KSC 2003 ANNUAL REPORT

2003

ANNUAL REPORT

TABLE OF CONTENTS

Center Director’s Message.............................................................. 1

NASA Vision and Mission ................................................................. 3

The President’s Management Agenda .......................................... 4

Significant Events ............................................................................. 6

Safety and Health First ..................................................................... 9

Build Reliance and Teamwork Everywhere ................................. 11

Satisfy Our Customers’ Needs Anytime, Anywhere .................... 13

Environmental Leadership ............................................................. 16

Space Shuttle Program .................................................................. 18

International Space Station and Payload Processing ................ 22

Future Launch Operations ............................................................. 25

Payload Carriers............................................................................. 28

Launch Services Program.............................................................. 29

Spaceport and Range Technologies ........................................... 32

Partnerships..................................................................................... 37

KSC Reservists Called to Serve ..................................................... 39

Columbia Recovery and Reconstruction .................................... 40

Education ........................................................................................ 43

Outreach to the World ................................................................... 45

KSC Business Report ....................................................................... 50

Economic Impact ............................................................... 51

Workforce Diversity............................................................. 53

Procurement Report ........................................................... 54
KSC 2003 ANNUAL REPORT

A MESSAGE FROM

THE CENTER DIRECTOR

1

With the loss of STS-107 and the Space

Shuttle Columbia in February 2003, the

public may have expected NASA and

the Agency’s John F. Kennedy Space

Center to stop meeting the challenges

of space exploration. However, the

challenge of restoring the Space Shuttle

program to safe flight serves as the

perfect platform for KSC to flourish.

As a Center built upon inspirational

visions, dedicated workers and an

unquenchable thirst for exploration, we

accept unexpected diversions as

opportunities to test our strength. With

our mettle now forged by fire, we’ll

succeed in the future by overcoming

challenges and leading the world in

space exploration.

Fiscal Year (FY) 2003 was marked by

amazing milestones, especially our

workforce’s dedication to our Core

Values and acceptance of our Guiding

Principles. This approach is a passion of

mine because a shared vision provides

a foundation for future success.

We excel because our inclusive setting

not only respects differences, but

treasures everyone’s unique qualities.

We recognize the importance of each

person’s contribution to the Center and

how their perspective only makes our

results richer. By avoiding stagnant

management, the Center’s leadership

is fluid, serving as a catalyst for endless

new ideas.

The safety of our workforce, astronauts

and public remains our top priority,

serving as the Center’s backbone.

Whether supporting an awe-inspiring

event or routine task, safety is always

the unifying factor in everything we do.

While the Center prompts many special

professional and personal bonds, I

realize our families are what are most

important in life and I never forget that.

We remain good stewards of the

environment by protecting the serene

National Wildlife Refuge. KSC is living

proof our world can continue

progressing while responsibly caring for

our resources.

None of these principles are successful

without serving our customers with

excellence at all times and relying on

teamwork to accomplish this important

task. Our truly collaborative approach

creates a productive stability.

When my leadership journey with KSC

began this fiscal year, I joined a

tremendous heritage. I intend to

continue this legacy by expecting much

from the workforce, thus ensuring we

meet the public’s expectations of

continuing our space exploration

journey for the benefit of humankind.

Through remarkable teamwork in FY

2003, KSC supported eight Expendable

Launch Vehicle missions, three Space

Shuttle launches and two landings,

International Space Station processing,

our reservists fighting the war on terror

and much more. Our future comprises

ambitious goals as well, including

returning our Space Shuttle fleet to safe

flight and developing new technologies

and future vehicles supporting the Vision

for Space Exploration.

As KSC continues tirelessly inspiring

future generations and exploring the

universe, we should all look forward to

KSC’s future impact on our world.

James W. Kennedy
KSC 2003 ANNUAL REPORT 2
3 KSC 2003 ANNUAL REPORT

NASA VISION & MISSION

The NASA Vision

To improve life here,

To extend life to there,

To find life beyond.

The NASA Mission

To understand and protect our home planet,

To explore the universe and search for life,

To inspire the next generation of explorers

 ...as only NASA can.

A spiral galaxy as seen from the

Hubble Space Telescope.
KSC 2003 ANNUAL REPORT

THE PRESIDENT’S

MANAGEMENT AGENDA

KSC fully embraces the President’s

Management Agenda (PMA) to

achieve NASA’s Mission as safely and

efficiently as possible. Within the PMA

framework are five initiatives used to

improve government performance. KSC

continues to fully support the Agency’s

implementation of these initiatives.

Strategic Management of

Human Capitol

NASA strives to attract and retain the

best and brightest scientists and

engineers. KSC is enhancing recruitment

efforts, increasing technology-based

training opportunities and establishing

and aligning student programs to assure

a future “pipeline” of employees. In FY

2003, KSC rolled out the Agency’s

Strategic Human Capital Plan and

hosted expos to discuss new initiatives

and demonstrate new human capital

tools to employees. KSC actively

participates in the NASA Corporate

Recruiting Program, including leading

the recruiting trip to the University of

Puerto Rico, and spearheading

additional KSC-specific recruiting trips.

Using competency management and

training and development strategies,

KSC is aggressively seeking ways to

optimize its workforce to facilitate

staffing for Return to Flight, Orbital

Space Plane, the NASA Engineering

Safety Center and other Agency

priorities.

Competitive Sourcing

In the framework of the NASA

Competitive Sourcing initiative, KSC is

working to achieve efficient and

effective competition between public

and private sources, and is meeting

competitive sourcing goals defined by

the Office of Management and Budget

(OMB). The Center completed its

Competitive Sourcing Plan and

exceeded the 15 percent OMB

requirement for FY 2003. Future plans for

KSC include providing specific support

for the upcoming competition for the

NASA Shared Services Center, an

approach for consolidating specific

NASA business and technical support

services.

Financial Management

Significant achievements included

implementation of the Integrated

Financial Management Program’s

(IFMP) Core Financial and Travel

Manager modules in February 2003;

supporting the audit of NASA’s FY 2003

financial statements by providing

financial data and analysis to

independent auditors and NASA

KSC 2003 ANNUAL REPORT 4
5 KSC 2003 ANNUAL REPORT

Headquarters; and working with the

Competency Center to support full

cost configuration in Core Financial for

FY 2004 operations. Progress continued

in addressing Core Financial

stabilization and data issues.

e-Government

KSC continued implementation of a

common network infrastructure for

NASA e-Gov activities, as well as

participating in federal e-Gov

initiatives. This year, KSC completed its

network infrastructure upgrade plan,

designed systems to support the One

NASA portal, and led an Agency-wide

pilot at seven NASA Centers for the

Agency Security Update System. KSC

also leads the One NASA ePresence

pilot, and implemented Phase 1 of the

NASA Management Information

System. In addition, KSC manages the

Agency’s Cyber Identity Management

System Project, and leads the Office of

Space Flight ODIN WebEx pilot.

