October 2015

NASA/TM2015-218809

NESC-RP-15-01039

 

Glenn Extreme Environments Rig (GEER) 

Independent Review

Robert S. Jankovsky/NESC and Michael D. Smiles/NESC

Langley Research Center, Hampton, Virginia

Mark A. George

Glenn Research Center, Cleveland, Ohio

Mimi C. Ton

Jet Propulsion Laboratory, Pasadena, California

Son K. Le

Stennis Space Center, Mississippi
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October 2015

NASA/TM2015-218809

NESC-RP-15-01039

 

Glenn Extreme Environments Rig (GEER) 

Independent Review

Robert S. Jankovsky/NESC and Michael D. Smiles/NESC

Langley Research Center, Hampton, Virginia

Mark A. George

Glenn Research Center, Cleveland, Ohio

Mimi C. Ton

Jet Propulsion Laboratory, Pasadena, California

Son K. Le

Stennis Space Center, Mississippi
Available from:

NASA STI Program / Mail Stop 148

NASA Langley Research Center

Hampton, VA 23681-2199

Fax: 757-864-6500

Acknowledgments

The NESC team would like to acknowledge Mrs. Lori Arnett for assuring that the 

NESC team had access to whomever and whatever information was requested. 

Her efforts were essential to the efficient completion of this assessment. The 

NESC team also would like to acknowledge the following individuals for their 

openness during the facility inspections and tabletop discussion: 

• Leah Nakley – Lead Operations 

• Ken Gregg – Mechanical Design 

• Joe Rymut – Electrical Design 

• Alex Sgondea – Electrical Design 

• Jim Mullins – Facility Engineer 

• Rodger Dyson – Mechanical Design 

• Lori Arnett – Facility Manager 

• Dan Vento – Project Manager 

• Jim Hritz – Safety/Hazard Analysis 

• Tim Fiorilli – Industrial Hygienist 

• Chuck Druesedow – Pressure Systems Office 

The use of trademarks or names of manufacturers in the report is for accurate reporting and does not 

constitute an official endorsement, either expressed or implied, of such products or manufacturers by the 

National Aeronautics and Space Administration.
NASA Engineering and Safety Center

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Glenn Extreme Environments Rig (GEER) Independent 

Review 

September 10, 2015
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Report Approval and Revision History 

NOTE: This document was approved at the September 10, 2015, NRB. This document was 

submitted to the NESC Director on September 17, 2015, for configuration control. 

Approved: Original Signature on File 9/17/15

NESC Director Date

Version Description of Revision Office of Primary 

Responsibility Effective Date

1.0 Initial Release Mr. Robert Jankovsky, 

NESC Chief Engineer, 

GRC

9/10/15
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Table of Contents 

Technical Assessment Report 

1.0 Notification and Authorization ........................................................................................ 4

2.0 Signature Page ................................................................................................................... 5

3.0 Team List ........................................................................................................................... 6

3.1 Acknowledgements ................................................................................................. 6

4.0 Executive Summary .......................................................................................................... 7

5.0 Rig/Facility Description .................................................................................................... 8

6.0 Documentation ................................................................................................................ 14

7.0 Findings and NESC Recommendations ........................................................................ 18

7.1 Findings................................................................................................................. 18

7.2 NESC Recommendations...................................................................................... 20

8.0 Alternate Viewpoint ........................................................................................................ 20

9.0 Other Deliverables .......................................................................................................... 20

10.0 Lessons Learned .............................................................................................................. 20

11.0 Recommendations for NASA Standards and Specifications ...................................... 20

12.0 Definition of Terms ......................................................................................................... 21

13.0 Acronyms List ................................................................................................................. 21

14.0 References ........................................................................................................................ 21

List of Figures 

Figure 5.0-1. GRC GEER ............................................................................................................. 8

Figure 5.0-2. GRC Building 334 .................................................................................................. 9

Figure 5.0-3. Pressure Vessel ..................................................................................................... 10

Figure 5.0-4. Gas Cabinets ......................................................................................................... 11

Figure 5.0-5. Mixing Cabinet ..................................................................................................... 11

Figure 6.0-1. Electronic Folders with All Documentation Provided for Review ....................... 15

Figure 6.0-2. Review Documents Folder Contents .................................................................... 15

