NRO APPROVED FOR 

RELEASE 1 JULY 2015 ...MAL HANDLING 

SSS - 342 

Copy 4 of 5 

23 Jan 1967 

Page 1 of 81 

REVIEW OF MOL/DORIAN 

GROUND TEST PLANNING 

—S-E'eft-E-T--SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING 

555' )7q2- 

A 2- 

OUTLINE OF BRIEFING 

O OBJECTIVES 

O PARTICIPANTS AND RESPONSIBILITIES 

O PROCEDURE FOLLOWED 

O BASELINE TEST FLOW 

O DEVELOPMENT TESTING 

O QUALIFICATION TESTING 

O ACCEPTANCE TES TING 

O ACOUSTIC TESTING 

O SUMMARY RECOMMENDATIONS 

O IMPACT 

SECRET SPECIAL HANDLING 
55< 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 SPECIAL HANDLING 

OBJECTIVES 

555"- 7)(12' 

Pi 3 

RE-EXAMINE MOL/DORIAN SYSTEM TEST PLANNING TO: 

O ENSURE WELL INTEGRATED CONSISTENT TEST PROGRAM 

O REDUCE NEED FOR NEW FACILITIES AND OTHER COSTS 

CONSISTENT WITH THE OBJECTIVES OF THE PROGRAM 

O RESULT IN LEAST IMPACT ON PRESENT ROLES 

AREAS OF PARTICULAR CONCERN: 

O THERMAL VACUUM TESTING 

O ACOUSTIC TESTING 

O VIBRATION TESTING FOR MODES 

O OPERATIONAL DYNAMICS TESTING 

O TEST TIME PRIOR TO FLIGHT 

O IMPACT OF FLOW ON AGE/FACILITIES 

emit= SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

--6-PGR-E--T-SPECIAL HANDLING 

PARTICIPANTS AND RESPONSIBILITIES 

5 ci 2-- 

r 

TEAM CHAIRMAN - J. KENT 

CO-CHAIRMAN - N. NIEDERMAN 

CATEGORY CHAIRMEN PARTICIPANTS 

DEVELOPMENT TESTING - THERMAL - 

(F. W. BELINA) (R. D. LONG) 

QUALIFICATION TESTING - ACOUSTIC - 

(F. P. KIEFER/R. J. KREJCI) (D. L. VAN ERT/S . D. ZINN) 

ACCEPTANCE TESTING - DYNAMICS - 

(W. C. HAYDEN/F. W. MAC NAB) (J. E. ANDERSON/R. W. DEZELAN) 

EMC - 

(W. J. BALDAU) 

FACILITIES/AGE - (D. E. WILKINS) 

(R. E. FINNEY/E. F. SCHMIDT )' 

orcnrr SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING 

PROCEDURE FOLLOWED 

REVIE" ' OF FILES 

o MINUTES OF SYSTEM TEST MEETINGS 

o EXCHANGE HARDWARE LIST/TEST FLOW 

o SAFSL DOCUMENTS 

o CONTRACTOR DOCUMENTS 

SOW'S, CE'I'S 

PROGRAM PLANS 

PRELIMINARY TEST PLANS 

FACILITY PROPOSALS 

CONTRACTOR VISITS 

GE NOVEMBER 21/DECEMBER 13 

EK - NOVEMBER 22/DECEMBER 14 

o DAC - JANUARY 4 

ANALYSIS OF MATERIAL 

STUDY OF PROBLEM AREAS 

o PREPARATION OF RECOMMENDATIONS 

ESTIMATE IMPACTS 

D 

3ECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

-Seeltelf-SPE AL HANDLING 

/NTE6WATel, TEST Pb OR/ zdAl 

47149 66149 

IMAilia A soNOd irmordwas, 4 s 0 4,• peidedse,r 

s ss 2712- 

F

", 

49170 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

-9•E'efterf SPECIAL HANDLING 

555 )(1 2_ 

r ef "7 DEVELOPMENT TESTING 

KEY AREAS OF INVESTIGATION 

1. VALIDITY OF BASIC DEVELOPMENT TEST PHILOSOPHY 

2. VALIDITY OF PROPOSED DEVELOPMENT TESTS AND APPROACH 

o ACOUSTIC 

o VIB RATION 

o SHOCK 

o THERMAL/THERMAL-VACUUM 

o EMC 

o STATIC 

3. COMBINATION OF SELECTED DEVELOPMENT TESTS 

o GE AND EK THERMAL TESTING 

o GE AND DAC DRV TESTING 

D—grErmit-Laift-SPECIAL HANDLING 

, 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SECRET SPECIAL HANDLING 

DEVELOPMENT TESTING 

KEY AREAS OF INVESTIGATION AND SUMMARY RESULTS 

I. VALIDITY OF BASIC DEVELOPMENT TEST PHILOSOPHY 

EVALUATION CRITERIA OVERALL RESULTS 

DAC GE EK 

a. SUFFICIENT ENVIRONMENTAL TESTING TO ASSURE • OK OK ( I) ' 

A MINIMUM RISK QUALIFICATION PROGRAM 

b. FULL RANGE OF REQUIRED FUNCTIONAL PERFORM- OK OK OK 

ANCE DEMONSTRATED 

c. PROPER EMPHASIS ON NEW DEVELOPMENT AND OK OK OK 

MISSION CRITICAL ELEMENTS 

d. PROPER BUILD-UP OF TESTS FROM COMPONENT OK OK OK 

THROUGH SYSTEM LEVELS 

e. ORIENTED TOWARD MAXIMUM USE OF EXISTING OK OK OK 

FACILITIES AND EQUIPMENT 

(1) AS A GENERAL RULE EK DOES NOT PLAN TO EXPOSE FUNCTIONAL 

DEVELOPMENT COMPONENTS TO EITHER FLIGHT LEVEL OR 

QUAL LEVEL ENVIRONMENTS. ' 

...SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D SECRET SPECIAL HANDLING 

DEVELOPMENT TESTING 

KEY AREAS OF INVESTIGATION & SUMMARY RESULTS 

555 cf2, 

PI 1 

2. VALIDITY OF PROPOSED DEVELOPMENT 

ACOUSTIC 

COMPONENT(1) 

TESTS AND APPROACHES 

DAC GE EK 

OK (2) OK 

SYSTEM OK OK OK 

STATIC 

COMPONENT()1 OK OK OK 

SYSTEM OK OK OK 

SHOCK 

COMPONENT(1) OK OK (7) 

SYSTEM ( 3) OK OK 

VIBRATION 

COMPONENT") (4) . OK (7) 

SYSTEM (5) (6) OK (8) 

THERMAL 

COMPONENT(1) OK OK (7) 

SYSTEM OK OK OK 

EMC 

COMPONENT(1) OK OK OK 

SYSTEM OK OK OK 

(1) COMPONENT TESTS LARGELY UNDEFINED. 

"Treitffia-SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D SPECIAL HANDLING (Note 2) c 55-, 

io 

GE COMPONENT ACOUSTIC DEVELOPMENT TESTING 

BASELINE 

o INDIVIDUAL COMPONENT ACOUSTIC DEVELOPMENT TESTING PER 

SAFSL EXHIBIT 10003. 

o ACOUSTIC TESTING IN ADDITION TO COMPONENT VIBRATION TESTING. 

CONSIDERATIONS 

o ACOUSTIC TESTING OF COMPONENTS WITHOUT ATTACHING STRUCTURE 

NOT CONSIDERED VALID. 

IN GENERAL, VIBRATION TESTING OF SMALL COMPONENTS CONSIDERED 

ADEQUATE. 

RECOMMENDATION 

DIRECT GE TO DELETE INDIVIDUAL COMPONENT ACOUSTIC TESTING 

AS A GENERAL PRACTICE. 

o RETAIN COMPONENT ACOUSTIC TESTING ONLY FOR THOSE CONSIDERED 

SUSCEPTIBLE. 

IMPACT 

o MUST NECESSARILY AWAIT EVALUATION OF GE'S IMPLEMENTATION OF 

THIS PHILOSOPHY. 

......_sPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING 

(Note 3) 555- 

" 

MM DOOR JETTISON SHOCK DEVELOPMENT TEST 

BASELINE 

o MM TEST ARTICLE WITH SIMULATED COMPONENTS. 

o NO LM TEST ARTICLE DUE TO AVAILABILITY 'PROBLEM. 

RECOMMENDATION 

o LM STRUCTURE AND COMPONENTS SHOULD BE INCLUDED IN TEST 

CONFIGURATION 

o REASON - TO PROVIDE SHOCK DATA FOR LM INSTALLATIONS AND BETTER 

ENVIRONMENTAL SIMULATION (CONTINUOUS TEST ARTICLE AVOIDS 

REFLECTION PROBLEMS DUE TO STRUCTURAL DISCONTINUITY). 

o IMPLEMENTATION - PROGRAM DOOR EJECTION TEST ON STV IMMEDIATELY - ,/-I> f

SUBSEQUENT TO OV MODAL SURVEY (PRIOR TO DEMATE FOR LM ACOUSTIC 

TEST). 

IMPACT 

o SCHEDULE - POTENTIAL ADDITION OF ONE MONTH TO LM PORTION OF 

STY SCHEDULE. RESULTSIN ONE MONTH'S LESS WORTH OF POTENTIAL 

CHANGE INCORPORATION IN LM STRUCTURE FOR FV NO. 1 AND 2. 

o COST - INCREASE DUE TO SCHEDULE STRETCHOUT SHOULD NOT EXCEED 

$25, 000 (ROM). 

n CLCRET SPECIAL HANDLING 
LM Acoustic test for verification 

of internal vibration and external 

structure integrity LV (with G/B mass substitute) 

Vibration test for bending modes, 

torsion modes, damping 

(Development Test) 

(Development Tests) 

MM - Acoustic, as above 

Pres. 

Leak 

Burst 

Axial 

Load 

Shear 

Bending 

Leakage r 

Proof 

Diff. Pres. 

Burst• 

Leak 

Proof 

Pres. 

Cycle 

Ejection 

(Qualification Tests) 

Bending; Shear; Axial Load; 

Leakage; Pres. Cycle 

(Qualification Tests 

Unpress. 

Section 

Bending; Shear; Axial Load 

Birdcage 

Hatch 

DRV 

Press. 