Integrated Budget and

Performance

KSC prepared for implementation of

full cost accounting procedures in FY

2004. These included establishing a Full

Cost Team to implement full cost

practices at KSC; delivering a training

program for approximately 200 endusers; and updating and developing a

full cost budget submission for FY 2004

thru FY 2009. KSC also worked with

NASA Headquarters and the IFMP

program to standardize structures;

reconfigure the accounting system

and resolve operational issues; as well

as develop and deploy a program of

Change Management for the Center,

which included a “Full Cost 101 Road

Show” offered to all Center

employees.

Through this framework, KSC realizes its

strategic goals to assure and advance

access to space for exploration,

development and use; provide

innovative spacecraft and range

technologies for safe space operations

and exploration missions; and provide

and assure safe, world-class services.

KSC 2003 ANNUAL REPORT
KSC 2003 ANNUAL REPORT

SIGNIFICANT EVENTS

6

10/7/02 –STS-112/Atlantis launches to

deliver the S1 Truss to the International

Space Station, and attach it to the S0

Truss.

10/17/02 – The Tracking and Data Relay

Satellite-J (TDRS-J) arrives at KSC’s

Shuttle Landing Facility. The TDRS System

is the primary source of space-toground voice, data and telemetry for

the Space Shuttle.

10/18/02 –STS-112/Atlantis lands at KSC.

11/23/02 – STS-113/Endeavour launches

to transport the Expedition Six crew, and

deliver and attach the Port 1 Integrated

Truss Segment to the ISS.

12/4/02 - NASA’s third TDRS, TDRS-J, lifts

off from Cape Canaveral Air Force

Station (CCAFS), Fla., aboard an Atlas

IIA rocket.

12/6/02 – NASA chooses the Delta II

expendable launch vehicle, provided

by Boeing Launch Services, Inc., to

launch 19 NASA and NASA-sponsored

medium-class scientific payloads

between 2006 and early 2009.

12/7/02 –STS-113/Endeavour lands at

KSC.

12/17/02 – Final pieces for the Station’s

football-field-long backbone arrives at

KSC’s Shuttle Landing Facility.

1/12/03 – NASA’s Ice, Cloud and Land

Elevation satellite and Cosmic Hot

Interstellar Spectrometer satellite lift off

from Vandenberg Air Force Base (VAFB),

Calif., aboard a Delta II launch vehicle.

1/16/03 – Launch of STS-107/Columbia,

a microgravity research flight and an

Extended Duration Orbiter mission.

1/25/03 – NASA’s Solar Radiation and

Climate Experiment successfully

launches aboard a Pegasus XL rocket

from CCAFS.

2/1/03 – A Space Shuttle contingency is

declared in Mission Control, Houston, as

a result of the loss of communication

with the Space Shuttle Columbia at

approximately 9 a.m. EST as it

descended toward a KSC landing. No

communication and tracking

information are received in Mission

Control after this time. The STS-107 crew

members and Columbia are lost

because of a breach in the left

Reinforced Carbon Carbon wing

leading edge.
7 KSC 2003 ANNUAL REPORT

2/7/03 – Private KSC employee

memorial service occurs honoring the

departed STS-107 Columbia crew.

2/12/03 – Columbia Accident Investigation Board (CAIB) arrives at KSC.

2/24/03 – First of two Mars Exploration

Rovers, MER-2, arrives at Center from the

Jet Propulsion Laboratory in Pasadena,

Calif. The rovers serve as robotic

geologists to seek answers about the

evolution of Mars.

2/25/03 – Groundbreaking for the

second Operations Support Building

(OSB II). The site of the new six-story,

189,000-square-foot building is in the

Launch Complex 39 area near the

Vehicle Assembly Building.

3/6/03 – The Space Infrared Telescope

Facility (SIRTF) arrives at KSC for launch

preparations. On Aug. 25, SIRTF is

renamed the Spitzer Space Telescope in

honor of the late Dr. Lyman Spitzer Jr.

4/28/03 – NASA’s Galaxy Evolution

Explorer spacecraft launches from a

Pegasus XL rocket from CCAFS. The

mission features an orbiting telescope to

observe millions of galaxies across 10-

billion years of cosmic history.

6/1/03 – A major Station

component, NASA’s Node 2, arrives at

the Center. The European Space

Agency (ESA) in Italy built Node 2 for

NASA.

6/4/03 – A major Station component,

the Japanese Experiment Module (JEM),

arrives at KSC. The pressurized module is

Japan’s primary contribution to the

Station.

6/5/03 – KSC’s Web site celebrates its

first-time online coverage of an

expendable vehicle mission with the first

MER mission and its associated events.

6/10/03 – MER-A launches aboard a

Delta II launch vehicle from CCAFS.

6/18/03 – KSC ceremony highlights

arrival of Node 2 and JEM. The event

includes official transfer of ownership of

Node 2 between ESA and NASA.

7/7/03 – MER-B launches aboard a

Delta II launch vehicle from CCAFS.

7/7/03 – Several days of tours begin for

the workforce and their guests to view

Columbia debris. Experts are available

to provide information and answer

questions.
KSC 2003 ANNUAL REPORT 8

7/11/03 – NASA spacecraft, designed to

test two of Albert Einstein’s Theory of

General Relativity predictions, travels to

the VAFB launch site for the Gravity

Probe B mission.

7/15/03 – Flight demonstration tests KSCmanaged Space-based Telemetry And

Range Safety (STARS) at NASA’s Dryden

Flight Research Center demonstrating a

more effective, economical tracking

and communication technology.

7/28/03 – Two new security gates

complete the opening of Space

Commerce Park and a new roadway.

This provides an alternate route for the

general public between Titusville and

Merritt Island, Fla.

8/10/03 – James W. Kennedy becomes

8th KSC Director after serving as Deputy

Director since Nov. 2002. Gen. Roy D.

Bridges, former KSC Director, becomes

Director of the Agency’s Langley

Research Center, Hampton, Va.

8/12/03 – The Canadian Space

Agency’s Scientific Satellite Atmospheric

Chemistry Experiment launches aboard

an Orbital Sciences Pegasus XL at VAFB.

8/20/03 – The Center inaugurates the

Agency’s One NASA leader-led

workshops, helping employees better

understand the Agency’s overall

strategy and direction. One NASA is a

cultural change emphasizing a strong

commitment to teamwork, accessible

tools and a greater collaboration across

the Agency.

8/25/03 – The Spitzer launches aboard a

Delta II launch vehicle from CCAFS.

8/26/03 – CAIB releases its report on the

Columbia investigation. NASA

Administrator Sean O’Keefe accepts

CAIB Report recommendations and

findings.

9/17/03 – The Multi-Element Integrated

Test between the JEM and NASA’s

Node-2 is successfully completed inside

the Space Station Processing Facility.

