly

used treatment method for the

cleanup of chlorinated solvents

has been the pump-and-treat

method. With this method, the

groundwater is pumped to the

surface, and the contaminants are

either oxidized or removed with

an air stripper. Although the

pump-and-treat method was

originally thought to be a compeG7

Contaminant Plume Contaminant-Free

Water

Confining Unit

Reaction

Wall

Permeable Treatment Wall

tent remediation tool, it has

shown itself to be most effective

in groundwater plume capture

and containment. In general, it

can be said that the significant

operation and maintenance costs

associated with pump-and-treat

systems eliminate this remediation technique for large-scale

cleanups.

Within the last 5 years, a

substantial amount of research

focused on the use of zero-valent

metals to catalytically enhance

the abiotic degradation of chlorinated solvents. Of the zerovalent metals available and tested

(iron, cobalt, zinc, and nickel

prophyrins), iron is the most

attractive due to its low cost and

availability. With this technology,

iron filings are mixed with sand

and placed below the land surface and downgradient of the

contaminant source. Natural

groundwater gradient transports

the contaminated groundwater

through the iron/sand permeable

treatment wall. As the contaminant comes into contact with the

iron filings, catalytic degradation

of the chlorinated species begins

with what appears to be the

simultaneous oxidation of iron by

water and the subsequent reductive dechlorination of the contaminant.

In March 1998, a 40-foot-long

and 4-foot-wide permeable

treatment wall was installed at

Launch Complex 34 at Cape

Canaveral Air Station to a depth

of 40 feet below land surface. The

demonstration project tested a

new construction technique that

uses deep-soil mixing with vibroinstallation as a method for

getting the reactive iron into the

3O
subsurface. Preliminary analytical results indicate that

contaminants such as cis-l,2 dichloride have dropped

from an inlet concentration of greater than 13,000 _tg/L to

less than 60 _tg/L, which is the Florida drinking water

standard.

Key accomplishments:

• September 1997: Patent application submitted.

• August 1997: Field-scale design completed.

• March 1998: Construction completed.

Key milestones:

Wall monitoring will continue over the next year with

particular attention on contaminant degradation and

groundwater geochemistry changes.

Ultrasound field testing will be conducted on the wall

during the next year (see the KSC Research and Technology 1997 Annual Report), and a tracer study will be

initiated to examine groundwater flow patterns.

Contact: I. W. Quinn (lacqueline.Quinn-1 @ksc.nasa.Rov), ]J-D,

(407) 867-4265

Participating Organization: University of Central Florida

(Departments of Civil and Environmental Engineering and the

Department of Chemistry)

Fieht Application qflDeep Soil Mixing

Field Application of Vibroinsulation

31
Installation of a New Scrubber Liquorfor

the Nitrogen Tetroxide Scrubbers That

Produces a Commercial Fertilizer

ASA, in conjunction with

Dynacs Engineering Co.,

Inc., and United Space Alliance, is

installing a prototype of the new

scrubber-liquor control system

that converts nitrogen tetroxide

(the hypergolic oxidizer) to a

fertilizer. The fertilizer produced

by this process will be used on

the citrus groves at KSC. This

project is in Phase V of a fivephase program to comply with

Executive Orders 12856 and

12873, the Right-to-Know Laws,

and the Recycling and Waste

Prevention Law. Hypergolic

propellants are used in spacecraft

such as the Space Shuttle, Titan

IV, Delta II, and other vehicles

and payloads launched at KSC

and Cape Canaveral Air Station.

Monomethylhydrazine (MMH),

nitrogen tetroxide (N204 or NTO),

and hydrazine (N2H 4 or HZ) are

the main propellants of concern.

Fueling and deservicing spacecraft constitute the bulk of operations in which environmental

emissions of nitrogen oxide (NO)

occur. The scrubber liquor waste

generated by the oxidizer scrubbers (approximately 311,000

pounds per year) is the second

largest waste stream at KSC. The

disposal cost for this oxidizer

scrubber liquor waste is approximately $0.227 per pound or

$70,600 a year.

The new process will convert

the scrubber liquor to a highgrade fertilizer (see the flowchart). The process reacts N204

with hydrogen peroxide and

potassium hydroxide and produces potassium nitrate, a major

ingredient in commercial fertilizers. This process avoids the

generation of the hazardous

wastes, which occurs when

sodium hydroxide is used as the

scrubber liquor. A patent application that covers the process has

been filed with the U.S. Patent

and Trademark Office.

A feature of the new process

is lower NO emissions, since the

new scrubber is more efficient at

capturing nitrogen tetroxide than

the current scrubber liquor. For

example, when the two scrubber

liquors were compared under

similar test conditions, the emissions from the new scrubber

liquor were only 1 to 10 percent

of the emissions from the current

scrubber liquor. A major effect of

lower NO emission will be to

reduce the size of the area around

the oxidizer scrubbers that must

Current Process

Nitrogen

Tetroxide

Oxidizer

Scrubber

Sodium

Hydroxide

Byproducts are a

hazardous waste that

must be disposed of

Sodium Hydroxide

Sodium Nitrate

Sodium Nitrite

Nitric Oxide

Water

Modified Process

Nitrogen

Tetroxide

Water

Hydrogen i I

Peroxide Control

System

J

I I

...... I

Oxidizer

Scrubber

t

Potassium

Hydroxide

Byproduct is a high-grade I I

fertilizer that can be Potassium Nitrate

sprayed on the ground

32

Process Converting Nitr%,en Tetroxide Wastes to Potassium Nitrate, a Commercial Fertih'zer
corrected during the current installation by changing the point of addition of the reagents.

In summary, this change in the scrubber liquor

has eliminated the second largest hazardous waste

stream at KSC and produced a product that is

approved for application as fertilizer to the lawns

and citrus groves at KSC. This new scrubber liquor

is a 15-weight-percent potassium nitrate solution

with 0- to 1-weight-percent hydrogen peroxide and

a pH of 7. The system is more efficient and less

expensive than the current 25-weight-percent

sodium hydroxide, when all factors including waste

disposal, fertilizer replacement, and handling a

hazardous waste (the spent oxidizer scrubber

liquor) are considered.

Control Pam'l ,h_rthe Oxhtizer Scrubber

Contnd System

be cleared during operations, thus reducing the

impact of toxic hypergolic oxidizer emissions on

adjacent operations.

The new scrubber liquor and control system was

tested with nitrogen dioxide (NO2) concentrations

from low parts per million to pure vapor. To simulate operations at KSC where aspirators are used to

capture NO: vapor, up to 500 standard cubic feet

per minute of gaseous nitrogen (GN2) were added

to the NO 2 stream. In addition, approximately 90

pounds of oxidizer (vapor and liquid) were added

over a 1- to 9-minute period to the scrubber. Under

all of these test conditions, the new scrubber-liquor

system performed well and produced lower emissions. Tile only problem encountered during the

field tests, which will require slight modifications to

the scrubber, was due to inadequate mixing in the

scrubber sump. These mixing problems are being

Key accomplishments:

• Developed a method to eliminate the second

largest waste stream at KSC (oxidizer scrubberliquor waste).

• Developed internal diagnostics that monitor the

performance of the control system.

• Developed a production process for potassium

nitrate, a fertilizer currently purchased by KSC

for use on lawns and citrus groves.

• Demonstrated that the process control system is

robust and can withstand field operations.

• Demonstrated that the scrubber liquor is more

efficient with only 1 to 10 percent of the emissions

found with the current 25-weight-percent sodium

hydroxide scrubber liquor.

Contacts: R.C. Young (Rebecca.Young-l@ksc.mTsa.gov) and

D.E. Lueck, MM-G2, (407) 867-4439

Participating Organization: Dymws Engineering Co., Inc.

(C.F. Parrish, C.J. Schwimtt, T.R. Hody, and P.H. Gambh')

33
Less Toxic Orbiter TPS

Rewaterproofing Agent Study

he present orbiter Thermal

Protection System (TPS)

rewaterproofing agent,

dimethylethoxysilane (DMES),

performs exceptionally well in

preventing water absorption in

ceramic, silica-based materials.

DMES reacts with the surface of

glass fibers in the tile or the fabric

in blankets and deposits a film of

organic material that repels water.

Although the tiles and blankets

are waterproofed when fabricated, reentry burns out the agent

when temperatures reach 1,050

degrees Fahrenheit or greater,

thus requiring rewaterproofing

after each Shuttle mission. The

action of waterproofing results

from the bonding of dimethyl

silanol, an unstable reaction

intermediate, with hydroxyls on

the silica fiber surfaces. When a

typical 6- by 6- by 2-inch Orbiter

tile is rewaterproofed, 2 cubic

centimeters (cnl 3) of DMES is

injected with a needleless gun

into a small hole in the center of

the tile.

The threshold limit value

(TLV) for DMES is 0.5 part per

million (ppm). Some workers

complained of throat irritation

and light headedness after being

exposed to low-ppm levels of

DMES. Orbiter Processing Facility (OPF) ventilation system

modifications were made to

minimize this problem. In the

course of applying DMES before

a launch, toxic vapor emissions to

the OPF high bay are significant

enough to require the use of

protective gear and a breathing

apparatus. The bay must be

cleared of all nonessential personnel and cannot be reopened for

other vehicle work until the

DMES vapors measure 0.5 ppm.

Therefore, rewaterproofing must

be performed on the third work

shift and on weekends.

A KSC Shuttle upgrades

project was initiated to find an

alternative, less toxic rewaterproofing agent to DMES but

maintain acceptable waterproofing performance. Screening tests

were performed with 2-inch

LI-900 tile coupon cubes by injecting them with 0.5 cm 3 of

waterproofing agent. Also,

material compatibility tests were

performed with both types of

room-temperature-vulcanizing

(RTV) adhesives used in the

orbiter TPS bonding process. The

coupon screening tests uncovered

no waterproofing agent better

than DMES. However, five

carrier solvents [n-pentane; 2,3-

dimethlybutane (DMB); 2,3-

dimethyl pentane (DMP); acetone; and perfluorocyclobutane

(PFCB)] were down-selected to

dilute the DMES (decrease its

effective toxicity) and to enhance

its dispersion throughout the

silica fibers in the orbiter TPS.

Solutions of DMES in these

solvents were injected into 6- by

6- by 2-inch deep LI-900, reactioncured glass (RCG) coated orbiter

tiles at various concentrations,

and the resulting water uptake

was measured. Rewaterproofing

residue weight pickup was also

measured over a number of

cycles, and the results after

several injections showed insignificant accumulative weight

gains on the order of 0.2 percent

or less. Another test series, tile

off-gassing detection, was performed to measure the concentration and duration of the emitted

vapors. RCG-coated tiles were

injected with DMES/solvent

mixtures while the tiles were in a

Plexiglas chamber. This procedure was used to compare the

emission and decay rate of 100-

percent DMES versus DMES/

solvent combinations using the

Foxboro Miran 203 meter. A

Fourier Transform Infrared (FTIR)

method (measures each constituent separately), previously developed by the Toxic Vapor Detection Laboratory for DMES carts,

was used to measure the amount

of solvent (ppm) detected when

the Miran meter measured 0.5

ppm. This data was compared to

the TLV of the solvent to determine if concentrations were

acceptable.

Flexible insulation blankets

were also injected with the above

solutions of DMES using a needle

gun. After injection, several

droplets of water were placed on

the surfaces of the blankets and

observed for absorption. Two

tests each were performed with

20-percent DMES solutions in

DMP, DMB, and n-pentane. Two

tests were also performed with

10-percent DMES in PFCB. All

blanket rewaterproofing experiments were successful in preventing water droplets from entering

the blanket surface.

Overall, DMES solutions at 20

percent in solvents performed

34
successfully in tiles (i.e., the water absorbed in tiles

was less than 5 percent of the tile weight). All

solvents were also compatible with both RTV's.

N-pentane was finally selected as the solvent for

DMES due to its low toxicity and low cost, combined with its excellent repeatability with DMES. In

tests comparing off-gassing data, a TLV equal to 0.5

ppm was achieved 44 percent faster in a tile injected

with 20/80 DMES/n-pentane versus 100-percent

DMES (5.3 hours versus 9.5 hours) (see the figures).

In conclusion, n-pentane is recommended as the

carrier solvent for DMES to decrease the overall

agent toxicity. It has a low toxicity (TLV of 600

ppm), low cost ($4 per gallon), and excellent repeatability when combined with DMES. The new

recommended rewaterproofing combination is a

20/80 DMES/n-pentane mix. The benefits of using

the recommended mix are: (1) a decrease of DMES

vapors in the OPF; (2) a reduction in protective

equipment safety criteria; (3) a decrease in the cost

to perform rewaterproofing due to reduced safety

requirements, fan usage, and the cost of chemicals;

(4) a chemical cost saving estimated at $147,200 per

year (based on the current 100-percent DMES versus

20/80 DMES/n-pentane mix for eight flows per

year; (5) the number of clearances of the high bay

could be minimized, thus reducing rewaterproofing

flow impacts to long-term program manifest requirements; and (6) greater flexibility in the

rewaterproofing process.

Contact: S.R. Cunningham (Suzanne.Cunninghaml@ksc.nasa.gov), AA-D, (407) 867-7089

Participating Organizations: NASA-KSC (E ]ones, M.

Cardinale, D. Lueck, and J. Branard); Comprehensive Health

Services, Inc. q. Taffer); Boeing-Seattle (C. Newquist ); Dynacs

Engineering Co., Inc. (R. Barile, N. Bardel, ]. Curran,

T. Hodge, P. Gamble, C. Mattson, B. Meneghelli, amt

C. Parrish); NASA-JSC (C. Schomburg); BNA-Dowm,y

(D. Bell and M. Gubbert); Ames-Elorett (J. Pallix); United

Space Alliance (S. Nickell, G. Powers, R. Loeffler, amt

0. Torres); and KSC-BNA (R. Frittier)

6.00

5.00 _ M203, 11.05u

4.00

o 3.00

¢D

rr 2,00

cO

0

1.00

0.00 I I I I I i

Time

Tile Injection, 2 cm 20-Percent DMES in n-Pentane,

50 Liters per Minute, M203

6.00

5.00

E

4.00

t--

o 3.00

a: 2.00

0

1.00

0.00

3 Response, 11.05u

i

o o O o o

9. 9. 9. o 9.

0 0 0 0 0

9. o 9. .o.

Time, h0ur

Tile Injection, 2 cm _Pure DMES,

50 Liters per Minute, M203

35
Supercriticai Air-Powered Environmental

Control Unit for SCAPE

SG uses the Self-Contained

Atmospheric Protective

Ensemble (SCAPE) for the safeguard of personnel handling

rocket propellants. The existing

configuration relies upon the use

of a liquid-air-powered environmental control unit (ECU) that

has seen nearly 30 years of successful operation in support of

NASA and Air Force missions.

The Category I configuration of

this suit provides the user with

totally encapsulating protection

for over 2 hours. However,

several problems in the use of

liquid air have been identified

and remain unsolved. Training

and operational monitoring and

constraints have safely controlled

these problems to date.

A new initiative has begun for

the development of an Advanced

Protective Suit (APS) that will

meet future mission support

needs in an environment that is

expected to impose even lower

toxic threshold limit values for

human exposures. Initial efforts

have focused on the remediation

of liquid air system problems.

Specifically, these problems are

dependent upon (1) an upright

dewar (storage vessel) attitude,

(2) an unstable or nonhomogeneous liquid mix where the

liquid nitrogen component boils

off before the oxygen component,

and (3) the determination of

dewar quantity throughout the

service life when the ECU is on a

person's back and in motion,

which often is in an unusual

attitude.

A feasibility study of the

storage and use of air in a

supercritical phase has been

successfully conducted in the

Biomedical Laboratory at KSC.

This development was an extension of technology gained in a

Small Business Innovation Research project conducted by

Aerospace Design and Development, Inc., where a supercritical

air, positive pressure demand,

self-contained breathing apparatus was designed. The SCAPE

ECU is a constant-flow system

that supports respiration and

cooling of the user. The new ECU

stores 6.5 pounds of supercritical

air in a high-efficiency dewar and

provides the air, after conditioning, to the suit air distribution

manifold. The prototype design

will be further modified to employ a more effective liquidcooled garment in place of air

cooling. Problems with attitude

sensitivity, stability of the gas,

and quantity measure have been

solved in this relatively lower

pressure, cryogenic, gaseous

system.

Contacts: D.F. Doerr (Don.Doerrl@ksc.nasa.gov), JJ-3, (407) 867-3152;

and M.B. Brown, FF-D2-D, (407) 867-

7186

35
Advanced

Software

he goal of the Advanced Software program at the John F. Kennedy

Space Center (KSC) is to investigate

and develop cutting-edge advanced software technologies in support of launch and

ground processing functions. New software technologies are being developed to

improve capabilities and reduce operations

and maintenance costs for present and

future vehicles, payloads, and launch

systems.

To meet the challenge of becoming more

efficient in all aspects of KSC work, advanced software technologies are being

developed from the expanding technological base; and these technologies are being

used to improve performance, save time,

and increase productivity. This year's

Advanced Software program employs a

broad range of disciplines and technologies, including programs that process vast

quantities of data and make the data available for Operation's use through tools

(such as the Internet), model-based reasoning systems to autonomously manage

complex chemical processing systems, and

advanced mathematical techniques that

enhance capabilities for imaging and wave

analysis.

37
Mars ISPP Autonomous Controller

SC's Roadmap to the Future places an emphasis on

NASA's efforts to develop the

technologies necessary to send a

manned mission to Mars. A key

element of NASA's strategy to

send a manned mission to Mars is

the utilization of resources

present in the Martian environment. This element is known as

In Situ Resource Utilization

(ISRU). One component of ISRU

is the production of fuel and

oxidizer for the Crew Ascent

Vehicle. This is called In Situ

Propellant Production (ISPP).

Communication lags between

the Earth and Mars make it

impractical to control the ISPP

plant directly from Earth. Therefore, autonomous control software is necessary to operate the

ISPP plant with little or no help

from ground controllers. Since

Trans-Mars

Heat

Shroud

Heat

Shield

Propellant

Plant

3-Descent Engines

Mars ISRU Sample Return

Mars Entry Vehicle

pellant

Liquifaction Unit

3-Lander Leg

System

the plant has to operate for over a

year, the control software must be

adaptive. It must be able to

handle component failures as

well as degradation of the chemical processes. Because of the

broad applicability of autonomous control, this project will

help increase the body of knowledge for all control system needs

-- whether targeted at manned

missions to Mars or ground

launch systems for the Shuttle.

An important aspect of this

project is the partnerships with

other centers that make it possible. Johnson Space Center (JSC)

is the lead center for the development of ISRU technologies, but

they are partnering with other

centers to capitalize on their areas

of expertise. For the ISPP project,

both Ames Research Center

(ARC) and KSC have experience

with artificial intelligence (A1)

software for autonomous control.

For the ISPP effort, KSC will

create the AI program for autonomous control using a language

created by ARC. As the project

progresses, KSC will help ARC

extend the capabilities of their

language to incorporate more

dynamic process modeling

capabilities needed to fully

implement the ISPP controller.

The primary objective for the

Mars ISPP autonomous controller

project is to develop autonomous

control software that will operate

a prototype ISPP plant constructed at JSC. However, JSC is

still experimenting with several

techniques for ISPP, so immediate

pursuit of this objective is premature. In order to elevate AI

38
technology to the necessary

readiness level, a simplified

autonomous control package

using the ARC-developed language will be created to operate a

simulated ISPP plant. This will

facilitate development of software

modules to communicate with

the user and interface with the

hardware. It will also help

identify enhancements the ARC

language needed to handle

quantitative modeling issues

presented by ISPR

As these enhancement needs

are identified, KSC will work

with ARC to develop solutions.

Once the enhancements are

completed, KSC will use this

enhanced language to create a

comprehensive autonomous

controller for the ISPP simulation.

When the JSC ISPP prototype is

completed, KSC will deliver the

autonomous controller software

to JSC, where it will be integrated

with their adjustable autonomy

test bed. KSC will make all the

necessary modifications to adapt

the autonomous controller to the

JSC prototype hardware.

Key accomplishment:

1998: Demonstration of the

circuit breaker and power

distribution control system

using model-based reasoning.

Key milestones:

1999: Demonstration of a

preliminary ISPP monitoring

and control system. Continue

the development of ISPP

monitoring capabilities. Expand the functionality to

include quantitative and

semiqualitative diagnostic and

control functions.

Contact: W.E. Larson (William.Larsonl@ksc.nasa.gov), MM-G1, (407) 867-

6745

39
JView Internet Display of Shuttle

Real-Time Data Using Java

he rapid growth of Internet access to information since 1995 has resulted in a significant

paradigm shift in how information is accessed and

the resulting expectations of users concerning

information availability and ease of access. During

the past 4 years, however, the type of information

accessed on the Web has primarily been static in

nature. The recent availability of Java has enabled a

new class of applications that contains dynamic

content and real-time data sources over the Internet.

The use of Java for display of real-time Shuttle data

as presented here represents a demonstration of

how existing applications at KSC could be implemented using the Internet paradigm.

multiple computers of differing configurations

displayed the following data: (1) hardware (Intel

X86, Sun SPARC, and Motorola POWER PC), (2)

operating system (Solaris, SunOS, WindowsNT,

Windows95/98, and Macintosh Finder), and (3)

Web browser (Netscape Navigator, Version 4.0+;

and Internet Explorer, Version 4.0+).

In addition to demonstrating a single Web

browser/JView client display on each of seven

systems simultaneously, a test of nine different Web

browser/JView client displays on a single

WindowsNT system was possible. The best display

results were achieved using version 4.0 of Netscape

Navigator and Internet Explorer, which contain a

just-in-time compiler for Java, greatly improving

display performance by at least an order of magnitude.

The current display of real-time Shuttle data

involves a centralized server that receives data from

the common data buffer and sends it to Intel TM

processor PC clients who display it on predefined

screens. PC clients use MS-DOS TM and characterbased graphics with close ties to specific hardware,

operating systems, network interfaces, etc. This

implementation has no inherent security or ability

to work globally, and the PC becomes dedicated to

the display of data.

Using Java presents an ideal approach since

much of the effort in establishing a client/server

connection across a local or wide area network is

already provided. Java supports implementing

solutions as both applications and applets. The

applet was used for the client-side display of Shuttle

screens. The advantages of a Java-based solution

are geographic independence; shorter development

and training; write once, run anywhere applications; security; ease of administration; and multiple

Shuttle displays.

The initial goal for the Internet Display of

Shuttle Real-Time Data Using Java project was to

demonstrate the feasibility of using Java and a

commercial off-the-shelf (COTS) Web browser to

display real-time Space Shuttle data, equivalent to

the current application called PCGOAL. This was

successfully demonstrated in the Automated and

Intelligent Systems Computer Laboratory, where

The current phase involves taking the proof-ofconcept work completed earlier and applying the

technology to solve actual monitoring requirements

at KSC and other NASA centers. In conjunction

with this implementation, additional system design

and testing will be accomplished in the areas of

(1) tuning the applet (client) and application

(server) for maximum performance; (2) establishing

robust extensible class libraries of reusable software

components, applicable for present and future

projects; (3) analyzing network bandwidth utilization to support the maximum number of clients; (4)

providing direct connections to data sources, both

real-time and historical; (5) developing graphical

user interfaces with increased display options and

resizable screens; (6) developing advanced plotting

capabilities using Java "swing" technology to

maximize extensibility; and (7) extensive system

level testing and certification.

The viability of using Java, a relatively new

language/runtime environment, in conjunction

with a COTS Web browser to rapidly develop and

deploy process monitoring and control applications,

has been demonstrated. This new technology has

the potential of significantly reducing the time and

cost of developing and maintaining applications,

given the flexibility to write the application once

and run it anywhere. Use of COTS systems and a

Web browser minimizes the cost, configuration, and

training issues associated with deployment of new

4O
Research and Technology 1998

applications. This type of solution has great potential applicability at KSC, other NASA centers, and

industry technology transfer in the areas of: (1)

training using live or simulated data sources, (2)

real-time monitoring of live Space Shuttle data (or

any type of data source), (3) expert/advisory

systems for predictive analysis, and (4) historical

review for postmission data analysis and review.

Contact: K.C. Ballard (Kim.Ballard-l@ksc.nasa._,ov), MMG3, (407) 867-1720

Participating Organizations: Dynacs En_ineeHllg Co., Inc.

(J.M. Dockendorf, C.H. Goodrich, S.R. Beltz, and M.S. Lon_),

Florida Institute of Technology (Dr. R. Stans!h'r), Princeton

University (K. Gillett), and Duke University (W. Riddh'_

41
Automation of OMI $9002 for

Orbiter Processing

he term $9002 refers to the operations and maintenance

instruction (OMI) for the Posttest

Data Review by responsible

engineers of sensor data collected

during the certain critical processing of orbiters from the time of

landing up to and including

launch. OMI $9002 includes a

number of subordinate OMI's.

One is S0007, the OMI for orbiter

launch, which includes the

production of roughly 2,500

sensor readings (data products)

that require review by engineers

responsible for each of the

orbiter's subsystems and supporting subsystems (e.g., main

engines, hazardous gas systems,

auxiliary power units, etc.).

hours or days following a stop

event), DRR personnel log into

the central data system (CDS),

request a specific data product to

be run, and specify the printer or

plotter for the hard copy printout.

The hard copy is either picked up

or hand carried to the engineer

(will calls). The responsible

engineer then reviews the physical data product, analyzes the

data for potential problems, and

determines the health of the

subsystem (analysis of large

listings may take hours). The

engineer then returns to the DRR

to buy off the data product for

which he/she is responsible (this

can be I to 300 data products per

subsystem).

Data products are hard-copy

printouts of charts, plots, graphs,

or listings for specific sets of

periodic sensor readings, usually

specified for a predetermined

timespan, that include a start

event and stop event. Some data

products are also run on demand

at the request of a responsible

subsystem engineer (typically in

the firing room) who specifies

which data product to produce

and provides specific start and

stop times. These data products

are termed "will calls."

The present S0007 process

includes the following steps.

First, Data Review Room (DRR)

personnel physically monitor the

launch process for specific data

product start and stop events to

occur. Next, after certain stop

events occur (which may be

The original goals of the

$9002 automation project were

(1) to automate the generation of

greater than 80 percent of the

data products for OMI S0007,

with emphasis on hazardous gas;

(2) to enable the display, to review, and to sign off those data

products by responsible engineers from their desktop computers using the World Wide Web;

and (3) to investigate the use of

available commercial off-the-shelf

products and/or rule-based

technologies that could assist the

responsible engineers with the

analysis of the data products.

The $9002 database was

modeled, designed, and implemented using a full-function

RDBMS (Oracle 7) and a modem

Web server. Code was written to

automatically load the database

from all available legacy system

sources to include DRR Dbase IV,

CDS formatted files, CDS transaction files, and CDS FD files.

Listeners and agents were integrated into the database server to

enable a transparent interface to

all other $9002 subsystems,

whether local or remote, and

support many language interfaces.

An event monitor was designed and implemented using

the Java language to monitor the

occurrence of start and stop

events and was interfaced to both

the Shuttle Data Center (SDC)

and $9002 databases. An application server module was also

developed using the Java language, which communicates with

the event monitor, SDC, the

analysis module, and $9002

database to handle the scheduling

and control of data product

creation, transfer to the database

server, and the triggering of data

product analysis. In parallel, the

programs that actually produce

the data products (DAP's and

CAP's) were moved from the

CDS to the SDC and modified to

enable production of electronic

files. These programs also underwent significant coding modification to enforce standardization of

inputs, options, and functionality.

Tests where then performed to

make sure the new $9002 application server module could successfully call and execute these SDC

resident programs.

In another effort, an analysis

module was being investigated

and contrived. It was decided to

create a rule-based application

module that would perform the

42
Plea_z _¢lect Dented CrptJon."

$9002 l_lahl l_lenu For Admiltiso'ators

Responsible Enghteer Ftmctlous

View Data Ploduct .Mtd Stalalses

Display _MI Data Fol a Spedfic Data hodurt

Sign+off a Completed Data Pl oduct

Update Flow Constants (}L&ZGAS}

Actwate A Will ('all DP

BIowse $9002 Database

Change $9002 Passv+old

It)oemtert 0me

System Adminisn'afioit Flutelions

RPSPI A T(+ID Fo_ T_sting

Re-(heate A Job Qut.ue .

('1 Pate A New Flow...

Remove ++MrExistmg Flow..

C_eate Update Data P_oducts .

Create Update Events_

Set Ikianual Events and Flags..

_ .+,_ . . -_ ._+ ,++ //,

Top-Level Mem_ Page for Administrators

same steps as an engineer when

analyzing a large collection of

hazardous gas sensor data. A

complete set of rules was established for several of the largest

data sets by interviewing the

engineers and documenting their

thought processes. These rules

were then organized into a Java

application class, and methods

were written to enable reducing

the analysis to a single page

output that describes if there

were any anomalies found. If

there were anomalies, a brief

explanation of each would be

included along with violated

parametrics.