Figure 6.0-3. Released Electrical Drawings Folder Contents ..................................................... 15

Figure 6.0-4. PSO Supporting Documentation Folder Contents ................................................ 16

Figure 6.0-5. PSO Drawings Folder Contents ............................................................................ 16

Figure 6.0-6. Checksheets Folder Contents ................................................................................ 17

Figure 6.0-7. 7150 Documents Folder Contents ......................................................................... 17

Figure 6.0-8. On-line Safety Permit System with Links to PSO Certifications and Operation 

Procedures ............................................................................................................. 18

Figure 7.1-1. Pressure System Component Tags ........................................................................ 19
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Technical Assessment Report

1.0 Notification and Authorization 

The Chief of the Space Science Project Office at Glenn Research Center (GRC) requested 

support from the NASA Engineering and Safety Center (NESC) to satisfy a request from the 

Science Mission Directorate (SMD) Associate Administrator and the Planetary Science Division 

Chief to obtain an independent review of the Glenn Extreme Environments Rig (GEER) and the 

operational controls in place for mitigating any hazard associated with its operation. 

Mr. Robert Jankovsky, NESC Chief Engineer at NASA GRC, was selected to lead this 

assessment. 

The key stakeholders for this assessment are the NASA SMD, GRC, and the planetary science 

community.
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2.0 Signature Page

Submitted by: 

Team Signature Page on File – 9/22/15

Mr. Robert S. Jankovsky Date

Significant Contributors: 

Mr. Michael D. Smiles Date Mr. Mark A. George Date

Ms. Mimi C. Ton Date Mr. Son K. Le Date

Signatories declare the findings, observations, and NESC recommendations compiled in the 

report are factually based from data extracted from program/project documents, contractor 

reports, and open literature, and/or generated from independently conducted tests, analyses, and 

inspections.
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3.0 Team List

Name Discipline Organization

Core Team

Robert Jankovsky NESC Lead GRC

Michael Smiles NESC Chief Engineer SSC

Mark George Hazards Analyses NSC

Mimi Ton Industrial Hygiene JPL

Son Le Pressure Systems SSC

Linda Moore MTSO Program Analyst LaRC

Administrative Support

Erin Moran Technical Writer LaRC/AMA

3.1 Acknowledgements

The NESC team would like to acknowledge Mrs. Lori Arnett for assuring that the NESC team 

had access to whomever and whatever information was requested. Her efforts were essential to 

the efficient completion of this assessment. The NESC team also would like to acknowledge the 

following individuals for their openness during the facility inspections and tabletop discussion:

• Leah Nakley – Lead Operations

• Ken Gregg – Mechanical Design

• Joe Rymut – Electrical Design

• Alex Sgondea – Electrical Design

• Jim Mullins – Facility Engineer

• Rodger Dyson – Mechanical Design

• Lori Arnett – Facility Manager

• Dan Vento – Project Manager

• Jim Hritz – Safety/Hazard Analysis

• Tim Fiorilli – Industrial Hygienist

• Chuck Druesedow – Pressure Systems Office
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4.0 Executive Summary

Ms. Ann Over, Chief of the Space Science Project Office at Glenn Research Center (GRC), 

requested this assessment to satisfy a request from the Science Mission Directorate (SMD) 

Headquarters leadership for an independent review of the Glenn Extreme Environments Rig 

(GEER) hazards due to its large scale compared to what historically has been done [ref. 1].

The assessment included a review of existing GEER documentation (Section 6.0 Documentation) 

and a 1-day on-site inspection of the rig/facility (Section 5.0 Rig/Facility Description), including 

a tabletop review with the project/facility engineering team that designed and built the GEER.

The NASA Engineering and Safety Center (NESC) team found the hazards (high temperature, 

high pressure, toxic gases) inherent to GEER had been thoroughly and systematically addressed

and concurred the transition from commissioning to operations should continue. All other 

findings were considered minor. Three of the remaining findings were minor discrepancies

between documents and the as-built rig, or documented procedures, and those verbally discussed.

These discrepancies should be eliminated and changes to procedures reviewed with the 

operators. Four findings had to do with the main pressure vessel (referred to as TM9001), and 

maintaining its integrity and history for future recertification. The first of these four findings 

was that although the facility engineering team considered creep of the TM9001, they did not 

have a procedure for documenting the cycles, pressure, and temperature to support potential 

future analyses at different operating conditions. 