Section 

Dome MM - Bending; Shear, Etc. 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 ,e,„..„. SPECIAL HANDLING 

STRUCTURAL DEVELOPMENT AND QUALIFICATION TEST FLOW 

(Note: All structures are production hardware) 

555 -;y 2 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

ALTERNATIVES 

SECRET SPECIAL HANDLING 

METEOROID SHIELD FLUTTER TEST 

DEVELOPMENT - DAC 

CONSIDERATIONS 

1 n, /47v l'-k— 

f

t` 

o DYNAMIC PRESSURE LIMITATIONS 

REQUIRE MAGNESIUM MODEL veiv 

CONSTRUCTION 

BASELINE 

o MODEL FLUTTER TEST AT TULLAHOMA 

o MAGNESIUM MODEL TO OBTAIN DESIRED Q 

MARGIN 

o TRANSONIC TESTS ONLY 

o TEST WILL DEMONSTRATE Q MARGIN 

o MACH NUMBER RANGE INSUFFICIENT 

TO DEMONSTRATE M MARGIN 

o PLANNED TEST RUNS WILL NOT 

DEMONSTRATE MACH NO, MARGIN 

o OTHER TEST EXPERIENCE SUGGESTS 

CRITICAL Q'6, MAY OCCUR AT HIGHER 

MACH NUMBERS 

ALTERNATIVE 1 

o SUPERSONIC RUNS ADDITIONALLY 

RECOMMENDATION: 

ADDITIONAL RUNS BE SCHEDULED (SAME TIME, MODEL) IN SUPERSONIC TUNNEL TO 

DEMONSTRATE REQUIRED Q AND M MARGINS. 

IMPACT: 

COST4TUNNEL NO COST-TEST SUPPORT - $5, 000 (ROM) 

SCHEDULE:ADDED TUNNEL AND TEST TIME APPROX. 4 DAYS NO PROGRAM IMPACT 

SECRET SPECIAL HANDLING 
C ECRET SPECIAL HANDLING 

• 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING 

55S 34.2 

(Note 5) P/60fir 

BOOST PHASE VEHICLE MODAL SURVEY 

DEVELOPMENT (STV) - H. B. 

ALTERNATIVES CONSIDERATIONS 

o BASELINE o DETERMINE FREE-FREE VIBRATION 

MODES OF OV IN BOOST CONFIGURATION 

CONDUCT TEST ON STV SUSPENDED FOR VALIDATION/ CORRECTION OF 

VERTICALLY BY BUNGEE VEHICLE LOADS PREDICTIONS 

o ALTERNATE 1 - o FREE-FREE BOUNDARY CONDITIONS 

OF BASELINE TEST ARE NOT SUITABLE 

SUPPORT TEST ARTICLE AT BASE BY FOR VEHICLE MODE VERIFICATION 

FIXTURE SIMULATING T-IIIM ADAPTOR SINCE FLEXIBILITY OF MM SHELL IS 

FLEXIBILITY NOT PROPERLY EMPHASIZED, AND 

ADAPTOR LOAD DISTRIBUTION EFFECTS 

ARE OMITTED ENTIRELY 

.I.0■11.0■••■•••■=01 ■1 0,..wi NI•gaII 

RECOMMENDATION: 

CONDUCT TEST WITH SUPPORT SIMULATING TITAN ADAPTOR STRUCTURAL 

FLEXIBILITY 

IMPACT: 

NONE AS STATIC TEST FIXTURE SHOULD BE USABLE 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

S55.-3(12_ 

-6-Pe/telt-SPECIAL HANDLING \ (Note 6) '01 isORBITAL VEHICLE MODAL SURVEY 

DEVELOPMENT (STY) - H. B. 

ALTERNATIVES CONSIDERATIONS 

BASELINE o DETERMINE FREE-FREE OV 

VIBRATION MODES TO VALIDATE OR 

CONDUCT TEST AT DAC ON STV CORRECT PERFORMANCE PREDICTIONS 

SUSPENDED VERTICALLY INA FREEFREE CONDITION SUPPORTED BY o DOOR OPEN BUT REPLACED BY 

BUNGEE ATTACHED TO FWD END OF OV. STRUCTURAL TRUSS 

WITH TRUSS 

o ALTERNATIVE 1 o FLEXIBILITY OF OPEN MM DOOR IS 

EXPECTED TO BE IMPORTANT EFFECT 

REMOVE STRUCTURAL TRUSS 

o 

ON MODES 

DOOR TRUSS WILL ALTER STV 

DYNAMICS 

•••■■■••■■•••■••■■•••■••■••••••■••■•• •■•■•■■■—vovemex......./11■•••••■•••■• 

RECOMMENDATION: 

CONDUCT TEST ON STV WITH DOOR OPEN AND TRUSS REMOVED. 

IMPACT: 

NONE 

-S-EGWELF-SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

ALTERNATIVES 

D PECIAL HANDLING 

EK COMPONENT DEVELOPMENT TESTS 

CONSIDERATIONS 

BASELINE 

o EK PLANS ONLY LIMITED THERMAL-LOW 

VACUUM TESTING OF SELECTED OPTICAL 

PIECES 

o EK PLANS NO DYNAMIC TESTING OF 

COMPONENTS DURING DEVELOPMENT 

TESTING 

o DOES NOT INCLUDE ANY THERMAL OR 

THERMAL-HARD VACUUM EXPOSURE 

OF ANY OTHER FUNCTIONAL ELEMENTS 

ON A COMPONENT BASIS. SYSTEM 

LEVEL EXPOSURE ON THM AND EM NOT 

CONSIDERED ADEQUATE SUBSTITUTE. 

o DYNAMIC TESTS ON SDM AND EM NOT 

CONSIDERED ADEQUATE SUBSTITUTE 

ALTERNATIVE 

PLAN ON THERMAL, THERMAL-VACUUM, 

AND DYNAMIC EXPOSURES OF SELECTED 

COMPONENTS AT COMPONENT LEVEL TO 

ASSURE MINIMUM RISK QUAL PROGRAM 

TOTAL IMPACT MUST NECESSARILY 

AWAIT EVALUATION OF SELECTED 

TESTS. ALTERNATIVE PHILOSOPHY 

SHOULD BE CONVEYED TO EK, HOWEVER, 

AS A BASIC REQUIREMENT. 

RECOMMENDATION: 

• REVISE DEVELOPMENT TEST AND PROVIDE APPROPRIATE DIRECTION. 

--_R;":" SPECIAL HANDLING 
555- 312- 

'..P1 

SECRET SPECIAL HANDLING 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SECRET SPECIAL HANDLING 

EK GROUND CONDITIONING TEST (THERMAL MODEL) 

BASELINE: 

o CONDUCT GROUND CONDITIONING TEST TO DETERMINE IMPACT OF 

GROUND ENVIRONMENT (TRANSPORTATION AND PAD) ON MM. 

CONSIDERATIONS: 

o CONFIGURATION: 

▪ ENVIRONMENT ENCLOSURE ADJACENT TO CHAMBER A, 

ENVIRONMENT GENERATORS, INSTRUMENTATION, & TEST CONSOLE. 

o DURATION: 

▪ 42 DAYS INCLUDING SET UP & TEAR DOWN. 

RECOMMENDATION: 

o DELETE TEST - RESULTS WOULD BE INCONCLUSIVE. 

IMPACT 

COST SAVINGS: 

AGE & FACILITIES $ 150K 

OPERATION :32K 

ROM TOTAL = $ 182K 
tto6 ok, ) 

te, 

555 - 3 qzP1 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

PECIAL HANDLING 

COA MODE SURVEY TEST 

(DEVELOPMENT) 

ALTERNATIVES CONSIDERATIONS 

BASELINE 

o MODE SURVEY CONDUCTED ON DM 

o FREE-FREE SUPPORTS (BUNGEE) 

THF'SE DATA REQUIRED TO VALIDATE/ 

CORRECT THE COA DYNAMIC MODELING 

UTILIZED FOR PERFORMANCE AND LOADS 

PREDICTIONS 

o THE IMPORTANT EFFECTS OF LOCAL 

FLEXIBILITIES AT LOAD CONCENTRATION 

POINTS REQUIRES HARD POINT SUPPORTS 

o FIXED BOUNDARY CONDITIONS MATCH 

ANALYTICAL MODE PROCEDURES 

ALTERNATE I 

o MODIFY TEST CONFIGURATION BY 

PROVIDING FIXED SUPPORTS AT , 

THREE MOUNTING POINTS. 

•1•••■•1011.111.0=.1•••■•••••■ 

RECOMMENDATION: 

AN APPROPRIATE TEST-FIXTURE SHOULD. BE PROVIDED SO THAT THE DESIRED 

FIXED BOUNDARY CONDITIONS CAN BE SIMULATED•FOR THIS TEST. 

IMPACT: 

COST APPROX $20, 000 (MAX) FOR FIXTURE. NO PROGRAM SCHEDULE IMPACT. 

CICRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING 555-3y2 

F9 1' 

• DEVELOPMENT TESTING 

SPECIFIC AREAS OF INVESTIGATION & SUMMARY RESULTS 

3. COMBINATION OF SELECTED DEVELOPMENT TESTS 

o GE & EK THERMAL TESTING 

SCHEDULING PRECLUDES FURTHER COMBINATION 

GE REQUIRES MORE EXTENSIVE AND EARLIER DEVELOPMENT 

THAN EK CAN EFFECTIVELY SUPPORT 

- NO BENEFITS IN REGARD TO INTERFACE SUBSTITUTE SAVING 

o GE & DAC DRV TESTING 

- SCHEDULE PRECLUDES COMBINATION 

- BENEFITS SMALL DUE TO GE CANCELLATION OF REQUEST 

FOR COMPLEX LAUNCH TUBE SUBSTITUTE 

OEORET SPECIAL HANDLING 
3ECRDT SPECIAL HANDLING 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D

-SF,614=-SPECIAL HANDLING 

r criv CS-5-10- 3yz 

491}12 

1 

LM/GEMINI B ADAPTOR SEPARATION SHOCK DEVELOPMENT TEST : 

BASELINE 

TEST ARTICLE CONSISTS OF LM FORWARD UNPRESSURIZED 

COMPARTMENT WITH SEPARATION ZONE OF GEMINI B ADAPTOR 

CONSTITUTES QUALIFICATION OF LM ELECTRICAL COMPONENTS 

TO SHOCK 

TANKS ARE SIMULATED 

RECOMMENDATION 

INCLUDE GEMINI B ADAPTOR COMPLETE WITH COMPONENTS 

REASON -- TO REDUCE PROGRAM EFFORT THROUGH INTEGRAL' ION 

OF MAC AND DAC TEST OBJECTIVES 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

0 --ryReikELT-SPECIAL HANDLING 

S - 3 

QUALIFICATION TESTING 

DEFINITION 

CRITICAL FEATURES 

BROAD EVALUATION 

QUESTIONS 

BASIC EVALUATION 

PROBLEM 

▪ A TEST TO VERIFY THE MANUFACTURED DESIGN 

OPERATING UNDER ITS SPECIFIED ENVIRONMENTS WITH A MARGIN 

• CONTROL OF TEST SPECIFICATION AND REPORT 

BY CUSTOMER 

TEST SPECIMEN TRULY REPRESENTATIVE OF 

PRODUCTION HARDWARE 

▪ SUFFICIENT PRIOR DEVELOPMENT TESTING TO 

PROMISE SUCCESSFUL QUALIFICATION TESTING 

• EXAMINE CONTROL AND TYPE OF DEVELOPMENT 

TESTS WHICH ARE SOLE SOURCE OF QUALIFICATION INFORMATION 

▪ ARE SEGMENT OR SYSTEM LEVEL QUALIFICATION 

TESTS COMPARABLE? 