Being developed in parallel

with the other modules was the

user interface. This module was

scoped to run on platformindependent desktop computers,

with the only requirement being

that the platform support a

commercially available Web

browser. Two paths were taken

in the development of the GUI.

One implementation proposed

the use of uploadable Java

Applets for all menus and

screens, which yielded compatibility problems with browsers,

slow loading, and difficulties in

coding and maintenance. The

other implementation involved

the use of the PL/SQL language

for the dynamic creation of

Hypertext Markup Language

(HTML) sent to/from the client

platform, which yielded a

highly responsive, easy to code

and use interface with dynamic

screen sizing. While both

solutions could eventually be

made to work, the PL/SQL

solution was chosen for implementation of the $9002 automation at this time. Results of the

$9002 automation project to date

have exceeded the original requirements.

As a result of this project,

greater than 95 percent of data

products for S0007 (orbiter

launch) are run fully automatically and are typically available

for viewing within 30 seconds

after stop events occur. The $9002

database and application software supports all $9002 OMl's

(approximately 5,300 data products). Engineers can run any data

product at any time by specifying

both start and stop times (will

calls) and can create custom data

products at will and execute them

immediately. Several Space

Transportation System flows can

be run simultaneously without

conflicts. The rule-based analysis

of large volumes of data for

hazardous gas has proven to be

very efficient and has identified

in near real time many interesting

anomalies (gas leaks, power

supply outages, etc.) hours before

being discovered by the responsible engineers using manual

methods. Responsible engineers

now have a tool to monitor

subsystem health, review discovered anomalies, and electronically

sign off completed data products

without leaving their clesks.

Contact: W.C. Jones (William.lones3@ksc.nasa.,_ovl, MM-G3, (407) 867-

4181

Participatin X OtNanizatious: E)lt_lafS

Engim'erin S Co., hw. CW. Spiker, I1; ].M.

Dockemtorf; aud ]. ZambranoL I_luitcd

Space Alliance (W.S. Bayh's), amt

Boein S (D.]. Cox)

43
Web-Based Work Tracking Systems

he Logistics Operations

Directorate s Materials Science

Division (MSD) has a new software system running in real time

on the World Wide Web. This

system is named the Work Tracking System (WTS) and it demonstrates the integration of common

Web browsers with a commercially available relational database management system to

create a single, user-friendly

means of controlling work flow.

The MSD laboratories were

established during the Gemini era

to provide quick laboratory

support to vehicle and facility

operations at KSC. The MSD was

Government and contractor

operated but was converted to a

100-percent Civil Service operation in 1968 so unbiased investigations could be provided.

Prior to this new application,

each group in the MSD kept a

separate report log containing

unique fields, such as investigator

name, date started, date completed, and report number. The

WTS offers a single means of

maintaining the report log and

tracking the work flow, resulting

in a much more efficient operation for both laboratory investigators and their customers. The

WTS also aids the MSD in their

effort to become ISO 9000 compliant.

The benefits and features of

the WTS are many. The system is

hardware and software independent on the server side - practically all server manufacturers and

operating systems can run it. On

the client side, practically all

desktop computers, including

_"" Censo,ed""

MSL V_"ork Trackhig System Mahl Menu

F

] Request A New Job

Cleate NUblOb

1 Update .[ob Ntanlx

[ Update Pal t _iatl Lo( ;ItlOl[ "

] Display Job Data ! Update .Job hffonnanon

Assign .Job To A (_houp ]Update Pal t _latl hufolln;,tion

Assi__n ,Jot To .\ PI

Blowxe Database

i Cllan._e PasSWOl d

]Update ("uxt,)mel hff,_Haanon

1

i Update (_h uu I, PI .a.xsi_ned

44

Administrators Page
Macintosh, PC, and UNIX work

stations, can use WTS with a Web

browser.

WTS offers a full-function,

relational database management

system (RDBMS). Features

include referential integrity

checking, security, transaction

logging, and a distributed database. The RDBMS selected for

the WTS implementation is

Oracle because of its wide usage

at KSC.

The Web pages are dynamically created in real time based on

user inputs using Procedural

Language/Structured Query

Language (PL/SQL) that is stored

in the database itself. Browser

tables are also produced dynamically. The use of PL/SQL for

WTS implementation results in

fast system response time.

The WTS's current server

configuration is a Sun Sparc II,

running Solaris 2.5.1 (UNIX),

Oracle Enterprise RDBMS, and

Web server software. The client

needs only a PC, Mac, or UNIX

work station and a Web browser

(such as Netscape or Internet

Explorer) to access the system.

Similar systems were also

developed and implemented at

KSC, including the KSC Corrective and Preventive Action System tracking audit, nonconformity, and opportunity for improvement statuses. Other

systems still in development

include the KSC Centerwide

Awards system that will track all

NASA awards and the award

budget. Other WTS demonstrable features include:

Automatic e-mail to customers

with status changes, such as

job on hold, job complete

Automatic notification to MSD

personnel for new jobs and

status updates

• Ad hoc reporting

• Security and access control

with password and firewall

• Automatic file transfer

• Transaction logging

• Electronic signatures

Add and display job documents including pictures and

reports

• Job splitting

• Equipment calibration tracking

• Part/material tracking

Contacts: W.C. Jones (William./ones3@ksc.nasa.gov), MM-G3, (4(17) 867-

4181; and K.C. Ballard, MM-G3, (407)

867-1720

Participating Organizations: LO-G4-M

(S. Murray) and Dynacs En_ineerin_

Co., Inc. (N. Tuttle and W. Spiker)

45/46

Research and Technology 1998

Atmospheric

Science

heogy Atmospheric program at theSciences John F.TechnolKennedy Space Center (KSC)

addresses the impacts of weather on

ground, launch, and landing processing

with a view to increasing safety of personnel, protecting resources, and reducing lost work time by improving detection, analysis, and prediction of weather

events and protection from weather

events. Many of the weather impacts are

of a specialized nature, differing from

those felt by the public and even aircraft

operations, and require studies and

development that cross the lines of

conventional scientific disciplines.

Weather events focused upon by the

program include lightning and cloud

electrification, convective cloud growth,

atmospheric surface and planetary

boundary layer circulations and processes, wind shear effects, severe weather

phenomena, rain, wind, and fog.

47
Atmospheric Science

Hurricane Wind Sensor

he objective of this project is to

develop a low-cost, highspeed wind sensor and a selfcontained data acquisition system

for in situ measurement of winds

from hurricanes and tornadoes to

300 miles per hour. Scientists at

the National Oceanic and Atmospheric Administration (NOAA)

indicated a need for such a

system and have formally requested KSC to undertake the

development. When hurricane

Andrew struck South Florida in

1992, there was no reliable landbased, maximum wind speed

measurement. All known sensors

in Andrew's path of maximum

wind were destroyed, presumably in winds short of maxima.

The controversy continues today

Fi_,,ure1. New-Generation Wind Sensor Incorporates Strain Gage

Technology for Compact Design and High-Speed Performance

with some scientists estimating

Andrew's gusts at greater than

200 miles per hour. High wind

speed information is needed at

KSC to allow engineering assessment and recertification of facilities, ground support equipment,

and flight hardware should an

extreme wind event occur.

The high wind speed sensor

(see figure 1) at KSC uses two

different principles of physics to

provide two independent measurements of wind speed: (1) the

aerodynamic force imparted to a

low-profile, rigidly mounted

cylindrical rod and (2) the vibrating frequency of the rod as

vortices are shed from the cylindrical surface. A common set of

strain gages is used for both

measurements. The force measurement is proportional to the

square of the wind speed. Since it

is a vector quantity, it can also be

used to infer wind direction. The

vortex shedding frequency is a

scalar quantity and is linearly

proportional to wind speed. The

data system is battery operated,

designed for unattended operation, and hermetically sealed to

withstand driving rain and storm

surge flooding that is typically

associated with landfall hurricanes. The system will automatically acquire and store at least 72

hours of sustained and peakwind information for poststorm

event analysis.

A prototype data acquisition

system was designed and fabricated. Three generations of

prototype sensors were designed

and tested with each showing

48
g

Q_

Q_

(/]

140

120

100

8O

6O

40-

20

120

to. '°_ °

.o

[

1.........

o

o

Figure 2.

20 40 60 80 1O0 120 140

Turbine Speed (mph)

Raw Data Plot _f Strain Gage (SG) Anemomeh, r Versus Turbim" Air Speed Sensor

(Vehich' Test at the SLF)

significant improvement over its predecessor. The

functional characteristics revealed during preliminary wind tunnel testing of the first design were

used to refine the subsequent designs. The latter

designs were tested to 120 miles per hour on a road

vehicle at the Shuttle Landing Facility (SLF) (see

figure 2). Wind speed values inferred from static

strain (force) measurements agree well with those

obtained from a co-located turbine air speed sensor.

The frequency components of the sensor output, as

related to the probe's mechanical resonance and

vortex shedding vibration, have not been fully

analyzed but preliminary findings show promise

that independent wind speed measurements are

extractable from the frequency spectra.

Key accomplishments:

• Designed and fabricated a prototype data acquisition system printed circuit board.

• Designed, fabricated, and laboratory tested three

generations of prototype wind sensors.

• Proved that force measurement is a viable

method of inferring wind speed and direction to

at least 120 miles per hour (midcategory 3 hurricane).

• Initiated an investigation of vortex shedding

frequency as a function of wind speed.

Key milestones:

• Deployment of sensor during 1999 Atlantic

hurricane season.

• Final design and completion of sensor by October

1999.

Contact: J.A. Zysko (lan.Zysko-l@ksc.nasa.,govL MM-G2-A,

(407) 867-6532

Participatin_ Organization: D_/nacs En_im'cril_g C_ ., hw.

49
Single-Station Accurate Location of Lightning Strikes

he objective of this project is to

design an accurate singlestation lightning location system

to aid in the detection of lightning

strikes within the launch pad

perimeter. This project is an

upgrade to the lightning location

system first conceived in 1997.

Existing lightning location systems at KSC provide coverage of

a wide area extending over a 30-

mile radius but have an accuracy

on the order of about 500 meters

within the KSC area. These

systems cannot be used to determine, for instance, whether a

lightning strike occurred inside or

outside the perimeter of the

launch pads. Since electronic

equipment can be damaged by

the effects of nearby lightning

strikes, the accurate knowledge of

the striking point is important to

determine which equipment or

system needs to be retested

following a lightning strike.

The fast-varying electric

currents associated with lightning

strikes generate large electric field

variations. The electric field

waveform propagates at the

speed of light in a radial direction

from the striking point. The

sudden heating of the air caused

by the large currents associated

with the lightning discharge

produces a sudden expansion of

the air near the lightning channel.

This results in a sonic wave

(thunder) that initially, for the

first few meters, propagates at a

supersonic speed and later

propagates at a sonic speed. For

an observer located away from

the striking point, the electric

field waveform arrives earlier

since it travels at a speed of

300,000,000 meters per second

(m/s), while the sonic wave

travels at about 320 m/s. The

observer can determine the

distance to the striking point by

measuring the time between the

arrival of the electric field waveform and the arrival of the sonic

wave.

The improved lightning

location system consists of an

electric field sensor and five sonic

(thunder) recorders. Four of

these sonic sensors are located in

the perimeter of a 1- or 2-meterradius circle, 90 degrees apart

from each other, with the electric

field sensor placed in the center

of the circle. The fifth sonic

sensor is located 1 or 2 meters

above the plane formed by the

four sensors. Following a lightning strike, the sonic wave

arrives at each sensor within

milliseconds of each other, since

the distance to the striking point

is slightly different for each sonic

sensor. Based on the differences

in the time of arrival of the sonic

wave at each sensor, a set of

equations can be solved to determine the angle of arrival of the

sonic waveform. The differences

in the time of arrival can be

precisely measured, to better than

10 microseconds, by performing

real-time digital cross-correlations among the signals received

by the five sensors. The distance

to the lightning strike is determined by the time elapsed from

the detection of the electric field

to the detection of the thunder

5O
Research and Technology 1998

signal, since the thunder propagates at a known speed of

about 320 m/s.

Key accomplishments:

• Designed and prototyped the electric field sensor, the

sonic sensors, and the microprocessor-based controller.

• Developed an algorithm to combine the information

received from a network of sensors to determine the

angle of arrival of the thunder signal.

Key milestones:

Conduct field tests at the launch pads.

Evaluate the performance of the system and refine the

algorithms if needed.

Contact: C.M. lhlefeld (Curtis.Ihlefeld-l@ksc.nasa.gov), MM-G2-A,

(407) 867-6747

Participating Organization: Dynacs Engineering Co., Inc.

(P.]. Medelius, ].D Taylor, and ].]. Henderson)

51/52

Materials

Science

heprogramMaterialsat theScience John F. Technology Kennedy

Space Center (KSC) supports

advanced technologies directed toward

improving launch site safety, operability,

and maintainability. The program includes application materials engineering,

materials testing, chemistry, and other

science disciplines. The near-term program focuses on Shuttle ground processing improvement by providing materials

and coatings that afford better corrosion

control, materials with better hazardous

systems compatibility, and improved

testing methods and instrumentation.

The long-term program will (1) investigate materials technology that can be

used to develop new launch and processing facilities for future vehicles and

payloads, (2) reduce the cost of maintenance, (3) provide higher safety and

reliability, and (4) provide more environmentally friendly systems.

53
Materials Science

Study of Electrostatic Charging and Discharging of

Materials in a Simulated Martian Environment

he Materials Science Laboratory has been studying and

testing electrostatics of materials

for the past 25 years. Electrostatics (or triboelectricity) is concerned with the tendency of

materials to build up and hold a

potentially dangerous static

charge. Research efforts for

electrostatic testing of materials

under vacuum or in extraterrestrial environments do not exist.

The goal of this project is to test

the materials under vacuum that

will be used for future Mars

missions and to simulate Martian

conditions to determine their

triboelectric properties. Results

from this testing will guide the

selection of materials not only for

Martian exploration but for other

space exploration.

Vacuum Chamber

The potential issues regarding

triboelectric properties of materials have become significant with

the recent Pathfinder mission to

Mars. The surface of Mars mainly consists of iron oxides and

large amounts of very fine materials that are similar to talcum

powder. Particles of this size

pose special problems because

they have increased mobility and

can easily become attracted to

oppositely charged surfaces from

greater distances. The Martian

environment is windy (30 meters

per second at peak velocity) with

periods of low temperatures and

extremely dry conditions. This

provides ideal conditions necessary to generate triboelectric

charging.

The project was initiated in

March 1998. A vacuum chamber

40 inches in diameter by 60 inches

in length was purchased in April

1998 and is currently being

equipped with controls to simulate the Martian environment. A

robotic triboelectric tester is being

designed to operate remotely in

the vacuum chamber. A Martian

regolith soil simulant was obtained from Johnson Space Center

(JSC) for researching the possible

electrostatic charging of Martian

sands. The soil simulant is

volcanic ash from the Pu'u Nene

cinder cone on the island of

Hawaii. Consequently, a prototype was designed and built for

the soil simulant delivery system.

The prototype will simulate the

Martian atmospheric movement

of soil to determine if there is

54
Research and Technology 1998

electrostatic charge generation on

the selected materials. The

research efforts in the upcoming

year will focus on the vacuum

chamber, procuring the materials

selected for the future Mars

missions, and testing the simulant

soil and materials at ambient

conditions as well as in the

simulated Martian environment.

Key accomplishments:

• Procured a vacuum chamber.

• Obtained and analyzed the

Martian regolith soil simulant.

• Built and tested the first proofof-concept prototype for a soil

simulant delivery system.

• Initiated the design for the

robotic triboelectric tester.

• Mars electrostatic discharge

plan presented and accepted

by JSC in situ resource utilization leads.

• Collaborated with Lewis

Research Center, who is developing the methodology to

remove dust from photovoltaic

cell surfaces.

Key milestones:

• February 1999: Complete

modifications to the vacuum

chamber.

• September 1999: Complete the

testing and calibration of the

Martian Environmental Compatibility assessment electrometer attached to the Mars

robotic mission for the Jet

Propulsion Laboratory.

• October 1999: Determine the

triboelectric characteristics of

the simulant soil at ambient

conditions and in the simulated Martian environment.

Complete the fabrication and

testing of the robotic triboelectric tester.

• September 2000: Determine

the triboelectric characteristics

of the selected materials under

vacuum conditions and in the

simulated Martian environment.

• May 2001: Submit the contribution to the electrostatics

experiment package on the

2003 Mars robotic mission.

Identify and evaluate methods

to reduce charge buildup on

Mars Rover mission vehicles.

Contact: H.S. Kim, Ph.D. (Hae.Kiml@ksc.nasa.gov), LO-G3-C, (407) 867-

3911

Participating Or_,anizations: LO-G3-C

(D. Jackson), LO-G3-T (A. Finchum, Dr.

R. Gompf, Dr. R. Lee, D. Lewis,

M. Parenti, and N. Salvail), LO-G4-E

(J. Bayliss and J. Rauwerdink), LOG4-M (P. Richiuso), and Sweet Briar

College (Dr. C. Calle)

55
investigation of Water Soluble Polyaniline as a Replacement for

Chromate Coatings on Aluminum Alloys

esearch has been ongoing for

over 20 years at the KSC

Materials Science Laboratory to

find coating materials to protect

launch site structures and equipment from the extremely corrosive conditions present at the

launch complexes. The combination of proximity to the Atlantic

Ocean and acidic combustion

products from solid rocket boosters during launch results in

corrosive stresses unique to KSC.

In the mid-1980's, researchers at

the Materials Science Laboratory

became interested in polyanilines

(PANI's) as protective coatings

for metallic surfaces.

Several proprietary PANIbased coatings were tested at KSC

as possible coatings for the

protection of steel from corrosion.

Exposure of PAN|-coated steel

panels at the KSC beach corrosion

test site and evaluation by electrochemical impedance spectroscopy

(EIS) led to the conclusion that

the PANI-based coatings are not

suitable as corrosion inhibitors of

stainless steel.

The PANI-based coatings

previously tested for the corrosion protection of steel were not

water soluble. Water-soluble

PANI's have been synthesized

recently. Water solubility has

favorable economic and environmental advantages in terms of

ease of processing and of reduced

toxicity. Interest in new protective coatings for aluminum alloys

has been motivated by concern

for improved protection and the

environment. The availability of

the water-soluble PANI coatings

lead to the idea of testing them as

possible replacements for chromate coatings on aluminum

alloys.

In the present investigation,

EIS was used to investigate the

corrosion-inhibiting properties of

a PANI-based coating on aluminum alloys under immersion in

aerated 3.55-percent sodium

chloride. The coating was prepared by mixing a water-soluble

lignosulfonic acid doped

polyaniline with a high solids

methoxymethylated melamine

resin in a 1:2 ratio. The alloys

used were aluminum 2024, 6061,

and 7075.

Corrosion potential and EIS

measurements were gathered on

the test specimens over a 1-week

immersion period each. Nyquist

as well as Bode plots of the data

were obtained. The PANI-coated

alloys showed large fluctuations

in the corrosion potential during

the first 24 hours of immersion

that later subsided and approached a steadier change. The

EIS spectra of the PANI-coated

alloys were characterized by an

impedance that is higher than the

impedance of the bare alloy.

Changes in the EIS spectra were

similar for PANI-coated aluminum alloys 2024 and 7075. There

was a decrease in the rate of

corrosion of these alloys during

the first 24 hours of immersion

followed by an increase. The rate

of corrosion of PANI-coated

aluminum 6061 did not show the

initial decrease. The rate of

corrosion of bare aluminum 2024

decreased with immersion time.

The low-frequency impedance (at

0.05 hertz), ZI_, for the PANIcoated alloys decreased with

immersion time. Visible signs of

coating failure (in the form of

blisters) developed on aluminum

alloys 2024 and 7075.

Key accomplishments:

• Water-soluble polyaniline was

synthesized.

• A coating using water-soluble

polyaniline was formulated.

• Aluminum alloy panels with

water-soluble polyaniline

coating were prepared.

• EIS testing of polyanilinecoated aluminum alloy panels

was conducted.

Key milestones:

• Conduct tests of polyanilinecoated aluminum alloys including exposure at the KSC

beach corrosion test site and

EIS measurements.

• Perform analysis of the metal

substrate using metalography.

Contact: C.]. Bryan (Coleman.Bryan1@ksc.nasa.gov), LO-G3-C, (407)867-

4614

Participatin_ Organizations: RandolphMacon Woman's College (Dr. L. Calle),

LO-G4-M (L.G. MacDowell), and

University of Arkansas at Litth' Rock

(Dr. T. Viswanathan)

56
Qualified Materials Listings for

Plastic Films and Adhesive Tapes

A need existed in 1990 at KSC

for information that could

readily be available to engineers

who must make the choice of

which plastic film to use for a

specific application. Plastic films

are commonly used to wrap flight

hardware for ground processing,

to package small components

prior to delivery, or to provide

limited barrier protection from

minor (leaking) amounts of liquid

rocket propellant. The adhesive

tapes used to assemble and

secure these plastic films must

equally be readily available to the

engineer. The need for qualified

films and tapes was also driven

by safety requirements that are

unique to KSC (which include a

reasonable resistance to flammability, a material that is minimal

as an electrostatic generator, and

total ignition resistance to hypergolic rocket propellants). While

vendor literature could be used to

determine the mechanical properties of a film or tape, there was no

suitable industry data that could

address the above safety concerns

which would be acceptable to

KSC.

In order to tailor the program

for KSC, only those materials

requested by KSC contractors

were initially evaluated. Other

materials that were submitted by

other NASA centers or by vendors who wished to be included

in the listings were evaluated

when time and resources were

available. An electronic database

of test results was subsequently

established from which the

listings could be created. The test

methods used to produce these

test results were:

1. Flammability testing per

NASA-STD-6001

2. Electrostatic testing per KSC/

MMA-1985-79

3. Hypergolic ignition penetration testing per KSC/MTB-175-

88

Each film or tape was subsequently categorized based oil its

ability to meet some or all safety

requirements. This would enable

the user to quickly access candidate materials once the operational needs are determined. A

material must at least pass the

flammability acceptance criteria

before it can be included in the

qualified listings. These listings

are updated on a quarterly basis.

Contacts: N.P. Salvail (Napoleon.

Salvail- 1@ksc.nasa.gov) aud R.J.

Frankfort, LOIG3-T, (407) 867-1403

57
Determination of Sodium in Colloidal Silica

L udox AS-30, a product of

DuPont, is a colloidal silica

solution containing sodium that

is used in many aspects of the

orbiter's Thermal Protection

Systems. Ludox is incorporated

into thermal tile production and

repair and flexible insulation

blanket coatings and serves as the

basis for adhesives. The amount

of sodium present in the colloidal

silica solution used for these

purposes has a direct effect on

the level of crystallinity observed

due to the formation of cristobalite. The presence of cristobalite is detrimental to the performance of materials due to its

tendency to exfoliate or flake.

The Materials Science Division

Test Branch has been involved

with the development of a reliable and expedient method for

determination of the level of

sodium present in such silica

colloids.

Several methods have been

attempted in devising a quantitative analysis for sodium in silica

colloids. Initially, ASTM Method

C575-81, inductively coupled

argon plasma (ICAP), and ion

chromatography were used.

None of these procedures gave

reliable or reproducible results.

Following consultation with

chemists at DuPont, a modified

procedure using ICAP was

developed. This method involves

digestion of the colloidal dispersion using hydrofluoric acid and

nitric acid. After addition of the

acids, the samples are heated

inside a CEM MDS 81D microwave until complete dissolution

occurs. Presumably, acid digestion under these conditions has

the ability to physically break the

discrete uniform spheres of silica

present in the colloid to release

the sodium present. Digestion of

aqueous samples (as received)

was performed. The samples

were also dried by oven heating

and were digested using the same

procedure. Verification of

method reliability is accomplished by the addition of sodium

spikes at varying concentrations.

The precision of the results

obtained from the modified

procedure is acceptable. However, the recovery of sodium

added as a spike is consistently

deficient. Before considering this

procedure reliable, this anomaly

should be understood. Literature

research and additional testing

are ongoing.

Key accomplishments and milestones:

• Literature research.

• Collaborated with DuPont.

• Continue testing the Ludox

using different parameters for

the digestion procedure.

Contact: W. Marshall (Wayne.

Marshall-1 @ksc.nasa.gov.), LO-G3-C,

(407) 867-3910

Participating O¢_anizations: Boein[¢

North American, Inc. (K. Marshall),

DuPont (J. Ramsey), and LO-G3-C

(D. Jackson and L. Wellin_ton)

58
Inductively Coupled Argon Plasma Spectrometer

[Thermo Jarrell Ash Corporation (TJA 61E)]

59
Materials Science

Radiant Heating Facility

n order to perform testing on Thermal Protection System

(TPS) materials, a facility is

required to simulate a variety of

surface-heating conditions. In the

case of a vehicle reentering the

Earth's atmosphere, the heating

takes place under low atmospheric density conditions.

Within the Materials Science

Laboratory, there was a need to

build a small chamber that could

be used to simulate reentry

heating on various types of TPS

materials. It was decided to

fabricate a small 18- by 18- by 8-

inch chamber that could be

placed inside an existing altitude

chamber. With assistance from

personnel at Langley Research

Center and Ames Research

Center, a small chamber was

designed and fabricated. The

chamber uses 24 infrared heating

lamps to provide high surface

heating to reach temperatures of

over 2,200 degrees Fahrenheit.

The chamber enclosure is fabricated partially from fused silica

with a density of 24-pound-percubic-foot material provided by

the Shuttle TPS facility. A power

controller and separate temperature controller allow the user to

select a ramp rate for the heating.

Separate controls for the altitude

chamber control the pressure in

the radiant chamber during

heating operations.

Key accomplishments:

The chamber was fully activated and tested to over 2,000

degrees Fahrenheit.

Extensive waterproofing

burnout support was provided

to the Shuttle upgrade project

by looking at reducing the use

of dimethylethoxysilane during rewaterproofing in the

Orbiter Processing Facility.

Contacts: N.P. Salvail (Napoleon.

Salvail-l@ksc.nasa.gov) and D.C. Lewis,

LO-G3-T, (407) 867-1403

Participating Organizath_ns: United

Space Alliance (M. Martin) and Boeing

North American, Inc. (M. Gordon)

6O
Research and Technology 1998

X-33 Rocket System Fuel Tank

Electrostatic Coating

he X-33 rocket program will

demonstrate the key design

and operational aspects of a

single-stage-to-orbit reusable

launch vehicle. The fuel and

oxidizer tanks are covered by the

outer vehicle shell. This design

allows a small air space between

these tanks and the outer shell,

thus allowing a potential buildup

of fuel and oxygen vapors in the

space. Just prior to construction

of the first vehicle, it was discovered that these tanks were covered with an insulating foam that

had dangerous electrostatic

properties. A search and testing

sequence was then implemented.

The final result was the selection

of a lightweight electrostatic

coating for all fuel and oxygen

tanks that would neutralize the

charge buildup in this confined

space.

The coating is in an inaccessible location. The first coating

material chosen was a clear,

permanent, lightweight antistatic

coating. However, further investigation revealed the coating had

to survive an elevated temperature during reentry and survive

as many as 25 launches without

maintenance. These additional

restraints proved hard to satisfy

and resulted in the testing of

many coatings by the Materials

Science Laboratory before a

satisfactory coating was found.

The final coating consisted of

small foam beads coated with

silver and applied with an epoxy

base. The testing proved the

antistatic properties under the

high temperatures and the number of cycles required.

Contacts: R. Gompf (Raymond.

Gompf- l@ksc.nasa.gov), A. Finchum,

and N. Salvail; LO-G3-T; (407) 867-

4619

61
Analysis of Chloropel by Direct Pyrolysis/FTIR

nfrared spectroscopy is well recognized as a powerful tool in

the characterization of a wide

variety of materials including

polymers, biological substances,

and semiconductors. Unique

infrared spectra act as a molecular fingerprint for materials.

However, the information obtained using traditional Fourier

Transform Infrared (FTIR) analysis may be limited when analyzing opaque, nonvolatile, and

complex polymeric samples. For

example, signal masking and

interference may make it difficult

to determine the composition of

industrial polymer systems

containing plasticizers, modifiers,

and other additives.

Thermogravimetric analysis

was used to design an appropriate temperature profile. A heating schedule of controlled ramping at 20 degrees Celsius per

minute (°C/rain) and isothermal

holds at 290, 445, 700, and 900 °C

was used to isolate characteristic

pyrolysates.

Infrared spectra obtained

from the neat material using

high-pressure anvil diamond cell

and attenuated total reflectance

yielded very similar spectra.