In the second of the four related findings, the NESC team noted that although the facility 

engineering team had identified the facility sprinkler system activation while at temperature as a 

possible hazard, and closed it after testing, the hot vessel could not set off the sprinklers even 

without the ventilation system operating. The team did not consider other inadvertent sprinkler 

system activation, and as such have not completely considered the potential for rapid cooling of 

the TM9001 causing loss of containment. 

In the third related finding, the NESC team also found that in at least one instance pressure drop 

calculations on a pressure relief valve did not consider pipe diameter in accordance with 

American Society of Mechanical Engineer (ASME) Section VIII, Division 1 allowances. 

In the final related finding, the NESC team found that corrosion under the TM9001 insulation 

was not considered in accordance with American Petroleum Institute (API)-571 and is 

recommending an inspection/monitoring procedure be added. 

Lastly, it was found that the control room had no visual monitoring of the test cell. Although 

procedures are in place to ensure the area is clear before flowing gases, the NESC team 

recommends that a video system be installed.

In all cases, the Space Science Project Office and facility engineering team at GRC has accepted 

all of the findings and NESC recommendations and has either already completed them or they 

are in work.
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5.0 Rig/Facility Description

NASA recently started the commissioning process of the GEER (Figure 5.0-1), located in 

Building 334 (Figure 5.0-2) at GRC. The GEER is designed to simulate the temperature, 

pressure, and atmospheric compositions of bodies in the solar system, including those with acidic 

and hazardous elements. 

The GEER consists of a 0.79m3(28ft3), 304 stainless steel pressure vessel with Inconel®

sheathed resistance heaters and a Maximum Allowable Working Pressure (MAWP) of 

10.47 MPa (1518 psia) at 538oC (1000oF) (Figure 5.0-3); four gas cabinets to store up to eight

gas cylinders (Figure 5.0-4); a gas mixing cabinet to precisely mix the desired gas chemical 

composition (Figure 5.0-5); a gas booster to maintain the test conditions over a long period of 

time with allowable leaks (Figure 5.0-6); a Fourier Transform Infrared (FTIR) Spectrometer to 

measure chemical composition (Figure 5.0-7); and a vent stack to exhaust gases outside the 

facility (Figure 5.0-8). 

Figure 5.0-1. GRC GEER
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Figure 5.0-2. GRC Building 334

GEER
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Figure 5.0-3. Pressure Vessel

Heaters
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Figure 5.0-4. Gas Cabinets

Figure 5.0-5. Mixing Cabinet
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Figure 5.0-6. Gas Booster

Figure 5.0-7. FTIR Spectrometer
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Figure 5.0-8. Vent Stack
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Currently, GEER is configured for Venus surface conditions (Table 5.0-1) and is in the 

commissioning phase. 

Table 5.0-1. GEER Configuration during Commissioning

Chemical 

Species

96.5% carbon dioxide (CO2)

~3.4% nitrogen (N2)

130 ppm sulfur dioxide (SO2)

5 ppb hydrogen fluoride (HF)

0.5 ppm hydrogen chloride (HCl)

15 ppm carbon monoxide (CO)

27 ppm carbonyl sulfide (OCS)

30 ppm water (H2O)

Temperature 470oC (878oF)

Pressure 9.24 MPa (1340 psi)

A simplified outline of operations for the GEER is as follows: 1) the test operations start by 

purging and evacuating the TM9001; 2) component gasses are then blended using the gas mixer; 

3) the TM9001 is filled with the desired gas mixture up to 3.45 MPa (500 psi) (at ambient 

temperature) for the desired end-state chemistry; 4) heat is applied and controlled autonomously 

to bring the system to a steady-state operating point; and 5) after testing, chamber and plumbing 

are vented and purged. 