▪ DO COMPONENT QUALIFICATION TESTS SHOW 

SUFFICIENT SAFETY MARGIN IN DESIGN? 

▪ ONLY ONE COMPANY AS AN AGREED-UPON DETAIL 

AF-APPROVED TEST PLAN 

SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SECRET SPECIAL HANDLING 

555 - 30- 

DEVELOPMENT TESTS AS SOURCES OF QUALIFICATION DATA 

• MM STATIC 

DYNAMIC MM FWD STR (113D) 

▪ MIRROR AND MOUNTS AND SUPPORT EQUIPMENT -- VIBRATION 

▪ SUBSYSTEM -- EMC 

▪ LV MODE SURVEY 

▪ LM. ACOUSTICS 

• FWD UNPRESSURIZED COMPARTMENT - VIBRATION 

▪ LV BENDING MODES 

GEMINI B -- SEPARATION SHOCK 

• MM/TIII -- SEPARATION SHOCK 

• EMC 

• MM DOOR EJECTION 

• COA -- VIBRATION MODE 

MM AFT SECTION -- ACOUSTIC 

▪ MM -- ACOUSTIC 

▪ EQUIPMENT (DYNAMIC) MOTION TEST 

NOTE: THESE TESTS PROVIDE DATA UPON WHICH THE COMPONENT QUALIFICATION 

TEST REQUIREMENTS ARE BASED 

SECRET SPECIAL HANDLING 

GE 

DAC 

EK 
Dome MM - Bending; Shear, Etc. 

Birdcage 

Hatch 

DRV (E) 

(Qualification Tests) Press. 

Section 

Bending; Shear; Axial Lo ad; 

Leakage; Pres. Cycle 

(Qualification Tests 

tInpre s s 

Section 

Bending; Shear; Axial Load 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 DErFverR-F1+ SPECIAL HANDLING 

STRUCTURAL DEVELOPMENT AND QUALIFICATION TEST FLOW 

(Note: All structures are production hardware) 

LM 

(Development Tests) 

MM - Acoustic, as above 

S55- 3 '12 

PI 

Acoustic test for verification 

of internal vibration and external 

LV (with G/B mass substitute) structure integrity 

Vibration test for bending modes, 

torsion modes, damping 

(Development Test) 

( 

Pres. 

Leak 

Burst 

Axial 

Load 

Shear 

Bending 4' 

Leakage 

Proof 

Diff. Pres. 

Burst 

Leak 

Proof 

Pres. 

Cycle 

Ejection 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING 

s. .s- s - 

SEGMENT SUB-SYSTEM GROUP LEVEL QUALIFICATION PI 3-m 

DAC 

▪ 

LMQTV 30-DAY TEST IN THERMAL-VACUUM 

▪ EC/LS -- A COMPLETE SUBSYSTEM UNDER ENVIRONMENT (T/V) 

▪ ACTS/PROP -- A COMPLETE SECTOR AMBIENT 

MAJOR STRUCTURAL ELEMENTS OF LM (BIRDCAGE, THERMAL 

RADIATOR, PRESSURIZED COMPARTMENT, UNPRESSURIZED 

COMPARTMENT, DRV) 

EMC ON LV PRESENTLY PLANNED -- FOLLOWED BY EMC ON 

OV AT VAFB 

GE 

• 

NO SYSTEM LEVEL DUAL CONSOLE AND LM EQUIPMENT TESTS -- 

THIS VALIDATION IS OBTAINED AS PART OF LM AND MM 

QUALIFICATION TESTS 

EMC OF SUB-SYSTEM GROUP 

TM BAY QUAL (# 115) 

EK MM QUAL (60 DAYS) IN THERMAL-VACUUM FOLLOWING 30-DAY 

T/V OF COA 

▪ EMC ON LMPE AND EXPERIMENTAL SUPPORT EQUIPMENT 

NOTE: ACOUSTIC QUALIFICATION OF LM RECOMMENDED BUT NOT IN PLAN 

ODCrtET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SECRET SPECIAL HANDLING 

KEY AREAS OF INVEST3ATION AND SUMMARY RESULTS 

VALIDITY OF PROPOSED QUALIFICATION TESTS AND APPROACHES: 

555 - 

pq 2, 5"-- 

ACOUSTIC 

STATIC 

SHOCK 

VIBRATION 

THERMAL 

EMC 

DAC GE ONF 

(1) (2) OK 

(3) OK OK 

OK OK OK 

OK OK OK 

OK OK OK 

(4) OK OK 

-SELeftec-SPECLA L HAND LING 

• 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

—teetk-F7S-SPECIAL HANDLING 

COCRET SPECIAL HANDLING (Note 1) 

Ss -3q2- 

LM FORWARD UNPRESSURIZED COMPARTMENT COMPONENT r1.24 

VIBRATION QUALIFICATION TEST 

BASELINE 

▪ LOW FREQUENCY SINUSOIDAL VIBRATION TEST 

• RANDOM VIBRATION APPLIED AT BASE TO PROVIDE SPECIFICATION 

LEVELS (SAFSL EXHIBIT 10003) AT COMPONENT MOUNTING POINTS 

RECOMMENDATION 

REPLACE RANDOM VIBRATION WITH ACOUSTIC EXCITATION 

• RETAIN SINUSOIDAL TEST .1•••■•• 

▪ REASON -- TO AVOID UNREALISTIC FAILURE MODES; IMPROVES 

ENVIRONMENTAL SIMULATION BY PROVIDING UNIFORM EXCITATION 

OVER EXTERNAL SURFACE 
CECRET SPECIAL HANDLING (Note 2a) 

GE SUBSYSTEM COMPONENT ACOUSTIC QUAL TESTING 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

BASELINE 

INDIVIDUAL COMPONENT ACOUSTIC QUALIFICATION TESTING PER TEST 

PLAN 

ACOUSTIC TESTING IS IN ADDITION TO COMPONENT VIBRATION TESTING • 

RECOMMENDATION 

• DELETE INDIVIDUAL COMPONENT ACOUSTIC TESTING AS A GENERAL 

PRACTICE 

• RETAIN COMPONENT ACOUSTIC TESTING ONLY FOR COMPONENTS 

CONSIDERED SUSCEPTIBLE (DELICATE COMPONENT WITH LIGHT 

CONSTRUCTION AND LARGE SURFACE AREA) 

• REASON -- TO AVOID UNNECESSARY COMPONENT QUALIFICATION TESTING 

—Eriaeftelf-SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

54BeftLPT-SPECIAL HANDLING (Note 2b) 

55c - 3 YZ 

e '2, 4 

TM BAY VIBRATION QUALIFICATION TEST 

BASELINE 

SINUSOIDAL VIBRATION TEST ONLY 

RANDOM VIBRATION MAY BE ADDED BASED ON DATA FROM MM 

ACOUSTIC DEVELOPMENT TEST 

RECOMMENDATION 

• DELETE TM BAY VIBRATION QUALIFICATION TEST 

▪ REPLACE WITH TM BAY ACOUSTIC QUALIFICATION TEST AT ROCHESTER 

• REASON -- TO PROVIDE MEANINGFUL CONSISTENT QUALIFICATION 

TEST PHILOSOPHY 

SECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CECI1ET SPECIAL HANDLING 

MISSION MODULE SHELL STRENGTH TEST QUALIFICATION 

(Note 3) 

5-55- 9 2"-- PT. 29 9i,- 

c1,94' 

Q. 

) 

ALTERNATIVES CONSIDERATIONS 

• SHELL SUPPORTED BY SIMULATED 

TIIIM/MM INTERFACE STRUCTURE 

▪ SUBJECTED TO LIMIT AXIAL, SHEAR, 

B ENDING MOMENT COMBINATIONS 

DIFFERENTIAL PRESSURE NEGLECTED 

BASELINE: 

STATIC LOADING TO LIMIT VALUES 

ALTERNATE 1: 

INCLUDE DIFFERENTIAL PRESSURE 

SHELL EXPECTED TO BE SENSITIVE TO 

CRUSHING PRESSURE LOADING 

OMISSION OF INCREMENTAL PRESSURE 

EFFECTS IS UNCONSERVATIVE 

RECOMMENDATION: STATIC LOADING OF SHELL STRUCTURE SHOULD BE COMBINED WITH 

MOST CRITICAL INCREMENTAL PRESSURES ANTICIPATED FROM 

VENTING STUDIES 

SECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CECRET SPECIAL HANDLING (Note 4) 

LM/MMFS EMC "PRE-QUAL" TEST AT DAC 

OPTION 0 PRO/0 CON 

SPECIAL HANDLING 

RETAIN BASELINE 

TEST 

ELIMINATE BASELINE 

TEST 

O PROVIDES LM/MMFS EMC TEST SIX MONTHS SOONER 

• LM/MMFS MATE AND ACCEPTANCE EXPERIENCE 

BEFORE FV3 

O ONLY THREE WEEKS IN BASELINE FOR MATE/ 

ACCEPTANCE/EMC TEST 

O COA NOT PRESENT 

O PERMITS EARLIER LM QUAL THERMAL/VACUUM TEST 

O IMPROVES ACCEPTANCE SCHEDULE 

O ENHANCES MMFS FLIGHT OPTION 

O LMQTV CURRENTLY PROVIDES LM EMC QUALIFICATION 

RECOMMENDATION: ELIMINATE BASELINE TEST 

ti 
QUALIFICATION TESTING -- CONCLUSIONS 

DAC - SAMPLE SIZEOFME 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

GE 

EK 

SECRET SPECIAL HANDLING 

55-5 3 1/ zP7 3i

. 