Characteristics matching those of

a polyester plasticizer typically

found in polyvinyl chloride or

chlorinated polymeric materials

dominate the spectra.

These interferences may be

overcome by combining infrared

spectroscopy and pyrolysis, the

thermal degradation of a material

in an inert atmosphere. As the

sample is pyrolyzed, the addition

of thermal energy causes molecules to fragment according to

the relative strength of bonds. A

pyroprobe inserted into the FTIR

interface places the quartz boat

sample cell a few millimeters

below the infrared beam. Materials evolved upon heating a

sample pass through the infrared

beam path and are detected.

The utility of direct pyrolysis/

FTIR in elucidating the composition of a complex polymeric

material was demonstrated. The

degradation of chloropel, a polymeric fabric used in protective

suits for hazardous operations,

was investigated.

Pyrolysis/FTIR provided

additional information that

facilitated the identification of

other components in the chloropel material. The spectra of

materials evolved at 250 °C (see

the figure) showed the loss of

hydrochloric acid (HC1) concurrently with the polyester plasticizer. This is evident in the

distinctive HCI pattern of sharp

peaks overlapping the hydrocarbon stretching between 2,560 and

3,060 wave numbers (cm-t).

Spectra of another evolved

species contained characteristics

indicative of polyethylene. Residue remaining at temperatures

above 1,000 °C indicates the

presence of an inorganic additive.

In this study, components that

were masked in traditional

infrared analysis were identified

62
Research and Technology 1998

Us_Spec_um

i ......... I ......... I ......... I ......... i ......... I ......... i .....

4000.0 3500.0 3000.0 25000 2000.0 1500.0 I000.0

Polyester and HCI Pyrolysates

using pyrolysis/FTIR. Chloropel was found to contain a chlorinated polyethlyene polymer, polyester plasticizer, and inorganic additive such as a coloring agent.

Pyrolysis/FTIR was also used to study wire insulation that had significantly degraded and resulted in a failure. Pyrolysis/FTIR can provide valuable information into

the chemical composition and degradation process of polymeric and composite materials.

Key accomplishments:

• Developed method parameters for pyrolysis/FTIR using a pyroprobe.

• Results indicate pyrolysis can be used to study the chemical composition and degradation process of polymeric materials.

• This technique will be used in failure investigations and polymeric research.

Contacts: M.K. Williams (Martha. Williams-l@ksc.nasa.gov) and J.J. Palou, LO-G3-C, (407) 867-3910

Participating Organization: C.M. Bradford, NASA Scholar (Georg(iaInstitute of Technology and Spehnan

College)

83
Hydrolytic Degradation of Poiyimide

Wire insulation

p olyimide wire insulation has long been the coating of

choice because of its excellent

electrical, mechanical, and chemical properties. The most common

among the wire insulations used

is the polyaromatic type that is

routinely synthesized by the

reaction of pyromellitic

dianhydride (PMDA) and

oxydianiline (ODA). Investigations carried out in the past

several years showed that the

polyimide class of wiring insulations was the subject of much

debate. Wiring problems were

encountered in the aircraft industry where it was found that the

use of alkaline cleaners in contact

with polyimide materials resulted

in degradation of the coatings,

thus resulting in fire hazards and

electrical shorts.

Laboratory tests conducted at

KSC revealed that polyimide wire

coatings show degradation when

exposed to hydrazine fuel. Hydrazine is used as a part of the

propulsion systems and auxiliary

power units (APU's). The APU's

are used to power the hydraulic

system of the Shuttle and other

space vehicles. The hydrazine

fuel has the property of acting as

both an oxidizing agent and a

reducing agent. It is also a weak

base.

The laboratory tests conducted at KSC included reactions

of polyimide with dinitrogen

tetroxide, aqueous ammonia (30

percent), anhydrous ammonia

(100 percent), and hydrazine fuel

(100 percent). Fourier Transform

Infrared (FTIR) analyses were

performed on the wire test

samples before and after exposure to the chemicals. Except for

the dinitrogen tetroxide, a reaction product was observed on all

other test specimens. The reaction product consisted of a yellow

powder. Polyimides undergo

hydrolytic degradation when

Use_ Spe_um

r r 1 r "r

3500.0 3000.0 2500.0 2000.0 1500.0 1000.0

:_.8 38325,o,m

Bio-Rad FT£

Comparison of Virgin and Exposed Polyimide (AscendiG_ Order)

64
exposed to alkaline solutions, and

the yellow powder formed is

characteristic of this reaction.

The postreaction FTIR analysis of the test specimens indicates

the presence of two spectral

bands not observed in the virgin

polyimide material (see the

figure). These bands occur at

approximately 1,650 and 1,550

cm _. Literature references indicate the degradation products for

this type of reaction are cyclic

hydrazides and amines. The

spectral bands observed therefore

correspond to a carbonyl functional group (1,650 cm _) and the

amine C-NH functionality (1,550

cm-l).

Each of the alkaline solvents

exposed to the polyimide insulations produced the same reaction

product; however, the hydrazine

fuel reacted most vigorously. The

next series of tests included only

the hydrazine, but the test specimens were exposed by direct- or

drip-type application, total

immersion, and vapor exposure.

Results showed all the polyimide

coatings reacted. After dissecting

the wire insulation, it was observed that the hydrazine vapors

even penetrated the second

polytetrafluoroethylene (PTFE)

layer and also the subsequent

polyimide layers. The PTFE layer

had a thickness of 0.001 inch (an

increased thickness would serve

as a better barrier).

Tile aircraft industry is thoroughly investigating this problem

in light of recent accidents and

because of the increased age of

many of the aircraft still in service. As a result of degradation

caused by many alkaline cleaners

used in tile aircraft industry,

several manufactures of polyimide materials are now using

more layers of PTFE and are also

searching for new polymer

materials that can serve as chemical barriers (resistance to alkaline).

Key accomplishments:

• Data confirmed that exposure

to hydrazine (and other alkaline chemicals) results in the

degradation of polyimide

insulation.

• The volume of exposure and

performance of insulation

should be addressed when

investigating possible polyimide insulation failures.

Contacts: 1.1. Palou (]aime.Paloul@ksc.uasa.y, ov) and M.K. Williams,

LO-G3-C, (407; 8_7-3910

Participati_<g Opxanizations: Wiltcch

Corporation and LauRh'y Research

Center

65
Epoxy Bonding Agents

poxy resins are characteristi- cally strong and resistant to

heat, water, and organic solvents.

It is for these reasons that epoxy

resins are used in diverse applications, one of which is attaching

strain gages to stainless-steel

bolts. Since epoxy resins are

capable of crosslinking without

the emission of volatile components, they are particularly suited

to application on impervious

materials such as stainless steel,

aluminum, and glass, which can

then be bonded with little or no

pressure.

In an investigation involving

a strain gage attached to a stainless-steel bolt, erratic voltage

readings were observed. Visual

inspection revealed the presence

of red liquid pockets in the epoxy

material. The red liquid was

analyzed by Fourier Transform

Infrared (FTIR) spectroscopy for

molecular composition and was

identified as an uncured epoxy

material. After removal of the

epoxy from the top of the strain

gage, more uncured liquid was

found next to the strain gage

circuit. Further analysis determined that the cure of the epoxy

material was inhibited by moisture absorption. Moisture increases the pH (more alkaline) of

the epoxy's curing agent. The

higher pH can have corrosive

effects on copper components,

which along with electrical

supporting data suggested the

failure mode of the strain gage.

Although there are several

types of epoxy bonding agents

available, this particular type is a

two-part system in which an

amine is used to induce the

crosslinking/cure process.

Amines are basic materials (pH is

greater than 7). The mixing

instructions for the epoxy state

that, after the amine curing agent

is added, the epoxy should be

mixed for 5 minutes and allowed

an additional 5 minutes before

applying the epoxy. Simulations

of this application process in the

laboratory still indicated the

presence of uncured epoxy

(confirmed by FTIR analysis).

To evaluate the root cause of

the curing problem and to identify any interfering components,

several tests were performed to

assess the application process.

Contamination from the flux

(rosin) material used in soldering

was found to induce no adverse

effects (acidic pH was approximately 6). However, as expected,

when minute quantities of water

were added, an inhibitory effect

on the epoxy cure was observed.

The application of the epoxy

appeared to be most successful at

room temperature when the

epoxy was mixed for 5 minutes

and then applied after an additional 10 to 15 minutes (may vary

with the temperature and humidity of the room). The additional

time allows for the crosslinking

process necessary to obtain a full

cure and decreases the interference of the moisture. The addi66
3.50

Uee Spectrum

...... i ......... i ......... i ......... i ......... i ......... i • " .I

1800.0 1600.0 14000 1200.0 10000 800.0

19172 1579.5, 078 7267

Bio-R_ FTS

Note: A similar chemical pattern is exhibited in the fingerprint region of each infrared spectrum.

Comparison of Liquid Amine Curing Agent and Reddish Liquid Contaminant (Descendiu_ Order_

tional time will ensure a good cure and still be within the shelf life stipulated by

the manufacturer. Another recommendation for the application process is to use

a nitrogen purge.

Key accomplishments:

Results suggested a failure mode for the strain gage.

Recommendation for improvements in the application of epoxy used for strain

gages.

Contacts: M.K. Williams (Martha.Williams-l@ksc.nasa.gov) and J.J. Palou, LO-G3-C,

(407) 867-3910

Participating O_xanization: LO-G4-E (J.A. Bayliss)

67
Materials Science

Cryogenic insulation Systems for Soft Vacuum

A cryogenic insulation system

for an operation under a soft

vacuum was developed at the

KSC Cryogenics Test Laboratory

in 1998. Conventional insulation

materials for cryogenic applications can be divided into three

levels of thermal performance, in

terms of apparent thermal conductivity (k-value in mW/m-K).

System k-values below 0.1 can be

achieved for multilayer insulation

operating at a cold vacuum

pressure (CVP) below lx10 -4torr.

For fiberglass or powder operating at a CVP below lx10 -3tort,

k-values of about 2 are obtained.

For foam and other materials at

ambient pressure, k-values

around 30 are typical. New

industry and aerospace applications require a versatile, robust,

low-cost thermal insulation with

an overall performance in the

moderate range. The target for

the new composite insulation

system is a k-value below 3 mW/

m-K at a soft vacuum level (from

1 to 10 tort) and boundary temperatures of approximately 77

and 293 kelvin. Many combinations of radiation shields, spacers,

and composite materials were

tested from high vacuum to

ambient pressure using cryostat

boiloff methods. System design

considerations included installation, outgassing, evacuation,

compression, and end effects. As

shown in the figure, significant

improvement over conventional

systems in the soft vacuum range

was demonstrated. The new

layered composite insulation

system was also shown to provide key benefits for highvacuum applications as well.

Optimization of the insulation

system for specific applications

(such as liquid oxygen storage on

Mars, liquid nitrogen conduit for

superconducting power lines,

advanced launch vehicles, and

Shuttle upgrades) is planned for

1999.

Contact: J.E. Fesmire (James.Fesmire1@ksc.nasa.gov), MM-J2, (407) 867-

7969

Participating Organization: Dynacs

Engineering Co., htc. (S. Augustynowicz)

68
Research and Technology 1998

rX

L

E 10

"0

tO

o

g

0.1

E

I1)

100 , [ ........ :........ L

I . l ! -

I

!

J

0.01 ........................

0.01 0.1 1 10 1O0 1,000 10,000

Cold Vacuum Pressure (microns)

Thermal Conductivity as a Function of Cold Vacuum Pressure

[Comparison of Layered Composite Insulation (LCI) and Multilayer Insulation (MLI)]

69
Permanent Antistatic SCAPESuit Coating

A research grant was given to

Belland Corporation of

Andover, Maine, to develop an

easy-to-apply, permanent, clear

antistatic coating. This coating is

to be applied to the Self-Contained

Atmospheric Protective Ensemble

(SCAPE) used during toxic fueling

operations at KSC. The evaluation

testing is currently being done by

the electrostatics engineers of the

Materials Science Division (MSD).

The SCAPE suits presently

used for worker protection during

Shuttle fueling operations are

electrostatically capable of generating voltages in excess of 20,000

volts. This is a high voltage capable of producing catastrophic

electrostatic discharges. This

potential was controlled in the past

with an application of topical

antistatic spray. This solution has

several disadvantages. It is only

temporary since the solution must

be applied to the suit every hour

during work. There is an everpresent danger if the antistatic

material is rubbed off during the

team to remove the injured

worker is difficult due to the slick

nature of the spray. The potential

hazard of not using this spray

was clearly demonstrated in a

previous incident where a small

fuel fire was ignited during

Orbiter Processing Facility operations in the Orbital Maneuvering

Subsystem pods. An electrostatic

discharge from the uncoated suit

material was the most probable

cause of the fire.

Test results of one promising

version of the coating reduced the

maximum suit voltage generation

from above 20,000 volts to below

1,000 volts. At this time, the

testing is concentrating on the

adhesive properties and the

chemical compatibility with a

variety of fuels and chemicals.

These test results are encouraging, and the coating seems to

improve the suit protection for

certain fuels.

Contacts: R. Gompf (Raymond.Gompfwork and there is some concern l@ksc.nasa.gov,) LO-G3-T, (407) 867-

about exposure to the spray during 4619; M. Parenti, LO-G3-T, (407) 867-

application. If a worker becomes 8433; and N. Salvail, LO-G3-T,

injured, the ability of the rescue (407) 867-1404

7O
Hondestructive

Evaluation

he Nondestructive Evaluation (NDE) Technology program at the John F.

Kennedy Space Center (KSC) includes

the development of inspection and verification instruments and techniques that can

provide information (external or internal) to

hardware and component structures in a

nonintrusive manner. The technology

includes, but is not limited to, laser, infrared, microwave, acoustic, structured light,

other sensing techniques, and computer and

software systems needed to support the

inspection tools and methods.

The present effort in this discipline is being

directed toward reducing Shuttle processing

costs using these technologies. The longterm effort of the program is to develop

cost-effective NDE techniques for inspecting

and verifying space vehicles and their

components during manufacture and to

continue validating those items during

assembly/launch and on-orbit or during

space flight.

71
Hondestructive Evaluation

Condition Monitoring and Fault Identification

in Rotating Machinery (CONFIRM)

oading of the Space Shuttle

external tank with liquid

oxygen is accomplished via a

pumpmotorbearing assembly

located at the northwest comer of

Launch Complex 39. Since the

assemblage is vital to the success

of any mission, it is continuously

monitored to detect, identify, and

assess its condition and take

appropriate actions to minimize

the impact on launch. Condition

or health monitoring technologies

that are being considered for use

fall into two major categories:

Mechanical Vibration Signature

Analysis (MVSA) and Motor

Current Signature Analysis

(MCSA). Also, the Acoustic

Emission (AE) technique and a

Lube-Oil Analysis (LOA) will be

used as early warning tools for

predicting impending failures.

Mechanical, electrical, and flowinduced problems will be addressed in this multiyear research

program.

The present effort is directed

toward the installation of a

pump/motor/bearing assemblage at the Launch Equipment

Test Facility (LETF) to simulate

Launch Complex 39. This setup

will provide a test bed for research and development, testing

of variable frequency drives, and

hands-on training for launch pad

personnel. The assemblage will

serve as a platform for the evaluation of newer online condition/

health monitoring technologies.

Such online machinery monitoring will lead to improvements in

operational efficiency, eliminate

shutdowns, reduce maintenance

costs, and prevent catastrophic

failures. Early detection and

correction of impending failures

will significantly improve reliability while enhancing safety.

Key accomplishments:

1998: Implemented the liquid

oxygen pump assemblage at

the LETE Validated the use of

AE, MVSA, and MCSA techniques in identifying rotating

machinery defects.

Key milestones:

1999: Assess condition monitoring technologies and variable frequency drives on the

300-horsepower pump assemblage. Additionally, validate

the MCSA technique and

coordinate with MVSA methods.

Contact: A.F. Rodriguez (Andres.

Rodriguez-1 @ksc.nasa.gov), MM-J2,

(407) 867-7969

Participating Organizath_ns: Dynacs

Engineering Co., Inc. (R.N. Marwsahayam and M.]. Ynclan) and

hfformation Dynamics, Inc. (L. Albrikqlt

and O. Varosi)

72
Pump

Vibration

Sensor

Acoustic

Emission

Sensor

Water Loop

Simulated LETF Water Pump Motor Facility

73
Evolved Expendable Launch Vehicle (EELV)

Hydrogen Testing

his report describes the equip

ment, procedures, and qualification testing to be used to evaluate the mixing of hydrogen and

oxygen in the simulated plume of

the EELV RS-68 engine. The

EELV engine is similar to the

Shuttle engine, which uses hydrogen as the fuel and oxygen as the

oxidizer. These engines start the

flow of hydrogen before oxygen

is added during the launch

sequence, and the oxygen flow

stops before hydrogen upon shut

down. Both of these situations

leave hydrogen, which must be

burned off before the area is safe.

Therefore, this excess hydrogen

must be burned in a manner that

precludes detonation. The procedure is to entrain oxygen from air

in hydrogen to provide a combustible mixture, then to ignite this

mixture so a controlled burn

occurs.

The primary objective of this

test program is to qualify a

combustion ignition system that

would burn hydrogen from an

aborted launch. To simulate the

firing of the EELV engine, nitrogen will be released into a 1/7-

scale flame trench. These releases

will last 0.7 second and will

include hydrogen combustion as

part of the simulation. This

project has three phases: Phase 1

requires analysis of ambient

oxygen in nitrogen, Phase 2

requires analysis of hydrogen

added to ambient oxygen in

nitrogen, and Phase 3 requires

analysis of hydrogen burning

with ambient oxygen in nitrogen.

To make these measurements,

grab-samples of the atmosphere

will be collected just before

release, during release, and just

after release. The sampler (see

figure 1) is constructed of sections

of tubing linked between valves

so the flow rate of the sample

matches the total tubing length.

Therefore, each section represents

a time history of the concentration of the gases as they pass the

sample inlet. The contents of the

sample tubes will be analyzed by

gas chromatography, a method

Sample In _'_ _;_/ _X] _:_N /_ _ample_Out

Sample Tubes Valves Pump

Sample _ow

F_c,ure 1. Sampling Setup for One Point of Six Sample Points Across the Exhaust Duct

74
Research and Technology 1998

Figure 2. Sampling System With EELV Test Simulation llqmt,m'ptt

that can measure the concentration of each gas at 0.2

percent.

The sampling system

seen in figure 2 shows the

sample lines, valves, and

sequencer that times the

opening and closing of the

valves which separate the

samples. The procedure to

be used will clamp the

sample tubing on either side

of the valves to isolate the

sample. This will allow a fast

turnaround of the sampling

system, since it will only

require replacing the sample

tubes with new precut

tubing. The samples in the

tubes can be analyzed by a

gas chromatograph independently of the EELV testing.

Key acconlplishments:

• Developed a method to measure the concentration profile

as a function of time during

EELV testing.

• Designed and produced six

units to capture the test

samples.

• Developed the sample introduction system for the gas

chromatograph.

• Demonstrated that the method

could measure the concentration of oxygen and hydrogen to

less than I percent in nitrogen.

CmHacts: R.C. l_._nn,¢(l@t,vcca._i_mt_-

l@ksc.nasa.,1ov) amt I).t-. Ire'ok, MMG2 (407>807-4439

Participatin< ( )r<anizatimt: l):mm's

Enlim'erin f Co., Inc. (C.I. Parrish, C.].

Schwimtt, T.R. t lodoc, amt P.tt. (;ambh')

75
Nondestructive Evaluation

Thermography for Nondestructive Evaluation

and Laser Shearography

ASA, United Space Alliance, Boeing North American, Inc.,

and Dynacs Engineering Co., Inc.,

engineers and scientists performed shearography and thermography inspection of Atlantis

(OV-104) payload bay doors at

Palmdale, California. The payload bay door structure is composed mostly of graphite-epoxy

honeycomb and laminate. No

existing inspection can adequately inspect this composite

structure. Two new techniques,

shearography and thermography,

were used to inspect about 70

percent of the structure shell in 7

working days (one shift). Both

techniques worked well regarding the rate of inspection and

sensitivity. Several defects were

detected, most resulting from

maintenance-induced damage.

All suspect defects were corroborated with ultrasonic inspection

before defining any repair.

These results are a continuing

effort at KSC to develop a reliable

inspection method for composites. Two other vehicles, Discovery (OV-103) and Endeavour (OV105), have had similar inspections

with good results. Boeing has

written specifications certifying

these techniques for use on the

Shuttle.

Future actions include developing the sensitivity and accuracy of each technique in various

applications, developing operator

procedures and certification, and

extending the applications to

other areas including the external

tank and solid rocket booster

thermal protection system and

leak visualization.

Key accomplishments:

• 1996: Discovery payload bay

door inspection.

• 1997: Endeavour payload bay

door inspections and shearography and thermography

specifications published.

• 1998: Revised shearography

and thermography specifications to include a general

procedure. Atlantis payload

bay door inspection.

Key milestone:

1999: Probability of detection

curves for the most common

composites for the orbiter.

Contact: C.K. Davis (Christopher.

Davis-1 @ksc.nasa.gov), PK-H, (407)

861-3636

Participating Organizations: United

Space Allhuzce (K.R. Wagner), Boeiny

North American, Inc. (A.M. Koshti),

and Dynacs Engineering Co., Inc.

(l. Donahue)

76
Research and Technology 1998

Process/industrial

Engineering

N ASA's Kennedy Space Center (KSC) is devel- oping as a world-class spaceport technology

center. Process/industrial engineering technologies are integral spaceport technologies. From a

process or industrial engineering (IE) perspective,

the facilities used for flight hardware processing at

KSC are NASA's premier factories. The products of

these factories are among the most spectacular

products in the world - safe, successful Shuttle and expendable vehicle launches carrying tremendous

payloads. The factory is also the traditional domain of the discipline of IE. IE is different in many

ways from other engineering disciplines because it is devoted to process design, management, and

improvement, rather than product design. IE also emphasizes the relationships of workers with

systems and processes. Spaceport processes have many unique aspects that require development of

innovative IE technologies, such as complex and risky depot-level maintenance processes, highperformance system test and checkout procedures, and low-volume manufacturing processes.

Process/industrial engineering technologies address the generic challenge of "doing more with less."

IE is typically used to optimize the operational phase of a program. IE technologies introduced early

in the program life cycle (during concept, design, and development phases) generally deliver outstanding results. The Space Shuttle is NASA's first major program with a long-term operational

phase, and many current and potential future programs (i.e., the International Space Station, X-vehicles, and human space flight to Mars) also are projected to have lengthy operational phases. Therefore, the strategic importance of process/industrial engineering research and technology development

to NASA is rapidly increasing.

Technologies include methods, tools, techniques, and processes as well as hardware and software.

Most IE technologies evolved from the need to improve shop floor productivity. IE technologies are

now successfully used to design and enhance every type of process in Government agencies, production industries, service industries, and academia. Therefore, spaceport process/industrial engineering

technologies can be effectively transferred to a variety of additional organizations.

The growing need to do things better, faster, cheaper, and safer has improved the potential value of

process/industrial engineering technologies. The articles in this section are divided into five interrelated areas of process/industrial engineering: Management Support Systems, Human Factors Engineering, Work Methods and Measurement, General IE, and Process Modeling and Analysis. Your

feedback to the contacts listed in these articles is appreciated.

77
Process/industrial Engineering

Management Support Systems:

Goal Performance Evaluation System

n 1993, Congress passed the Government Performance and

Results Act. A key requirement of

this legislation is that all Federal

agencies develop strategic plans.

A 1997 Congressional report

graded the strategic plans that

were submitted. The report

noted that agencies failed to

explain how their goals linked to

their day-to-day operations and

to each individual employee's

performance plans/appraisals.

NASA's Strategic Plan states

that each NASA Center Implementation Plan should be "...the

communication tool used to

enable the Center's customers to

see that their requirements are

being addressed and to ensure

that employees understand their

contribution to the highest level

strategies and objectives of

NASA. The final linkage is made

through each individual's performance plan appraisal" (from

NASA Strategic Management

Handbook, October 1996). The

Goal Performance Evaluation

System (GPES) was developed to

make this "final linkage" to bring

the NASA Center Implementation

Plan to the employee and to

encourage strategic linking and

implementation at every level in

the organization.

The potential for this research

was to address the execution of

an agency's strategic plan. Ultimately, the employees of an

organization are responsible for

the action planning, task execution, and accomplishments of

their organization. However, few

tools exist that accommodate

these objectives or that focus on

the specific needs of a Federal

agency. The GPES was developed to aid NASA in implementing the Vision and Strategic

Objectives outlined in the Agency

plan.

The GPES was developed as a

Web-based strategic planning tool

used for planning, managing, and

evaluating employee contributions to NASA Center and NASAwide strategic objectives. Each

employee performance plan

contains objectives and strategies •

derived from directorate-level

goals and objectives. All directorate objectives are electronically

available in the GPES, including

the links to higher level goals.

The supervisor defines employee

performance by selecting objectives and strategies from a "drop

down" menu. Since the supervisor no longer has to write job •

elements and performance requirements for every employee,

the supervisor can focus on

individual goals. Employees can

enter their achievements and

track them throughout the year. •

Status reports are available at the

directorate and Center levels.

The GPES tracks the links

from directorate mission objectives and mission strategies to

Agency and Center strategies and

links from individual performance objectives to directorate

objectives and strategies. Metrics

are maintained for status of

performance plans, links to

objectives and strategies, system

utilization, performance indicators, and the number of World

Wide Web accesses to related

promotional banners of interest to

employees.

The GPES is fully operational

at KSC and is being used for the

1998/99 employee appraisal

period. The GPES was presented

and well received by all NASA

Center Directors and the NASA

Administrator and is currently

being implemented at Johnson

Space Center (JSC). The GPES

software continues to be enhanced with additional features,

such as:

Supervisor safety and health

metrics (via an automated

point system)

• Supervisor 360 assessment

feature

• Online performance award/

evaluation

Online collection of community

outreach activities for employees

Key accomplishments:

1998: Successfully developed

and implemented the Webbased GPES for all Civil Servants at KSC and implemented

the GPES for all Civil Servants

at JSC.

Key milestone:

1999: Continue deployment of

the GPES to other Manned

Space Flight Centers.

78
Research and Technology 1998

GPES Command Center Menu:

• Automates the employee performance appraisal

process, from planning through appraisal.

Provides a direct link between overall

organization/directorate strategic plans and

employee performance.

• Integrates business goals and objectives with

daily work processes

• Provides centralized data for summary

evaluation of organizational objectives.

• Aligns resources toward successful achievement

of overall goals/mission.

• Affects behavior toward strategic thinking and

implementation.

Beneficial software design attributes include:

• Easy customization.

• Intuitive graphical user interface.

• Web-based or intranet application.

• Integrated application using off-the-shelf tools.

Contacts: C.J. Carlson (Christopher.Carlson-l@ksc.nasa.gov), ST-B, (407) 867-6450; J.C. Kunz,

ST-B, (407) 867-6411;and L.B. Roe, ST-B, (407) 867-6472

79
Process/industrial Engineering

Management Support Systems: Organizational

Change Models for Strategic Management

overnment organizations, as

is the case with private

organizations, are being required

to change their present operations

to align with the ever-changing

environment. Often this change

need leads to a large-scale transformation including a change in

mission or core business. With

the change in mission, the organization must also change the

manner in which it completes its

core business (i.e., the processes,

tools, and people). One of the

first steps in achieving successful

change and transformation is to

create a vision of the future.

Strategic management has been

offered as a method to drive

organizational change. Strategic

management is a continuous

process aimed at aligning everyday actions with the long-term

direction of the organization

based on the needs of the cus8O

Strategic

Planning

ee'°rmance _ i 'rnP_a_enn_tion

Evaluation

_ Execution i_

Strategic Management Process

tomer. An organization can use

strategic management to achieve

a set of strategic thinking outcomes and produce a set of

products to move the organization forward. The objective of

this research is to understand and

demonstrate the use of the strategic management process to drive

large-scale transformation.

As shown in the figure, the

process of strategic management

includes the functions of strategic

planning, implementation planning, execution, and performance

evaluation. KSC used this process to develop a set of products:

a strategic direction, project

plans, an initial set of performance measures, strategic results,

and lessons learned.

Strategic planning is a group

process by which the organization defines or refines the

organization's mission (core

business statement), vision (ideal

future state), goals, and objectives. The process involves

understanding both the internal

and external environments (e.g.,

strengths, weaknesses, opportunities, threats, etc.). The output of

strategic planning is an integrated

set of goals, objectives, strategies,

and projects to improve performance.

For KSC, the strategic planning process focused on defining

a strategic direction with products of a future state, core business, and strategic roadmap. The

Center Director shared the message via a KSC-wide rollout

process he presented at an allhands meeting and then visited

with each directorate at KSC. The

Strategic Plan became real
throughtheimplementation

planningprocess.