9/23/03 – Atlantis continues

preparations for Return to Flight. Some

of the work includes reinstallation of the

Reinforced Carbon-Carbon panels on

the Shuttle’s wing leading edge, wiring

inspections, and checks of the Shuttle’s

engines in the Orbital Maneuvering

System.
KSC 2003 ANNUAL REPORT

SAFETY AND HEALTH FIRST

Addressing safety and health concerns

and continuously improving employee

wellness, the Center tirelessly supports its

top priority and one of KSC’s four

Guiding Principles — Safety and Health

First.

After a two-year endeavor, KSC

became Voluntary Protection Program

(VPP) qualified by the Occupational

Safety and Health Administration

(OSHA). The Center selected VPP to

ensure continuous safety and health

program enhancements, and

certification as a “Star” site constitutes

recognition as an exemplary safety and

health program. At least 78 percent of

KSC’s workforce, including two major

contractors, are VPP Star certified. The

Center is currently the only federal site in

the region (Florida, Georgia, Mississippi

and Alabama) VPP Qualified.

During the VPP certification audit, OSHA

representatives conducted formal and

informal interviews with civil servants,

gauging employee awareness and

involvement in KSC’s safety and health

program. OSHA representatives also

reviewed safety and health

documentation, and inspected work

sites verifying consistency and

compliance.

KSC not only complied with approximately 500 OSHA requirements, but

several areas were also recognized as

best industry practices. These included

the Center Director’s use of electronic

communications to the entire workforce

highlighting safety and health aspects,

such as employee and management’s

safety and health roles and responsibilities, employee rights such as “stop work

authority,” incident and close call

reporting, and unannounced monthly

workplace inspection results.

OSHA also noted the establishment of

“RehabWorks” (an on-site occupational

health rehabilitation center), employee

awareness and knowledge of VPP, the

Center’s Employee Safety and Health

Pocket Guide, and KSC’s Business World

Web site with safety and health links.

The annual Spaceport Super Safety and

Health Day increased awareness for

practicing “Safety and Health First” both

in professional and personal activities.

More than 120 exhibitors, located at

various Spaceport locations, offered

safety and health related information,

training sessions and demonstrations.

Activities also included astronaut

appearances, award presentations, a

health fair and KSC Fitness Centers’

open houses. 

9

Top: Promoting wellness, the annual Spaceport Super

Safety and Health Day included a blood pressure

check station.

Right: Spaceport Super Safety and Health Day offers

the workforce informative presentations and exhibits

to reinforce safe and healthful behaviors.
KSC 2003 ANNUAL REPORT

KSC’s Occupational Health Program

continuously promoted employee

wellness throughout the year with

activities such as Fitness Center events,

physical exams, inoculation programs,

health education and screening

programs and the Employee Assistance

Program (EAP). During the fiscal year,

employees made more than 3,000

RehabWorks visits and 88,741 KSC Fitness

Center visits. The Fitness Centers offered

motivational programs such as the

President’s Adult Active Lifestyle award,

which promoted physical fitness.

Screening programs include

cardiovascular disease risk reduction

and breast and colorectal cancer

screenings. An employee health and

fitness day taught employees about

community health and wellness

programs and provided health

screenings, as well as nutrition and

exercise counseling. Additionally, the

workforce can receive free flu shots as

well as counseling services through the

EAP.

10
KSC 2003 ANNUAL REPORT

BUILD RELIANCE AND

TEAMWORK EVERYWHERE

11

As we strive for mission success in all our

endeavors, our dependence on one

another to provide services is critical.

Therefore, KSC builds upon its strengths

in reliance and teamwork and commits

to completing opportunities for

improvement consistent with the

Center’s Guiding Principle to Build

Reliance and Teamwork Everywhere.

These efforts assure future strategic

goals of KSC and the Agency are

realized.

Perhaps the most poignant display of

the Center coming together in the

fiscal year was the STS-107 Space

Shuttle Columbia recovery project. To

collect debris, 870 KSC civil servants

and contractors helped with the tasks

in East Texas. Workers searched a

ground area corridor 250-miles-long by

10-miles-wide. About 38 percent of

Columbia’s dry weight was recovered.

Additional in-depth information about

the loss of Columbia and its crew can

be found throughout this document.

Last year, the Senior Management

Team reviewed the Center-wide KSC

Reliance and Teamwork Survey;

subsequently, a One KSC Team formed

to address feedback results. This team

initially focused on a targeted

approach to achieving One KSC and

making changes to make reliance and

teamwork a way of life at the Center.

In addition to One KSC, the Agency

initiated One NASA, a cultural change

emphasizing a strong commitment to

teamwork, accessible tools and a

greater collaboration across NASA.

Selected by NASA Headquarters, KSC

hosted the first One NASA leader-led

workshop Aug. 20, a direct response to

workforce feedback. One NASA also

introduced key leaders from other

enterprises participating in Center

workshops. KSC Director James

Kennedy visited the Jet Propulsion

Laboratory Oct. 16-17 to participate in

its One NASA activities, including a town

hall meeting.

KSC 2003 ANNUAL REPORT

NASA worker Joy Huff (right) shows Stafford-Covey

Return to Flight Task Group members a wing leading

edge subsystem bonded to tile.
KSC 2003 ANNUAL REPORT

U.S. Forest Service members walk a grid during a

Columbia Recovery search near the Nacogdoches,

Texas site. A space program worker able to identify

potential hazards of Shuttle parts accompanies the

group.
13 KSC 2003 ANNUAL REPORT

SATISFY OUR

CUSTOMERS’ NEEDS

ANYTIME, ANYWHERE

Integral to KSC’s strategic planning is

building and maintaining customer

satisfaction through relationship

management. Satisfying Our Customers’

Needs Anytime, Anywhere is one of

KSC’s four Guiding Principles. The

Customer Assurance and Analysis Office

serves as an independent advocate for

systematically managing customer

knowledge and feedback to develop

strategies for improvement and new

opportunities.

The ultimate goal is to ensure a

customer focused culture with

customers consistently choosing KSC as

their launch site. To achieve this, our

core customers use customer

satisfaction data to drive change and

lead continuous improvement. KSC’s

core customers are Launch Services

Program (LSP), Shuttle/International

Space Station (ISS) and Spaceport

Engineering and Technology.

The LSP acquires commercially

available ELV launch services for NASA

and its customers. LSP ensures mission

success, provides low cost services on

time and maximizes customer

satisfaction. LSP improvements include

a Launch Services Connections

newsletter and a new launch services

mission budget policy. Responding to

customers’ requests, these additions

facilitate additional communication,

thus educating customers on financial

regulations, launch services, outreach

materials and more.

The Shuttle Processing Directorate

prepares the Space Shuttle for safe and

successful missions. The ISS/Payload

Processing Directorate identifies and

satisfies ground processing and support,

as well as test and integration

requirements, ensuring a successful

mission. Shuttle/ISS Improvements

include updating the Directorate

Information Technology Policy,

publishing a Payload Processing Guide,

and documenting standard/

nonstandard international customer

services. There is an ongoing effort to

update customer orientation packages

and establish a single point of contact

for communicating capabilities and

requirements.