• PRESENT TEST SCHEDULE UNREALISTIC (TOO SHORT) AND DOES NOT 

MESH WITH DEVELOPMENT TESTS 

NO ACOUSTIC EST OF LM -- A COSTLY ADDITION 

SPO CONTROLS ARE ADEQUATE 

ENVIRONMENTAL DEVELOPMENT IS ADEQUATE 

• AEROSPACE RECOMMENDATIONS ON SPECIFIC TESTS CAN BE

d 

 INCORPORATED 

• SAMPLE SIZE ADEQUATE (,)tr'- g..)44 C-44-tk-ejStcA ifrtY 4-V1/4 

7tb. C}4- 

• DEVELOPMENT TESTS FOR PREPARATION ADEQUATE 

SCHEDULE TIGHT 

SPO CONTROLS ADEQUATE 

▪ AEROSPACE RECOMMENDATIONS ON SPECIFIC TESTS CAN BE INCORPORATED 

• COMPONENT PLANS ARE NOT DOCUMENTED 

60-DAY MM QUALIFICATION UNREALISTIC 

INSUFFICIENT PREPARATION IN DEVELOPMENT BEFORE COMMITMENT 

TO QUALIFICATION 

- CONTROLS UNDEFINED 

SECRUT SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CECRET SPECIAL HANDLING 

S55- 2 

QUALIFICATION TESTS -- RECOMMENDATIONS 

<I/e 4 

1. ACOUSTIC QUALIFICATION -- UNDER STUDY -- AWAITING HARD DOLLAR ESTIMATE ■ 

FROM DAC. A DESIRABLE TEST. 

2. EMC TEST OF LV AT DAC PRIOR TO LMQTV T/V TEST IS TIME CONSUMING AND 

("W 

COULD BE ELIMINATED. IMPORTANT TEST IS ONE AT VAFB. 

3. AMEND PRESENT DAC GROUND TEST PLAN WITH SUGGESTIONS FROM DISCIPLINE? 

EXPERTS. <( 

4. AMEND GE PLAN SIMILARLY BEFORE AGREEMENT. 

5. EXPLORE EK PLAN -- MAINTAIN QUALIFICATION T/V TEST OF COA AT 30 DAYS 

AND DESIGNATE REMAINDER AS MM RELIABILITY TEST, OR CONSIDER REDUCTION. 

6. DELETE ACROSS—THE—BOARD ACOUSTIC TESTS FOR COMPONENTS AT GE. Nc.P 

7. IN ALL CASES, MAKE CERTAIN THAT QUALIFICATION LEVELS, PARTICULARLY IN 

VIBRATION AND TEMPERATURE, PROVIDE A SUFFICIENT MARGIN OF SAFETY. 

8. INCREASE THE SAMPLE SIZE OF CRITICAL COMPONENTS SUBMITTED TO 

QUALIFICATION TESTING BY DAC. 

SECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEAS,V1 JULY 2015 

FErGR-AZ— SPECIAL HANDLING 

SECRET SPECIAL HANDLING 

LM CRITICAL COMPONENTS -- SAMPLE SIZE BREAKDOWN 

EC/LS WAS IS 

1 

1 

1 

TEMPERATURE CONTROL VALVE 

WATER PUMP PACKAGE 

VALVE, MOLECULAR SIEVE 

2 

1 

1 

CONTROLLER, 2 GAS 1 1 

PPO2- PRESS. TRANSDUCER 1 1 

FAN, CABIN 1 1 

TIMER, MOLECULAR SIEVE 1 1 

VALVE, CABIN DUMP & RELIEF 2 1 

0

2 ACCUMULATOR 2 1 

TANK - HZ

- 02 2 1 

TANK He 1 1 

ELEC. POWER 

FUEL CELL PURGE TIMER 1 1 

INVERTER, ELEC. LAB 1 1 

DA TA MGT 

COMPUTER CONTROLLER 2 1 

COMPUTER 1 1 

CENTRAL P CM ASSY. 

COMMAND LOGIC UNIT 2 

( 55- 5- ;5f 2- 

/9/, 33 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

GECRET SPECIAL HAND LING 

LM CRITICAL COMPONENTS -- SAMPLE SIZE BREAKDOWN 

INSTR. DISPLAY WAS IS 

MONITOR & ALARM ASSEMBLY 

ACTS/SCE 

2 

INTERFACE & DISPLAY' 1 1 

HORIZON SENSOR 1 1 

ATTITUDE GYRO ASSEMBLY 1 1 

INVER TER 1 

ACT'S/PROPULSION 

TANK ASSEMBLY, He 2 1 

RELIEF VALVE, LO-He 1 1 

PLENUM ASSEMBLY, LO, He 2 1 

FLIGHT CREW EQUIPMENT 

BIOLOGICAL DOSIMETER MON. 2 1 

NOTE: RECOMMEND STUDY OF ADDITIONAL TEST SPECIMENS ON GROUND RULE 

OF TWO OR MORE FOR CRITICAL COMPONENTS. 

-.S.F.Git-E-1" SPECIAL HAND LING 
NRO APPROVED FOR 

RELEASE >JULY 2015 

CECRET SPECIAL HANDLING 

POSSIBLE DAC COMPONENT QUALIFICATION TEST IMPROVEMENTS 

0 INCREASE SAMPLE SIZE OF CRITICAL COMPONENTS FROM 1 TO 2 

a. INVOLVES 32 COMPONENTS AS PRESENTLY DEFINED 

b. MORE DIFFICULT TO "TAILOR-MAKE" 2 UNITS TO PASS QUAL. 

c. GREATER CONFIDENCE NEEDED BECAUSE OF MISSION EFFECT 

OF FAILURE. 

555- "W-2- 

p 

O IMPLEMENT THE EFFECTIVENESS (RELIABILITY) TEST PLAN 

a. PLAN IS TO BE SUBMITTED UNDER SAFSL-21013 BUT NOT 

IMPLEMENTED. 

b. AIMED AT NEW, UNFLOWN, CRITICAL COMPONENTS. 

c. PLAN TO EXPLORE SAFETY MARGIN IN DESIGN--BOTH IN 

PARAMETRIC LEVEL AND OPERATING TIME. 

d. CAN BE IMPLEMENTED AS FOLLOW-ON TO PRESENT QUAL. 

PROGRAM. 

e. BRIDGES THE GAP OF KNOWLEDGE BETWEEN FLOWN, MATURE 

COMPONENTS AND NEW, UNTRIED COMPONENTS. 

NOTE: THESE ADDITIONS MAY BE COSTLY AND ARE CURRENTLY OUT-OF-SCOPE. 

••■ 

SECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SECRET SPECIAL HANDLING 

ACCEPTANCE TESTING 

VALIDITY OF PROPOSED ACCEPTANCE TESTS 

DAC GE EK 

THERMAL/VACUUM (1) OK OK 

STRUCTURAL DYNAMIC (2) (3) (4) 

OPTICAL PERFORMANCE - ..,.. (5) 

AMBIENT PERFORMANCE (6) (7) OK 

EMC OK OK (7) 

NOTE (5): ELAPSED TIME FOR EK OPTICAL TESTS APPEARS EXCESSIVE 

-SEIGR-E-T--SPECIAL HANDLING 
cEenrir SPECIAL HANDLING 

LV THERMAL VACUUM TESTING AT DAC 

(• PRO/0 CON) 

3-1- 3 qz 

ALTERNATIVES CONSIDERATIONS PT >7 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

LAB VEHICLE THERMAL/VAC TEST • POSSIBLE HIGHER CONFIDENCE '‘1: 

THERMAL INTERFACE 

O POSSIBLE CONTAMINATION 

O HANDLING PROBLEMS 

O SCHEDULE DELAY DUE TO FINDING 

LM PROBLEMS IN LV CONFIGURATION 

LM THERMAL/VAC TEST • SAVES 280 HOURS OF MM REDUNDANT 

TESTING 

O AVOIDS POSSIBLE MM CONTAMINATION 

O AVOIDS HANDLING PROBLEMS 

• FINDS PROBLEMS IN SIMPLER CONFIGURATION 

O 5-WEEK LAUNCH SLIP UNLESS DELETE 

PRE-QUAL EMC AND IMPROVE ECLS 

TEST SCHEDULE 

RECOMMENDATION: T/V TEST LM INSTEAD OF LV,'REVISE TEST FLOW TO ALLEVIATE 

SCHEDULE PROBLEM 

3Ecnra-GPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING (Note la) 

I 

o 

Lit 

0P2 1,,k-ff% 

I/R ARRAY AND LN PANELS MUST BE REMOVED FOR LV INSTALLATION AND SECTIONS 49, 

REASSEMBLED AROUND LV. LV DAMAGE RISK, MULTIPLE CONNECTIONS INVOLVED. 

5-5-5- 3 5/2- 

3‘? 

o INSTALLATION OF LV IN CHAMBER INVOLVES USE OF TWO BRIDGE CRANES FOR TILT 

CAPABILITY. LV DAMAGE RISK INCURRED. 

o EXISTING FACILITY HEIGHT PRECLUDES USE OF THERMAL SUBSTITUTES. 

o EXISTING FACILITY AIRLOCK MUST BE REMOVED TO PROVIDE LV HANDLING SPACE. 

CHAMBER CONTAMINATION RISK INCURRED. 

• EXISTING FACILITY SPACE LIMITATIONS REQUIRE TH AT SPOOL PIECES, CHAMBERLID, 

I/R ARRAY, LNz PANELS BE STORED OUTSIDE DURING LV INSTALLATION. CONTAMINA-

' TION PROBLEM INCURRED. 

OIL DIFFUSION PUMPING RESULTS IN LOW PROBABILITY OF OIL CONTAMINATION OF 

LV DURING ACCEPTANCE TESTING. TEST PROGRAM NEEDED TO ASSESS CONTAMINATION ON LEVELS IN DAC CHAMBER. 

o TEST VEHICLE AND/OR SUPPORT EQUIPMENT OUTGASSING HAS HIGH PROBABILITY OF 

CONTAMINATING CRITICAL SURFACES. 