6.0 Documentation

The NESC team was provided access to all project documentation for review. Figures 6.0-1 

through 6.0-8 summarize the documentation that was made available to the NESC team. The 

NESC team selectively reviewed these documents with a focus on the hazards analyses, pressure 

systems, industrial hygiene, and procedures (e.g., startup, shutdown, and operating/emergency). 
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Figure 6.0-1. Electronic Folders with All Documentation Provided for Review 

Figure 6.0-2. Review Documents Folder Contents

Figure 6.0-3. Released Electrical Drawings Folder Contents
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Figure 6.0-4. PSO Supporting Documentation Folder Contents

Figure 6.0-5. PSO Drawings Folder Contents
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Figure 6.0-6. Checksheets Folder Contents

Figure 6.0-7. 7150 Documents Folder Contents
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Figure 6.0-8. On-line Safety Permit System with Links to PSO Certifications and Operation 

Procedures

7.0 Findings and NESC Recommendations

7.1 Findings

The following findings were identified:

F-1. The Process Hazards Analysis (PHA) and Facility Hazards Analysis (FHA) were 

complete and up to date. The inherent hazards of high pressure, high temperature, and 

toxic gases were thoroughly and systematically addressed.

F-2. No procedure exists for documenting the operational history (e.g., cycles, pressure, and 

temperature) of the 304 stainless steel TM9001.

F-3. There is a potential for thermal shock to the GEER TM9001 if the wet fire suppression 

system in the test cell is inadvertently activated.

F-4. The pressure system relief valve inlet piping pressure drop calculation did not consider 

changes in pipe diameter.

F-5. The cited MAWP were not consistent across data sources (e.g., Piping and 

Instrumentation Diagram (P&ID), relief device data sheets, Pressure Systems Office

(PSO) data book).
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F-6. Corrosion of the TM9001 under the insulation material was not considered in inspection

or maintenance planning. In accordance with API-571, for 304-type stainless steel

equipment that are insulated, operate intermittently, or operate between 60oC (140oF) and 

204.4oC (400oF), corrosion under insulation is a concern.

F-7. The written procedure for manually drawing a gas sample from the TM9001 was 

inconsistent with the procedure described by the qualified operator during the rig/facility 

inspection. 

F-8. The relief valve (TM2703/RV6094) from the booster vessel was not installed in 

accordance with the P&ID.

F-9. Facility engineering’s component tags were not secured permanently and were not found 

in some locations on the rig (Figure 7.1-1).

F-10. Two configuration management systems (PSO and facility engineering) are being used 

for pressure system components (Figure 7.1-1).

Figure 7.1-1. Pressure System Component Tags

F-11. There is no means to visually monitor the test cell from the control room.

F-12. The test cell ventilation assessment was thorough and included multiple smoke tests.

Pressure Systems Office 

Component Tags

Facility Component

Tags
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7.2 NESC Recommendations

The following NESC recommendations were identified and directed toward GRC’s Facility, Test 

and Manufacturing Directorate unless otherwise identified:

R-1. Due to prolonged operation at elevated temperatures, procedures should be modified to 

include the documentation of the TM9001 operational history (cycles, pressure, and 

temperature) for consideration of material deformation below yield strength (creep)

during future recertification or delta certifications. (F-2)

R-2. Determine the risk associated with rapid cooling of the TM9001 while at temperature by 

the existing wet fire suppression system. Consider a dry fire suppression system as an 

alternative if risk is unacceptable as currently installed. (F-3)

R-3. Verify inlet and discharge piping pressure drop do not exceed ASME Section VIII,

Division 1 allowances for all relief valves on rig. (F-4)

R-4. Update analyses and any required design, inspection, and monitoring procedures to 

include consideration of external corrosion over the range of anticipated environments for 

the TM9001. (F-6)

R-5. Update all documentation to be consistent with present design and operating procedures 

and review the changes with all qualified operators before the rig is operated each time. 

(F-5, F-7, F-8)

R-6. Install a video monitoring system between the test cell and the control room as a 

verification of no personnel in the area before flowing gas and to facilitate compliance 

with the buddy system requirement. (F-11)

8.0 Alternate Viewpoint

There were no alternate viewpoints identified during the course of this assessment by the NESC 

team or the NRB quorum.

9.0 Other Deliverables

No unique hardware, software, or data packages, outside those contained in this report, were 

disseminated to other parties outside this assessment.

10.0 Lessons Learned

No applicable lessons learned were identified for entry into the NASA Lessons Learned 

Information System (LLIS) as a result of this assessment.