The Spaceport Engineering and

Technology Directorate provides

innovative and integrated solutions to

complex technical problems with

customer satisfaction as a priority. New

to this effort, the directorate established

its customer base. The directorate will

use both internal and external customer

feedback to improve processes and

customer support.
KSC 2003 ANNUAL REPORT

With cables released, the first of two Mars

Exploration Rovers sits on the floor of

the Payload Hazardous Servicing Facility.
KSC 2003 ANNUAL REPORT

An owl is held

just before its release.
KSC 2003 ANNUAL REPORT

ENVIRONMENTAL

LEADERSHIP

Launch Complex-34 areas were

polluted during the space program’s

early history when DNAPLs cleaned

Apollo rocket parts. Because DNAPLs

tend to sink to the bottom of the water

table and collect in pools, these solvents

can contaminate fresh water sources

when left untreated in the ground.

Methods to clear up this potential

problem are bio-augmentation, which

degrades some environmental

contaminants through the addition of

nutrients, and Emulsified Zero-Valent Iron.

This approach uses environmentally

friendly oil and water to neutralize

DNAPLs. Micro-organisms are also

added, rendering contaminating

chemicals harmless.

A Florida Power and Light (FPL)

alternatively financed project remedied

some of the Center’s inefficient energy

operations. FPL provided a loan for upfront project costs and KSC uses energy

bill savings generated by the project for

financing.

Projects in the high bays of the Space

Station Processing and Operations and

Checkout facilities produced significant

energy savings of about $500,000

annually. A Payloads/Station Team

reduced heating, ventilation and air

Situated on 140,000 acres, that include

a wildlife refuge, the Center continues

to operate in the ultimate marriage of

nature and technology. KSC spent the

fiscal year preserving and improving

that union.

The Merritt Island Spaceflight Tracking

and Data Network won the Federal

Energy and Water Management Award.

It was chosen by the Department of

Energy for its long-term efforts to

improve energy efficiency at the

tracking and data relay station. This

group saved KSC approximately

$100,000 annually in energy bills.

Thousands of sites across the world are

contaminated with dense, non-aqueous

phase liquids (DNAPLs). DNAPLs

commonly come in the form of cleaning

solvents. KSC implemented new cleanup technologies to help fight this battle.

KSC 2003 ANNUAL REPORT 16

Nature thrives with technology as seen in this photo

of the Vehicle Assembly Building and surrounding

grounds and water. In the foreground, perched on a

plant, is an anhinga—a common Center inhabitant.
KSC 2003 ANNUAL REPORT

conditioning system energy costs to onetenth the previous levels while improving

temperature and humidity conditions.

The team received a 2002 KSC

Environmental & Energy Bi-Annual Award

for their success.

Similarly proactive, KSC’s Energy Working

Group provided educational

opportunities, making the workforce

knowledgeable about energy

efficiency. Included were tours of KSC’s

largest mechanical equipment room

and the Central Heat Plant, covering

topics such as resourcefully maintaining

critical work conditions.

Learning about Earth-friendly personal

and professional practices was

stimulated by Environmental and Energy

Awareness Week (EEAW) traveling

presentations, tours, seminars and

exhibits.

Dr. Stuart D. Strahl, President/CEO of

Audubon of Florida, spoke at the EEAW

Opening Ceremony. Audubon works to

ensure that conservation becomes a

common interest in Florida rather than

being relegated to a special interest

group. Audience members learned the

importance of discovering and

protecting Florida’s environmental

diversity.

Supporting environmentally friendly

transportation, employees inspected an

Alternative Fueled Vehicle and Global

Electric Motorcar (GEM). The workforce

also test-drove a Segway Human

Transporter, and discovered using the

device is as natural as walking.

Providing an opportunity to put

knowledge to use, Amnesty Days

allowed KSC workers to dispose of

unwanted government chemicals

excluding biohazardous, radioactive or

explosive materials. In all, 20,166 pounds

of excess materials were collected.

Furthermore, KSC is home to some 25

threatened and endangered species,

both permanent residents and annual

migratory types. The U.S. Fish and

Wildlife Service manages the Center’s

land. Efforts to increase population and

habitat usage included controlled

burning, wetlands enhancement and

exotic, invasive plant removals. These

species continue to use KSC lands for

wintering, spawning and thriving.

17 KSC 2003 ANNUAL REPORT

New methods of environmental cleanup are explained at Launch Complex 34A.
KSC 2003 ANNUAL REPORT

SPACE SHUTTLE PROGRAM

18

Although STS-112 (launched 10/07/02)

and STS-113 (launched 11/23/02) were

processed and launched during FY 03,

the tragic loss of Columbia and her

seven-member crew prior to landing

Feb. 1, 2003, brought Space Shuttle

launch activities at KSC to a halt. The

loss changed the focus of processing

activities to support the investigation.

For the next several months, KSC and

contractor workers were involved in

Columbia debris recovery and

reconstruction efforts and Columbia

processing reviews, and they assisted

the Columbia Accident Investigation

Board in determining the root cause of

the accident.

NASA and contractor workers

concentrated on implementing process

improvements, performing upgrades to

the remaining fleet of orbiter vehicles

and developing new processes,

hardware and tools to comply with CAIB

recommendations to prepare the

orbiters for Return to Flight.

With a renewed emphasis on safety and

reliability, a number of new processes

and upgrades were implemented at

KSC to support future Space Shuttle

missions.

Shuttle Processing and Return to

Flight Activities

As part of Return to Flight activities and

in consideration of CAIB recommendations, Non-Destructive Evaluation (NDE)

testing was performed on all orbiter

vehicle Atlantis (OV-104) wing leading

edge Reinforced Carbon Carbon (RCC)

panels. Insulator hardware was disassembled, and Atlantis’ wing leading

edge RCC panels were shipped to

Lockheed Martin Missiles and Fire Control Division to re-perform the original

NDE testing and visual inspections. KSC

Logistics packed and shipped the

panels, and developed and coordinated turnaround schedules to support

the upcoming launch schedule. Attachment hardware for wing leading edge

reinstallation and panel reassembly

were identified and procured.

Spaceflight Operations Contractor

United Space Alliance (USA) and NASA

The afternoon sun casts a shadow on Space Shuttle

Atlantis as it launches on its journey to the

International Space Station (STS-112).
19 KSC 2003 ANNUAL REPORT

continuously improve risk-management

decisions regarding ground operations.

The latest improvement uses the Process

Failure Modes and Effects Analysis

(PFMEA) tool to analyze a process. The

objective of PFMEA is to document

potential failures that could occur

during a particular process and to

recommend actions to eliminate the

failure mode or control the hazard. The

analysis quantifies risks to personnel

safety, flight hardware and schedule

delays. The PFMEA tool was used to

complete more than 13 assessments this

year.