D 

PROBLEMS IN DAC SPACE SIMULATION LAB 

o INSTALLATION OF SPOOL PIECES AND CHAMBER LID INVOLVES RISK OF DAMAGE TO 

LV BECAUSE OF EXISTING FACILITY HEIGHT LIMITATION. 

fl 3LICRET SPECIAL HANDLING 
SECTION A-A IR ARRAY CREW 

ACCESS 

MANLOCK 

DIFFUSION 

PUMPS 

2 PANEL 

20° K 

CRYOPANEL 

LN2 ELBOW--1' 

WATER BAFFLE 

A 

TO MECHANICAL -we-i 

PUMP 

OIL DIFFUSION 

PUMP 

A 

39 ft DIA. 

EXISTING 

CHAMBER 

SPECIAL HANDLING 

AIROSPAC I CORPORATION 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 SECRET SPECIAL HANDLING (Note 10) • 

LABORATORY VEHICLE T/V TEST-DOUGLAS 555" -3 4/2-- 
NAO APPROVED FOR 

RELEASE 1 JULY 2015 (Note 1c) 

S.55--3 Y.2.— 

PT 

"S-Lreltrr SPECIAL HANDLING 

LV I NSTAIJATIoN IN .1.AC T/V C.1-tAt\/\13ER 

BRIKE CRANE SPOOL PIECE 

crcitrT SPECIAL HANDLING 

.-=1NALLS • d* ROOF\ 

SPACE SIMULATION_ 

LABORATORY 

ExtsTrNcl AIRLOCK 

(Tot REmoveD) 

, CHAMBER 

LID 

EXISTING 

391DIA.CHAMBER 

5t.9.1" 

LV 
555 , 3"- 

PI 41 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

f .A.r_i-SPECIAL HANDLING 

MMFS MODE VERIFICATION TEST 

ACCEPTANCE 

ALTERNATIVES CONSIDERATIONS 

I. NO ACCEPTANCE MODAL VERIFICATION 

IS PRESENTLY PLANNED IN BASELINE 

o A STATIC DEFLECTION MEASUREMENT 

IS TO BE PERFORMED ON THE SPIDER 

STRUCTURE ONLY 

2. PERFORM A MMFS MODE VERIFICATION 

MEASUREMENT ON EACH ASSEMBLY AS 

A PART OF ACCEPTANCE PROCEDURE 

o TM DYNAMIC CHARACTERISTICS ARE 

ONE OF MOST CRITICAL STRUCTURAL 

CONSIDERATIONS 

o MODE MEASUREMENTS OF MMFS 

ASSEMBLY IS BEST METHOD OF 

VERIFICATION 

o FIXTURE REQUIRED FOR HARD SUPPORT 

AT MMFS/LM INTERFACE STATION 

RECOMMENDATION: 

A MODE VERIFICATION TEST OF THE MMFS BE INCORPORATED INTO THE GE 

ACCEPTANCE TEST PROGRAM. 

'or 

-8•Eleit-E4--SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 20,15 

SECRET SPECIAL HANDLING 

COA MODE SURVEY TEST 

(ACCEPTANCE) 

(Note 4b) 555 - 3 yz- 

, ri 42- 

ALTERNATIVES CONSIDERATIONS 

BASELINE 

MODE SURVEY OF COA NOT PLANNED 

ON EACH ARTICLE 

ALTERNATIVE 

CONDUCT MODE SURVEY SIMILAR TO 

DM TEST 

o THE RESULTS WILL VERIFY THAT 

DYNAMIC PROPERTIES OF COA ARE 

AS PREDICT ED 

o WILL PROVIDE MINIMUM SHAKE-OUT 

OF WORKMANSHIP 

RECOMMENDATION: 

A MODE SURVEY TEST SHOULD BE CONDUCTED ON EACH FLIGHT ARTICLE. 

THIS TEST SHOULD UTILIZE HARD-POINT SUPPORT FIXTURE AS DESCRIBED 

FOR DM TEST 

SECRET GPECIAL HANDLING 
ki}D ter" I, 

(Note ,2b) L 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SECRET SPECIAL HANDLING 

ORBITAL VEHICLE MODAL SURVEY 

ACCEPTANCE (VEHICLES 3 & 6) 

ALTERNATIVES CONSIDERATIONS 5-5 

BASELINE - 

, 7' 

CONDUCT TEST ON VEHICLES

, 

 3 &16' o 

o 

VERIFY THAT LOW FREQUENCY OV 

MODAL CHARACTERISTICS ARE NOT 

SIGNIFICANTLY DIFFERENT FROM STV 

TO CAUSE SERIOUS PERFORMANCE 

DEGRADATION 

OV SUSPENDED VERTICALLY BY 

BUNGEE WITH DOOR CLOSED 

ALTERNATE 1 

CONDUCT TEST WITH DOOR OPEN 

o 

DOOR OPEN 

DESIRED OV CONFIGURATION REQUIRES 

ALTERNATE 2 

DELETE TEST 

• 

----...........----- 

o 

o 

M... .......■■■••■•• • 

IF ANALYTICAL STUDIES PREDICT 

ACCEPTABLE MARGIN OF DYNAMIC 

PERFORMANCE 

IF STV TEST VERIFIES PREDICTED 

MODES 

— 

jo 413 

RECOMMENDATION: 

o ALTERNATE 1 - PERFORM TEST WITH DOOR OPEN 

o RE-EVALUATE NEED WHEN STV TEST RESULTS AND DYNAMIC PERFORMANCE 

PREDICTIONS It COMPLETED/MINORITY SAY "DELETE NOW" 

—&E'eft-Erf-SPECIAL HANDLING \i 
ALTERNATIVES CONSIDERATIONS 

1. BASELINE ACCEPTANCE TEST 

o MM WITH SIMULATED LM 

SUSPENDED IN VACUUM CHAMBER 

o TM IN LAUNCH LOCKS 

o PM ON AIRBAG 

o FEASIBILITY OF BASELINE TEST AS 

A PERFORMANCE MEASUREMENT 

UNCERTAIN 

o RESULTS OF ANALYTICAL STUDIES 

WILL AID IN DETERMINING VALUE 

OF TEST 

o PROVIDES A MEANS TO EVALUATE 

TFST FROM A PHYSICAL AND 

PRACTICAL STANDPOINT 

o PROVIDES DATA FOR CHECK OF 

ANALYTICAL MODELING 

2. RETAIN TEST ON A DEVELOPMENT BASIS 

NRO APPROVED FOR 

RELEASE 1 JULY 2015. 

SPECIAL HANDLING (Note 

rte 4 

OPERATIONAL DYNAMICS TEST 

ACCEPTANCE 

RECOMMENDATION: 

o RETAIN TEST ON A DEVELOPMENT BASIS 

o RE-EVALUATE TEST AS AN ACCEPTANCE PROCEDURE WHEN RESULTS 

OF SUPPORTING ANALYTICAL STUDIES ARE AVAILABLE 

f 

itA-•-,rt/COr 

S ECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CECRET SPECIAL HANDLING 

(NOTE 6 a) 

555 34/2- 

U~J y5 

APPROACH 

LM/ MM FUNCTIONAL TESTING AT DAC 

(0 PRO/0 CON) 

CHECK OUT DAC LM AVE ALONE 

BEFORE MATING WITH GE LM AVE 

(CHANGE) 

O INCREASED ASSURANCE OF COMPATIBILITY 

O REQUIRES ADDITIONAL SUBSTITUTE AND SOFTWARE 

O ADDS 6 DAYS, 96 HOURS TO SCHEDULE WITH ADDED 

AVE COMPLEXITY 

O SYSTEMS ARE CHECKED INDIVIDUALLY BEFORE 

INSTALLATION 

NOT RECOMMENDED 

cEcarT SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 SPECIAL HANDLING 

LM/MM FUNCTIONAL TESTING AT DAC 

APPROACH (0 PRO/0 CON) 

(Note 6b) 555 4`l' 

t )1 

CHECK OUT LM BEFORE 

MATING WITH MM 

(BASELINE) 

O INSIGNIFICANT HARDWARE ACCESSIBILITY 

IMPROVEMENT 

O REQUIRES 8 DAYS, 128 OPERATING HOURS 

O LM/ MM INTERFACE TESTED PREVIOUSLY 

O NECESSARY BEFORE LM THERMAL/ VACUUM 

TEST 

RECOMMENDED 

—43•Eleft-E-T- SPECIAL HANDLING 

ID 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CECRET SPECIAL HANDLING 

V-a- pf 9'7 

(NOTE 6 c) 

LM/MM FUNCTIONAL TESTING AT DAC 

APPROACH (0 PRO/0 CON) 

CHECK OUT MM AT DAC 0 DUPLICATES PREVIOUS TESTS AT GE & EK 

BEFORE MATING. WITH LM 0 LM/MM INTERFACE TESTED PREVIOUSLY 

(BASELINE) 0 REQUIRES SUBSTITUTE CAPABILITY NOT IN 

GE BASELINE ($200-500K) 

O SIGNIFICANT FACILITY IMPACT (VERTICAL 

TESTS) 

NOT RECOMMENDED: ABSORB IN PART IN LV TEST 

--CECRET SPECIAL HANDLING 

D 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

DAC/GE AGE INTERRELATION 

555-‘72- SECRET SPECIAL HANDLING 

(Note 6d), 

APPROACH (• PRO/0 CON ) 

INDEPENDENT FUNCTIONAL TEST 

CAPABILITY FOR MPSS, AFTER 

MATING MM TO LM 

O CAPABILITY FOR INDEPENDENT OPERATION 

(BYPASSING DAC TELEMETRY AND COMPUTER, 

OPTIONAL BYPASS OF DAC POWER) IS DESIGNED 

AND COSTED IN GE HARDWARE/SOFTWARE 

O USE OF THIS CAPABILITY FOR ABNORMAL (DAC 

AVE OR AGE DISABLED) TROUBLE-SHOOTING 

WOULD PROVIDE VALUABLE OPERATING FLEXIBILITY. 

O PLANNED, NORMAL INDEPENDENT OPERATIONS 

AFTER GE AND DAC AVE HAS BEEN INTERCONNECTED WOULD PROVIDE NO ADVANTAGE & 

WOULD REQUIRE MORE TEST TIME. 

O SLIGHT MODIFICATION TO NORMAL LV TEST 

CONFIGURATION REQUIRED. 