Implementationplanningis

theprocessby which theorganization developsspecificstrategies

or actionsto implementthe

strategicdirectionand definesthe

specificmeasuresof performance

thatwill determinetheprogress

of theplannedactions.Implementation planning provides the

detailed performance planning

and proposed resource allocation

to implement the Strategic Plan.

An organization uses the implementation plan to guide day-today behavior or execution. Execution is the carrying out of the

implementation plan.

Performance evaluation is the

process by which the organization understands the impacts of

the projects on the goals and

objectives. The use of performance measurement and evaluation creates tangible results that

can be studied to produce lessons

learned and recommendations on

how to improve the organization

and adjust the Strategic Plan.

The customer satisfaction

process is tile foundation for tile

strategic management process by

providing infornlation and knowledge about how KSC can meet and

exceed customer needs.

Key acconlplishments:

• 1997: Conducted an internal and

external research study on the

success factors for strategic

management.

• 1998: Conducted a cycle of

strategic management with KSC.

Key milestones:

1999: Refinement of a set of

processes and integrated schedule for strategic management.

Development of a best-practices

model for deploying strategic

management.

Contact: I.W. l,y0Hs (]cmliti'r.l.yopts

l@kscmasa.sovl, AG, (4¢)7) 807-2512

Participatin S,()pNaui:ati(m: thHvcrsity of

Central Florida ¢T. Kohwur, Ph.D.

81
Process/induslriai Engineering

Management Support Systems: Methodology

To Harvest Intellectual Property at KSC

nformation and data obtained

through problemsolving and

decisionmaking can be converted

into intellectual capital. The need

to acquire intellectual capital

created the knowledge management movement, which aims to

develop new practices and tools

to capture knowledge. Knowledge management in general tries

to organize and make available

important know-how, wherever

and whenever it is needed. This

includes processes, procedures,

patents, reference works, formulas, "best practices," forecasts,

and fixes. One kind of knowledge management project attempts to manage knowledge

assets from a financial perspective. KSC's focus on this project

is on intellectual capital and

harvesting little-used patents and

intellectual assets. As the Center

responsible for preparing and

launching space missions, KSC is

placing increasing emphasis on

its technology development

program. KSC maintains a

vigorous applied research program in support of Shuttle launch

activities. Ground support

systems, launch and processing

facilities, and environmental

protection all require continued

attention for KSC to remain the

Nation's premier state-of-the-art

spaceport. Focusing predominantly on applied research

prompted KSC to develop new

technologies and expertise directly applicable to commercial

products and manufacturing

needs.

Technology commercialization is a primary goal of NASA's

Technology Transfer Program.

Patent and copyright licensings

are key mechanisms to accomplish this goal. In order for

NASA to continue to increase the

110

120 101

03

.m

C

0

0_

100

80

60

40

20

0-

15

ca

O u_

t38

78

number of successfully commercialized technologies, NASA must

identify commercial applications

for its new technology and effectively seek out commercialization

partners.

Key accomplishments:

52

82

Potential Markets

Technologies

1997 and 1998: Alternative

commercial applications were

identified for 11 KSC-developed technologies. Four

technologies were analyzed in

the last half of 1997 and seven

in the first three-quarters of

1998. These advanced technology development projects have

been proposed, are currently

under development at KSC,

have been completely developed, or have already received

intellectual property protection. Potential markets associated with the new applications

were investigated, which

provided profiles of key companies that may be interested

in partnering with NASA. The

current state of similar or

107

97

03 09 03 (.9 03 m (5 03

< O n < n u_ O

J rr (5 _ ILl .j n U_

O9 "1-
Research and Technology 1998

applicable commercially available technology and potential for

dual-use development with industry was investigated. Assistance

in identifying and characterizing qualified leads associated with

commercializing NASA technologies was provided. Companies

were categorized primarily on the basis of capabilities, interests,

and areas of expertise. A comprehensive report containing a synopsis of each advanced technology project as well as a review of

possible partners and applicable commercially available technologies was prepared. KSC was provided with 668 leads for potential

commercialization partners and 110 new potential uses for the

following technologies (the figures show detailed information of the

new uses and potential commercialization partners):

Environmentally Controlled Abrasive Blastsuit (ECAB)

Hydrogen Fire Detector Calibration Unit (HFDCU)

Liquid Air Mixing System (LAMS)

Low Differential Pressure Generator (LDPG)

Mapping Analysis and Planning System (MAPS)

- Particle Fallout Monitoring System (PFM)

- Portable Ultraviolet Flame Simulator (PUFS)

- Remote Monitoring and Alarm System (RMAS)

- Supersonic Gas-Liquid Cleaning System (SGLCS)

- Test Aerosol Generator (TAG)

- Turbine-Driven Pipe-Cleaning Brush (TDPCB)

Key milestone:

1999: Ongoing identification of

alternative commercial applications for additional NASAdeveloped technologies.

Contact: G.A. Buckingham (Gregg.

Buckingham-1 @ksc.nasa. gov ), HM-C IC,

(407) 867-7952

Participating Organizations: NASA

Technology Programs and Commercialization Office (K. W. Poimboeuf and

D. Makufka) and Florida International

University (I. Becerra-Fernandez)

25

22

¢/J

(i)

Z

2O

15

10-

5 m

0 -

10 10

i

_3

(.3

O_

£3

O9

U_

n <

._1

9

15 15

03 o9 (.9 03 rn (.9 03

< (.) _ o_ < n u_ o

.-.J F-: < O O _ r'_

rr (.9 _ U2 _ 0_ u_

03 1-

Technologies

"New" Technology Uses

88
Process/Industrial Engineering

Management Support Systems:

KSC Customer Focus Process Development

s part of the KSC Strategic Roadmap, customer satisfaction

has been identified to be both an objective and a strategy.

These customer satisfaction objectives and strategies will support the Center's vision and will help in achieving KSC's stated

goal as the worldwide launch site of choice. The objectives and

strategies will also drive improvements in KSC's core capabilities

by addressing the tools, expertise, facilities, and business processes that support the customer. To address these customer

satisfaction objectives and strategies, research was conducted in

customer satisfaction, which included customer elements from

the Baldrige award criteria and President's Quality Award.

Based on the research, a customer focus model was developed

(see the figure). The model delineates a six-element scope

defined as follows:

1. Customer Knowledge: This element defines and segments

current and potential strategic customers and identifies their

needs, with additional information gathered regarding their

requirements, expectations, and critical success factors.

2. Customer Satisfaction Determination Tools and Methods:

These processes include collecting feedback from multiple

types of methods over the duration of the customer experience

at KSC, feeding that information back to the appropriate

organizations, using the information to drive improvement

projects, and reporting the improvements back to the customer.

3. Benchmark Best Practices: Benchmarking becomes an ongoing process of seeking out continual improvements in both the

practices and processes of improving customer satisfaction.

4. Customer Satisfaction Leadership: This element uses the

previous element results to create a customerkeeping vision,

to saturate KSC with the voice of the customer, and to develop

performance expectations related to customer focus.

5. Relationship Management: Relationship management uses

processes for interfacing and supporting the customer to

maximize customer loyalty and retention and analyzes complaints and lost customers.

. Customer Satisfaction Improvement and Results: This element develops and tracks customer service standards based

on outcomes from the previous elements, including customer

satisfaction metrics and customer business results for KSC.

This model is being used as the

blueprint to develop and implement processes and leadership for

a customer-driven KSC. Once

implemented, the results of the

processes will be used as an integral component of the Center's

strategic planning efforts.

Key accomplishments:

1998: KSC customer base

identified and segmented.

Surveyed KSC management for

perceived barriers and enablers

of customer satisfaction. Completed a test case for the first

segment for customer satisfaction determination. Reported

the test case results to senior

management and to those

customers interviewed.

Key milestones:

1999: Determine customer

satisfaction baseline for all

segments. Refine processes for

all customer focus elements.

Develop an Integrated Management System to assimilate

customer data. Train KSC

employees for customer awareness and understanding of

customer processes.

2000: Implement the Integrated

Management System. Establish

and use processes for ongoing

customer satisfaction measurement.

Contact: L.K. Buckles (Linda.Buckh, sl@ksc.nasa.gov), AG, (407) 867-2512

Participating Organizations: University

of Central Florida q. Matkovich and

T. Kotnour) and the KSC Customer Focus

Team (NASA, United Space Alliance, and

Boeing)

84
Customer

Focus Model

1.

Customer

Knowledge

• Determine existing and

future strategic customer

base

• Determine critical success

factors in meeting

customer expectations

2.

Customer

Satisfaction

Determination

Tools and Methods

• Develop tools/surveys for

measuring customer

satisfaction

• Drive improvement

• Report to customer

3.

Benchmark

Best Practices

• Determine benchmark

criteria

• Learn from best

practices

4.

Customer

Satisfaction

Leadership

• Create a customerkeeping vision

• Saturate KSC with the

voice of the customer

• Develop performance

expectations

• Customer satisfaction

reviews

5.

Relationship

Management

* Interface issues with the

customer

• Implement a complaint

management process

• Develop customer loyalty

processes

• Lost customer analysis

6,

Customer

Satisfaction

Improvement

and Results

• Customer satisfaction

measurement

• Implementation projects

• Customer satisfaction

process improvements

• Customer satisfaction

President's Quality Award

• Expanding the customer

base

85
Process/Industrial Engineering

Management Support Systems:

Balanced Scorecard Metrics

ue to the requirements of the

Government Performance

and Results Act of 1993, which

was designed to improve the

accountability of Federal agencies, and to KSC's commitment to

manage strategically, selected

indicators with performance

targets were needed to evaluate

the Center's performance. The

KSC Strategic Roadmap had been

developed; however, to bring the

roadmap to life, measures were

needed to determine if the

strategy was being implemented

and getting results. A lesson

learned from the National Performance Review study on metrics

suggested that a specific framework should be defined to develop measures of organization

performance.

A team representing all areas

of the Center was formed to

analyze the existing strategy and

to understand the expected

outcomes from implementing

KSC's strategy. A review of the

literature on organizational

measurement systems and input

from experts was balanced with

KSC corporate knowledge of

current operations. Small groups

were used to facilitate inspection

of the category functional areas.

The Agency, enterprises, and

Center management were viewed

as customers of the process.

Seventeen high-level indicators

that were balanced between nearterm and long-term outcomes

were selected. These metrics map

to Agency and Center goals and

form the KSC balanced scorecard.

As each high-level metric is

developed, it will be added to the

champion organization's Web site

and linked to the KSC Business

World Scorecard. The scorecard

will be reviewed each quarter at

an executive management review.

A "drill down" to lower level

metrics that track to root cause/

individual contributors will be

added. Each organization will be

tasked to define a "balanced

scorecard" related to its products

and services.

Key accomplishments:

• November 1997: Senior managers reviewed each strategy in

the KSC Roadmap and attempted to further define them

with metrics.

• December 1997: 187metrics

were identified, at least one for

each strategy and objective of

the KSC Roadmap.

• January 1998: A team was

formed to refine the indicators

for consistency and linkage.

• March 1998: The team began

to define a framework/approach for KSC metrics.

• April 1998: Roadmap indicators were grouped into eight

categories and evaluated to

balance across the Kaplan and

Norton model.

• May 1998: The Center Director

introduced the KSC Scorecard

at a Strategy Update Briefing to

all employees.

86
Vision and Strategy

• NASA Programs

• Enterprises

• Customer Agreements

• Support Agreement

Framework Metrics

Sample Metric

,,.....

Sample Metric

 ii:ii

Sample Metric

u...,o... No, =.,

Sample Metric

.,,..,_. No_ =.,

KSC Oq_anizational Performance Measurement Structure

• August 1998: Top-level indicators were selected for each scorecard category.

• October 1998: Directorates were selected to champion each top-level metric.

• November 1998: The KSC Scorecard was added to the Business World Web site with place holders for

each metric chart.

Key milestone:

• February 1999: A Center Performance Review was made using KSC Scorecard metrics.

Co, tact: M.A. Bell (Michael.Bell-2@.ksc.nasa._ov), AG, (407) 867-2512

Particil,ati,g Or_ap_izations on the KSC Metrics Integrated Product Team: AF-A (G. Swmlson), AB-G2 (D. Armstrong), AI

(R. SharumL BC (L. Buckles), EC-C (R. Tilley), EY-B-PA (B. Monson), FF-D1-A (R. Poptik), FF-13-A (M. Steele), GG-C-B2

¢K. Buclmer), HM E (L. Boyd), JJ-5 (C. Quincy), LO (B. Franklin), LO (M. Stelzer), MM H (A. tfeard), OP-OSO

(M. Krisbc_X), I'H (S. Roblin_), PZ-AI (T. Barth), and ST-B (]. Kunz)

87
Process/Industrial Engineering

Management Support Systems: Program Corporate Memory ---

a Knowledge Repository for KSC

any organizations depend on

decisionmakers to create

mission-critical decisions that are

grounded on information from

various areas. The typical

decisionmaker has a deep understanding of specific domains that

affect the decisionmaking process

combined with the experience

that permits the individual to

react immediately and decisively

on the knowledge. A prominent

decisionmaker has also gained

extensive experience and implicit

knowledge from years of work in

such domains. An advancing

trend today is downsizing; many

organizations make a conscious

decision to downsize in order to

cut back spending and better

compete in an increasingly

aggressive market. Among the

many side effects of downsizing

is the dissipation of the "knowledge resources" of the organization; hence, organizations end up

devitalized (e.g., decreased

morale, commitment, quality,

teamwork, productivity, and

innovation). To conserve the

existing knowledge, a practical

knowledge management (KM)

system demands that it be obtained/produced, shared, regulated, and leveraged by a steady

conglomeration of individuals,

processes, information technology applications, and organizational culture. KSC is currently

facing a wave of employee turnover as a result of Federal Government downsizing, retirement,

and work redefinition. In order

to prepare for these imminent

organization challenges, KSC

commissioned a Knowledge

Management Assessment (KMA)

study.

In order to assess the areas of

intellectual capital for KSC, a

KMA was designed and implemented. The purpose of the

KMA was to (1) identify key

competencies for KSC, (2) perform a knowledge asset inventory, (3) perform a process evaluation, (4) analyze KM cultural

readiness, (5) perform a technology evaluation, (6) develop a KM

strategy deployment roadmap,

and (7) propose the necessary

next steps.

For this purpose, a series of

KM assessment interviews were

designed and implemented with

the cooperation of representatives

from the majority of the functional groups at KSC. The goal of

the KM interview was to assist

KSC in identifying key competencies and to analyze the current

knowledge architecture for the

Center. This step will ensure the

appropriate methodology is

recommended at the end of this

phase. An important desired goal

of this effort was to gather data to

implement a prototype that will

address some of KSC's KM needs.

Anecdotal results of the KMA

interview for two functional

directorates at KSC are described

in detail in the project's final

report. The findings from the

KMA included KM needs and

possible enhancements to the

existing KM environment. These

findings also comprise cultural

needs, which address the promotion of a knowledge-sharing

culture versus a culture where

"knowledge is power."

Key accomplishments and milestones:

• A KMA study was designed

and implemented between

February and April 1998. In

order to accomplish the assessment, eight technical groups

were interviewed at KSC. The

KMA findings obtained from

the groups interviewed revealed KSC's KM needs and

possible enhancements to the

current KM environment.

• Following the KMA interviews,

two directorates were selected

by KSC executives for a 3-hour

detailed second-stage drilldown interview. The two

groups chosen were the Shuttle

Processing and the Payload

Processing Directorates. The

purpose of the second-stage

drill-down interviews was to

identify a focus area to serve as

a test bed for a KM application.

Representatives from the two

functional directorates were

interviewed during the secondstage KMA.

• Illustrative prototypes were

generated for each of the four

recommendations presented to

KSC executives. The prototypes were created using data

from the groups at KSC. Findings were presented to the

executive team in July 1998.

88
Research and Technology 1998

• A written report was compiled and distributed to the executive team as well as to each of the

participating directorates in July 1998. The written report also included a literary review on

what organizations are currently doing in KM.

• A number of presentations were made to some of the functional groups that participated in

this effort. Ongoing presentations are expected.

• Proposals to address some of the required organizational KM systems were prepared and

submitted.

Contact: G.A. BuckiGgham (Gregg.Buckingham-l@ksc.nasa.gov), HM-CIC, (407) 867-7952

Participating O_xanization: Florida International University (I. Becerra-Fernandez)

KMA Summary of Findings: Knowledge Manajcement Tools

(Number of Functional Groups With Need for KM ToolTotal Functional Groups Interviewed)

• Expert Knowledge Elicitation and Virtual Mentoring Tools: 6/8

Elicit, capture, and transfer the knowledge of experts acquired through the ,,,ears of experience

at NASA

• Expert Seeker: 6/8

Skills database with pointers to experts with a particular background

• Collaborative Tools: 6/8

Internet/intranet based tools that capture knowledge as teams create it

• Decision Support and Expert Systems: 5/8

Enhance decisionmaking and facilitate the decision process by incorporating knowledge factors

from past projects

• Centerwide Lessons Learned Repository: 5/8

Include a synopsis of why certain decisions were made, rather than simply which decisions

were made

• Knowledge Management Procedures To Harvest Knowledge: 5/8

Procedures to harvest organizational knowledge

• Electronic Document Storage: 4/8

Would allow departments and teams to share work files and relevant data

• Centerwide Self-Assessment: 1/8

Tool to identify what is organizationally known and what is unknown

• Translation Software: 1/8

For NASA documents and Web pages

89
Process/industrial Engineering

Human Factors Engineering: Root-Cause Analysis System

he Root-Cause Analysis

(RoCA) system helps engineers analyze and track the root

causes of process anomalies due

to human factors issues at the

organizational, team, and individual levels. Such process

anomalies include incidents that

cause personnel injuries, damage

facilities, incur additional costs,

or delay processing. The system

is being implemented under a

Phase II Small Business Innovation Research (SBIR) contract.

(RoCA is the new name of a

system originally called HF-TAS,

for Human Factors Trending and

Analysis System.)

The development of RoCA is

motivated by the weaknesses of

existing root-cause analysis

techniques. Although statistical

quality control methods (i.e.,

methods for assessing whether a

process is in control) are quantitatively robust, widely used, and

successful, only very simple

qualitative methods (e.g.,

fishbone diagrams) are available

for root-cause analysis (understanding why a process is not in

control). The result is that industries frequently spend millions of

dollars fixing the wrong process

problems. The other major

motivation for RoCA is the focus

on the importance of human

factors in industrial accidents.

Research has shown that avoidable human errors are a significant source of process anomalies

in many industrial processes (e.g.,

aircraft manufacturing and

maintenance).

RoCA has many possible

KSC, NASA, and commercial

applications. The first application

of RoCA at KSC is assisting the

Human Factors Team in investigating and analyzing the contributing causes of Shuttle ground

processing accidents. The major

technical innovation of RoCA is

the anomaly process diagram

(APD). The APD is a new, theoretically well-founded methodology for root-cause analysis

focused on the representation of

causal, probabilistic relations

between process variables.

RoCA is being developed

through rapid prototyping with

significant design inputs from the

eventual user community (i.e., the

Human Factors team). Major

upgrades to the software were

delivered every few months in FY

1998. The latest delivered version

includes a new "qualitative

analysis" module for graphically

editing and relating the contributing factors in an event investigation through an anomaly process

diagram. It also includes a

variety of predefined, standard

reports the user can produce with

only a few mouse clicks. These

software capabilities build upon

previously delivered versions to

help human factors analysts

perform event analyses, communicate their analyses electronically, and understand the trends

in the mishap data using on-line

analytical processing (i.e., pivot

table) technology. Future versions of the system will extend

the qualitative analysis capability

to perform analyses quantitatively.

Key accomplishments:

• 1995: Phase I SBIR contract

awarded.

• 1996: Completion of the Phase

I feasibility study and demonstration software.

• 1997: Award of the Phase II

SBIR contract. Developed and

delivered the initial software

prototypes to KSC.

• 1998: Delivery of the first

RoCA system for operational

use. Commercialization success of NASA-sponsored

technologies through small

business acquisition. KSC

decision analysis workshop.

Key milestones:

1999: Refinement of operational prototype at KSC. Additional commercialization of

RoCA and anomaly process

diagram technologies. Decision analysis workshop at

Johnson Space Center supporting the Exploration Office.

Contacts: T.S. Barth (Timothy.Barthl@ksc.nasa.gov), PZ-Q-A, (407) 861-

6663; and ].R. Boogaerts, EI-HF, (407)

867-7721

Participatin_ O_¢,anizations: Previshnl,

Inc., which is now part of Fair Isaac, Co.

(R. Fung and B. Del Favero); United

Space Alliance; NASAAmes; and

NASA/KSC (Shuttle Processing and

Human Factors hltG, ration Office)

9O
I FileEdit Ev_t Vmw Tools _'wwJow Help

CauseCede D "" Conbibution

 -High

D1 IW'or_pace Design 15"H-_gh

IOesc_n forCauseCode ContributionforT1-2

I

{Task run infrequently]

Forallthreeofthepossiblecauses,thistaskisperformedveryinhequently.Therefore,

any

would

of

not

thepotential

havebeen

causes

aware

could

ofthe

have

potential

occurred

problem.

and thetechniciansand engineers I

Thisi__ -- -

Engineer"

_avel

lAna@st:JohnDoe [Database:C:\MvProiects\hftaskdartabasekdemo1_ ,_.

RoCA Analysis Entry Display

91
Human Factors Engineering: Applications in

the Checkout and Launch Control System

K SG is recognized as NASA's

Center of Excellence for

launch and payload processing

systems. Due to the continually

increasing maintenance costs,

technological obsolescence

problems, limited system flexibility, and desire for improved

Shuttle processing efficiencies, a

new launch system is being

developed. The Checkout and

Launch Control System (CLCS)

will replace the current Launch

Processing System (LPS). By

increasing system reliability and

reducing the hardware, software

code lines, and facility space, the

team projects a yearly operational

cost savings of 50 percent once

the new system is fully deployed.

Human factors is a specialty

concerned with the well-being of

people in complex systems. It

focuses on human beings and

their interaction with products,

equipment, facilities, procedures,

and the environment. Three

major human factors applications

on the CLCS project are:

Ergonomic assessment: An

ergonomic assessment survey

was developed for the CLCS

project personnel. Overall, the

availability of basic ergonomic

aids was determined to be low.

Participants rated the intensity

and frequency of pain or

discomfort they feel in various

areas of their bodies. The

figure summarizes the pain

intensity reported in the survey. Neck, shoulder, and lower

back were the areas cited with

the greatest frequency and

intensity of pain among the

CLCS personnel.

OMI conversion: Operations

and maintenance instructions

(OMI's) are the written work

25

20

2 3 4

Intensity Levels

Intensity of Pain

• Neck

• Shoulder

[] Forearm

[] Wrist

• Fingers

[] Lower Back

[] Legs

92
Research and Technology 1998

instructions used to process

Shuttles and payloads. These

provide detailed step-by-step

instructions for engineers,

technicians, and inspectors

participating in the various

operations and were written

for the existing LPS. As the

new CLCS software is implemented, the existing work

instructions will need to be

modified for the new system.

A work measurement analysis

was performed to estimate the

time required to convert these

OMI's. Approximately 950

OMI's from 24 Shuttle systems

were reviewed. Due to the

uncertain nature of the conversion process, "best case,"

"worst case," and "most likely"

scenarios were developed.

MMT console design: A significant portion of the CLCS

project is the replacement of

the existing equipment in the

firing rooms. Several console

designs were considered for

the Mission Management Team

(MMT) working in the firing

rooms. Five ideas were developed for the MMT console

designs. Console design and

vendor selection is ongoing.

Contact: L.K. Rupe (Linda.Rupel@ksc.nasa.gov), LM/CLCS, (407) 861-

7323

Participating Organizations: University

of Missouri-Rolla (S. Murray) and

Lockheed Martin

08
Process/industrial Engineering

Human Factors Engineering: Human Error Research in Shuttle

Processing and Aircraft Maintenance Operations

umerous safety studies have shown that the causes of

aviation accidents and incidents

are more likely to be related to

human error than mechanical

failure. However, human error

may occur both in flight and in

the ground operations that

support them. Several recent

aviation accidents have determined the probable cause to be

maintenance related.

Thus, there is a growing

recognition of the importance of

maintenance human factors and

the need for operational research.

Past accidents have dramatically

demonstrated the potential

impact of human error problems

in maintenance areas such as

training for maintenance and

inspection, tracking of maintenance responsibility, procedures

and task documentation, work

environment conditions, verbal

and written communications, and

leadership and teamwork.

Although the aviation industry has been innovative in developing flight training technologies,

human-centered automation,

multimedia information, and

decision-aiding systems, the

adaptation and transference of

human factors tools, techniques,

and principles to ground operations have been limited. The goal

of this research is to better understand human error in maintenance operations in order to

improve procedures, training

interventions, and other maintenance task aids that will ultimately reduce human error and

enhance safety in maintenance

operations.

Striking similarities in human

factors issues across Shuttle and

aircraft maintenance have led to

technology transfer meetings on

topics of mutual interest. Figure

1 shows the Shuttle in the Orbiter

Processing Facility, which has a

work environment and work

processes similar to those in

depot-level aircraft maintenance

centers (see figure 2).

This Ames Research Center

(ARC) and KSC collaboration is

intended to (1) promote human

factors awareness, (2) exchange

research information and results,

and (3) when feasible, conduct

joint human factors research

using KSC's unique technology

test bed capabilities. These goals

are being accomplished in the

following ways:

Technology transfer workshk0_p_: The overall goal is to

identify issues, problems, and

"lessons-learned" in common

interest areas across spacecraft

processing and aircraft maintenance. Topics such as human

error and incident analysis, risk

analysis techniques, human

factors training, and human

performance measurement are

included.

Figure 1. Space Shuttle Orbiter Entering Its Maintenance Facility

94
Research and TeChnology 1998

Figure 2. Aircraft Engine Maintenance

Human factors research: The goal is to combine

research efforts that involve similar human

factors goals and issues across multiple operational settings. KSC provides a test bed for

operations research in depot-level maintenance.

These efforts demonstrate an area of synergy

between NASA's Aeronautics enterprise and Human Exploration and Development of Space

(HEDS) enterprise. In 1998, the NASA Aviation

Safety Program initiated an element focusing on

human factors in aircraft maintenance operations.

This program is closely coordinated with the Federal Aviation Association and supports many

research efforts that can also apply to Shuttle operations. This opportunity has been used to increase

the collaboration between ARC and KSC and look

forward to valuable results supporting the goals

and objectives of both enterprises.

Key accomplishments:

• 1991 to 1993: Initial application of human factors

technologies developed for flight crews to aircraft

maintenance crews. Team effectiveness research

on Shuttle maintenance crews. Memorandum of

understanding between ARC and KSC signed.

1994 to 1995: Initial collaboration with the KSC

Shuttle Processing Human Factors Team in the

area of human error investigation and analysis.

1996: Incident Investigation Workshop hosted by

ARC. This workshop focused on the human

factors aspects of incidents, accidents, mishaps,

and close calls in spacecraft and aircraft maintenance.

1997: Human Factors Training Workshop hosted

by KSC. This workshop focused on human

factors training issues.

1998: Written Procedures Workshop hosted by

KSC. This workshop focused on work instructions and task analysis (two task areas in the

Aviation Safety Program, Human Factors in

Maintenance) and supported the Shuttle Work

Instruction Task Team and airline and military

maintenance operations. Memorandum of

understanding between ARC and KSC updated

and signed by the Center Directors.

Key milestones:

1999: Continued collaboration in incident investigation, root-cause analysis, and task analysis.

Possible workshop focusing on statistical process

control applications to system performance data

collected during maintenance operations. Formalize the KSC process/industrial engineering

test bed.

Contacts: T.S. Barth (Timothy.Barth-l@ksc.nasa.gov), PZQ-A, (407) 861-6663; and B. Kanki, ARC, (650) 604-5785

Participating Organizations: United Space Alliance,

Transport Canada, National Transportation Safety Board,

Aerospace Safety Advisory Panel, Northwest Airlines, United

Airlines, Continental Airlines, U.S. Airways, Idaho National

Engineering and Environmental Laboratories, Federal

Aviation Administration, and U.S. Air Force

95
Work Methods and Measurement:

Expert System To Generate Job Standards

SG industrial engineers are

actively engaged in identifying techniques to improve the

efficiency and effectiveness of

Space Shuttle ground processing.

One approach that has demonstrated a high potential for

success is the use of industrial

engineering techniques to measure work. Although many work

measurement techniques are best

suited for short-duration, highrepetition activities, there are also

approaches to successfully

measure the time associated with

long-duration, low-repetition

tasks like those inherent in

Shuttle ground processing.