KSC Shuttle Processing implemented an

updated electronic logbook (ELOG) to

disseminate information between

Shuttle Processing engineering, quality

and operations personnel and other

Space Shuttle program projects on a

daily basis.

ELOG’s future uses include surveillance

database modules for Shuttle Processing

Engineering and Safety & Mission

Assurance, closed-loop accounting of

surveillance plans and generating

surveillance metric reports.

In conjunction with Agency experts, KSC

Shuttle Processing successfully

completed the inspection of Main

Propulsion System Propellant Feed Line

Ball Strut Tie Rod Assembly (BSTRA)

components following the observation

of a cracked BSTRA ball in Discovery

(OV-103). The inspection required

development of new tools and

techniques at KSC and a multi-Center

failure analysis investigation. KSC

developed new procedures resulting in

the execution of the first-ever removal of

a 17-inch (diameter) liquid oxygen

propellant feed line from Discovery in

order to return it to the vendor for repair.

USA accomplished a substantial

procedural improvement by utilizing the

Boeing Delta Mariner facility at Port

Canaveral. Starting with the delivery of

External Tank (ET)-119, the ET Barge,

temporarily moored at the facility, is

transported up the Banana River to the

newly developed temporary mooring

site at the Vehicle Assembly Building

basin, allowing for easy ET offload.

During launches, the barge is moved to

the VAB turn basin, eliminating the need

for towing back to Port Canaveral and

returning after launch. The combined

use of the Boeing Delta Mariner facility

and the temporary VAB mooring site

resulted in savings of more than $40,000

on each delivery.

A team of KSC engineers and

technicians and the Cryogenics Test

Laboratory developed a safe and

reliable technique to isolate a column of

liquid oxygen behind a plug of frozen

liquid precision-cleaning agent (Freon).

The technique permitted successful

replacement of a cracked gasket in a

liquid oxygen block valve at Shuttle

Launch Pad 39A without draining (and

potentially wasting) thousands of gallons

of liquid oxygen. The technique will

undergo further development for use on

larger line sizes with different fluids. A U.S.

patent is pending.

Upgrades

A new Space Shuttle Main Engine

(SSME) horizontal handling truck arrived

to supplement the single truck in service

since the beginning of the program. The

new truck features an updated design,

increased capabilities and improved

portability for support of SSME removal in

the event of a Trans-Atlantic Landing.

During performance of normal

refurbishment programs on Crawler

Transporters 1 and 2, failed bearings

were found on the jacking and leveling

cylinder bearings. USA ground

operations engineering removed and

replaced 64 bearings on each of 32

cylinders, which weighed 10,000 pounds

each. Extensive modifications to the

Crawler Transporter 2 cab and exhaust

system were also completed during the

window provided by Return to Flight

activities.
KSC 2003 ANNUAL REPORT

Workers in the Orbiter Processing

Facility remove one of two Orbiter

Maneuvering System pods from

Endeavour.
KSC 2003 ANNUAL REPORT

Infrastructure Improvements

and Modifications

FPL and the Shuttle Program completed

the largest energy conservation project

in KSC history with no up-front cost to

the taxpayer. The project, which in total

addresses $3.2 million worth of energy

efficient upgrades and revitalization,

was financed by FPL with loan

payments repaid completely from the

accrued savings. The project earned

KSC the Department of Energy’s

“Energy Champion” award as NASA’s

most outstanding initiative for the year.

For the first time in KSC history, a

detailed account of energy transferred

in the form of chilled and hot water is on

the horizon. A Center-wide project,

begun this year, will provide instrument

readings (in BTUs) from KSC’s north and

south ends. Installation of ultrasonic flow

measurements at key locations will tie

them into the Kennedy Complex

Control System (KCCS) through the

Ethernet. Completion of this

measurement project, in conjunction

with ongoing KCCS installations, will

place KSC at the forefront of all NASA

Centers in network-based facility

management.

KSC recruited nationally recognized

technical experts from the Department

of Energy to develop projects for energy

savings opportunities. These audits, as

well as those performed in-house by the

Shuttle Program and FPL, form the basis

for future energy reduction initiatives.

Future projects may include additional

Launch Complex 39-area generation

capability and software-based load

control.

Following the loss of Columbia,

infrastructure modifications continued

at Launch Pads 39A and 39B. Pad A

projects included upgrades to the

following:

• Orbiter Mid-body Umbilical Unit

Support System,

• Corrosion Control and Pneumatic

Tubing Replacement,

• Slidewire System Cable

Replacement, and Rotating Service

Structure Elevator Control System

Upgrade,

• Payload Ground Handling

Mechanism Enhancement

Modification including Stem Strain

Modification, and

• Engine Service Platforms “Frog” Rails

repair.

Pad B modifications included:

• Corrosion Control of the Rotating

Service Structure,

• Payload Change-Out Room Door

Repair, and

• New Hydraulic Power Unit fuel

servicing carts fabrication testing

and validation.

21
KSC 2003 ANNUAL REPORT

INTERNATIONAL

SPACE STATION AND

PAYLOAD PROCESSING

KSC’s Space Station Processing Facility

(SSPF) is one of the world’s most unique

processing resources. It is home to all

Station elements prior to launch from

KSC on their journey to the International

Space Station (ISS). It is inside this facility

that Station assembly components from

U.S. and international partners are

received, tested, integrated and

validated, in preparation for their final

destination. Reflight carrier elements,

which are required for logistics and

science resupply and return-to-earth,

are processed here. In addition, the

SSPF supports the final integration and

checkout of ISS science prior to flight.

KSC currently houses 10 Station

elements, in various processing and

testing stages. As NASA looks forward to

Return to Flight in 2004, planning and

processing for the third phase of Station

assembly has begun.

During the fiscal year, the Center

completed its third Multi-Element

Integration Test (MEIT 3), which included

the European-built Node 2 module, the

Japanese Experiment Module (JEM)

Kibo Pressurized Module and an ISS

simulator. MEIT 3 required assembly of an

integrated international and multiCenter/contractors team at KSC, and

proved the hardware/software

relationships of these elements met

requirements.

To accomplish the test, multiple cables

were connected between the two

modules and the on-orbit Station

emulator, providing electrical power,

data, command, and cooling to

validate the compatibility of the systems.

Test results confirmed that both modules

would interact properly when delivered

and attached to the Station. On future

ISS missions, Node 2 will be attached to

the U.S. Lab Destiny and the JEM “Kibo”

module will be attached to Node 2.

Following delivery of Node 2 from Italy,

an integration systems test was

completed successfully. This included

emulating the Space Station on-orbit

configuration, testing the command and

tracking systems that support the audio

and video systems on-orbit, and the

caution and warning systems that

monitor life support systems in the

module.