RECOMMENDATION: 

CONSIDER BACKUP UTILIZATION OF CAPABILITY PRIOR TO START 

OF LV CHECKOUT AND FOR TROUBLESHOOTING. 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D 

APPROACH 

BASELINE - FLIGHT CAMERA ARRIVES 

WITH MM. 

PERFORM LM CHECKOUT WITH REAL 

RATHER THAN DUMMY CAMERA 

(CHANGE) 

RECOMMENDATION: 

c5S- 340- 

(Note 6 e) 

(0 PRO/0 CON) 

O PERMITS USE OF FLIGHT CAMERA 

FOR MM ACCEPTANCE TESTING 

O REQUIRES USE OF DUMMY CAMERA 

FOR LM CHECKOUT 

O ESTABLISHED INTERFACE NOT 

BROKEN 

• PERMITS COMPLETE LM-MPE 

TEST BEFORE INSTALLATION 

O REQUIRES USE OF NON-FLIGHT 

CAMERA FOR MM TESTING 

• MINIMIZE MAJOR INSTALLATION 

TASK AFTER LM IS CHECKED OUT 

SPECIAL HANDLING 

SHIP FLIGHT CAMERA WITH OTHER 

EK LM/MP EQUIPMENT FOR INSTALLATION DURING LM ASSEMBLY. 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D SPECIAL HANDLING (Note 7) 

css- 3 YL 

ry 5-o 

MISSION MODULE TESTING 

APPROACH (0 PRO/0 CON) 

EMC TESTS AT EK DO NOT PROVIDE 

DATA FOR GE 

(BASELINE) 

o PROMOTES INDIVIDUAL TEST REPETITIONS 

INSIGNIFICANT ACCESSIBILITY PROBLEM y 

RECOMMEND COMBINING THE TESTS 

o REPEATS IMMEDIATELY PRIOR TEST 

o HARDWARE IS MOVED IN INTERIM 

RECOMMEND ACCOMPLISH JUST ONCE 

o GE GETS NO DATA ALTHOUGH THEIR 

EQUIPMENT OPERATES AS PART OF NJIV4_,,, . 

EK TEST (..) 

RECOMMEND JOINT EK/GE TEST 

SEPARATE COMPATIBILITY AND 

PERFORMANCE TESTS AT GE, 

BEFORE & AFTER INSTALLING 

TM SIMULATOR 

(BASELINE) 

GE AMBIENT BASELINE REPEATED 

FOR FINAL DEMONSTRATION 

(BASELINE) 

3ECRET SPECIAL HANDLING 

A 14•/1s' 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D Cr RET SPECIAL HANDLING 

55C- 3 yZ 

jog 51 

DETAIL REPETITIVE TESTING 

o PROVIDE BACKUP INDEPENDENT GE TEST CAPABILITY AT DAC t■A-P 

o CONDUCT JOINT EK/GE MM EMC TEST Ot4.., 

o PERFORM MM C/0 AT DAC AFTER LV MATE, INTEGRATE MPSS AND LV TESTS <j--/ 

o PROVIDE FLIGHT• CAMERA INSTEAD OF DUMMY FOR LM CHECKOUT AND LM-MPE 1 9/' 

CONSOLES• TEST (DAC) 

o REVIEW TIMES ALLOCATED FOR OPTICAL TESTS 

o COMBINE GE COMPATIBILITY AND PERFORMANCE TESTS 

ACCOMPLISH GE FINAL BASELINE JUST ONCE 

• 

D —ftEeik-E-T—SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D GECRET SPECIAL HANDLING 5sy - 3y2- 

SCHEDULE PROBLEMS 

OVERLAP OF QUALIFICATION AND ACCEPTANCE 

EXCHANGE HARDWARE DELIVERIES 

LM THERMAL/VACUUM ACCEPTANCE 

SPECIAL HANDLING 

A/6 
1970 

I I 1 

1969 

I T I I I 1 1 

Sys Accp A 

Sys Devpmt Test 

MAC 

lAccp 

) Sys Qual 

Sys 

_.,..,.......,_ SPECIAL HANDLING 

NRO APPROVED FQR 

RELEASE LY 2015 

QUALIFICATION-ACCEPTANCE OVERLAP 

1967 1968 

II- 111111- 11r 

jSS Development Testi 

Sys amelopment Test1 

GE Comp Qual 

1 

Sys Qual 

Sys A= 

SS Development Test 

Devpmt Test. 

SS Qualification 

A 

1 

Sys Qual 

DAC 

MOO 

Sys 

Sys Accp 

SS Development Test 

Sys Development Test 

I SS Qual 

L.Sys Qualification 

i

SS Development Test 

I SS Qualificationl 

SPECIAL HANDLING 

EK 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

ameit51.SPECIAL HANDLING 

DELIVERY OF EK CONSOLE COMPONENTS 

555 

pi 59 

(ARRIVAL DATES) 

EK TO GE 

GE TO DAC 

.EX TO DAC 

FOR LMQTV FOR FV3 

REQ'D EK RESPONSE R E Q FD EX RESPONSE 

22 JUL 68 

1 SEP 68 

1 SEP 68 

22 DEC 68 

__-- 

22 DEC 68 

1 DEC- 68 

7 JAN 69 

14 JAN 69 

14 JAN 69 

---- 

14 JAN 69 

_f_. —6,VwC,Perw-T—SPECIAL HANDLING 

Ale6 
EK 

GE 

Need Date 

Install Support T/V Test Prep 

Consoles 

Test DAC 

Response Date 

EK TO DAb • VISUAL OPTICS, FILM CHUTE, PROCESSOR (CAMERA) 

-frEGPeg4T—.S PECIAL HANDLING 

NRO APPROVED Fna 

RELEASE YJULY 2015 

CECIIE'T SPECIAL HANDLING 

EK CONSOLE COMPONENTS FLOW 

FLIGHT VEHICLE 3 

.27PPT C 

Nov Dec Dec Dec Dec Dec Jan Jan 

26 3 10 17 24 31 7 14 

1968 1969 

EK TO GE: CAMERA ELECTRONICS, BAYS 2-8 CONTROLS 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

GECRDT SPECIAL HANDLING 

LMQTV ORK-AROUND APPROACH 

BYPASS GE FOR ALL EK CONSOLE COMPONENTS (LMQTV ONLY) 

VISUAL OPTICS ASSEMBLY DELIVER TO DAC BY 1 SEPTEMBER 1968, INSTALL 

CABLES, HARNESS BEFORE BIRDCAGE IS INSERTED IN LM 

FILM PROCESSOR (DESIRABLE) 

FILM CHUTE (DESIRABLE) 

CAMERA ELECTRONICS DELIVER TO DAC BY 22 DECEMBER 1968 FOR 

BAYS 2 AND 8 CONTROLS INDIVIDUAL INSTALLATION THROUGH CONSOLE 

CAMERA FRONTS 

SECRZT-SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CECRET SPECIAL HANDLING 

ACCEPTANCE ALTERNATIVES 

555-- `OP, 57 

COMPLETE BAYS 2-8 AT GE PER PERMITS COMPLETE BAYS 2-8/MMFS TEST AT 

PRESENT BASELINE GE 

GE RESPONSIBLE ASSEMBLY PERFORMED AT GE 

▪ SIX WEEKS (LAUNCH SLIP OR EK ADVANCEMENT) 

COMPLETE BAYS 2-8 AT GE 

AFTER T/V TEST 

COMPLETE BAYS 2-8 AT DAC 

BEFORE LM ASSEMBLY 

PERMITS BRIEF BAYS 2-8/MMFS TEST AT GE 

GE RESPONSIBLE ASSEMBLY PERFORMED AT GE 

• THREE WEEKS (LAUNCH SLIP OR EK ADVANCEMENT) 

• NO BAYS 2-8/MMFS ACCEPTANCE TEST AT GE 

▪ 

BRIEF BAYS 2-8 TEST AT DAC 

GE RESPONSIBLE ASSEMBLY PERFORMED AT DAC 

• TWO WEEKS (LAUNCH SLIP OR EK ADVANCEMENT) 

RECOMMENDATION: OPTION 1 

SECRET SPECIAL HANDLING 
MM ED 

V 

LV 

/LM C /0 I I 

DAC THERMAL TEST SCHEDULE PROBLEM 

- 1969 

Jul Aug Sep Oct Nov Dec 

Chamber Cleared, Qual Test.Vehicle 

I/N./late/Test 

V 

T/V 2(.2.6<1 Prep_i 

v 

VAFB 

Baseline (LV Test) 

NRO APPROVED FOR 

RELEASE 1 Y 2015 

Jun 

Launch 

SPECIAL HANDLING 

55-5 - 

1197 Ssr 

1970 

Jan 

5 

14— Weeks 

MM E 

}Mate/Test 

T/V VAFB 

Prep 

LM C/O 

Launch 

Alternate (LM Test) 

•• 

SECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 Y 2015 

SPECIAL HANDLING 

DAC SPACE CHAMBER USAGE 

c /o Mte/EMC 

Flight Vehicle #3 iLM C/O Mt e 

SECRET SPECIAL HANDLING 

1968 1969 

1 Jul [Aug 1 Sep I Oct Nov ' IDec Jan I Feb I Mar 'Apr 1 May Jun Jul I Aug 1 

EC & LS 

Development 

EC & LS 

Qual 

Ship Date V V Need Date / LM 

LMQTV 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 D-92eitE43--SPECIAL HANDLING 555 - 3(12- 

ACCEPTANCE TEST RECOMIs/E NDATIONS 

o RETAIN PRESENT MODULAR ACCEPTANCE APPROACH, REDUCING MMFS OPERATING TIME 

BY CONDUCTING LM TH ERMAL/VACUUM TEST INSTEAD OF LV TEST 

• IMPROVE STRUCTURAL DYNAMIC ACCEPTANCE TESTING BY: 

ADDING MM MODE VERIFICATION TESTS /LVD 

• REVIEWING MM OPERATIONAL DYNAMICS TEST AFTER THOROUGH ANALYSIS , 

OF TEST CONSTRAINTS 4:1 

ci 

IMPROVE REPETITIVE TESTING OPERATIONS BY: 

PROVIDING BACKUP INDEPENDENT GE TEST CAPABILITY AT DAC • 

▪ CONDUCTING JOINT EK/GE MM EMC TEST 

• PERFORMING MM CHECKOUT AT DAC AFTER LV MATE, INTEGRATING MPSS 

AND LV TESTS 

PROVIDING FLIGHT CAMERA INSTEAD OF DUMMY FOR LM CHECKOUT AND 

LM-MPE PRE-INSTALLATION TEST 

REVIEWING TIMES ALLOCATED FOR EK OPTICAL TESTS 

COMBINING GE COMPATIBILITY AND PERFORMANCE TESTS \ 

▪ ACCOMPLISHING GE FINAL BASELINE JUST ONCE . 