A challenge to work measurement practitioners is that there is

no guidance on which of several

available measurement techniques to use. Practitioners must

rely on their own experience, onthe-job training, previous approaches used by their predecessors in the organization, and trial

and error. These methods for

choosing a work measurement

technique can lead to ineffective

results. The literature is of little

help and there are no references

to guide the practitioner. KSC

industrial engineers have recognized this deficiency and have

taken steps to fill the void.

In 1994, KSC industrial

engineers and their support

contractors began to develop an

expert system to (1) help the job

standards developer select an

appropriate measurement technique and (2) guide the job

standards developer through the

steps required to develop a job

standard when using a work time

estimation technique. The Job

Standards Development System

(JSDS) delivered to KSC in 1998

asks questions relevant to technique selection and, on the basis

of responses by the user, provides

a list of techniques suitable for

the application. If desired by the

user, the JSDS will recommend a

specific technique determined to

be appropriate for the application

defined by the user.

When estimation is the appropriate technique, the system

guides the user through data

acquisition from the domain

expert and computes the standard time of the job. In addition

to providing the standard time,

the system provides an estimate

of job duration and information

about each resource required to

complete the job.

The JSDS has two primary

applications. First, any organization that develops job standards

(or less formal job time estimates)

would benefit from the expertise

embedded in the work measurement technique selection module

of the system. Second, the system

will help organizations document

and quantify skill and work time

requirements for work composed

of long-duration, low-repetition

tasks. This type of work is often

associated with equipment and

facility maintenance activities and

functions. The JSDS extends

supply chain management down

to the individual task level since

job time estimates are an important ingredient to project scheduling. Candidates for commercial

96
applicationof theJSDSinclude

operationsof stateand local

governments,healthcarefacilities,publicutilities, andaircraft,

rail, and ship maintenance and

repair facilities.

Key accomplishments:

• 1994: Successfully demonstrated the prototype expert

system to select an appropriate

work measurement technique.

• 1995: Identified the work

measurement techniques to

include in the expert system.

• 1996: Conducted a small-scale

test of a work measurement

technique in the KSC environment.

• 1997: Conducted a comprehensive field trial of the work

measurement technique tested

in 1996.

1998: Completed the development of the ]SDS. The JSDS

includes expert systems that

select a work measurement

technique, guide the measurement of work when work time

estimation is appropriate, and

compute the job standard.

Key milestone:

• 1999: Ongoing identification of

commercial applications.

Contact: M.M. Groh-ftamnlond

(Marcia.Groh-ftanmlond- I @kscmasa.

_ov), PZ-Q-A, (407) 861-0572

Participatin_ O_xanixations:

OMNI Engincerin_ and Technology,

luc. (N. Schmeidh'r), Affinity Logic

Corporation (G. RibarL am United

Space Alliance

JobStandardSummarybyResource

PRIMARY THRUSTER _m_L RETEST

VSD45.004-06

Job I,,o.,.) :,o,, ]houds)

Type Resource Name Max Oty Task Using

Used Oty

On-Task Labor Technician

_n-Task Labor Quality, Witness 1.94 4

l

Job Stamtard Summar)

97
Work Methods and Measurement:

Electronic Portable Information Collection

rork procedures for payload processing and checkout

operations at KSC are executed

using a paper system. With this

system, a procedure is generated

using a word processor. The

procedure is then printed out,

copied, and distributed to members of the task team. When the

work procedure is executed, a

single master copy is kept up to

date by using a pen to record the

test data and notes and by using

quality and technician ink stamps

to verify the work steps as they

are performed. Test team members maintain their own copies of

the procedure. Deviations to the

work instructions that occur

during the execution of the

procedure must be documented

on a paper form. These deviations require approval signatures.

Once approved, the deviation is

copied and distributed to the task

team. The completed master

work procedure, including

deviations, is scanned into a

computer and stored electronically.

The Electronic Portable

Information Collection (EPIC)

system was developed to automate this procedure. EPIC was

formerly known as the Portable

Data Collection (PDC) System.

With the EPIC system, the procedure is converted from a word

processor document to a database. It is then executed using

portable computers. Data is

entered electronically, either with

a keyboard or a pen, using handwriting recognition. The system

distributes this data to all other

terminals. The ink stamp is

replaced with an electronic stamp

that meets the form, fit, and

function of the old ink stamp. A

programmable memory chip

inside the electronic stamp stores

a unique identifier. All team

members have their own electronic stamp.

This electronic stamp adds a

secure mark to a step, identifying

who performed that step and the

date and time the step was performed. The electronic stamp is

read using a stamp reader connected to the serial communication port of the computer. The

system provides protection

mechanisms to ensure data and

stamp integrity. Once the procedure has been worked to completion, it is converted to a portable

document format (PDF) and

stored electronically in a documentation system.

The main components of the

EPIC system are the central data

server (CDS) and the portable

data terminals (PDT's). The CDS

is the main computer that serves

as the network host and database

server. PDT's display procedure

steps and enable users to collect

test data and stamps. The PDT's

are standard personal computers

(PC's) running Windows 95 or

Windows for Workgroups operating systems. Various PC's are

used as PDT's, including desktops, laptops, wearable computers, and pen-based tablets. The

CDS is a high-end PC running the

Windows NT operating system.

The project was developed

jointly by Sentel Corporation and

KSC, the lead center for payload

processing. The prototype system was developed under a Small

Business Innovation Research

(SBIR) contract that was awarded

to Sentel Corporation to develop

the capability to capture technician and quality stamps and test

data electronically. The operational version was developed

under a Space Act Agreement

between NASA and Sentel Corporation. The following benefits

are provided by the EPIC system:

• All test team members see

changes to the document

instantly, providing greater

assurance that all team members are properly informed and

the data is accurate.

• Accuracy of the procedure is

improved as deviations are

incorporated directly into the

appropriate sequence of the

procedure. The time to process, approve, and distribute a

deviation is also reduced.

Information availability is

improved. Test data can be

searched and retrieved through

a standard database.

Queries can be made for

management reporting or

incident investigations.

The need to print and distribute procedures prior to testing

is eliminated.

• The need to scan the procedure

for storage is eliminated.

• Emergency procedures can be

accessed immediately.

• Paper usage is reduced.

98
The system was modeled after

the existing paper system using

the existing business rules.

Presently, the system is being

developed to support Space

Station processing. EPIC is being

marketed to the airline industry

for use in airplane maintenance

and to the electrical power industry for use in power substation

maintenance.

Key accomplishments:

• 1993: Completed the Phase I

study for the SBIR contract.

• 1996: Completed Phase II of

the SBIR contract. Demonstrated the proof of concept for

this system. Received the

NASA SB|R Technology of the

Year Award in the computer/

software category. Completed

pilot study 1. The first pilot

study was conducted in the

Operations and Checkout

Building using the EPIC electronic system in parallel with

the paper system.

• 1998: Upgraded the system

from a prototype to an operational system. In pilot study 2,

tested the EPIC system in the

KSC Space Shuttle Main Engine Shop and Space Station

Processing Facility.

Team Members Using EPIC

Key milestone:

1999: Implement the EPIC

system to be used by NASA,

Government contractors, and

private industry.

Electronic Stamp and Stamp Reader

Contact: D.H. Miller (Darcy.Millerl@ksc.nasa.govLVC-B1, (407) 867-3523

Participating O_xanizations: Sentel Corporation (K.L. Jackson and M.R. Kappel)

and Mississippi State University (L.K. Moore)

99
Work Methods and Measurement:

Work Instruction Task Team

he Shuttle Processing Work

Instruction Task Team (WITT)

was chartered to develop and

implement a comprehensive

vision for future work instructions used in ground processing

of the Space Shuttle fleet. The

goals of the new work instruction

system are to improve the efficiency of the processes used to

generate and maintain the written

procedures, to improve the

efficiency of shop floor task

execution using the new procedures, and to improve workplace

safety by reducing the potential

for human errors.

The team analyzed the current work instruction generation

processes and products (the

written procedures). Several

opportunities for improvement

were identified to improve the

cycle time and to reduce the labor

hours associated with delivering

the work instructions to the shop

floor to support a specific task.

Existing work instructions are

rule based, are highly detailed,

and frequently contain information not needed for a specific task.

Examples of nonvalue-added

information include drawings for

other orbiter vehicles and work

steps for testing only performed

at specified intervals. The written

procedures varied widely in

"look and feel" for the users,

which will become increasingly

important as workers are more

frequently assigned to different

orbiter and ground systems or

different facilities.

The WITT collected data from

approximately 20 different KSC

teams working on various aspects

of improving work instruction

processes. The team also gained

valuable information and insight

through participation in a Written

Procedures Workshop co-sponsored by Ames Research Center

and KSC. Finally, the team

collected benchmark data during

site visits to three different industry organizations. The result of

the team's research was a vision

for the future of KSC work instructions based on the following

eight key actions:

Use a standardized format for

the work steps in all Shuttle

Processing procedures.

• Increase shop involvement in

the authoring process.

Deliver "lean, clean work

instructions" with only the

information needed for the

current task and a level of

detail consistent with the

results of a task analysis conStandard

Format

100

Shop

Involvement

Skill-Based

Work Force

Minimize Approvals,

Buyoffs

I..... ,ore.- L I

-i i

!

II

Figure 1. KL_ Elements of tilL'Shuttle Processing Work Instruction Vision
sidering task frequency and

criticality/complexity.

• Take advantage of KSC's skillbased work force.

• Minimize approval, buyoff,

and closure requirements.

Incorporate all permanent,

successfully executed work

instruction deviations prior to

release of the next revision.

Optimize the data collection

processes through innovative

methods to capture nontaskrelated data and ensuring that

all data is analyzed and used.

Use the latest commercial offthe-shelf technologies to

enhance the new work instruction process.

Key accomplishments:

1998: Completed the work instruction vision and obtained approval from KSC and Space Shuttle Program management to begin

implementation. Designed and implemented "test cases" to demonstrate the feasibility of the proposed new work instruction system. Supported a team to significantly reduce the number and

complexity of the requirements for KSC work instructions. Developed a standardized format and writers guide (based on the Department of Energy's guide) for implementation in all areas of

Shuttle Processing. Developed an initial KSC task analysis procedure with support from the University of Central Florida. Integrated efforts with several additional teams.

Key milestone:

• 1999: Charter implementation teams for all key vision elements.

Contact: T.S. Barth (Timothy Barth-l@ksc.nasa._ov), PZ-Q-A, (407) 861-6663

Participatiny, Organizations: NASA Shutth' Processing (R. Blackwchh'r,

M. Wilhoit, and G. Glochick), United Spat(' Ol_eratious (D. Bla)lkmalm-Ah'xauder,

D. Ciccat('ri, R. Corsilh), S. Dcfillips, ]. Entin\,er, C. Hamu_s, K. Jones, B. Kidd,

B. McKenzie, S. Morrison, V. Neal, I. Rooker, J. Swanson, and (7. ]om's), and

Unit,crafty of CcutrM Vl,)rM,_(1. P_'t-Edre,,rrds)

The recommendations directly address the root causes of

the systemic problems associated

with KSC's written procedures.

The relationship between the

eight vision elements is shown in

figure l. The team also con- High Task

structed several conceptual Frequency

models showing the relationship

between task frequency/complexity/criticality to the level of

detail, ski/l-based training, and

approval/buyoff requirements.

The level of detail model is

illustrated in figure 2.

Low Task

Frequency

• Minimum instruction detail • Moderate instruction detail

• Maintenance manual for reference • Partiat rule-based instructions

• Moderate instruction detail * Maximum instruction detail

• Partial rule-based instructions • Rule-based instructions

Low Task High Task

Critica lity/ .A_, "-,,v Critica lity /

Complexity Complexity

Figure 2. Work Instruction Levd of Detail Mode/

101
Work Methods and Measurement:

Industrial Engineering Decision Support Tool

he objective of this research was to develop a methodology for a

user-friendly decision support software system for the application

of innovative industrial engineering (IE) models and technologies for

complex processes at KSC. To illustrate the feasibility of this approach, AET, Inc., developed a model for a KSC work process using

historical data collected over 10 Shuttle missions.

The technical approach used for the modeling was the application

of Multiple Regression Systems (MRS's) for estimation of indirect

work content and performance. MRS applies the statistical technique

of multiple regression to analyze the output of one or more operators

engaged in a variety of tasks in order to estimate the time used to

produce a single unit of output for each of the tasks. This model is

shown in the equation:

Hours = 9.29 + 0.278 • SeqO01 + 0.235 • SeqO03 - 0.08. SeqO05 + 0.547.

SeqO06 + 0.318 • SeqO08 + 0.017. SeqO09 + 0.062. Seq024

The coefficients in the model equation have special significance.

They may be used to estimate the average time required to complete a

step in each of the sequences analyzed. For example, 0.278 man-hour

would be the expected requirement for completing a step in sequence

001. For illustration purposes as well as data limitations, the assumption that all steps in an individual sequence require equal amounts of

time was made. This equation may be used to predict the total manhours required for any number of steps performed in any of the

sequences.

The application of this model in the area of decision support is

extremely powerful. This model can be used to support changes in

sequence steps. By qualitatively predicting the number of work hours

required, a direct link to labor cost is established. Therefore, a decision to change a process can be supported by objective data and not

just subjective estimates. The prototype software system is shown in

the figure.

102
Roseal'Ch and Technology 1998

Key accomplishments:

1998: Phase 1 Small Business Innovation Research (SBIR)

project. Performed statistical analysis on data collected from a

structural bonding experiment. Identified, together with KSC

ground operations and IE personnel, appropriate work processes for analysis and modeling. Developed an analytical

model of the process under study and gathered data for estimation of model parameters. Completed a final report specifying

the technical results achieved in this project.

Key milestone:

• 1999: Potential continuation of research.

Cm#act: T.S. Barth (TJmothy.Barth-l@ksc.nasa.A, ov), PZ-Q-A, (407)861-6663

Participatin_ Organizations: AET, Inc. (Dr. G.T. Hess) and Lehis, h University

(Dr. L. Martin-Vega)

KSC

IE

Process

Models

STADIUM TM

User-Friendly Simulation Interface

Simulation Data I Data Control Control I Analysis

• Analysis

and ] HtSK Analysis,

Processing a^nd^_ 3_sing /[ D:c_sdion

L oaei,ng

Proposed Software-Based Decision Support System

103
General: Center for Applied Research in

Industrial and Systems Engineering

A partnership was developed

between NASA and Florida

International University (FIU) to

establish the Applied Research in

Industrial and Systems Engineering (ARISE) Center. The partnership seeks to establish a combined research and educational

program to attract and retain

women, Hispanics, African

Americans, and other individuals

from minority groups to engineering. Students participating in

the program:

• Are exposed and trained in

NASA's mission.

Are given seminars on a variety of issues, including the

realities of the workplace,

diversity, and gender issues.

• Participate in applied research

projects.

Are instructed on the benefits

of pursuing postgraduate

studies in the hopes of increasing their chances to succeed in

the workplace as well as

increasing their stature as role

models for future generations.

Have a 4-week on-site internship so they become acquainted with the various KSC

processes needed to complete

the projects.

Receive a stipend during the

academic year and the summer

terms.

An important objective of this

effort is to foster partnerships

between FIU and NASA and

between FIU and local industry.

The initial partners in this effort

were FIU in Miami, Florida, and

KSC. FIU was the lead institution, whereas KSC provided

steering guidance and was a

source to implement some aspects

of the program. The initial

timeframe of this effort was 2

years. In this timeframe, it was

expected that various aspects of

the model should be tested,

rethought, and retested as needed

so the model could become an

appropriate model for industryuniversity partnerships. Specifically, a proposal was developed

to begin selling the model to local

industry. The proposal highlights

the benefits local industry may

derive from the ARISE Center

and the impact their sponsorship

will have in shaping the lives of

future community leaders.

Key accomplishments:

1997:

Established an applied

research center where participating students have

access to the necessary tools

to start and complete industrial and systems engineering

projects related to NASA

operations and processes at

KSC. Selected and set up

hardware and software.

Selected/purchased other

equipment needed for the

ARISE Center.

Recruited students, which

involved the development of

a brochure and the development of a Web site for adver104
Research and Technologv 1998

tising the existence of this opportunity

(arise.eng.fiu.edu/). Students from under-represented groups who had a grade point average

of 3.0 were identified and a letter of invitation

was sent. Eight students were selected.

Developed activities for the ARISE Center that

were attractive to students.

1998:

Purchased computer equipment and software.

The Center has one server, two networked laser

printers, and 15 PC's. The Center has licenses

for a variety of software. The FIU industrial

and systems engineering department provided

laboratory space and furniture to house the

Center.

Held six seminars, including an overview of

NASA, Space Shuttle history and assembly

process, and gender and racism in the workplace.

Visits to KSC for a special tour to see various

processes at KSC. Students participated in a 4-

week internship during the summer. This

internship enabled them to work next to practicing engineers while developing their

projects.

Students worked in teams of two on selected

projects. Two projects were done for Logistics,

two for Installation Operations, and one for the

Checkout and Launch Control System (CLCS).

Curriculum Integration. Credit for projects

was given as part of a technical elective course.

The projects were presented in the Project

Management course as well as in the 1998

Annual Industry Projects Conference.

One-to-one conversations were used to let the

students know what graduate school is all

about and how it can fit their career plans.

During the summer, a workshop was given on

statistical analysis to the Payloads office personnel. New avenues of collaboration were

investigated. New projects and liaisons were

identified.

Fourteen students were recruited for the second year. New students will be selected in

December 1998.

A proposal was prepared and is being discussed with local industry. The Web site is

continuously being updated.

Key milestones:

• 1998: Discussion of projects occurred in January,

August, and December. Project development

occurred over the academic year. A Projects

Conference was held in April, which showcased

some of the projects to industry. Continued the

Industrial Portfolio to recruit industrial partners.

Seminars continued on a two-track level.

• 1999: Projects Conference in April. A conference

paper and journal paper will be published.

Contact: M.M. Groh-Hammond (Ma_via.Groh-Hammomtl@ksc.nasa.gov), PZ-Q-A, (407) 861- 5428

Participating Organization: Florida International Llnivcrsity

(M. Centeno and M. Resnick)

105
General. Key Characteristics in

Manufacturing and Maintenance

eY characteristic (KC) methodologies are used by a wide

variety of companies to help

manage variation risk in the

design and manufacture of

complex products. Complex

products can contain millions of

dimensions and characteristics

(voltages, forces, etc.), each of

which impacts the performance

of the product. In addition, each

of these features as manufactured

will deviate from its nominal

value because of inherent variability in manufacturing, assembly, and environment. However,

only a few of the millions of

features, the KC's of the product,

will significantly affect the final

quality, performance, and cost of

the product. The KC's of a

product link the product requirements that are variation sensitive

to the part and process characteristics that contribute to their

variation.

following: Allied-Signal discussed the implications of KC's

on suppliers; GE discussed the

design for six sigma; Xerox,

Kodak, and Boeing gave overviews and examples of KC implementations; and IBM gave a

presentation on the implication of

statistical tolerancing.

Four strategic research and

development issues emerged

from the 1998 symposium: how

to take a system view of variation

risk management, the meaning of

KC's to suppliers, a potential U.S.

standard for KC's, and the cost

implications and benefits of KC

methodologies. In addition,

working groups were formed to

continue discussions. These

groups are: Costs, Standards,

Statistical Tolerancing, Process

Capability Databases, Metrology,

Supplier Relations, and Models

and Tools. Information about the

conferences, the working groups,

and other KC resources can be

found at the Web site: http://

cardamom.mit.edu/K C/kc.html.

Identify KC's

I Identify product-KC's

¢

I Set product-KC latitudes

l Create KC flowdown

KC methodologies include

tools processes to identify the

select features, assess their impact

on the quality of the product, and

mitigate the effect of their variation. Variation mitigation techniques include robust design,

process control, variation reduction, and inspection. The figure

shows a typical KC methodology.

The first annual KC Symposium in 1997 brought 40 people

from 11 organizations together to

discuss general problems and

issues surrounding KC implementation. The 1998 KC symposium was hosted by KSC. Thirteen presentations included the

I .......

I

._/ Determine need to bewhich verifiedKC's

- - - _ Chart process

;// Determine which KC's Z

need to have variation reduced/

¢

.... Reduce variation

.__ needDetermine continual whichmonitoring KC's

........... t

I

....... I

Ongoing process control

Typical KC Methodology

106
Research and Technology 1998

Additional research and technology development was proposed by developing KC spinoff

common interest groups. KSC does not have highvolume manufacturing operations like the organizations represented by most existing KC symposium

participants, but the fundamental principles of

statistical quality control (SQC) and key characteristics apply to many other areas. KC methodologies

may require customization in order to be useful in

KSC operations. Potential spinoff common interest

groups could customize and apply basic KC and

SQC methodologies to different domains. Two

candidate spinoff areas are:

1. SQC applications to very low-volume or unique

space hardware production: The potential exists

to apply SQC techniques to the manufacture of

low-volume or unique hardware elements. In

these cases, the data elements are usually operating measurements of the machinery used to

produce hardware rather than the hardware

itself, since the extremely low-volume/unique

products will not supply enough data for meaningful statistical analysis.

2. SQC applications to aircraft/spacecraft maintenance (test and checkout) data: NASA and

United Space Alliance system engineers are

currently applying SQC analysis techniques to

Shuttle system performance data under the

ongoing surveillance effort. The analysis results

will support certification of flight readiness

(COFR) and identification of enhancement opportunities. The KSC COFR process now involves

verification of process stability and capability.

Key characteristic methodologies can be applied

to select those system performance data sets most

important for determining flight readiness and

opportunities for enhancements and upgrades.

Based on preliminary research, it appears that

Department of Defense and industry aircraft maintenance centers could also benefit from additional

applications of SQC tools to system performance

data collected during maintenance operations.

Key accomplishments:

1997: First annual KC Symposium hosted by the

Massachusetts Institute of Technology.

1998: Second KC Symposium hosted by KSC.

Strategic project approved to pursue funding for

development of key characteristic methodologies

supporting KSC operations.

Key milestone:

• 1999: Third KC Symposium to be hosted by

Motorola in Phoenix, Arizona.

Contact: T.S. Barth (Timothy.Barth-l@ksc.nasa.gov),

PZ-Q-A, (407) 861-6663

Participating Organizations: Massachusetts Institute of

Technology (A. Thornton), Allied-Signal, Alcoa, British

Aerospace, Ch_sler Corporation, DARPA, Eastman Kodak,

Ford, Embry-Riddle Aeronautical University, GE, GM,

Honeywell, IBM, IDA, ITT, Lockheed Martin, NASA, NIST,

Northrop Grumman, Pratt and Whitnel/, Quality Associates,

Raytheon, Textron, Boeing, United Space Alliance, University

of Florida, University of Maryland, and Xerox

107
Process/Industrial Engineering

General- Searchable Answer Generating Environment---

a Knowledge Management System To Seek Experts

in the Florida State University System

he need to acquire intellectual capital has created

the Knowledge Management (KM) movement,

which aims to develop new practices and tools to

capture knowledge. An indepth examination of

current KM projects revealed that a large percent

attempt to create some kind of a knowledge repository. Current studies identify three types of knowledge repositories. One of these types attempts to

manage organizational knowledge by storing

pointers to those who have specific knowledge

within the organization. In this light, this report

discusses the development of the Searchable Answer Generating Environment (SAGE) application

prototype. The development of this application

prototype was funded through the NASA/Florida

Minority Institution Entrepreneurial Partnership

(FMIEP) grant.

The purpose of this KM system is to create a

repository of experts in the State of Florida State

University System (SUS). Currently, each of the

state universities in Florida maintains a database of

funded research, but these databases are disjointed

and disparate. This application creates one single

Web-enabled repository that can be searched in a

number of ways including research topic, investigator name, funding agency, or university. The benefits of SAGE are: (1) SAGE is a repository of

intellectual capital within the Florida SUS; (2) SAGE

helps locate Florida SUS researchers for collaboration with industry and Federal agencies, thus

increasing the potential for research funding to the

SUS; (3) SAGE enhances communication and grants

Florida SUS experts more visibility, making universities more marketable; and (4) SAGE combines and

unifies existing data from multiple sources into one

user Web-accessible interface.

Ideally the aggregated data would be accessible

from one point of entry. For example, the data

being accessed may consist of multiple data types

that have been converted to a standard file format.

SAGE consists of the typical university-sponsored

research data incremented by object-oriented data

such as research topic, investigator name, funding

agency, or university. One of SAGE's advantages

is that there is only one point of entry or a Webenabled interface, allowing multiple occurrences of

the interface and giving the end user deployment

flexibility. The main interfaces on the query engine

(in SAGE) use text fields to search the processed

data for key words, fields of expertise, names, or

other applicable search fields. The application

processes the end user's query and returns the

pertinent information. The information is collected

from a conglomeration of multimedia databases and

then presented as queried (see the figure).

Key accomplishments (1998):

• The development of the SAGE database involved

an initial design followed by the incremental

implementation phases:

The initial design phase constituted a comprehensive survey of available tools and methodologies. An assessment was carried out to

select the most efficient approach to data

storage and data retrieval. A middleware

development environment was selected

because of its significant application strengths

and demonstrated database interaction capabilities. Additionally, it provided the ability

for secure transactions.

The implementation phase of SAGE involved

the design of the middleware modules, each

with an assigned task. Querying modules

were used to provide search capabilities. Each

query interface involved several modules that

interacted with the database.

A sample database was obtained from the

Florida International University (FIU) Division

108
Research and Technology 1998

I

UWF Extraction

FAMU Extraction

UNF Extraction

FSU Extraction

UF Extraction

UCF Extraction

USF Extraction

FAU Extraction

State University System

Sponsored Research

Standard Query Language (SQL)

Compatible Databases

FlU Extraction

I

I

FGCU Extraction

I

I

I

SAGE Architecture

SAGE Interface (Web Browser)

SAGE Application

of Sponsored Research and Training (DSRT) to

provide a prototype data storage structure.

After applying an extraction algorithm to the

data, the SAGE database was populated with

FIU data.

The SAGE application was then Web-enabled

on the primary server for its current wave of

beta testing.

The SAGE prototype was then populated with

the University of Central Florida DSRT database. Some of the technical challenges faced

during the design and implementation of this

project included the fact that databases from

Florida SUS DSRT offices were dissimilar in

design and file format and in duplicate data

occurrences, field names, and stored architecture. PERL scripts were used to solve the

database disparities, and a data dictionary was

implemented to eliminate redundancies.

Key milestones (1999):

• Migration to a relational database structure is

currently underway. This is a necessary step

because of its efficiency and scalability with data.

The middleware source is currently being

recoded to take advantage of the improved data

structures. This new relational architecture will

also alleviate the data inconsistency problem

across SUS platforms.

• Population of the SAGE database with each of the

remaining SUS DSRT databases.

Contact: G.A. Buckingham (Gregg.Buckingham- l @kscmasa.

gov), HM-CIC, (407) 867-7952

Participating Orga,ization: Florida Interm#iom_l Llniversity

(I. Becerra-Fernandez)

109
Process/industrial Engineering

Process Analysis and Modeling: Statistical Process Control

Techniques for Variable Shuttle System Performance Data

ASA Shuttle Processing has shifted to an insight focus requiring the use of statistical techniques

for analyzing system performance data to evaluate

Certification of Flight Readiness (COFR), to determine requirements for enhancement/upgrades, and

to evaluate contractor performance. Several case

studies were developed to demonstrate the application of statistical techniques to assist in the insight

role. Case studies completed during this project

analyzed Space Shuttle system performance data

engineers identified as critical variables indicating

the health of the associated system (see the table).

The analyses provided information that could be

used to determine if there is evidence to support the

need for a system enhancement/modification.

One of the studies supporting an enhancement

was the potable water case study. Water is a key

ingredient to a successful Shuttle mission. Water

storage space aboard the orbiter is limited to four

potable water tanks with a usable capacity of 165

pounds. Astronauts also use water generated as a

byproduct of the electrical generation system when

hydrogen and oxygen are combined in the orbiter's

fuel cells. The water produced by the fuel cells is

stored in the potable water tanks for use during

flight. It is important to ensure the quality of the

water is satisfactory for human consumption. To

monitor the quality of the water, the nickel concentration is measured. Analysis of the nickel concentration requires monitoring the stability of the nickel

concentration for each vehicle. To monitor the

stability of the nickel concentration, Individual X

and Moving Range charts were constructed for each

vehicle at 15 (L-15) and 3 (L-3) days prior to launch.

In the case of Atlantis (OV-104), the Moving Range

chart indicated a stable process, while the Individual X chart demonstrated a statistically significant pattern indicating that the nickel concentrations have increased significantly beginning with

STS-66. Research shows this coincided with an

extended maintenance period at Palmdale, California.

Prior to using the statistical analysis tools,

system engineers plotted the nickel level versus the

mission. The resultant charts made it appear there

may have been a worsening nickel level. This case

study, however, showed the process to be stable

after the initial step function increase was noticed.