Additional significant ISS elements

processed for ISS missions included:

• Starboard 1 Integrated Truss segment

for Mission STS-112

• Port 1 Integrated Truss segment for

Mission STS-113

KSC 2003 ANNUAL REPORT 22

Astronaut Soichi Noguchi (left), with the Japanese

Aerospace Exploration Agency, examines data during

a Multi-Element Integrated Test of the U.S. Node 2

and the Japanese Experiment Module in the Space

Station Processing Facility.
KSC 2003 ANNUAL REPORT

STS-113 astronauts Michael Lopez (red stripe)

and John Herrington service the newly installed

International Space Station Port One truss
KSC 2003 ANNUAL REPORT

• Starboard 6 Truss segment, final

sections of the Station’s truss system,

arrived at the SSPF for testing and

validation for a future Station mission.

Columbia Recovery Support

The ISS and Payloads Processing team

supported the recovery and

reconstruction of Columbia. At the KSC

Columbia debris hangar, experienced

payload engineers combed through

debris to separate and identify payload

and experiment hardware. Amidst the

payload debris, the team found intact

experiment samples that contained

valuable science.

The Biological Research in Canisters

(BRIC) experiments still contained living

worms and moss growth. The Zeolite

Crystal Growth Furnace (ZCG)

contained crystal samples, and the

Commercial ITA, Inc. Biomedical

Experiment (CIBX) still held samples of

an experiment that might yield new

anti-cancer drug delivery systems.

The BRIC experiment yielded two

surviving types of samples. First, living C.

Elegan worms were recovered from

canisters on April 28, 2003. Since the

worms have only a seven to ten day life

cycle, it was determined they were

fourth or fifth generation descendants of

the worms launched on STS-107.

Second, researchers found moss intact

with growth patterns that will enable

researchers to learn how gravity and

light affect cell organization. BRIC was

able to download temperature data

recorded on three data loggers,

including temperatures recorded while

on the ground in Texas.

Liquid was extracted from the ZCG

Furnace autoclaves thought to still

contain Zeolite crystals flown in zero

gravity that could be recovered later in

the lab. The durable and complex

crystals are known for their high

adsorption properties and are often

used as catalysts in petroleum and

pharmaceutical industries.

Samples recovered from the CIBX-2,

that studied developing technology for

drug delivery systems to combat

cancerous tumors and cancer

metastasis, revealed

microencapsulation. The drug delivery

technology uses co-encapsulation of

antibodies and immune stimulants into

micron microcapsules.

KSC 2003 ANNUAL REPORT 24

Technicians supervise the transfer of the Integrated Equipment Assembly, a major component of the

International Space Station’s Starboard 6 truss segment.
25 KSC 2003 ANNUAL REPORT

FUTURE LAUNCH

OPERATION

KSC 2003 ANNUAL REPORT

The Center workforce looked forward this

year and positioned KSC for future

launch operations.

The Space-Based Telemetry And Range

Safety (STARS) project demonstrated a

space-based platform’s Range Safety

and Range User capabilities for various

launch vehicles. Range Safety includes

flight-termination processing from both

space and ground resources and

vehicle tracking using the Global

Positioning System satellites. Range User

includes high-return link data rates for

voice, video and vehicle data. The brain

of STARS, is known as the Command and

Data Handler. Estimates show that these

new methods could reduce costs by up

to $40 million per year.

Much of the STARS hardware was put to

the test during the fiscal year. The trials

exercised the equipment as it will be

used during flights. These tests prepared

for Flight Demonstration 1, which

analyzed different functions, capabilities

and environments. This was a “high

dynamics” flight with STARS hardware

and antennas located in an F-15B

aircraft. At NASA’s Dryden Flight

Research Center in California, the

aircraft performed the dynamic

maneuvers to determine antenna

coverage.

The latest in ground-based operations,

launch and payload check-out

automation systems were demonstrated

as well, using a combination of flight

qualification and ground hardware. The

Advanced Checkout, Control and

Maintenance System (ACCMS)

optimizes ground resources and

processes needed to meet possible

Reusable Launch Vehicle (RLV)

turnaround goals, safety standards and

efficiency objectives.

This technology will help alleviate the

complexity of many time-consuming

personnel tasks, automate routine tasks

and reduce organization support

requirements. Most significant for RLV

operations, ACCMS will reduce risk and

time associated with unplanned

maintenance activities.

Additionally, Sierra Lobo, Inc., a

contractor supporting KSC’s efforts, won

NASA’s Small Disadvantaged Business

Prime Contractor Award. The Ohiobased company was recognized for its

Densified Propellant Management

System contract work. The densified

propellants project is considered an

“enabling technology” for some RLVs

because it can decrease vehicle mass.

Another KSC effort is the Operations

Concept Development (OCD). The OCD

turns operational concepts into

transportation elements. It clarifies

system operations, requirements, ideas

and boundaries. KSC’s significant OCD

expertise included pre-launch

processing, launch operations, landing

operations and system design.

KSC also supported the Lessons Learned

Database. This key development
KSC 2003 ANNUAL REPORT 26

Members of the Space-based Telemetry and Range Safety project support a flight demonstration, which tested

hardware on an F-15B aircraft.

captures knowledge from previous and

existing human space flight programs

and dozens of space flight experts.

To maximize industry’s creativity and

technical proficiency, NASA defined

necessary capabilities for a potential,

new transportation system. KSC also

provided technical leadership. The

Center assessed these requirements that

will ensure final contractor products

have the integrity needed to progress.

KSC completed seven trade studies to

determine feasibility of future operation

requirements, supported a Systems

Requirements Review milestone,

compared various spacecraft

concepts, and provided data for the

future evaluation of contractor

proposals. The Center also began two

trade studies analyzing facility, launch

site and control center requirements.

KSC also supported a Marshall Space

Flight Center acquisition project by

contributing Ground Operations,

Ground Processing Systems, Integrated

Logistics Support, and Ground

Operations Training sections for the

Alabama-based Center’s drafting

process.

The Launch Services Program (LSP) is

integrally involved in these efforts, as

well. LSP workers, including contractors,

provided and analyzed ELV data

supporting concept development

efforts. The LSP also evaluated

modifications required for existing ELV

designs and launch complexes.

Additionally, the LSP is participating in

human and risk analyses and continuing

development of independent and

reliable ELV modeling capabilities.
29 KSC 2003 ANNUAL REPORT

International Space Station elements are

processed for future Space Shuttle flights.

The JEM pressurized module and the

U.S. Node 2 are a few of the elements

that line the SSPF’s high bay walls.
KSC 2003 ANNUAL REPORT 28

PAYLOAD CARRIERS

Program Improvements

The Payload Carriers Program continued

efforts to improve carrier support for

International Space Station payloads

and initiated structural rework of the

Lightweight Multi-Purpose Experiment

Support Structure to provide required

support for Return to Flight activities.

A study by Kansas State University to

determine the useful life of payload

carriers was expanded to document all

payload carriers throughout NASA. The

database expansion provides corporate

memory to future generations of the

science community for delivery systems.

It also provides life expectancy analysis

capability for each individual carrier, as

well as the fleet. These analyses allow

informed carrier selection and cost

estimation decisions.