ALLEVIATE SCHEDULE PROBLEM BY: 

▪ ADVANCING EK LM COMPONENTS DELIVERIES C\VAELIMINATING LMQTV EMC TEST TO ADVANCE THERMAL/VACUUM TEST 

▪ REVIEWING LV MODAL SURVEY AFTER FURTHER DYNAMIC ANALYSIS 

1,)ae fr

., 

3ECRDT SPECIAL HANDLING 

A 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING D 

ACOUSTIC AND VIBRATION TESTING 

--erzeitef-SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

CECIlET SPECIAL HANDLING 

TEST OBJECTIVES 

o DEVELOPMENT TESTING 

• ENGINEERING TEST TO PROVIDE COMPONENT ENVIRONMENTAL 

DESIGN AND QUALIFICATION TEST DATA, AND TO VERIFY 

STRUCTURAL DESIGN MARGIN 

QUALIFICATION TESTING. 

• PROVE DESIGN IS ADEQUATE FOR EXPECTED ENVIRONMENT 

WITH MARGIN 

ACCEPTANCE TESTING 

PROVE PARTICULAR ARTICLE IS FREE OF WORKMANSHIP 

DEFECTS, PERFORMS TO SPECIFICATIONS AND READY FOR 

FLIGHT 

SECI1DT SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D SPECIAL HANDLING 

SEGMENT FLOW 

LM 

SEGMENT 

MM - FWD 

TM BAY 

MM SEGMENT 

MM = TM BAY + COA BAY 

LV 

SYSTEM 

CECR ET OPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

--g-Befter-SPECIAL HANDLING S5-S' 3y 2'- 

1)1 "v 

PRESENT MOL DYNAMICS TEST PROGRAM (NOVEMBER 1966) 

TEST PHASE 

System System Segments Components** 

LV = LM + MM LM TM Bay*1 COA Bay* LM TM Bay COA Bay 

DEVELOPMENT Acoustic Acoustic 

Modal Survey 

QUALIFICATION Vibration Acoustic Vibration Vibration 

& Acoustic 

Vibration 

AC CEPTANCE Vibration Acoustic Vibration Vibration 

& Acoustic 

Vibration 

*MM = TM Bay + COA Bay 

**Acoustic testing will be performed on limited and fragile components as.defined by analysis from 

the development and qual test program 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

-43"LPeirfarSPECIAL HANDLING 4 Sss - 3 Lf zT 

PROPOSED SYSTEM-SEGMENT ACOUSTIC TESTS 

TEST PHASE System 

LV = LM + MM 

System Segments 

. LM 

MM* 

TM Bay ' COA Bay 

DEVELOPMENT 

QUALIFICATION 

ACCEPTANCE 

/ 

/ / Local Excitation 

at Inteiface Hard 

Points ,- -\-- 

. 

Acoustic 

Acoustic 

Ac i ic ," 

. 

,......-.41.0.

,_ 

Acoustic 

Acoustic 

Acoustic 

. I 

ckit 

AAA:, 4 4,txLevettitio /0-w 9,0 

. 

*MM = TM Bay /+ COA Bay 

A/kept "At tArel, 

cp, 104,..1.4v (4-vt-A0-4- -SE.GRErgP-SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 115-E-6it-E-T-SPECIAL HANDLING 

555 3 V2- 

ACOUSTIC FACILITY COSTS - SEGMENT TESTING 

EK 

.40 

.20 

.04 

.66 

.36 

.15 

.23 

.42 

DAC 

.40 

.06 

.05 

.25 

.23 

.01 

WYLE 

NEW (MM) MODS (LM ONLY) MODS (LM & MM-DEV ONLY) 

CHAMBER 

8 HORNS S2-MKVII 

6-EPT-200 

MODEL TEST PROGRAM 

AIR SUPPLY SYSTEM 

CONTROL ROOM & INSTR. 

ASSY & PREP AREA 

MECHANICAL AGE 

ENGINEERING 

GRAND TOTAL 

NEW BUILDING 

3 HORNS (EPT-200) 

SHROUD 

INSTRUMENTATION 

ENGINEERING 

AIR SUPPLY 

ADDITIONAL MODS (MM) 

EXCAVATE CH\. MB ER 

6 HORNS (EPT-200) 

MODEL TEST PROGRAM 

AIR SUPPLY SYSTEM 

MECHANICAL AGE 

ENGINEERING 

GRAND TOTAL $1.00 

08 

.13 

.04 

.18 

.12 

.54 

$1.'00 M 

.06 

.22 

.01 

.09 

M 

3 HORNS (EPT-200) 

COMPRESSOR 

LINES 

ENGINEERING 

$2.5..M.. GRAND TOTAL 

.38 M 

$1.38 M 

SECRET SPECIAL HANDLING 
J AS OND 

19 67 

JF MA JJ AS 

1968 

0 N D J F J 

19 69 

SECRET SPECIAL HANDLING r 

te'V'AIA/ 144 

---Sireittur- SF ;IAL HANDLING 

PROPOSED MM ACOUSTIC TEST SCHEDULING 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

sss OD7 4,17 

DEVELOPMENT TESTING 

ALIGN & MATE 

SHIP TO DAC 

LV MODAL SURVEY & DOOR EJECT. 

SHIP TO ONF 

MM ACOUSTIC TEST 

SHIP TO DAC 

STRUCTURAL LOAD TESTS 

ACOUSTIC QUAL TESTING 

USE 114E AND EM 

ACOUSTIC ACCEPT. TESTING 

FV #3 

ACOUSTIC FACILI AT ONF ft) 

DESIGN 

CONSTRUCTION 

EQUIPMENT INSTALLATION 

FACILITY CALIB RATION 

I 

J F 

D 
V 

fig Atvr,A1A0 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

555 - y2- 

—Stitltrr-SPECIAL HANDLING 

RECOMMENDATIONS 

o SEGMENT LEVEL ACOUSTICAL QUALIFICATION TESTING SHOULD BE 

ADOPTED UNIFORMLY THROUGHOUT THE PROGRAM FOR MINIMUM RISK. 

o ACCEPTANCE TEST FOR WORKMANSHIP .AN_D_FUNCTIONAL CONTINUITY 

SHOULD BE IMPLEMENTED AT THE -StAJMENT,LEVEL. 

,(11,0Zelit s, 

SECRET SPECIAL HANDLING 

/7/ 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D SPECIAL HANDLING 

IMPLEMENTATION OF ACOUSTIC TEST RECOMMENDATIONS 

(MISSION MODULE) 

PURCHASE ACOUSTIC FACILITY AT ROCHESTER (MINIMUM CONFIGURATION $2• 5M) 

DEVELOPMENT' -- ACCEPT PROPOSED MM ACOUSTIC TEST SCHEDULE 

QUALIFICATION -- QUALIFY MMFS 114E WITH EK ENGINEERING MODEL 

ACCEPTANCE -- INCORPORATE MM ACCEPTANCE INTO EK ACCEPTANCE PLAN 

-44-6 

Lutla,,,Linft,"" 144 

CECRrif SPECIAL HANDLING 

11114r AlAel (i/AilVtUtv‘i 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SECRET SPECIAL HANDLING 55C-3Y 2- 

r '70 

IMPLEMENTATION OF ACOUSTIC TEST RECOMMENDATIONS 

(LAB MODULE) 

USE SANTA MONICA FACILITY WITH MINIMUM MODIFICATION 

tki>11<\ DEVELOPMENT -- NO SCHEDULE PROBLEM 

QUALIFICATION -- COMPLETE COST STUDY BEFORE FINAL RECOMMENDATION 

ACCEPTANCE -- INCORPORATES CCEPTANCE INTO ACCEPTANCE PLAN 

A/A/4"Yr 

'SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

SPECIAL HANDLING 

IMPLEMENTATION OF ACOUSTIC TEST RECOMMENDATIONS 

(VIBRATION TEST OF LAB VEHICLE) 

D 

ACCEPTANCE -- SYSTEM IS DYNAMICALLY EXCITED AT INTERFACE HARD 

POINTS TO CHECK INTERFACE CONNECTIONS (EXCITER 

' MAY BE LOCAL ACOUSTIC HORN WITH A DUCT, OR A 

SMALL SHAKER OR RIVET GUN) 

6 , 4 

D SECRET SPECIAL HANDLING 
SECTLET 3PECTA.L HANDLING 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 RECOMOE D DEO TES 7 pz. OW Re,r/s/aivs 5 - 

r, 72 471aa 43169 69 170 

M, AMdeJASOA/49 ir 441 oti c." a i¢3 0 is/ a A.,,, A/ Dc/ 04' 

Al/ 

AI A 41 e /.41 s 0 D F M 4I 4 cl 414 S 0 A/ p 4./ F 'Ili 4 Al a ci A< S 0 Al .D 

48149 47 148 49 i7o 

GECIZET SPECIAL HANDLING 

4/yfory 1 -r/v I Dige 

70 

FY 4 - `VA FS 

A 

AY 3 lost Tb 09,17/ 44 

ofeerearic 

7-EST 

M 

114E 

OVALIFicAri0A/ 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

AIR VENT 

fin/11'!i . SOUND 

? PNE.SS IOW 

555 - 3(17-- 

ACOUSTIC -11.1.517•FACILITY p, 73. 

2.7% 3t5' )450' I .Dills. 

TuBE Su't'dRT 

To pr.: it pirr 

vuatcp.L. 

Apj abiT 

••• 

15'g151 

Liv Vrr 200 

ELecicko- PNE umAnc 

TeAntscluceg.s 

3-EA I l) 

AIR 5-rb cAA 

Soo 0 Cu. c7, 

Z- NoRt1/4Covsrt 1114.yu 4E/4E. KA'T 'KS 

tiNci4 R.EAF, Co R. e.1:2, END S1r4l/LATol'is 

ttiCs SIMUlttleg 

• CONT g-0•- 

Roots 

20'040° 
0Y' I 

tp-x 

NRO APPROVED FOR 

RELEASE 1,JULY 2015 9 -

SECIteif- SPECIAL HANDLING 

SUMMARY RECOMMENDATIONS 

5ss 

PI 77 

DEVELOPMENT TESTING 

,) (1 

• 

DIRECT GE TO DELETE INDIVIDUAL COMPONENT ACOUSTIC DEVELOPMENT, V,--- 

TESTING AS A GENERAL PRACTICE. 