If statistical quality control techniques had been

used, systems engineers would have reconsidered

the conclusion to remove and replace the existing

chilled heat exchanger because of the "apparent"

continuing increase in the nickel level.

Key accomplishments:

• 1994: Completion of variable-form data collection and analysis on two Thermal Protection

System processes.

• 1995: Collaboration with USBI for analysis and

improvement of solid rocket booster processes.

An orbiter structural bonding process improvement effort was initiated.

• 1996: Phase II of the structured experimentation

supporting the orbiter structural bonding process

improvement was completed.

• 1997: Held a series of three workshops for NASA

and contractor engineers to develop skills in

collecting, analyzing, and interpreting results

from variable-form data.

• 1998: Case studies depicting the application of

statistical techniques to evaluate COFR and

determine requirements for enhancements/

upgrades were developed.

Key milestones:

1999: Implementation of statistical techniques

supporting process analysis throughout Shuttle

Processing. Implementation of process improvements recommended through the case studies

and measurement of the effectiveness of process

changes. Investigate potential technology transfer/synergy to the Orbiter Reliability-Centered

Maintenance effort, Checkout, Launch and

110
Control System project, and Integrated Vehicle Health Monitoring. Investigation of key characteristic

methodologies for selecting system performance parameters on which to apply statistical process control

techniques.

Contacts: T.L. O'Brien (Timothy.OBrien-2@ksc.nasa.gov), PZ-Q-A, (407) 861-3968; and T.S. Barth , PZ-Q-A, (407) 861-6663

Participating Organizations: Embry-Riddle Aeronautical University (D. Osborne), NASA/KSC Shuttle Processin_ (S. Minute,

V. Elentri, T. Draus, H. Johnson, S. Greemvell, C. Estrada, C. Mariano, and F. Jones), Boeing (T. Damoff), Unih,d Space

Alliance, and University of Central Florida (Y. Hosni and R. Safford)

Case Studies Demonstrating the Application of Statistical Techniques

Orbiter System Data and Subsystem Studied

Thermal Protection System Nose landing gear door corner laser step and gap measurements

Orbiter processing facility dewpoint temperature measurement

Orbiter Structures Bond pull tests

Guidance, Navigation, and ADTA/AADT test set transducer data from air data system

Control System

Main Propulsion System LH2, LO2, GH2, GO2, and helium subsystem data

Orbiter Maneuvering System/ OMS/RCS helium isolation valve data from the helium pressurization subsystem

Reaction Control System

Primary RCS regulator data from the helium pressurization subsystem

Environmental Control and Nickel concentration data from the supply and waste water management system

Life Support System

Orbiter Mechanisms Extension times from the landing gear subsystem

Orbiter/ET umbilical bolt ultrasonic measurement data from the orbiter/external

tank separation system

111
Process/Industrial Engineering

Process Analysis and Modeling: intelligent

Assistant for Optimization Modeling

ver the last 40 years, the versatility of optimization

modeling has established it as a

popular decisionmaking aid.

Optimization encompasses a suite

of powerful decision support

paradigms that enable the modeling of any decisionmaking environment in terms of objectives,

decisions influencing the objectives, and constraints binding the

decisions. However, the potential

of these powerful techniques has

remained largely unharnessed

due to the following inherent

difficulties in constructing optimization models:

objectives were realized during

this initial effort. The research

team developed a structured

method of optimization model

development and created a

structured, ontology-based

method for knowledge acquisition and analysis. Another key

objective was to develop a knowledge base of heuristics, principles, and rules that assist in

optimization model development.

Templates were created that

encapsulated the knowledge of

optimization modeling paradigms for both applicationspecific and generic modeling.

1. Optimization models typically

address aspects of the domain

that are often hidden or invisible to casual observers.

2. Highly specialized skills are

required to design and generate executable models.

3. Optimization-based decision

support systems typically

depend on building custom

solutions for different domain

situations.

4. There are few available tools

able to leverage the expertise of

domain experts.

Preliminary research to

alleviate these difficulties was

conducted under a Phase l Small

Business Innovation Research

(SBIR) contract. The central

product of this effort was a

prototype implementation of the

Optimization Modeling Assistant

(OMA). Several key Phase [

The Phase II technology

hardening efforts identified

another important factor that

limits widespread application of

optimization techniques to

practical problems: the unavailability of much of the information

needed for developing optimization models. While optimization

techniques provide analytically

sound solutions, their success

hinges on the availability of

accurate input data. Often, the

input data required to develop

valid optimization models does

not exist or is unaccessible in

most domains. Recognizing this,

Knowledge Based Systems, Inc.,

expanded the architecture of the

Phase II OMA to include simulation-based optimization. Simulation will be used to generate the

necessary input data, which is

then used by OMA for optimization. Using the two powerful

decision support techniques

together, OMA will deliver

comprehensive decision support

112

analysis capabilities to managers

and decisionmakers. The enhanced OMA software implementation was completed in 1998 (see

the figure).

Phase III activities planned in

1999 include (1) exercising the

OMA software with KSC domain

data, (2) refining the OMA for

commercial applications, and (3)

demonstrating the OMA on

sustainment and remanufacturing

applications at Tinker Air Force

Base, Oklahoma City, Oklahoma,

as part of another Phase II SBIR

initiative.

Key accomplishments:

• 1996: Completion of the Phase

I SBIR contract. Development

of a prototype OMA. Selection

for Phase II follow-on research.

• 1997: Defined the OMA prototype and templates. Designed

OMA extensions for simulation-based optimization. Developed KSC process models

for the OMA application.

• 1998: Prototyped simulationbased optimization. Completed OMA implementation.

Acquired KSC domain data for

the OMA application.

Key milestones:

1999: Complete the OMA

application at KSC. Demonstrate the OMA at Tinker Air

Force Base. Commercialize the

OMA.

Contacts: T.L. O'Brien (Timothy.

OBrien-2@ksc.nasa.gov) and D. Correa,

PZ-Q-A, (407) 861-5428

Participating Organization: Knowledge

Based Systems, Inc. (Dr. P.C. Benjamin)
Research and Technology 1998

°_

Q

/

113
Process/industrial Engineering

Process Analysis and Modeling:

Vision Spaceport Model Development

here is a need for a better

understanding of the interactions that occur between flight

systems and their required

launch infrastructure (the spaceport). Visibility and understanding of these interactions are

needed to dramatically improve

the design of future launch

systems with a focus on reducing

the cost of access to space. A

reduction in the cost can only be

achieved with designs that

improve life-cycle cost factors,

one of the main objectives of the

Vision Spaceport project. The

Vision Spaceport project has a

goal to develop models that allow

vehicle designers to understand

the effect of vehicle design parameters on spaceport operations.

JKnowledge Base • Afforclabilily Drivem J

[--_ Concept Design

Questions

Concept

Operations

Factors

Demand Driven

Economics

(Ib/year)

Database

Nonrecurring Factors

(Vehicle Development Cost,

Purchase Costs, etc.)

Productivity

Measures ($, Times,

Each Facility)

+

J FLEET/SPACEPORT J

Productivity Measures

I_ ($' Times, # of Facilities,

# of Vehicles)

÷

1andu++.-o..j $/Ib vs. Flight Rate

Figure 1. Spaceport Model Definition and AATe Basic Structure

The required models will provide

vehicle designers with critical

measures of performance that

define system costs (for example,

single vehicle flight rate, the type

and number of facilities required,

and the cost of operations per

flight).

During the summer of 1998, a

Vision Spaceport project task

developed a prototype model that

combined a knowledge-based

approach with existing data. The

model, called the Architectural

Assessment Tool - enhanced

(AATe), is traceable to the national team called the Space

Propulsion Synergy Team and

supports NASA's Highly Reusable Space Transportation study.

The tool uses a series of multiattribute utility functions to

correlate concept design parameters to spaceport facility requirements. These functions capture

not only the relation of a particular choice to the outputs but also

the strength or importance of the

broader context being addressed.

In this way, the model behaves

with some similarity to "real

world" interactions and thus

reflects cost and performance

cause and effect.

The cost assessment for a

vehicle concept is based on how it

interacts with 12 generic spaceport operational modules (figure

1) that represent functional cost

centers. Each module has a

knowledge-based utility function

that is calculated as the user

inputs the concept vehicle (figure

2). Inputs consist of a set of

114
Research and Technology 1998

i Loada _ _vea

C_pt C_ce_

• Inputs,

proceed to

function

calculation

Qll. Fluid seJe_tion --(DF#I):

1- Use= ho toxic fluids in flight or ground system that

restti_:t ground handling operations

2- Uses no toxic fluids in flight or ground system that

restrict ground handling operations at launch site--sore e

toxics used for manufacturing, assembly and cleaning only

3- (ATG) Uses no toxic fluids for flight minimum ground

system restriction for on- line ground handling operations al

launch site (like TPS water-proofing), except those that ere

serviced end seeled in off-line facilities--some toxics used

for manufacturing, assembly and cleaning only

4- (STS) Uses some toxic fluids for flight and ground

operations

5- Current definition of concept insufficient to determine

Fi,_ure 2. User Interface

o_ J

questions for the concept being

assessed, and these questions are

based on the knowledge capture

of spaceport cost drivers. The

data set used to calculate the

measures of performance includes a baseline (the Shuttle in

this case) as well as a series of

extrapolations, which are higher

or lower costs and cycle times.

Key accomplishments (1998):

Model methodologies that

integrate flight architectures

with the ground infrastructure

(spaceport); that correlate

spaceport modules to an

integrated single vehicle

performance (flight rate,

operational cost, and investment cost); and that assess lifecycle costs for various demand

scenarios.

Software that tested all the

previously mentioned methodologies.

Key milestones (1999 and 2000):

• Working product for top-level

vehicle system architectures.

• Use of the tool in space launch

assessments.

Contacts: C.M. McCleskey (Carey.

McCleskev-l@ksc.nasa.gov), PK-K,

(407) 861-3775; E. Zapata, PK-G, (407)

861-3955; and R.E. Rhodes, PK-G, (407)

861-3874

Participatin_ Organizations: Ames

Research Center, Command and Coutrol

Technologies, Boeing, Lockheed Marti,,

United Space Alliance, University of

Central Florida Center (or Simulatimt

and Training, and Florida Gidf C_ast

University (A.J. Ruiz-Torres)

115
Process/industrial Engineering

Process Analysis and Modeling: Intelligent Synthesis Environment

n recent years, NASA has been challenged to perform missions

under reduced budgets and

decreased timelines. NASA has

also recently implemented

changes in structure that reduce

duplication of engineering resources throughout the Agency.

Centers of Excellence have been

established to focus technical

expertise in response to a shrinking work force. Therefore, many

engineering tasks that once could

be accomplished completely

within one NASA center now

must be distributed among the

centers to capture the necessary

level of technical expertise. The

distributed nature of NASA's

technical expertise and the need

to perform in a "faster, better,

cheaper" environment have

driven the Agency to develop

new capabilities. At the same

time, NASA has been asked to

help lead U.S. companies into the

21 _'century through a deployment of cutting-edge systems at a

level of affordability that has not

been seen to this date.

The Intelligent Synthesis

Environment (ISE) program seeks

to address the geographical

challenges as well as help improve the engineering tools,

technologies, and methodologies

for NASA and U.S. industry. In

general, these have not advanced

significantly over the past several

years. A plan is being made

whereby technologies developed

in the NASA research centers or

their partners are deployed as

prototypes across the Agency. As

these become mature, contractors

chosen to maintain the prototypes

will be able to market them to

U.S. industry. With the commercialization and subsequent reduction of the cost of these systems, it

is hoped the private sector will be

able to benefit from the systems

engineering efforts funded by

NASA.

The Agency started the

process this year by deploying a

Collaborative Engineering Environment (CEE) infrastructure

across the Agency. Each center

received one of the Core Capability Rooms with the option to buy

more out of their own budgets.

The Core Capability Rooms

contain audio and video

conferencing as well as a data

conferencing capability through

netmeeting. These rooms are

maintained through a contractor

set up to handle the Agency's

needs.

Reentry Thermal Analysis (From Langly Research Center)

In the next year, the plan is to

deploy the Immersive Environment (IE) or 3-D data visualization tools as well as a data storage

infrastructure to support Agencywide reality conferencing. With

these tools in place, the Agency

will have the capability to develop and run systems through a

complete life cycle in a synthetic

environment. This will aid in the

understanding of the complex

issues involved in the development and deployment of space

technologies without reliance on

expensive physical modeling or

paper analysis.

116
Rosearch and Technology 1998

craft lu|rl,_nts not di_

International Space Station Simulation (From Langl!/ Research Center)

In the future, NASA as well as industry and academia partners

will develop new tools and methodologies that address the flow of

information from initial concept through manufacturing.

Key accomplishments:

• 1998: The NASA ISE Team was formed; the initial kickoff meeting

was held; and the initial collaborative infrastructure was deployed°

Key milestone:

• 1999: Install IE's at all centers and a data storage infrastructure

across the Agency.

Contacts: M.P. Conroy (MichaeI.Conroy-l@ksc.nasa._ov), VC-B1, (407) 867-4240;

and T.E. Fredrickson, MM-G1-B, (407) 867-2970

117
Process/industrial Engineering

Process Analysis and Modeling.

Virtual Shuttle Processing Model

he Virtual Shuttle Processing

(VSP) Collaborative Engineering Environment (CEE) project is

developing new engineering tools

and capabilities at KSC. The new

technologies allow engineers to

bring their efforts to the next level

of excellence and standardize

their use across all NASA centers.

Level I consists of basic data

conferencing and is being provided through ODIN for KSC

desktops and some conference

rooms. Level 2 consists of audio,

video, and data conferencing.

Level 3 adds the immersive

environment and reality conferencing capability to the audio,

video, and data conferencing.

The VSP model is being

developed to enhance engineering design, improve processing,

and enhance technical training.

Maintenance of the Shuttle

orbiter in its processing facility is

being modeled.

Key accomplishments:

1998: Project initiation. Delivery of Level 1 and Level 2 CEE

capabilities.

Key milestone:

1999 and beyond: Delivery of

Level 3 CEE capabilities and

multiple applications.

Contacts: M.M. Groh-Hammond

(Marcia.Groh-Hammond- l @ksc.

nasa.gov), PZ-Q-A, (407) 861-0572; and

K. Iftikhar, PZ-Q-A, (407) 861-6671

Participating Organizations: United

Space Alliance, Boeing Aerospace, and

NASAAmes

118
Rgsearch and Technology 1998

Automation

and Robotics

he Automation and Robotics program at the John F. Kennedy Space Center (KSC) is focused on advanced development cutting-edge technologies to

enhance KSC's core mission of launch and landing

ground operations. The program also provides a

partnering with other NASA research centers to demonstrate advanced mobile base ground processing technologies for problems that must be addressed and solved for

future space missions, such as remote autonomous Mars

operations. In this role, KSC is developing state-of-the-art

technologies in sensors, mechanisms, manipulators, and mobile bases for ground operations that

can be applied to future NASA mission scenarios. This field testing has selected space mission

technologies that are also applicable to ground processing applications and problem areas. KSC

provides the opportunity to take these technologies out of the laboratory and apply them to

actual ground operations at KSC. Technologies addressed in this section include advanced cable

inspection capabilities, improved data collection and intuitive graphical user interfaces, and

automation of large mechanical load-carrying devices.

Technology areas that KSC is working to develop and apply include: integration of real-time

controls with advanced information systems, obstacle-avoidance sensors and systems,

multidegree-of-freedom robotic devices and systems, intelligent control systems, imbedded and

distributed controls, inspection sensors and systems, integration of advanced software technologies in control and sensor interpretation, and model- and rule-based systems for health monitoring and diagnosis. All these technologies can be applied to automating ground processing tasks.

Application areas that are currently being addressed in this year's report include the Solid

Rocket Motor Stacking Enhancement Tool, Automated Ground Umbilicals, and the Cable Line

Inspection Mechanism.

119
Advanced Life Support Automated Remote

Manipulator (ALSARM)

he objective of the ALSARM

project is to develop a prototype system to take environmental measurements inside the

Biomass Production Chamber

(BPC) breadboard project (also

known as the Controlled Ecological Life Support System or

CELSS) at KSC. The BPC is

operated by the Advanced Life

Support project office (JJ-G). The

ALSARM is performed in conjunction with the University of

Central Florida (UCF). A twosemester design course at UCF

resulted in several concepts for

the ALSARM. KSC and UCF

decided on a final concept that

meets all the system and BPC

requirements. The project is

complete and operational. Phase

II of the ALSARM project (development of an end-effector to take

plant samples remotely) will

begin in late 1998.

The BPC consists of two

separate levels used to grow

crops in an almost totally enclosed environment. The BPC

will help NASA understand how

to grow crops in space for Moon

or Mars bases. During the course

of study, technicians have to enter

the chamber to measure environmental parameters such as air

temperature, infrared temperature, relative humidity, air velocity, and light intensity. Entry of

personnel into the BPC disturbs

the environment in several ways.

The opening of the chamber door

accounts for about half the chamber daily leak rate. The technicians contaminate the environment by their respiration, which

expels carbon dioxide and organic products. The mere presence of technicians can modify

the air flow patterns in the BPC.

The environmental measurements, which take about an hour,

are performed serially. Also, it is

difficult for people to take measurements at exactly the same

points from one type of measurement to another or from one test

to another. The ALSARM will be

an automated method of taking

these measurements that will

eliminate personnel entry, reduce

the chamber leak rate, and allow

more consistent measurements.

The ALSARM integrates stateof-the-art systems in control,

mobility, manipulation, information management, and sensor

technologies to perform the BPC

environmental measurements.

The system will be expanded to

include an end-effector (or tool)

on the manipulator to take plant

samples and eventually perform

other functions such as planting

and harvesting. This end-effector

will be developed during Phase II

of the ALSARM project that

started in August 1998.

Key design features of the

ALSARM include: (1) automated

control via a tether cable, (2) a 3-

degree-of-freedom robot manipulator, (3) multiple sensor array, (4)

interfaces to existing NASA

databases, and (5) development

of an end-effector for plant

sampling.

ALSARM in the BPC

The accomplishments for 1998

include completion of operational

testing at the BPC, fabrication of a

120
Rosearch and Technology 1998

replacement sensor array, startup of Phase II (endeffector), and development of a preliminary endeffector design.

Completion of the preliminary end-effector

design and fabrication of the replacement sensor

array were the major efforts for the remainder of

1998.

Key accomplishments and milestones:

• August 1993: Project initiated and concept

designs evaluated.

• June 1994: Final report and design concept

completed.

• October 1994: Systems requirements review

completed.

• October 1994: 30% design review.

• November 1994: 60% design review.

• November 1994: 90% design review.

• December 1994: Final review.

• March 1995: Redesign of horizontal telescoping

arm started.

• August 1995: Redesign of horizontal telescoping

arm finished.

• October 1997: Fabrication of the ALSARM complete.

• December 1997: Laboratory testing of the

ALSARM complete.

• July 1997: Installation of the ALSARM into the

BPC.

• August 1997 to January 1998: Activation and

validation testing of the ALSARM.

• January to August 1998: Development and

fabrication of a replacement end-effector.

• Late 1998: Development of the ALSARM endeffector.

Contacts: M, Hogue (MichaeI,Hogue-l@ksc.uasa.A, ovL MMG3, (407) 867-1720; W.C. ]ones, MM-G3, (407) 8o7-4181;

A.J. Bradley, MM-G3, (407) 867-1720; and Dr. [.C. Sa_cr, ]]

G, (407) 853-5142

Participating Organization: University ¢_tCe_#ral Florida

(Dr. R. Johnson)

Motors

Flexible Shafts

Gripper/Cutter

ALSARM End-Effector Preliminary Design

121
Automation and Robotics

Advanced Payload Transfer Measurement

System (APTMS)

he objective of this project is

to develop a simple, robust,

centrally operated, and portable

system to automatically measure

Xo, Yo, and Zo offsets between

the trunnions and their support

during payload transfer operations in the Vertical Processing

Facility, Orbiter Processing

Facility, Operations and Checkout

Building, and Payload Changeout

Room. Each trunnion will be

instrumented and the misalignment will be displayed to the

move conductor. Future expansion capabilities include fast

calculation of the next move

command and closed-loop control of the operation. Key design

features of the APTMS include:

• Quick Xo, Yo, and Zo measurement and display of data to

move the conductor

• Small and portable transducer

• Versatile design for use at the

Vertical Processing Facility,

Orbiter Processing Facility,

Operations and Checkout

Building, and Payload

Changeout Room

• Off-the-shelf optical encoders

for angle measurement

• Laptop computer for ease of

portable data analysis and

display

• Wireless port connection

between a laptop and data

acquisition system

Programming capability to

calculate the next move command

First step for payload transfer

automation at the Vertical

Processing Facility and Payload Changeout Room

Benefits of the APTMS include:

• Capability enhancements

• Reduction of time and cost for

payload transfer

• Increase in measurement

accuracy and reliability; reduction of error opportunities

• Increase in payload and technician safety

• Avenue for payload transfer

automation of four different

locations

Commercial applications of the

APTMS include:

• Crane operations

• Construction

• Assembly

• Manufacturing

• Automotive

• Aerospace

Key accomplishments and milestones:

• Mechanical, electrical, and

software system testing has

been completed. Further

adjustments are in work to

meet the positioning requirements of 0.05 inch at a 6-inch

range.

• 1995: Developed prototype

unit.
APTMS in Operation

1996: Tested prototype unit and made modifications.

1997: Started development of production unit, design, and fabrication.

1998: Completed production unit and tested and implemented modifications to enhance

accuracy and ease of calibration. Developed a demonstration simulation tool for presentation to customers.

Contacts: W.C. ]ones (William.Joncs-3@ksc.nasa.gov), MM-G3, (4(17) 867-4181; mut E. l_opcz DcI Castillo and

F. Soto Tot'o, MM-G3, (407) 867-80(15

123
Automated Umbilical Mating Technology

umerous launch vehicles, planetary systems, and rovers require umbilical mating for fluid flow and electrical connections. Simple,

reliable, autonomous mating is required to make certain missions and

systems feasible (i.e., Mars methane fueled rovers) and to provide low- ,

cost, safe launch operations. The environment for mating (temperature, humidity, dust, cost, weight, and power) varies drastically from

system to system. However, a common core technology and numerous sensor and mating techniques are needed to provide low-cost,

common solutions for all systems. The technical approach involves

the following:

Development of a smart umbilical with a reconnect capability (This

project will leverage off an existing Small Business Innovation

Research (SBIR) project and additional available hardware.)

Autonomous or remote operations using vision systems,

force feedback, miniaturized

gas detection, and state-of-theart real-time control

Umbilical that provides the

capability to connect, disconnect, and reconnect during any

point in the launch countdown

process

Investigation of various sensor

and mechanism concepts for

different mating environments

SBIR Smart Umbilical

Existing IRB Robot

Used for Flight-Side

Excursions

124
r Research and Technology 1998

The benefits to NASA missions involve the following:

Autonomous methane-fueled

Mars exploration rovers (required for Mars sample return)

Capability to connect, disconnect, and reconnect during any

point in the countdown process

for the Reuseable Launch

Vehicle (RLV), Liquid Flyback

Booster (LFBB), and Evolved

Expendable Launch Vehicle

(EELV) (Low-cost, high-reliability autonomous mating will

enhance all future launch

vehicles.)

• Cheaper, safer launch operations

• Increased launch reliability

Currently, a Phase II SBIR

project is investigating and

developing a highly reliable, safe,

and smart automated ground/

flight umbilical carrier plate for

remote installation and removal.

The umbilical plate will contain

multiple service connections for

cryogenic propellants, pneumatics (gaseous nitrogen and gaseous

hydrogen), environmental control

gases, and electrical power and

data. The umbilical will have the

ability to mate, demate, and

remate with little or no human

intervention. Flight side and

ground side will be demonstrated

with dynamic excursions based

on real-world data.

The smart umbilical mating

system will provide for two fluid

connections and four electrical

connections. After the operator

manually drives the umbilical to

within its alignment area, the

vision control system will take

over and drive the umbilical to

mate with the flight-side plate.

The operator has the option to

give the final permission to

perform each step in the mating

process and can interrupt the

mating process at any time.

When the mating process is

interrupted, the umbilical will

return to the previous safe step in

the mating process or will return

to the home position, depending

on how it is interrupted.

After the umbilical plate has

been connected and latched to the

flight-side plate, the umbilical

system goes into a passive mode,

whereby it follows the excursions

of the flight side. Then the

electrical and fluid connections

are verified for leaks and connectivity.

The operators will access

system controls through the

software loaded into the control

console computer. From this

console, the operator will have

control of and feedback from the

entire system as well as the

camera view of the vision system.

All data acquisition hardware is

also interfaced to this industrial

computer. Additional design

requirements include:

• Compliant self-aligning

ground-side carrier plate

• Traceability to a nonsing|e

point failure design

• Real-world dynamic and static

vehicle excursions

Quick and reliable remote

verification of interface integrity

• IRB 90 robotic arm to mimic

vehicle excursions

Key accomplishments and milestones:

• June 1998: Completion of the

SBIR mechanical design.

• October 1998: Completion of

the SBIR electrical design.

• 1999: Completion of the SBIR

automated umbilical and test

and modify to provide full

automation capability.

Contacts: T.C. Lippitt (Thomas.Lif_flittl@ksc.nasa.gov), MM-G3, (407) 867-

I720; and W.C. Jones, MM-G3, (4071

867-4181

125
Payload Ground Handling Mechanism

(PGHM) Automation

he PGHM is located in the Payload Changeout Rooms of

Space Shuttle Launch Pads A and

B at KSC. The PGHM is used to

remove or insert the Shuttle

payload from both the orbiter

payload bay and the payload

transport canister. The PGHM

provides the capability to load/

access payloads when the vehicle

is at the launch pad. Upgrades to

PGHM systems are required to

provide United Space Alliance

operations personnel the capability to process vertical payloads in

a safer and more efficient environment. The PGHM consists of

the following mechanisms:

• Power X: coarse vertical

motion

• Power X Stop Nut: redundant

safety feature of Power X

• Power Y: coarse side-to-side

motion

• Payload Support Beam X

(PLSB X): fine vertical motion

• Payload Support Beam Z

(PLSB Z): fine insert and

retract motion

• Stern Strain: PGHM weight

distribution stability

• J-Hooks: X, Y, and Z: very fine

motion

The current PGHM design

uses pneumatics and manpower

for axis actuation. Through

automation, position feedback

circuits, and the elimination of

hazardous manual drive systems,

the proposed upgrades will

provide a safer, more efficient

processing environment. The

project scope will be divided into

two major efforts:

1. Automated Control of Mechanisms. The Power X, Power X

Stop Nut, Power Y, Payload

Support Beam X, Payload

Support Beam Z, and Stem

Strain mechanisms will be

automated using commercial

off-the-shelf electronic control

systems. Numerous hardwarecritical failure points and

human-intervention-dependent operations will be eliminated. A centralized control

console with a graphical user

interface will be provided for

the PGHM Move Director to

command operations. The

main objectives are to:

• Eliminate the hardware single

failure points.

• Eliminate the operations in

which human error could

cause hardware damage or

human injury.

• Provide better control and

feedback to the payload Move

Director and technicians.

• Increase the operational efficiency and reduce the number

of personnel required for

payload transfer.

2. J-Hook and Orbiter-to-Payload

Position Measurement Study.

J-hook and orbiter-to- payload

position measurement requirements will be detailed and the

system design approach will be

determined in a study.

Contacts: W.C. ]ones (William.]ones3@ksc.nasa.gov) and A.J. Bradl W,

MM-G3, (407) 867-4181

Participating Organizations: United

Space Alliance and Dynacs Engineering

Co., Inc.

126
Research and Technology 1998

NT Office

SCADA _ Workstation

Server I,_ Windows 95/98

t I

I

/ --q---- --

Integrated PC-Based

Control Pendant

NT

Workstation

E

I

Gateway

PitCh L_IHM'

_T _M°dbus

PLC5

Compressed

Video/Audio

_J

Integrated Operations Development System

Passive

Backplane ['

PC t

(PGHM Test '

Platform)

Ethernet I/O

Neural

Net

Workstation

l

TCP/IP 100BT I [_Wireless

Fiber ...... t l

/ I

/ _ IRDA Port

/FIIHM,

• l_Foundat,on

/ _ Field Bus

_r___-i=i Ethernet

LI._.! !111 _ PLC

/4 v _ Direct

/ _ Connection

__ Motion To Ethernet

Controller

_-_ Embedded

_PC Controller

Wireless

Device Net

PLC

PLC

Wireless

Multiplexed

__ Vision

127
Automation and Robotics

Cable and Line Inspection Mechanism (CLIM)

iannual inspections of the

seven slide-wire cables used

in the Emergency Egress System

at both Launch Pads A and B

require inspection crews to

visually verify the integrity of the

cable as the crews are lowered

down the cable in the slide-wire

baskets. Due to the type of cable

used as slide-wires (i.e., stainless

steel), magnetic resonant devices

normally employed to inspect

cables are inadequate. This manintensive and time-consuming

operation prompted a request to

the Automated Ground Support

Systems Laboratory to develop a

stand-alone system for automated

cable inspection. In addition, no

method exists for inspection of

the lightning cables at each

launch pad due to their inaccessibility.