11.0 Recommendations for NASA Standards and Specifications

No recommendations for NASA standards and specifications were identified as a result of this 

assessment.
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12.0 Definition of Terms 

Finding A relevant factual conclusion and/or issue that is within the assessment 

scope and that the team has rigorously based on data from their 

independent analyses, tests, inspections, and/or reviews of technical 

documentation.

Lessons Learned Knowledge, understanding, or conclusive insight gained by experience 

that may benefit other current or future NASA programs and projects.

The experience may be positive, as in a successful test or mission, or 

negative, as in a mishap or failure.

Observation A noteworthy fact, issue, and/or risk, which may not be directly within the 

assessment scope, but could generate a separate issue or concern if not 

addressed. Alternatively, an observation can be a positive 

acknowledgement of a Center/Program/Project/Organization’s operational 

structure, tools, and/or support provided.

Problem The subject of the independent technical assessment.

Recommendation A proposed measurable stakeholder action directly supported by specific 

Finding(s) and/or Observation(s) that will correct or mitigate an identified 

issue or risk.

13.0 Acronyms List

API American Petroleum Institute

ASME American Society of Mechanical Engineer

FTIR Fourier Transform Infrared

GEER Glenn Extreme Environments Rig

GRC Glenn Research Center 

JPL Jet Propulsion Laboratory

MAWP Maximum Allowable Working Pressure

MTSO Management Technical Support Office

NESC NASA Engineering and Safety Center

NRB NESC Review Board

NSC NASA Safety Center

P&ID Piping and Instrumentation Diagram

ppm Parts Per Million

psi Pound Per Square Inch

psia Pounds Per Square Inch Absolute

PSO Pressure Systems Office

SMD Science Mission Directorate

SSC Stennis Space Center
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14.0 References

1. Kremic, Vento, Lalli, Palinski. Extreme Environment Simulation – Current and New 

Capabilities to Stimulate Venus and other Planetary Bodies, (2014).

2. API-571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industries, 

April 1, 2011.
REPORT DOCUMENTATION PAGE Form Approved

OMB No. 0704-0188

2. REPORT TYPE

Technical Memorandum

4. TITLE AND SUBTITLE

Glenn Extreme Environments Rig (GEER) Independent Review

5a. CONTRACT NUMBER

6. AUTHOR(S)

Jankovsky, Robert S.; Smiles, Michael D.; George, Mark A.; 

Ton, Mimi C.; Le, Son K.

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

NASA Langley Research Center

Hampton, VA 23681-2199

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration

Washington, DC 20546-0001

8. PERFORMING ORGANIZATION

REPORT NUMBER

L-20620 NESC-RP-15-01039

10. SPONSOR/MONITOR'S ACRONYM(S)

NASA

13. SUPPLEMENTARY NOTES

12. DISTRIBUTION/AVAILABILITY STATEMENT

Unclassified - Unlimited

Subject Category 18 Spacecraft Design, Testing and Performance

Availability: NASA STI Program (757) 864-9658

19a. NAME OF RESPONSIBLE PERSON

STI Help Desk (email: help@sti.nasa.gov)

14. ABSTRACT

The Chief of the Space Science Project Office at Glenn Research Center (GRC) requested support from the NASA 

Engineering and Safety Center (NESC) to satisfy a request from the Science Mission Directorate (SMD) Associate 

Administrator and the Planetary Science Division Chief to obtain an independent review of the Glenn Extreme Environments 

Rig (GEER) and the operational controls in place for mitigating any hazard associated with its operation. This document 

contains the outcome of the NESC assessment.

15. SUBJECT TERMS

Glenn Extreme Environments Rig; NASA Engineering and Safety Center; Hazard Mitigation

18. NUMBER

OF

PAGES

27

19b. TELEPHONE NUMBER (Include area code)

(443) 757-5802

a. REPORT

U

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b. ABSTRACT

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ABSTRACT

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Prescribed by ANSI Std. Z39.18

Standard Form 298 (Rev. 8-98)

3. DATES COVERED (From - To)

May 2015 - September 2015

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

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11. SPONSOR/MONITOR'S REPORT

NUMBER(S)

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gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this 

collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and 

Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person 

shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number.

PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS.

1. REPORT DATE (DD-MM-YYYY)

01- 10 - 2015