The NASA/Boeing Launch Services

Simulation and Analysis Laboratory

(LSSAT) team developed an innovative

strategy and integration tool used to

analyze payloads and achieve the best

use of carrier space for payloads to be

installed in the Shuttle. The tool

incorporates precise 3-D modeling and

real-time simulation.

KSC’s LSSAT was recently recognized by

the National Systems Training

Association as the best application in

2002 for Modeling and Simulation

Analysis. The tool has the potential for

future applications in other programs

including ELVs.

Mission Support

Payload processing support was

provided for mission STS-107. Experiments

supported by payload carriers in the

Shuttle’s payload bay included the Fast

Reaction Experiments Enabling Science,

Technology, Applications and Research

(FREESTAR) Hitchhiker, which comprised

six experiments.

The program supported the CAIB by

providing flight hardware identification,

flight documentation support and

personnel interviews during debris

recovery and reconstruction efforts.

The U.S. Node 2 moves toward a workstand in the

Space Station Processing Facility. The Italian-built

component is the second of three ISS connecting

modules.
29 KSC 2003 ANNUAL REPORT

LAUNCH SERVICES

PROGRAM

During the year, LSP managed the

launch of eight missions, including two

powerful new Mars Exploration Rovers

(MER) that traveled to the red planet

aboard Delta II launch vehicles. MER-A

“Spirit” launched June 10, 2003, and

MER-B “Opportunity” launched July 7,

2003. The identical rovers reached Mars

in January 2004 and are exploring

different areas of the planet’s surface in

search of evidence of water that may

have been present in the planet’s past.

TDRS-J, the second TDRS of three,

launched aboard an Atlas IIA launch

vehicle Dec. 4, 2002. TDRS-J will provide

improved communications to the Space

Shuttle, ISS, Hubble Space Telescope

and other Earth-orbiting satellites well

into the 21st century.

NASA’s Ice, Cloud and land Elevation

Satellite (ICESat) and Cosmic Hot Interstellar Plasma Spectrometer (CHIPSat)

launched Jan. 12, 2003, aboard a Delta

II. ICESat is the benchmark Earth Observing System mission for measuring ice

sheet mass balance, cloud and aerosol

heights, as well as land topography and

vegetation characteristics. CHIPSat, a

University-Class Explorer mission funded

by NASA, will use spectroscopy to study

very hot plasma believed to fill the local

interstellar bubble.

The first time a spacecraft was mated at

KSC to an ELV occurred inside the MultiPayload Processing Facility Jan. 15,

2003. The Solar Radiation and Climate

Experiment (SORCE) vehicle was mated

to the Pegasus XL during pre-launch

processing. A successful launch aboard

Pegasus Jan. 25 sent SORCE to orbit the

Earth and provide accurate

measurements of solar energy.

NASA’s Galaxy Evolution Explorer

(GALEX) launched April 28, 2003, from a

Pegasus XL vehicle. GALEX, an

ultraviolet imaging and spectroscopic

surveyor, will map the global history and

probe the causes of star formations and

their evolution.

Scientific Satellite Atmospheric

Chemistry Experiment (SCISAT-1/ACE),

the first Canadian scientific small

satellite in more than 30 years, launched

aboard a Pegasus XL vehicle Aug. 12,

2003, from VAFB. SCISAT’s two-year

mission will monitor and collect

information about Earth’s ozone

providing improved measurements and

understanding of the chemical

processes that control the distribution of

ozone in the Earth’s atmosphere,

particularly at high altitudes.
KSC 2003 ANNUAL REPORT

 The Mobile Service Tower begins to

 roll back at Cape Canaveral Air Force

 Station’s Launch Complex 17B,

 revealing the Delta II Heavy launch

 vehicle carrying the rover

“Opportunity” on the second Mars

Exploration Rover mission.
KSC 2003 ANNUAL REPORT

Another milestone was reached when

the Spitzer Space Telescope (formerly

SIRTF) launched on a Delta II ELV Aug.

25, 2003. Spitzer, named for Dr. Lyman

Spitzer Jr., one of the 20th century’s most

distinguished scientists, is the largest

infrared telescope ever launched into

space and the last of four missions in

NASA’s Great Observatories Program.

Previous missions included the Hubble

Space Telescope, the Compton

Gamma-Ray Observatory and the

Chandra X-Ray Observatory.

At any given time, KSC’s LSP manages

30 to 40 current and future ELV missions.

The LSP team works with other NASA

Centers—Jet Propulsion Laboratory:

Marshall Space Flight Center in

Huntsville, Ala.; and Goddard Space

Flight Center in Greenbelt, Md.—to plan

and process NASA’s scientific, research

and communications spacecraft for

launch on ELVs.

Missions involve multi-year planning and

development between KSC’s program

office and NASA Centers. Ground

Operations, Payload Safety and Mission

Integration Working Groups are involved

in planning and processing for all

launches. Facilities at KSC and VAFB in

Calif. are used to process payloads and

launch vehicles. Facilities outside NASA,

such as Astrotech in Titusville, Fla. and

Spaceport System International in

Lompoc, Calif. are sometimes used to

process payloads.

As the year winds down, the Launch

Services team prepares for future

Eastern and Western Range launches.

Mission Integration and Ground

Operations Working Groups continue to

monitor planning and processing of

vehicles and spacecraft. Among future

scientific missions are Aura, NASA’s

follow-up mission to Aqua and a key

part of the Earth Observing System;

SWIFT, a mission that will study the

“afterglow” of gamma ray bursts; and

the Geostationary Operational

Environmental Satellite (GOES-N) that

will launch aboard NASA’s first flight of

Boeing’s Delta IV launch vehicle.

Future planetary missions include the

MErcury Surface Space ENvironment

GEochemistry Ranging (MESSENGER)

spacecraft that will fly by and then orbit

the planet Mercury to conduct the first

study of the planet; and Deep Impact,

a mission that will use an infrared

spectrometer to study a comet.

31
KSC 2003 ANNUAL REPORT 32

SPACEPORT

AND RANGE

TECHNOLOGIES

Continuously electrifying NASA’s

technology efforts, KSC made several

contributions this year in areas of

applied research & development,

engineering development and

laboratory services.

R&D Magazine selected a KSC

researcher as the recipient of the

prestigious “R&D 100 Award” for the

product, “Flexible Aerogel

Superinsulation.” R&D considered the

creation to be one of the most

technologically significant products of

the year. This is the first such award won

by KSC.

Water intrusion into Space Shuttle

Thermal Protection System tile is an old

problem. During ascent, water can flash

off, potentially causing tile damage.

Due to this concern, for many years

heat lamps were used for hours on end

to dry out tiles in case an orbiter was

exposed to rain. Rectifying this tedious

task, KSC developed a method to

detect water intrusion in tile, as well as a

method for water removal using a small

vacuum system attached to existing

waterproofing holes.