The cable failures to be identified by the automated system, per

the applicable Operations and

Maintenance Requirements

Document (OMRS File IV), are

characterized by frayed strands,

bird nesting, stretching, and

corrosion. The cable undergoes

load testing on a periodic basis

and is man rated by weighting

the egress baskets with sandbags

and sending them down the

cable. Consequently, this is not a

task for the automated system.

The inspection teams rely on a

visual inspection of the surface of

the cables with a cursory check of

the cable diameter using a go/nogo gage every 10 feet. The targeted cables were identified to

have an inclination of no more

than 45 degrees, a length of

approximately 1,200 feet, and a

diameter of 1/2 to 3/4 inch.

Finally, a prototype unit had

already been developed for the

project but required testing. A

production unit based on the

prototype design was needed.

control scheme using a radio

frequency control system for

radio-controlled airplanes was

employed. A method of measuring the cable diameter was found.

Finally, a microcomputer to

control the unit was used. Due to

the limited accessibility to power

over the distances involved, the

unit operates on batteries.

The prototype unit was tested

on 300 feet of guy wire supporting the 500-foot weather tower

north of the Vehicle Assembly

Building. The guy wire was 3/4

inch thick and at an inclination of

15 degrees. The unit was operated on the cable until the distances required for the slide-wire

inspections were obtained. The

data captured from the test was

graphed for demonstration.

Problems were identified and

alternate equipment was chosen.

Currently, the manufacture of a

production unit is in process for

use by the customer. A 75-percent

drawing package has been released.

Key accomplishments:

• 1997: Identified customer

requirements.

• 1998: Tested the prototype

unit. Manufactured the production unit.

Key milestone:

• 1999: Assemble, test, and turn

over the production unit.

CLIM Cable Video

Contacts: W.C. Jones (Will&m.Jones3@ksc.nasa.gov), MM-G3, (407) 867-

4181; and R.L. Morrison, MM-G3,

(407) 867-4156

Participating Organizations: NASA

MM-G3 (R. Morrison, I. Bonner, and

M. Hogue), NASA PK-J (K. Nozvak),

NASA MM-E (J. Richards-Gruendel

and L. Parrish), and United Space

Alliance (G. Hajdaj and M. Olka)

128
Prototype Unit on the Test Cabh'

Launch Pad Tower View off the Slide Wires

129
Automation anl Robotics

OmniBot Mobile Base

he objective of the OmniBot

project is to develop a hazardous duty mobile base as an

advanced development test bed

to research alternate technical

approaches for remotely controlled operations in hazardous

areas. In addition, this base will

be used to test various automated

umbilical technologies for autonomous mobile vehicles. In

hazardous environments where it

is too dangerous to send in

unprotected personnel, a mobile

base could be used to perform

remote inspections, site surveys,

and operations.

The OmniBot is driven with

four brushless servomotors

connected to omnidirectional

wheels (Mechanum). This allows

for complete 2-degree-of-freedom

motion, which results in extremely high maneuverability.

The benefit of this motion profile

can truly be appreciated when the

vehicle is operated in a teleoperational mode.

Currently the vehicle can be

controlled with a radio frequency

(RF) control box or with a

hardwired joystick. With the

video transmission gear installed,

teleoperation is possible up to a

distance of 1,800 feet.

The next phase in the project

is the construction of an

operator's control station, a

sensor package, and manipulator

systems.

Key accomplishments and milestones:

• January 1997: Construction of

the motion base.

• June 1997: Testing of the

motion base and control system.

• March 1998: Construction of

the RF control system.

• August 1998: Selection/

procurement of the multitasking system.

• September 1998: Installation of

the video RF gear.

Contacts: T.C. Lippitt (Thomas.Lippittl@ksc.nasa.gov) and W.C. ]ones, MMG3, (407) 867-4181

OmniBot Mobile Base

Closeup of Omni (Mechanum) Wheels

130
Research and Technology 1998

Electro-Mechanical Actuator

he objective of the Electro-Mechanical Actuator

(EMA) project is to evaluate and demonstrate

the viability of electro-mechanical actuators to

replace pneumatic actuation for use in launch

processing ground support equipment (GSE) at

KSC. The current pneumatic actuation systems,

such as the cryogenic fuel and oxidizer systems,

firex systems, sound suppression system, etc.,

require high maintenance and the components are

becoming old and obsolete. These systems are

located at the launch pads and are exposed to the

rigors of launch and the high humidity and salty

seaside environment. Use of EMA's has the potential to reduce the complexity and number of components required by as much as 80 percent.

Commericial off-the-shelf electro-mechanical actuators are being evaluated, and methods of providing

high reliability through redundancy are being

addressed. Higher position accuracy and repeatability are also potential benefits from the use of

EMA's.

The EMA system consists of one electromechanical actuator controlled by two programmable logic controllers (PLC's) and two servodrives in a parallel configuration for highly reliable

operation. Commercial use of single-string control

using PLC's and servo-drives for EMA's has proven

these system components to be highly reliable,

accurate, and economical. Once studied and proven

for dual-control redundancy, the concept could

provide the same benefits for critical systems.

Key accomplishments and milestones:

• April 1998: Design and layout of the EMA test

plan.

• June 1998: Procurement and mounting of Allen

Bradley PLC's and servo-drives.

• September 1998: Procurement of Class I, Division

I, electro-mechanical actuators manufactured by

Exlar Corporation.

• January 1999: Testing and evaluation of EMA

configurations, operating characteristics, and

reliability and repeatability.

Contacts: W.C. Jones (William.Jones-3@ksc.nasa.govL MMG3, (407) 867-4181;and T.H. Miller, MM-G3, (407) 867-4156

Participating Organizatiotls: NASA Process En_,,inccriH<_

Directorate and United Space Alliauce

131
Solid Rocket Motor (SRM) Stacking

Enhancement Tool (SSET)

he NASA Automated Ground

Support Systems Lab (MMG3) of the Engineering Development Directorate is developing

the SSET, a mobile data acquisition system used to monitor the

Space Shuttle solid rocket motor

stacking process in the Vehicle

Assembly Building (VAB) at KSC.

Four SRM segments are mated

together to form a solid rocket

booster, with two completed

boosters used for each Space

Shuttle. SRM segments are

attached to a four-point lifting

beam, a device that can vary the

load of each of its attachment

points and modify the segment

shape to match that of its partner.

The entire assembly is then

hoisted by a crane and lowered

onto the SRB under construction.

The segment junction points, or

field joints, are critical interconnections whose failure could

cause a catastrophe.

The stacking process takes

many hours and is manpower

intensive, so delays due to system

failures are costly. The SSET

replaces and combines the functions of two antiquated systems

already in use, the Temposonics

measurement system and the

lifting beam load panel. The

Temposonics measurement

system is composed of four onedimensional (1D) sensors (which

are located at 90-degree intervals

Lifting Beam

0

/

Connector Panel

DTM Sensors

SSET Panel

o_o

o _;. ]

°

° llll}li]l}li

Control

Panel

UPS

Power

Plug

Figure I. SRM Stacking Enhancement Tool

between the two segments) and a

data acquisition computer system

(used to display and record the

numerical measurements). The

measurements are used to determine the distance to mate, levelness, and lowering rate. The

lifting beam load panel uses six

strain-gage-type load cells located

in the SRM lifting beam to measure the loads and levelness

forces of the suspended segment.

Currently, no data recording is

available for the loads.

The SSET provides current

technology data acquisition

equipment to measure the existing sensors. Some benefits of the

SSET are:

A single display unit reduces

the number of equipment items

(figure 1).

The information is displayed

on an intuitive graphical user

interface and is easy to interpret (figure 2).

• All measurement data will be

recorded.

The modular design allows for

system modifications and

updates.

The onboard uninterruptible

power supply (UPS) guards

against data loss due to power

failure.

Advisory functions help

operators maintain segment

levelness.

• Built-in test ports allow for

easy troubleshooting.

132
Research end Technology 1998

Eli I_ t_ :| _], LTJI_ r.]|_,.[4._1 __'_F"3B:] i|l[I] :1:IB =r.] ,['.]i_T:T_ [

Fi_e Sample FIa_e CoNigura_ion System Func_ion_

Figure 2. Graphical User lnte_ifacc

• All operator events and configuration values are logged for future reference.

• Up to 1 hour of real-time data is maintained for review during stacking.

• Data review software is provided for posttest analysis.

Three production units are fabricated and undergoing certification at KSC. SSET

operational readiness is scheduled for early 1999.

Key milestones:

• Completed proof-of-concept shadowing operation of an SRM stacking and destacking.

• Completed electromagnetic interference susceptibility tests.

• Completed the initial inert segment stacking operation.

• Scheduled the design certification review and operations turnover for 1999.

Contacts: W.C. /ones (William.]ones-3@ksc.nasa._ov) and A.J. Bradley, MM-G3, (407) 867-418I

Participatin,_, Organizations: Dynacs Eny,ineering Co., Inc., NASA PK-H, and United Space Alliance

133/134

Research and Technology 1998

!

Electronics and

instrumentation

he Electronics and Instrumentation Technology program at the John E

Kennedy Space Center (KSC) supports the development of advanced

electronic technologies that enhance safety

and quality, decrease launch vehicle and

payload ground processing time and cost,

and improve process automation. The

program includes the application of

applied physics and chemistry and electrical and electronic engineering, particularly in the areas of sensors, data acquisition and transmission, advanced audio

systems, digital computer-controlled

video, contamination and gas detection

instrumentation, field inspection and

nondestructive testing, and circuit monitoring instrumentation. The near-term

program focuses on Space Shuttle, payloads, and Space Station ground processing enhancement by developing instruments in monitoring, testing, and vehicle

processing. The long-term program is

developing technology for support of

future space vehicles, payh_ads, and

launch systems by advancing the state of

the art in launch vehicle and payload

processing electronics and instrumentation to reduce costs and improve safety.

135
136

Space Shuttle Integrated Vehicle Health

Management (IVHM) Flight Experiment

he IVHM Human Exploration

and Development of Space

(HEDS) Technology Demonstration (IVHM HTD) flight experiment was the first KSC designed

and built payload. Its purpose

was to demonstrate competing

modern, off-the-shelf sensing

technologies in an operational

environment to make informed

design decisions for the eventual

orbiter upgrade IVHM. There are

three objectives of IVHM:

. More autonomous operation in

flight and on the ground,

which translates to reduced

work load on the ground

controller team. Near Earth

space operations provide the

luxury of having a ground

team evaluate vehicle data to

make real-time decisions. On a

Mars mission for example,

there is a 40-minute time delay

to send and receive a message.

Therefore, future vehicles will

require more autonomous

capabilities.

. Reduced ground processing of

reusable vehicles due to increased performance of system

health checks in flight rather

than back on the ground.

. Enhanced vehicle safety due to

the ability to monitor system

health even inside the harsh

environment of an engine

combustion chamber as well as

prediction of pending failures.

The "integrated" piece of

IVHM is the total integration of

flight and ground IVHM elements. The four elements of

flight IVHM are advanced lightweight/low-power sensors,

distributed data acquisition

architecture, data processing, and

mass storage. The three elements

of ground IVHM are evolved

control room architectures,

advanced applications, and

automated ground processing

systems. While incorporation of

an IVHM architecture into a new

vehicle is a complex process in

itself, implementation of IVHM

into the Space Shuttle program

must deal with additional considerations such as not impacting the

flight manifest, cost/payback

analysis, evaluation of military

and commercial off-the-shelf

(COTS) components, and vehicle

retrofit installation considerations. The first IVHM HTD

flight experiment was successfully flown on Discovery on STS95 from October 29 to November

7, 1998. The second IVHM HTD

flight experiment will re-fly all

elements as well as additional

sensing systems on STS-96 with a

planned launch date of May 13,

1999.

During cryogenic propellant

loading in the terminal launch

countdown, the 1VHM data

stream was routed out of the

orbiter's T-0 umbilical for transmission, processing, and viewing

in the Launch Control Center

(LCC) via a new Ethernet network installed in the Mobile

Launcher Platform, using existing

fiber-optic lines connecting the

launch pad with the LCC and

using the new Checkout and

Launch Control System (CLCS)

elements. The IVHM processor

autonomously began recording

data at T-10 seconds prior to
SpaceShuttlemain enginestart. •

Datawasrecordedduring ascent

andon-orbitduring daily 1-hour

snap-shotperiods. Theprocessor

wasdumpedto theCLCSafter

theorbiterlandedandwas rolled

into its OrbiterProcessingFacility

bay. Flightdataevaluationof the •

first flight experimentisunderway,andapreliminary assessmentisthat thesystemhad100

percentperformance.Thefollowing listscontainthedemonstrated

technologiesandtheorganizationsresponsiblefor theirdevelopment.

IVHM HTD-1

• Micro-electromechanical

systems (MEMS) hydrogen

detection - LeRC, Case Western Reserve University/Makel

(G. Hunter)

• Galvanic cell oxygen detection

- KSC

• Main propulsion system (MPS)

vacuum-jacketed (VJ) line

pressure sensing - KSC

RS485 smart sensor technology

for hydrogen detection, oxygen

detection, and VJ pressure -

KSC

MPS helium leak detection

using thermal flow technology

- KSC

Integration/flight certification

testing (thermal, vacuum,

vibration, radiation, EMI, and

EMC) of COTS conduction

cooled VME bus architecture,

flash memory, PowerPC processor, IRIG interface card, and

all sensors - KSC

Data processing software

architecture (scheduler, internal

health checks, and data acquisition) using VxWorks - KSC

Ethernet ground data processing system - KSC

IVHM HTD-2

• Hydrogen detection using

fiber-optic Bragg-Grating

technology - LaRC and University of Maryland (K. Vipavetz)

• Structural strain and temperature determination using fiberoptic Bragg-Grating technology

- Rockwell Science Center (B.

Christian)

• Distributed data processing

using X-33 Remote Health

Node technology - Lockheed

Martin, Sanders Division (R.

Garbos)

• Fiber Distributed Data Interface (FDDI) technologyHampshire Vanguard Technology Associates (T. Hardy)

• Space Shuttle Main Engine

(SSME) pump vibration monitoting system with digital

signal processing technology -

MSFC (T. Fiorucci)

Additional information is

available on the World Wide Web

at: http://www.ksc.nasa.gov/shuttle/

up_rades/ksc/ivhnl/data depot/

ivhmhonle.htm

Contacts: I. Fox (]ack.F_x-l@ksc.nasa.

,_ov), R. tfmlso11, aud S. Wilsou, AA-D,

(407) 807-2001

Vacuum-Jacketed Line Smart Sensor

lq_and O: Smart Sensors

137
Electronics and Instrumentation

Orbiter Jack and Leveling Operations

fter landing, the orbiter is towed into the Orbiter Processing Facility (OPF) and positioned so the pair of nose landing

gear (NLG) tires and each pair of

main landing gear (MLG) tires are

centered on a floor lift. The lift

under the NLG tires raises the

nose of the orbiter until the pitch

of the orbiter is horizontal; then

the three lifts simultaneously

raise the orbiter to a specified

height (the maintenance height)

while maintaining the horizontal

pitch. The proper maintenance

height of the orbiter is critical

because the surrounding facility

platforms are designed for this

height. Once at the maintenance

height, the orbiter jacks are

installed and the lifts are lowered

to the ground. During a typical

orbiter processing flow, the rear

support of the orbiter is transferred from the aft jacks to the

MLG floor lifts and then back

again while the forward jacks

remain attached.

These operations require a

height measurement accuracy of

+1/4 inch. This is currently

achieved with a set of calibrated

measuring sticks to determine the

height at each of the four jack

attach points. The disadvantages

to this measuring technique are

(1) the sticks are long and thin

and technicians have difficulty

maintaining them vertical to the

ground, (2) the distance read

varies with the force the user

exerts when pressing the rod

against the orbiter, and (3) this

technique is time consuming and

uses a significant number of

Figure 1. Four Leica Laser Rangefinders

people. Furthermore, the long

sticks are awkward to handle and

there is potential for orbiter tile

damage when the top of the stick

is raised to vertical. Due to these

difficulties, a replacement to the

measuring sticks is desired.

The key to solving this problem is the use of the Leica laser

rangefinder. This device allows a

user to aim a laser beam at a

target and read the distance to

that target to within +1/8 inch

from distances between 5 and 200

feet. A system (see figure 1) was

developed whereby four of these

rangefinders were used, two to

measure the height from the floor

to the aft jack attach points and

two to measure the height from

the floor to the forward jack

attach points. All four communicate their results to a central

computer on a desk located to the

left side of the orbiter midbody.

Each of the Leica units is held

in a vertical orientation by an

aluminum framework. The

electrical connection to the Leica

rangefinder provides RS-232

communication (9,600 baud) and

power. The Leica rangefinder

and its framework have been

attached to a triangular base with

a bubble level, two tilt adjustment

screws, and a fixed foot. The tilt

adjustment feature allows compensation for small variations in

the flatness of the floor of the OPF

to ensure the laser beam points

near vertical.

The signals from the rangefinders are brought back to the

central computer. The software

was written in LabView, which

allows for direct control of an

138
Research and Technology 1998

Fi_un' 2. ComFuter Display q( Leica Laser Rauyfimh'r Results

RS-232 as well as the Leica rangefinders. An image

of the orbiter is displayed with four bars (see figure

2; note that no bars are visible) reaching from below

the orbiter up to the jack attach points. The height

in inches from the floor to each jack attach point is

shown and the bar is color coded to indicate the

status of the measurement. Typically the bars are

red if the distance is an inch or more too low, are

yellow if the distance is within 1-1/4 inch too low,

green if the distance is within 1/4 inch of the desired distance, and flashing red if the distance is

more than 1/4 inch too high.

If a Leica rangefinder returns an error condition

to the LabView software or if it does not respond at

all, the software displays an error condition and

counts the errors. It takes less than 3 seconds typically for all four Leica rangefinders to perform a

distance measurement and for the software to

receive and display these numbers. If, for some

reason, the software detects a problem with a

specific Leica rangefinder, it displays a "Data Drop

Out" message in the error status window and does

not display the distance data.

A fifth mounted Leica rangefinder with full

cabling was provided as a spare. All five Leica

systems were fabricated so they are within a few

hundredths of an inch of each other in height and

can be interchanged.

Contact: C.B. Mi=cll (Caroh/11.Mizdl-l@ksc.nasa.govL MMH-A, (407) 867-7705

Participatin_ Organizations: United Space Alliance

(M. McChtreL PK-tt (C. DavisL amt D!macs E_lqim'cri_lg

Co., Inc. (B. Burns, W.D. ttaskell, T.]. (_)Falka,I.D. Polk, amt

R.C. Yolm_cquist_

139
Leak Detection and Visualization

Using Laser Shearography

here are currently over 12

techniques used to detect and

locate leaks in the various fluid

systems that are part of both

ground and flight equipment in

the Space Shuttle program. Often

times, detection and location are

carried out by completely separate methods that add both time

and cost to the testing. A "full

field" method for detecting,

locating, and visualizing leaks

was desired, and laser shearography has shown promise in

this respect.

Laser shearography is an

interferometric technique, meaning it is sensitive to constructive

and destructive interference from

phase differences in coherent

light. "Shearing" optics are used

to image multiple points of a

laser-illuminated object onto a

single picture element or pixel. In

a real-time laser shearography

system, like the one used in this

investigation, the phase information at these points is collected by

a video camera pixel array. At the

beginning of a test, an initial

video frame (called the reference

frame) is captured and from

which all subsequent live frames

are subtracted. Differences,

caused by phase changes, between the reference frame and the

live frame are displayed in live

shear images on a video monitor.

Any change in the phase relation

measured at an individual pixel,

whether due to a path length

change of some of the light

initially imaged on that pixel or

due to the bending of light causing more or fewer object points to

be imaged onto that pixel, shows

up in the live shear image as a

variation in gray level. Laser

shearography is, thereby, well

suited to locate and measure very

slight out-of-plane displacements

or, as in this case, to locate substances that change the index of

refraction in the object space.

Two captured images of leaks

are shown in the figures. Figure 1

shows a very slight leak from an

air duster can that is otherwise

invisible to the naked eye. The

air from the can, which is colder

and denser than the ambient air,

can be seen to be flowing downward in the image. Figure 2

shows a leak from a calibrated

helium leak system of 2.8 x 10 3

c3/s at I atmosphere. In this

image, the helium (which is

lighter than air) can be seen to be

flowing upward.

What appears as two leaks in

each of these images is actually a

single leak and its "shadow." The

laser illumination source was

located approximately I inch

above the camera, which explains

the shadow of the leak fixture

seen just below the actual leak

fixture. The leak "shadow" was

produced in a similar way. Light

from the laser had two opportunities to pass through and be

affected by the leak - once on its

way from the laser source to the

background (located approximately 3 inches away) and once

on its way from the background

to the camera. Since the laser was

located above the camera, the

upper indication is due to light

passing through the leak after

being reflected off the background. The lower indication is

due to light passing through the

leak before reaching the background. Where the two leak

indications overlap is where light

passed through the leak in both

directions.

It was determined that helium

leaks as small as 10-3C3/S at 1

atmosphere could be detected

without additional image processing. Leaks were much more

apparent in the live video as often

the motion of the leak helped set

it apart from background noise.

Better results were obtained by

capturing reference frames at

short, regular intervals which

helped eliminate the slow, constant increase in noise caused by

slight changes in the surrounding

environment. Future plans for

leak detection with laser shearography include a probability of

detection study of helium leaks in

air and in a vacuum and studies

of other types of leaks in several

different environments.

Contact: ].D. Collins (David.Col/insl@ksc.nasa.gov), MM-G, (407) 867-

7069

Participating Organizations: 1-NET,

Inc. (S.M. Gleman) and Dynacs

Engineering Co., Inc. (J. Donahue, S.W.

Thaver, and D.L. Thompson)

140
Research and Technology 1998

Figure 1. Air Duster Can Leak

Figure 2. Helium Leak 2.8 x 10 _c _at 1 Atmosphere

141
Electronics and Instrumentation

Support of the Linear Aerospike

SR-71 Experiment (LASRE)

SC has been launching vehicles for almost 40 years.

The knowledge gained over this

time has proven to be of use to

other NASA centers and support

contractors. One such area is that

of checking vehicles for fuel leaks

before launch. Recently, personnel from KSC were requested to

assist Dryden Flight Research

Center (DFRC) personnel in their

effort to determine if the LASRE

was safe for flight. Because the

engine used gaseous hydrogen

and liquid oxygen for the fuel

and oxidizer, the experiment

could not be flown until it was

demonstrated to be free of leaks.

KSC was contacted to assist

DFRC because of difficulties

arising while trying to leak check

the engine.

The LASRE test plan included

a small half-span model of the

X-33 Aerospike Engine mounted

onto an SR-71 aircraft. The

engine was then to be flown to an

altitude and test-fired. These

experiments would answer

questions about the performance

of the engine as well as how a

reusable launch vehicle's engine

plume would affect the aerodynamics of its lifting body shape at

specific altitudes and speeds.

However, before the engine could

be fired at altitude, it had to be

shown to be free of fuel and

oxidizer leaks.

In response to the request for

support, KSC sent a mass-spectrometer-based system, namely

the Interim-Hydrogen Umbilical

Mass Spectrometer (I-HUMS),

and personnel to DFRC to support the leak tests. I-HUMS was

developed during the summer of

1990 to help find the leaks on the

orbiters for flights STS-35 and

STS-38. Helium and hydrogen

Fi_,ure 1. I-HUMS Under the SR-71 for Leak Checks

were the only gas species monitored for these experiments, even

though the I-HUMS can monitor

additional gases. This report

covers one of the two tests supported by KSC. This test was

deemed the most valuable.

Figure I shows the I-HUMS

attached to the LASRE during a

cold firing of the engine.

The leak test performed on

the LASRE was based on the

Shuttle Aft Helium Signature

Leak Test (V1202), which is

currently performed before each

launch. The entire system was

characterized because the LASRE

had no history or baseline. The

test required the I-HUMS to

monitor helium at one sample

location; the I-HUMS can support

up to 16 sample locations. Because the purge was not a simple

in/out model, it also was characterized. This is due to the fact

that the feed system is distributed

throughout the purged environment (see figure 2). Venting is

through many tiny holes throughout the skin of the test article.

Both of these characteristics made

the purge path unknown.

The I-HUMS was used to

monitor the purge of the LASRE

while a calibrated helium leak

rate was injected into multiple

locations in the test article. The

injection of a known leak rate into

a known purge was used to

characterize the engine purge.

This characterization was subsequently used to determine the

minimum signal that would be

detected for a given engine leak.

A second calibrated helium leak

rate was injected to enable

quantitation of any engine leak.

142
Research and Technology 1998

Purge

I f .V I

I/ H20 Tanks' GH2 Tanks Canoe /f_ [

Sample of the He

_ Injection Locations

_ Monitoring

Location

Fiy,ure 2. Layout of I.ASRE Leak Checkin_

After the engine purge was

characterized, the engine was

pressurized with helium. The

I-HUMS was then used to monitor the helium levels in the purge

until a level reading was reached.

The helium pressure in the engine

was then increased to a higher

pressure. The helium levels in

the purge were again monitored

until a stable reading was

reached. The recorded values

were used to predict the operating leak rate. The planned operating time of the engine during

altitude tests was extremely short,

less than 15 seconds, so that only

a fraction of the calculated leak

rate would be introduced into the

chamber during an actual flight.

These tests demonstrated that

KSC has the knowledge and

capabilities to help solve many

problems at other centers. A

further demonstration of the

flexibility of the personnel and

equipment at KSC is the fact that

they will be used to support the

X-33 launches.

Contacts: R.]. Beil (Robert.Beil1 @ksc. nasa._,ov), PK-G, (407) 861-3944;

and F.W. Adams, MM-G2, (407t 867-

4449

Participating OG,anizations: Dryden

Flight Research Center (N. Hass) and

Dy,acs Engineering Co., hw. (T.P.

Griffin a,d G.R. Naylor)

143
Electronics and Instrumentation

Ferroelectric Camera for Infrared Fire Imaging

I nfrared cameras are currently used at the launch pads to

monitor hydrogen flow lines for

fires. This is necessary because

hydrogen fires, like natural gas

fires, emit very little visible

radiation and are virtually invisible under daylight conditions to

the human eye or to normal

silicon-based charge-coupled

device (CCD) cameras. The

currently used infrared cameras

are deteriorating and the manufacturer, Insight Vision, has gone

out of business, resulting in

excessive maintenance costs and

eventually, as spare parts run out,

the loss of this capability. In

order to deal with this problem, it

was decided to replace the old

infrared cameras with new, stateof-the-art cameras. A low-cost

camera was located that appeared to provide adequate

infrared images. This camera, a

Palm IR 250 ferroelectric device,

is popular as a nighttime people

locator used by law enforcement

groups and the Coast Guard. It is

rugged, does not require cooling,

and provides images in the 8- to

12-micron region of the spectrum.

One of these cameras was purchased and configured for field

operation at the launch pad with

the goal to produce an image

adequate to meet the monitoring

needs of operations personnel.

Before purchasing the Palm IR

250 infrared camera, several

versions were brought to KSC for

field testing. They produced

good images of the Shuttle on the

pad from inside the perimeter

fence and easily imaged hydrogen fire at the flame stack. A

standard hydrogen fire (about a

1-foot-high flame) was set up at

the fire training facility and was

imaged from several distances

against a variety of backgrounds.

In all cases, the images of the fire

stood out clearly and the performance was acceptable to operations personnel. One camera

was aimed into the sun to see if

the camera was damaged by a

bright exposure such as it would

see during a launch. The camera

became saturated but recovered

quickly with no apparent damage. Based on these successful

demonstrations, a Raytheon TI

Palm IR 250 infrared camera was

procured for the Optical Instrumentation Laboratory to use

during the STS-91 external tank

(ET) tanking test and launch

(May 1998).

In summary, the camera was

strapped down to a plate with a

power supply and microcontroller strapped down behind it. This

plate sits on a set of six vibration

isolators attached to a slide rail

assembly welded to the backplate

(see the photo). Standard operational television (OTV) connectors were placed on the backplate

with the pan-and-tilt signals fed

through the camera housing to a

pan-and-tilt connector. A germanium window was mounted in

the frontplate, allowing the

camera to look out of the housing

in the 8- to 12-micron region. A

Blue Earth Research microcontroller was programmed to allow the

OTV analog voltage levels to be

converted into RS-232 commands

to control the camera. Gain, level,

auto/manual switching, and

focus were provided as operatorcontrollable features through this

communication system. Significant effort went into ensuring the

housing was well sealed so it

could be pressurized to a few

pounds per square inch in the

field and would hold this pressure for a period of days.