DIRECT DAC TO CONDUCT THE MM DOOR JETTISON SHOCK TEST IN LV 104 

CONFIGURATION. 

DIRECT DAC TO CONDUCT SUPERSONIC, AS WELL AS TRANSONIC, METEROID 

SHIELD FLUTTER TEST. 

DIRECT DAC TO CONDUCT BOOST PHASE MODAL SURVEY WITH STV BASE ,),( 

SUPPORTED BY A STRUCTURE SIMULATING TITAN ADAPTOR;) 

DIRECT DAC TO CONDUCT ORBITAL PHASE MODAL SURVEY ON STC, SUS- took-, 

PENDED VERTICALLY IN FREE-FREE CONDITION, WITH MM DOOR REMOVED C 

AND WITHOUT DOOR TRUSS. 

REVIEW THE EK COMPONENT DEVELOPMENT TEST PROGRAM TO ENSURE 

THAT CRITICAL DEVELOPMENTAL COMPONENTS ARE SUBJECTED TO THERMAL, 1 

THERMAL-VACUUM AND DYNAMIC EXPOSURES TO PROVIDE A MINIMUM RISK 

COMPONENT QUALIFICATION PROGRAM: 

DIRECT EK TO-rgEniabRE P-rilD GROUND CONDITIONING TESTS (TEMPERA- 1A,f"--0 

rURE, HUMIDITY, ETC.) OF MM THERMAL MODEL. 

DIRECT EK TO PERFORM THE COA MODAL SURVEY WITH THE BARREL ATTACHED 

TO FIXED SUPPORTS AT THE THREE MOUNTING POINTS INSTEAD OF SUSPENDED A 

`v4r 

IN A FREE-FREE CONDITION. 

kb.S, 

1

(?-6":44.1341AAi s ' /1-4-5 \-1:1-1: 

--EpriveRer—SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

• 

D

, SECRET SPECIAL HANDLING 

SUMMARY RECOMMENDATIONS 

QUALIFICATION TESTING 

--\ 

42CT DA TO UT ZE ACO IC EXCITA ON RATHE 

TION FOR QUALIFYING HE COMPO NTS 0TH 

ARTMENT. (jcOMBINE wirji LM AC UST •UAL EST-IF 

-TED.) 

2. DIRECT GE TO DELETE INDIVIDUAL COMPONENT ACOUSTIC QUAL TESTING 

AS A GENERAL PRAC TICE (RETAIN COMPONENT VIBRATION QUAL '11 

TES TING. ) 

DIRECT GE TO DELETE THE PLANNED TM BAY VIBRATION QUAL TEST. 

DIRECT EK AND GE TO PERFORM THE TM BAY QUAL TEST USING 114E kt J5. DIRECT DAC TO PERFORM THE MM SHELL STRENGTH QUAL TEST COMBINING f-Z) 

DIFFERENTIAL PRESSURES WITH *ENDING MOMENTS. 

• • • 

THAN RANDOM 

LM UNP SSURIZED 

IF TTE 

• 

REVIEW THE POSSIBILITY OF CONDUCTING AN LM ACOUSTIC QUALIFICATION. 

SECRET SPECIAL HANDLING 
555 - 3 iKz.- 

el 1' 

SPECIAL HANDLING 

SUMMARY RECOMMENDATIONS 

NRO APPROVED FOR 

RELEASE 1 JULY.2015 

L 

DIRECT EK TO PERFORM A COA MODE VERIFICATION ACCEPTANCE TEST ON 

EACH FLIGHT ARTICLE. 

n SECRET SPECIAL HANDLING 

ACCEPTANCE TESTING 

DIRECT DAC TO PERFORM A T/V ACCEPTANCE TEST ON EACH LM; DELETE' 

T/V ACCEPTANCE TEST OF LV 

DIRECT GE TO PERFORM AN MMFS MODE VERIFICATION ACCEPTANCE TEST 

ON EACH FLIGHT VEHICLE. 

DIRECT DAC TO PERFORM ORBITAL PHASE MODAL SURVEY ON VV'S 3 & 6 

WITH THE MM DOOR REMOVED AND WITHOUT TRUSS. (CONSIDER DELETION 

OF TEST AFTER ANALYSIS OF DYNAMIC PERFORMANCE PREDICTIONS AND/ 

OR FOLLOWING REVIEW OF STV MODE SURVEY TEST RESULTS.) 

CONSIDER DELETION OF THE OPERATIONAL DYNAMICS ACCEPTANCE TEST 

AT ROCHESTER FOLLOWING ANALYSIS OF THE OV DYNAMIC PERFORMANCE 

PREDICTIONS AND THE PROPOSED TEST PROCEDURES. 

REJECT GE RECOMMENDATION THAT THE DAC AVE BE CHECKED OUT 

INDEPENDENTLY BEFORE MATING WITH GE LM AVE. 

REJECT DAC RECOMMENDATION THAT THE LM NOT BE CHECKED OUT PRIOR 

TO MATING WITH THE MM. 

REJECT THE GE RECOMMENDATION THAT THE MM BE CHECKED OUT AT 

DAC PRIOR TO MATING WITH THE LM. 

DIRECT DAC TO PROVIDE FOR RETENTION OF THE CAPABILITY FOR GE TO 

PERFORM BACKUP INDEPENDENT MPSS TESTING AFTER LV MATE. 

DIRECT EK TO SHIP FLIGHT CAMERA TO DAC, WITH OTHER EK LM/MP 

EQUIPMENT, FOR GE CONSOLES TEST AND INSTALLATION DURING LM 

ASSEMBLY. 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 D.4.2_6PECIA.L HANDLING 

ACCEPTANCE TESTING (CONTD) 

555- - 

PI 77 

11. DIRECT EK AND GE TO CONDUCT JOINT MM EMC ACCEPTANCE TEST AT 

ROCHESTER. 

REVIEW EK TEST PROPOSAL TO SEEK REDUCTION OF THE TIME PLANNED 

BY EK FOR THERMAL-OPTICAL ACCEPTANCE TESTS. 

13. DIRECT GE TO COMBINE COMPATIBILITY AND PERFORMANCE ACCEPTANCE 

TESTS AND TO PLAN FOR THE CONDUCT OF THE FINAL BASELINE ACCEPTANCE TEST ONLY ONCE. 

IMPROVE THE EK SCHEDULE FOR DELIVERY OF CABLES AND HARNESS FOR 

THE LMQTV TO DAC BY 1 SEPTEMBER 1968, AND THE OTHER EK LM/MP 

COMPONENTS FOR THE LMQTV BY 22 DECEMBER 1968. 

IMPROVE THE EK SCHEDULE FOR DELIVERY TO GE OF THE EK LM/MP 

COMPONENTS FOR THE FLIGHT VEHICLES BY SIX WEEKS. 

..s.r.64k-LP11—SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

0 3ECR1DT SPECIAL HANDLING 

MAJOR RECOMMENDATIONS AND IMPACT 

SECRET SPECIAL HANDLING 

tt --w 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

-43Eeltrif- SPECIAL HANDLING 

MAJOR RECOMMENDATIONS AFFECTING EK 

S5-5 - 3`/-2.- 

P7 7'7 

RECOMMENDATION 

O APPROVE MM ACOUSTIC FACILITY AT ROCHESTER 

O DELETE GROUND CONDITIONING TEST 

O USE TM BAY 114E FOR DEV. & QUAL. 

IMPACT ROM COST 

NEW 

FACILITY +$2.5 M 

ELIMINATE 

TEST & -$182 K 

FACILITY 

REDUCE 

AGE -$1. OM 

TEST 

SUPPORT 

REDUCT. -$500 K 

REDUCE 

SPARES -$200 K 

SPECIAL HANDLING 
niAJOR RECOMMENDATIONS AFFECTING GE 

555 - 3N4.1 

P 7 

NRO APPROVED FOR 

RELEASE 1 JULY 2015 

—S-Lrrltrr SPECIAL HANDLING 

RECOMMENDATION IMPACT ROM COST 

0 MODIFY TEST FLOW 

DYNAMIC QUAL VEH # 114E ELIMINATE 

(NO VIB QUAL OF 115) TEST -$100 K 

USE QUAL VEH #115 AS FV #4 ELIMINATE 

ONE SET -$5 M to 

GE-AVE $6.5 M 

ELIMINATE 

TEST -$70 K 

ELIMINATE 

TEST FIXTURE -$50 K 

O DIRECT GE TO DELETE MOST COMPONENT ELIMINATE 

DEVEL. & QUAL. ACOUSTIC TESTS TEST S -$100 K 

0 ELIMINATE PRE- QUAL EMC TEST AT DAC ELIMINATE 

VEH #115 

SUPPORT 

AT DAC -$100 K 

O REJECT GE PROPOSAL TO TEST MM ELIMINATE 

BEFORE LM/MM MATE SPECIAL AGE -$200 K 

n SECRET SPECIAL HANDLING 
NRO APPROVED FOR 

RELEASE 1 JULY 2015 

D CECRET SPECIAL HANDLING SS'S ?Y 2- 

MAJOR RECOMMENDATIONS AFFECTING DAC 

RECOMMENDATION IMPACT R. 0. M. COST 

O APPROVE LM ACOUSTIC FACILITY FACILITY 

MODIFICATION +$1. 0 M 

O CONDUCT LM ACOUSTIC TEST IN 

DAC FACILITY 

DEVELOPMENT 

QUALIFICATION 

TEST REDUC T. -$10 K 

TRANSPORT -$20 K 

A VE -NEW OR +$3 M to 

REFURB. LM +$20 M 

TEST INCR. +$50 K 

T EST INCR. +$250 K 

FIXTURE -$ 25 K 

ELIMINATION 

ELIMINATE 

TEST -$25 K 

ELIM. TEST -$500 K 

ELIM, CONTAM. 

TEST -$60 K 

ACCEPTANCE 

O COMBINE ACOUSTIC QUAL OF LM 

UNPRESSURIZED SECTION WITH LM 

O DELETE PRE-QUAL LV EMC TEST 

O T/V ACCEPTANCE OF LM INSTEAD OF LV 

ELIM. BUILD. 

MOD. -$150. K 

--Errtreft-LAI" SPECIAL HANDLING