United Space Alliance tested

and verified the performance of

the completely housed and

configured camera system, and

the system was installed on

Launch Pad 39A. The video

signal was sent through the

Launch Control Complex OTV

routing system.

Initially, the camera was

aimed at a variety of objects

around the pad and produced

good infrared images; however in

the cool early morning hours, the

camera showed a dark image

with minimal imaging. This was

explained as a limitation in the

sensitivity of the camera. Earlier

testing had not disclosed this

because the testing was done

during warm daytime conditions.

During a cool night when the

ambient temperature dropped,

the camera had trouble seeing

background objects and produced

a dark image. This condition

would make it difficult to locate

the position of a fire if background objects could not be seen.

It was decided, however, that the

Palm IR camera would be left in

the field for the ET tanking test

and the launch.

144
The camera performed well during the tests. It

produced good infrared images of the orbiter before

and during launch and was able to remain running

even during launch. This was important because

the existing Insight Vision cameras must be shuttered during actual launch, which prevented monitoring the area for fires during a short but critical

period. The Palm IR camera actually spotted a fire

after the launch; a patch of dried grass near the pad

had caught fire during launch. Shortly after launch,

the camera was brought back to the Optical Instrumentation Laboratory, and the decision was made

that a better (i.e., lower detection temperature)

camera was required for fire imaging at the launch

pad. Work is ongoing to choose such a camera and

to procure one or more for field trials during 1999.

Contact: C.B. Mizell (Carolyn.Mizell- I@ksc.uasa.gov),

MM-H-A, (407) 867-77(15

Participating Organizations: United Space Alliam'c

(D. Carter amt D. Exh,y), MM-J1-A (I.. HmnfL PK-G

(K. Brvck), and Dymws EngiHcerm_ Co., IHc. (R.B. Cox,

W.D. Haskell, F. Lorenzo-Luaces, aud R.C. }l_uuxquist )

145
6U VME Universal Signal Conditioning Amplifier (USCA)

Interface Module

he objective of this project is to

develop a 6U VME bus card

and software to interface with the

USCA's. The combination of the

6U VME module and the hardware will allow users to develop

customized data acquisition

solutions using USCA's and

commercial off-the-shelf 6U VME

hardware.

The module will receive serial

data streams from the USCA's,

will decode and buffer the data,

and will transport the data over a

VME bus for data archival and

transmission. The module will

also be used to communicate

commands to and receive status

information from USCA's in the

field.

Key accomplishments:

A low-speed prototype was

designed and built.

The development of a

VXWorks driver for the card

was started.

Key milestone:

Complete the development of

the 6U VME interface module

and supporting hardware.

Contact: C.M. lhlefeht (Curtis.lhlefeldl@ksc.nasa.gov), MM-G2-A, (407) 867-

6747

Participating Organization: Dynacs

Engineering Co., Inc. (P.J.Medelius and

1.1.Henderson)

146
F Research and Technology 1998

Medical Aeronautical Communications System

SC relies upon Department of

Defense helicopters to support search, rescue, and medevac

for flight crew and personnel

supporting Shuttle program

launches and landings. These

helicopters are normally configured for military combat missions

and must be reconfigured rapidly

to support the NASA mission on

launch and landing days. Communications are necessary with

KSC medical, fire, safety, and

rescue radio nets as well as

hospital emergency rooms

throughout the state. However,

military communications systems

aboard these helicopters are not

compatible.

The Biomedical Laboratory

has designed, fabricated, and put

into place a Medical Aeronautical

Communications System that

provides (1) VHF-FM/simplex

radio communications capability

on all KSC radio nets; (2) UHFFM/duplex communications to

hospitals, the Launch Control

Center (LCC) firing room, and the

clinic; and (3) a seven-station

private/helicopter intercom

system. This allows the physician

aboard the helicopter to talk with

the two assigned pararescuemen

as well as the two patients. The

flight engineer also has access to

the system, and a spare access is

provided. The system has been

programmed to permit communications on U.S. Coast Guard

frequencies for those helicopters

providing Range Safety clearing

of shipping assets in the solid

rocket booster drop zones at sea.

This system is battery operated and interfaces the helicopter

intercom system with impedance

that makes it appear as a single

headset. A unique external

antenna system is provided that

exchanges the standard hoist

hook access door with a similar

functioning structure which

exposes VHF and UHF antennas

out of the bottom fuselage of the

airframe. Testing and mission

usage thus far aboard four HH60G Blackhawk helicopters have

shown the system to be a significant improvement over the

previously disclosed portable

system carried aboard these

helicopters.

Contacts: D.E lgocrr (D_;_;.Doerrl@ksc.nasa.sov), ]J-3, ¢407) 867-3152;

mtd tt.E. Reed, JJ-3-B, (407; 867-7551

147
Electronics and Instrumentation

Portable Magnetic Field Sensor for

Measuring Lightning Effects

he objective of this project was

to design a reliable sensor for

measuring magnetic fields inside

the Payload Changeout Room

(PCR) on each launch pad. Information obtained by the sensor

will be used to determine the

magnitude of the voltages induced into cables by the magnetic

field generated by a lightning

strike. Depending on the distance to the lightning strike and

the area covered by the conductors, the induced voltage can

reach several thousand volts for a

duration of close to 100 microseconds.

A complete magnetic field

measurement requires the use of

three orthogonally placed antennas. This requires the use of three

data conditioning, digitization,

and storage channels. It is important to keep the total power

consumption to a minimum in

order to extend the lifetime of the

batteries in the sensor.

The sensor was designed with

three data conditioning and

digitization channels, with only

the first channel continuously

powered up. Under normal

operating conditions, data from

the three orthogonal antennas is

sampled sequentially at a 1 mega

sample per second (MS/s) rate.

Upon detection of a nearby

lightning strike, the following

actions take place:

1. The data from the preceding

100 microseconds is stored.

2. The power to digitization

channels 2 and 3 is restored.

3. The multiplexer stops alternating among the three channels

and connects each antenna to

each digitization channel.

4. The clock signal for all three

digitizers is set to 30 megahertz.

5. Data is acquired for an additional 100 microseconds at a 30-

MS/s rate.

6. The power to channels 2 and 3

is removed.

The data preceding the trigger

is sampled at 1 MS/s, and the

data following the trigger is

sampled at 30 MS/s. The latency

between the onset of the trigger

and the sampling clock switch is

in the order of a fraction of a

microsecond. This operation

results in most of the information

being sampled at the fast rate,

thus preserving the data integrity.

Since the sensor is never put into

a "sleep" mode, even magnetic

fields from a first lightning strike

can be acquired. A significant

reduction in power consumption

is achieved by powering up only

one digitizing channel and multiplexing all three measurements

through that channel and digitizing the measurements at a reduced sampling rate.

148
Research and Technology 1998

T

Key accomplishment:

• The circuit schematic design was completed.

Key milestone:

• Continue monitoring induced magnetic

fields inside the PCR.

Contact: C.M. lhlcfeld (Curtis.lhh'feh#

l@ksc.nasa._ov), MM G2-A, (407) 867-6747

ParticipntiJ G, Or_,,auizati_ul: D)pmcs EJlqiHcerin_,,

Co., luc. (P.]. Medclius_

149
Electronics and Instrumentation

Inline Gas Analyzer for Cryogenic Hydrogen

A prototype inline gas analyzer (IGA) for cryogenic hydrogen

was designed, constructed,

tested, and temporarily installed

at the hydrogen flare stack on

Launch Pad 39B. NASA's intent

is to use the IGA system to reduce

the man-hour requirements and

material costs of vehicle preparations for cryogenic fuel loading

and safing during and after Space

Shuttle launch operations. With

the IGA system, measurements of

the cryogenic operations can be

monitored from a remote, safe

location during hazardous operations. The current method for

doing these measurements is to

take a melon sample for each test

point and analyze it in the laboratory using a mass spectrometer

and manual field verification of

gas concentrations. If the prototype program is successful, the

final design will be permanently

installed at the hydrogen flare

stack, the Mobile Launcher 1.

Platform (MLP) liquid hydrogen

(LH2) high point bleed (back

porch), and the Fixed Service

Structure (FSS) gaseous hydrogen

(GH2) vent line at Launch Pads

39A and 39B at KSC. The IGA

contains hydrogen, oxygen, and

water sensors to monitor critical

concentrations of each of these

materials. The flow path of the

sample gas is from the hydrogen 2.

cryogenic line through the IGA

and back to the cryogenic line

(see figure 1). In addition to the

concentration data for hydrogen,

oxygen, and water, the system

provides calibration parameters,

the ability to recalibrate the

sensors, flow rates through

sensors, the temperature and

pressure of the sample gas, and

error data for essential components. The following are general

characteristics of the IGA:

The hydrogen sensor can

measure the concentration of

hydrogen at +1 percent full

scale over the range of 0 to 10

percent. It can operate over the

temperate range from -10 to 60

degrees Celsius (°C) and can

withstand the sound and

vibration conditions of a

Shuttle launch.

The oxygen sensor can measure the concentration of

oxygen at +1 percent full scale

and has a range of 0 to 2 percent. It can operate over the

temperature range from -10 to

40 °C and be able to withstand

the sound and vibration conditions of a Shuttle launch.

Hydrogen

Cryogenic

Line

CV

V2

r kJJ

V3 Flow 1

V4

;:lE

ku

V5 Flow 3

V1 Isolation Valve

V2 Back Pressure Valve

V3 H 2 Flow Control Valve

V4 0 2 Flow Control Valve

Flowmeters 1,2, 3

SV 1 Helium Zero

SV 2 CAL

Figure 1. Inline Gas Analyzer

. The humidity sensor can

measure the concentration of

water at 125 _+10 parts per

million (ppm) and has a range

from 125 ppm to 4 percent. It

can operate over the temperature range from -10 to 40 °C

and withstand the sound and

vibration conditions of a

Shuttle launch.

A microcomputer acquires the

data from the sensors and formats

the data in a manner suitable for

transmission over a serial data

line. In addition, provisions are

made to allow for control of

solenoid valves from a remote

terminal via the serial data line or

locally from the microcomputer

using pushbuttons. The microcomputer provides 12-bit analog

150
Research and Technology 1998

F_,,ure 2. luliHe Gas Analyzer With the Moisture, ttydro_eu, aud ()xl/_k,en AmEyzer

inputs, digital inputs, and digital outputs capable of driving the solenoid valves. The software

allows the sensor data to be formatted and the controls and valve talkbacks to be processed and

displays the results. The software also provides control via the serial port, which mimics tile

functions of the buttons and provides diagnostic functions. Figure 2 shows the installation of

the inline gas sensor at the hydrogen flare stack at Launch Pad 39B.

Key accomplishments:

• A prototype IGA was designed, constructed, tested, and temporarily installed at the hydrogen

flare stack at Launch Pad 39B.

• The IGA was successfully used to monitor a storage tank loading operation and found transients in moisture and oxygen previously unknown.

Contacts: R.C. Yoml_ (Rebecca.Yozm_:-l@ksc.nasa._ov) and D.E. Lueck, MM-G2, (407) 867-4439

Participating Organization: Dynacs Engineering Co., hlc. (C.E Parrish, C.J. Schwindt, S.]. Kliuko, and T.R.

Hods,e)

151
Space Shuttle Orbiter to

External Tank Mating Tool

uring Space Shuttle process ing, the orbiter is joined to the

external tank (ET) in a process

called mating. This takes place

with both the orbiter and ET in

the vertical position. Two mating

fixtures, located at the aft end of

the orbiter and ET, are used in the

mating process. These fixtures

are composed of ball-and-sockettype joints with the ball ends on

the ET side and the socket receptacles on the orbiter side (see

figure 1). During mating, the

orbiter is suspended by crane and

slowly brought into contact with

the fixed ET. Once the two are in

contact, bolts are attached

through the ball-and-socket joint

to secure the orbiter to the ET.

The mating operation is

currently accomplished using

caliper and eye-ball measurements in an iterative approach,

which carefully brings the orbiter

Orbiter Side

f--

f

/

/

..... '

t

i

i

N

\

ET Side

Bolt Clearance Hole

Figure 1. Mating Fixtures

into contact with the ET. The

orbiter is initially positioned at

approximately the correct height

and then slowly moved towards

the ET. As the orbiter gets closer,

measurements are made to

determine if the two mating

surfaces are aligned. If they seem

to be aligned, the orbiter is

moved slightly closer to the ET

and more measurements are

taken. If they are not aligned, the

orbiter is repositioned slightly

and then rechecked. This process

of checking for alignment, repositioning, and moving closer is

repeated until the orbiter and ET

mating surfaces are brought into

contact and the two are secured.

Due to the critical nature of this

task, a more precise guiding

technique was desired. A laserbased targeting system was

created that can be used to align

the mating components with

more precision and ease than

currently possible.

The laser targeting system is

composed of a laser mount that

goes on the ET side and a target

that goes inside the orbiter. Two

systems are required for each

mate, one for each side of the ET

and orbiter. The targets, which

are made of a type of plastic, fit

over the screws used to secure the

attachment nut inside the orbiter.

This nut is used to capture the

bolt for connection to the ET. The

targets are positioned to be

perfectly centered with respect to

this bolt.

The laser mounts (see figure

2) attach to the back side of the

bolt clearance holes in the ET

fixtures. The mounts are designed to fit snugly within the

152
FiA,u_v2. LaserMount

clearance holes to provide the

necessary concentricity for the

laser. The laser is positioned

within tile mount to shine down

the center of the clearance hole

and directly through the center of

the bolt hole. When the orbiter is

within range, a window cut into

tile mount allows the user to look

directly down the bolt hole and

into the aft compartment to see

where the laser spot falls on the

target. The target is equipped

with a graded scale so tile user

can tell exactly, to within 1/16

inch, how far out of alignment the

orbiter is at any given time. Two

sets are used to help ensure both

sides of the orbiter are at the

correct height necessary for mating.

This system has already

undergone preliminary testing

during the mating operation of

STS-88. Targets were not able to

be installed, but the laser mount

was tested for fit and functionality.

The laser mount was found to fit

extremely well within the ET

fixture and the laser spot could be

easily seen on the protective

backing placed behind the attachment nut inside the orbiter. Also,

using the inner diameter of the nut

as a reference, the laser spot was

used to roughly determine the

position of the orbiter. The position determined in this fashion

corresponded well to the position

determined using the current

procedure. A full test of the

system is planned for the mating

operation of Columbia mission

STS-93.

Contact: C.B. Mizell (Carolyn.Mizclll@ksc.nasa.gov), MM-H-A, (407) 867-

77O5

Participatin x Organization: Dynacs

Engineering Co., Inc. (R.B. Cox and

1. D_,lahm')
Electronics and Instrumentation

Main Three ContaminationMonitoring Cart

he Contamination Monitoring

Laboratory at KSC developed

a system that provides three

types of real-time molecular

contamination monitoring in one

system for support of highly

sensitive payload processing. It

incorporates an airborne hydrocarbon monitoring system based

on Fourier Transform Infrared

(FTIR) technology, real-time

optical fallout monitors to monitor particulate fallout, and Surface Acoustic Wave (SAW) nonvolatile residue (NVR) monitors

for sensing molecular contamination. The system consists of a

portable cart suitable for use in

class 1, division 2, environments

(see the figure) that is electromagnetic interference (EMI) shielded.

The capability to monitor

contaminants is essential in order

to protect sensitive optical payloads from performance degradation caused by the deposition of

surface films, other molecular

contamination, and particulate

fallout. Commonly used hydrocarbon monitoring instrumentation, such as flame ionization

detectors, yields no information

about the source or identity of the

compounds they detect. The

FTIR technology with its inherent

ability to discriminate a large

number of compounds offers a

tremendous advantage over other

types of instrumentation. Recent

developments in the areas of realtime detection of particulate

fallout and nonvolatile residues

have, for the first time, allowed

creation of an integrated instrument to provide fairly complete

monitoring of the contamination

risk to a payload during ground

processing.

The hydrocarbon monitoring

subsystem consists of two modified MIDAC FTIR instruments

mounted in a cart; a computer

providing control, user interface,

and communications; and a

sampling system. The graphical

user interface runs on the cart

controller computer, which has a

keyboard, mouse, and monitor.

The hydrocarbon portion of the

cart is capable of measuring a

variety of compounds and can be

reconfigured to accommodate

new compounds of interest. The

MIDAC instruments were modified by the addition of a small

computer inside the instrument

case that controls the operation of

the FTIR and provides deconvolution of spectral data. Each

FTIR module sends gas concentration data to the cart controller

computer, is equipped with a 1.8-

meter gas cell, and runs at a

resolution of 4 wavenumbers.

The sampling system consists of

two eductor pumps supplied by

the system purge gas. There are

also flow failure indicators that

are monitored by the cart controller computer. The FTIR module

makes use of a classical least

square (CLS) algorithm in the

analysis of spectral data. The

traditional CLS method has been

modified by the use of baseline

correction algorithms, which

correct errors due to instrument

warmup, aging of the source, and

degradation of the optics due to

contamination. This correction is

accomplished by performing a

parametric shape fit for the

baseline using three parameters:

bend, tilt, and offset.

The NVR's are monitored

with a Femtometrics SAW device

that consists of a control unit

inside the purged cart and a

sensor head with an exposed

quartz crystal to collect the

residue. The increase in mass due

to the residue deposition causes a

shift in the resonant frequency of

the crystal, which then can be

used to quantify the residue

mass. The SAW is extremely

sensitive, roughly 100 times the

sensitivity of a Quartz Crystal

Microbalance. A 50-hertz shift in

the frequency of the SAW crystal

corresponds to only 1 nanogram

per square centimeter mass

density.

Particulate fallout measurements are made by optical fallout

monitors (OFM's) that were

developed at KSC. These instruments measure the light scattered

from a specular surface by the

particles which land on that

surface. This instrument is

calibrated to read out in "percent

area coverage," which is the total

fractional area of the witness

plate obscured by particles.

The data from the two FTIR

modules, the two SAW devices,

and the two OFM's are integrated

into a single software package

that runs on the cart controller

computer. Here, the data are

logged in a disk file and presented to the user in several

154
Research and Technology 1998

Contamination

Monitoring

Instruments

Cart

Status

,,..--,,,,p,-,..--

N ,

_ Ng?51

/

/ Ca----gController

Computer

PCR Facility KSC

or Monitoring

VPF Station AREA

Remote

Monitoring Station

Contamination Monitoring Cart Data Flow

forms, including tabular and

graphical. The user can opt to

view any or all the cart measurements. The cart controller software was written in Microsoft

Visual Basic. All the data from

the cart is put into a single data

stream and sent via a serial link to

a remote computer that can be

located in another building.

Here, the data is presented in the

same way as on the cart controller

computer, so the user at the

remote site sees exactly the same

data in real time. This remote

system also is configured as a

user datagram protocol (UDP)

server and, if connected to a local

area network that supports the

lnternet Protocol, can broadcast

the cart data in real time to many

remote users simultaneously

anywhere in the world. These

remote users can see the same

screens as the local users but can

select their own options for which

data to view. The server can be

configured to only allow certain

domains to access the information

so the availability of the data can

be restricted to only those who

are authorized to see it. This is

the same technology that is used

for "Internet broadcasts" of video

and audio. To view the data from

anywhere in the world, all that is

required is the UDP client software (also written in Visual Basic)

and a personal computer compatible with an Internet connection

and authorization on the UDP

server to allow the user to connect.

Contacts: ].S. Abernathy (lean.

Abernathy-l@ksc.nasa.gov), NN-M4,

(407) 867-6152; and P.A. Mogan,

MM-G2, (407) 867-9167

Participating Organization: Dynacs

Engineering Co., Inc. (C.]. Schwindt and

C.B. Mattson)

155
Electronics and Instrumentation

Thermographic inspection of Subsurface

Voids in Composite Structures

omposite structures are

becoming more prevalent at

KSC and in many high technology industries. The ability to

nondestructively evaluate composite structures to detect and

locate surface and subsurface

defects is, therefore, becoming

increasingly important. Infrared

(IR) thermography can be extremely useful in this type of

nondestructive evaluation (NDE).

the 1- to 20-micron range). In

thermography, detectors sensitive

to IR wavelengths are used to

examine the thermal behavior of

test objects. As an object's temperature changes, the amount of

energy it emits in the detector

range also changes. Using an

array of detectors, an IR camera

converts these differing energy

outputs to video images of differing colors or gray scales.

Large temperature differences

in very hot objects can be seen as

changes in color, as in the color of

a flame or a star. In the same

way, slight temperature variations, at or about room temperature, can be seen as changes in the

IR range of the electromagnetic

spectrum (wavelengths usually in

Many objects change temperature inherently over time and

can be easily studied by monitoring their behavior with an IR

camera. For objects that do not

inherently change temperature,

heat excitation can be used so the

behavior of the object during

Figure 1. Surface Variations

cooling can be examined.

Flashlamps were used as the

heating source in all experiments

conducted for this report.

Flashlamps emit a short burst of

mainly visible and IR radiation,

part of which is reflected at the

object's surface; a large part is

absorbed. The absorbed radiation

is turned into heat at the object's

surface, which increases its

temperature. After the flash, the

surface temperature slowly

returns to ambient as the extra

heat dissipates deeper into the

test object and out into the surrounding environment. The

amount of excitation energy

initially absorbed and the rate at

which the surface returns to

ambient temperature can both be

used to detect anomalies on the

surface of and within the test

object.

Immediately after the excitation pulse (the flash), hotter or

cooler areas show where more or

less energy was initially absorbed

by the object. Figure 1 shows an

object with a temperature gradient from top to bottom as well as

a small "X" and a square (top left

and right center, respectively)

which were scratches in the

surface and several "hot spots"

(lower left and center). These

were all caused by differences in

a reflective surface coating on the

test object. Places that appear

darker in the image are actually

hotter and represent areas that

were not as completely covered

by the reflective coating.

As the object cools, anomalies

within the test object can be

detected through variations in the

rate of surface cooling. The

156
Research and Technology 1998

Figure 2. Subsm_fiwe Defects

dissipation of heat from the surface happens

through three different routes: (1) from the surface

into the surrounding environment, (2) from hotter

areas on the surface laterally to cooler ones, and (3)

from the surface into and through the test object.

Given the proper environmental and initial conditions, heat loss through the first two routes will be

fairly constant across the object's surface. In that

case, areas that exhibit anomalous cooling must be

due to variations in heat flow through the test

object.

The rate of heat flow through the test object is

dependent upon the path the heat must travel. The

presence of good heat conductors or good insulators

along this path will affect how quickly the heat is

able to leave the surface and how quickly the

surface can cool. For example, in these experiments,

the presence of voids (air pockets) in the interior of

the composite structure was of specific interest. Air

is a better insulator than the materials that make up

the composite structure so heat flow is slower along

a path with an air pocket. This results in the surface

above the air pocket remaining at a higher temperature than the surrounding surface for a longer time.

Hot spots that were not immediately visible which

appear during cooling could indicate possible voids

within the structure. Figure 2 shows several indications of voids in a preprogrammed test panel. Both

the size and shape of the voids are clearly visible.

The rightmost and bottom-center defects are both

1/4 inch in diameter and the total field of view is

approximately 6 by 8 inches. The resolution of

thermography is one reason it has proven so effective in this type of evaluation.

Thermography is a fairly old field, yet improvements are happening at an incredible rate. The

ability of thermography to work so well with

composite materials coupled with the dramatic

increase in IR detector capabilities suggests that

thermography will play a more important role in

NDE in the immediate future.

Contacts: C.B. Mizell (Carolyn.Mizell-1 @ksc.nasa.RovL

MM-H-A, (407) 867-7705; and C.K. Davis, PK-tt, (407) 861-

3636

Participating Organization: Dynacs Engineering Co., Inc.

(]. Donahue and S.W. Thayer)

157
Electronics and Instrumentation

Automatic Calibration Station for the Universal

Signal Conditioning Amplifier (USCA)

he goal of this project is to

design an automatic calibration station for the USCA. The

USCA is a self-configuring amplifier designed to interface with a

variety of transducers. Parameters such as gain, excitation

voltage, sampling rate, and

filtering are automatically set

based on information stored in a

small memory device attached to

the transducer. The data on the

Transducer Electronic Data Sheet

(TEDS) is read by the USCA

immediately after the connection

to the transducer is detected.

Calibration factors stored in the

USCA's memory are used to

ensure the accuracy of measurements is maintained within

specifications.

Following the manufacturing

process, the USCA has to be fully

calibrated before deployment in

the field. The calibration has to

be repeated periodically (every 1

or 2 years). The calibration

procedure also has to be repeated

following any repairs that involve

components associated with the

analog circuitry. The calibration

process includes measuring the

reference voltages that the USCA

uses for its self-calibration,

measuring the precision resistors

used for current measurements

and current excitation, correcting

for offsets, and others. The

manual process takes about 30

minutes to complete when conducted by an experienced technician.

The USCA requires certain

parameters to be stored in its

nonvolatile memory in order to

perform its continuous selfcalibration. These parameters

include three reference voltages,

zero offsets, current sensing

resistor values, excitation resistor

divider ratios, and input voltage

resistor divider ratios. A combination of custom-developed

software in the USCA and a

LabView-based program running

on a personal computer is used in

conjunction with an external

voltage/current source to fully

automate the calibration process.

The automated calibration process performs additional detailed

tests that are not normally conducted during manual calibration

and is expected to take about 15

minutes to completely calibrate a

USCA.

Key accomplishments:

• Started the design of the

Automated Calibration Station.

- Developed a method to fully

calibrate a USCA without the

need to remove it from its

sealed enclosure.

Key milestone:

• Evaluate the performance of

the system and refine the

software if needed.

Contact: C.M. Ihlefeld (Curtis.Ihlefeld1@ksc.nasa.gov), MM-G2-A, (407) 867-

6747

Participating Organization: Dynacs

Engineering Co., Inc. (P.]. Medelius,

J.D. Taylor, l.S. Moerk, J.l. Henderson,

and J.A. Rees)

158
i

REPORT DOCUMENTATION PAGE For,,,Approved

OMB NO 0704-0188

PubPIc reporting burden for th s :ollectlorl of information ,s estimated to _¢eraqe _ hour per respor'se, including the time for reviewing instructions, searching existing data sources.

gathering Jnd mamtaqnmg the data needed, and completing and reviewing the collection of reformat on Send comments regarding this burden estimate or any other aspect Of th $

collection of information, rncluding suggestrons for reducing this burden IO Washington Headquarters Serv ces. Directorate for Information Operat ons and Re_.orts. _215 _efferson

Davis Hiqhwa_, Su,te 1204, Arlington, 'J_ 22202-4302, and to th_ Office of Management and Budget, Paperwork Reduction Project (0704-0 88), Washington, DC 20503

1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE !3. REPORT TYPE AND DATES COVERED

December 1998 Technical Memorandum - 1998

4. TITLE AND SUBTITLE

Research and Technology

1998 Annual Report of the Kennedy Space Center

6. AUTHOR(S)

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

NASA John F. Kennedy Space Center

Kennedy Space Center, Florida 32899

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration

Washington, D.C. 20546

11. SUPPLEMENTARY NOTES

5. FUNDING NUMBERS

8. PERFORMING ORGANIZATION

REPORT NUMBER

NASA TM-1999-208545

10. SPONSORING / MONITORING

AGENCY REPORT NUMBER

12a. DISTRIBUTION / AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE

Unclassified- Unlimited

Subject Category 99

13. ABSTRACT (Maximum 200 words)

As the NASA Center responsible for preparing and launching space missions, the John F. Kennedy Space Center

(KSC) is placing increasing emphasis on its advanced technology development program. This program encompasses

the efforts of the entire KSC team, consisting of Government and contractor personnel, working in partnership with

academic institutions and commercial industry. This edition of the KSC Research and Technology 1998 Annual

Report covers the efforts of these contributors to the KSC advanced technology development program, as well as our

technology transfer activities.

Gale Allen, Associate Director of KSC's Technology Programs and Commercialization organization (MM-E)

(407) 867-6226, is responsible for publication of this report and should be contacted for any desired information

regarding the advanced technology program.

14. SUBJECT TERMS

Research and Technology

17. SECURITY CLASSIFICATION

OF REPORT

Unclassified

18. SECURITY CLASSIFICATION 19.

OF THIS PAGE

Unclassified

NSN 7540-01-280-5500

SECURITY CLASSIFICATION

OF ABSTRACT

Unclassified

15. NUMBER OF PAGES

16. PRICE CODE

i 20. LIMITATION OF ABSTRACT

Standard Form 298 (Rev 2-89)

PrescrtDed by _NC_l £td Z39-1_

298-102