KSC laboratories provided critical

support to the CAIB. This included

working in both the hangar and the

laboratories providing real-time failure

analysis, metallurgical and chemical

support. Activities included developing

an X-ray dot map of slag harvested

from Reinforced Carbon Carbon

leading edge wing debris using a

scanning electron microscope and

energy dispersive X-ray spectrometer, as

well as development of lexan wing

models for display of the RCC debris.

 A KSC research and development

team used a new hazardous gas

detection system to study Costa Rican

volcanic emissions. The new prototype

system, Aircraft-based Volcanic Emission

Mass Spectrometer (AVEMS), also

applies to the Space Shuttle program. It

is a step toward an advanced system

that detects toxic gas leaks and

emissions in Space Shuttle engine and

crew compartments, providing an

added level of protection. From air and

the volcano’s crater, the team analyzed

gases vented from Costa Rica’s

Turrialba volcano. The study was the first

to sample and quantitatively analyze

fresh volcanic gases in their natural

state. The new system shows

commercial promise and could be used

for breath, blood and workplace air

quality analyses.

NASA, the National Oceanic and

Atmospheric Administration (NOAA)

Dr. Richard Arkin records data as the

hazardous gas detection system

Aircraft-based Volcanic Emission

Mass Spectrometer analyzes the toxic

gases produced by Costa Rica’s

Turrialba volcano. The system detects

toxic gas leaks and emissions in the

Shuttle.
33 KSC 2003 ANNUAL REPORT

NASA, the National Oceanic and

Atmospheric Administration (NOAA)

and other ocean scientists studied and

mapped deep-sea corals off Cape

Canaveral’s shore. A multi-beam sonar

system provided the first high-resolution,

3-D map of the Oculina Banks. Formed

by a single species of coral, Oculina

Banks’ deep coral reefs occur no where

else on Earth.

NASA, NOAA, the Navy, the Coast

Guard, and the Florida Fish & Wildlife

Commission performed underwater

acoustic research involving sensor

technology demonstrations studying

fields ranging from marine biological

research to homeland security. The work

also served as a pilot project assessing

the agencies’ cooperation.

This is the fourth consecutive year KSC

earned more Space Act Award dollars

than any other NASA center. The fiscal

year 2003 award amount of $195,700 is

proportionately divided among award

areas.

More than 100 inventors received

recognition at the Sixth Annual KSC

Space Act Awards Luncheon. The

winners individually collected $500 to

$21,000. NASA retiree and exceptional

Space Act Award recipient, Adam

Kissiah, not only received praise for

inventing the cochlear implant 25 years

ago, but also accepted $21,000—the

largest award to a single inventor in KSC

history.

Aside from recognizing and granting

monetary awards for inventions and

other scientific and technical

contributions that support NASA’s

aeronautical and space goals, the

Space Act Awards program stimulates

and encourages creation and reporting

of similar contributions in the future.

KSC’s Technology Commercialization

Office received 128 New Technology

Reports for innovations developed at

KSC. These include patent and

copyright licenses, cooperative

agreements, and Space Act

Agreements. Some of KSC’s recent

patent and license awards and license

offerings include the Advanced SelfCalibrating, Self-Repairing Data

Acquisition System, the Multipurpose

Thermal Insulation Test Apparatus, and

the Cable and Line Inspection

Mechanism.

Technology Successes

NASA-KSC’s Technology Transfer Office

transfers developed technologies to

industry for commercial use as spinoffs

and leverages industry partnerships to

create “spin-ins.” Spinoffs typically are

license agreements with companies,

while spin-ins are performed primarily

through Space Act Agreements. The

KSC Technology Transfer Office identifies

partners for both and facilitates

agreement negotiations with industry

partners. Occasionally, a company

licenses a NASA technology for

commercial use and that company

partners with NASA to advance that

technology to better meet KSC’s needs

through a Space Act Agreement. In

2003, NASA-KSC signed seven

technology license agreements and five

technology Space Act Agreements,

listed below.

KSC’s patent license with Toxicological

and Environmental Associates, Inc.,

Baton Rouge, La., prompts the use and

sale of Emulsified Zero-Valent Iron.

Dr. Grant Gilmore sits alongside undersea expedition

equipment used to characterize the condition of the

deep-sea coral reefs and reef fish populations in the

Oculina Banks, a marine protected area, 20 miles

offshore of the east coast of Florida.
KSC 2003 ANNUAL REPORT 34

and other ocean scientists studied and

mapped deep-sea corals off Cape

Canaveral’s shore. A multi-beam sonar

system provided the first high-resolution,

3-D map of the Oculina Banks. Formed

by a single species of coral, Oculina

Banks’ deep coral reefs occur nowhere

else on Earth.

NASA, NOAA, the Navy, the Coast

Guard and the Florida Fish & Wildlife

Commission performed underwater

acoustic research involving sensor

technology demonstrations, studying

fields ranging from marine biological

research to homeland security. The work

also served as a pilot project assessing

the agencies’ cooperation.

This is the fourth consecutive year KSC

earned more Space Act Award dollars

than any other NASA Center. The fiscal

year 2003 award amount of $195,700 is

proportionately divided among award

areas.

More than 100 inventors received

recognition at the Sixth Annual KSC

Space Act Awards Luncheon. The

winners individually collected $500 to

$21,000. NASA retiree and exceptional

Space Act Award recipient Adam

Kissiah not only received praise for

inventing the cochlear implant 25 years

ago, but also accepted $21,000—the

largest award to a single inventor in KSC

history.

Aside from recognizing and granting

monetary awards for inventions and

other scientific and technical

contributions that support NASA’s

aeronautical and space goals, the

Space Act Awards program stimulates

and encourages creation and reporting

of similar contributions in the future.

KSC’s Technology Commercialization

Office received 128 New Technology

Reports for innovations developed at

KSC. These include patent and

copyright licenses, cooperative

agreements and Space Act

Agreements. Some of KSC’s recent

patent and license awards and license

offerings include the Advanced SelfCalibrating, Self-Repairing Data

Acquisition System, the Multipurpose

Thermal Insulation Test Apparatus, and

the Cable and Line Inspection

Mechanism.

Technology Successes

KSC’s Technology Transfer Office

transfers developed technologies to

industry for commercial use as spinoffs

and leverages industry partnerships to

create “spin-ins.” Spinoffs typically are

license agreements with companies,

while spin-ins are performed primarily

through Space Act Agreements. The

KSC Technology Transfer Office identifies

partners for both and facilitates

agreement negotiations with industry

partners. Occasionally, a company

licenses a NASA technology for

commercial use and that company

partners with NASA to advance that

technology to better meet KSC’s needs

through a Space Act Agreement. In

2003, KSC signed seven technology

license agreements and five technology

Space Act Agreements, listed below.

KSC’s patent license with Toxicological

and Environmental Associates, Inc., in

Baton Rouge, La., prompts the use and

sale of Emulsified Zero-Valent Iron.

NASA, University of Central Florida,

Department of Energy, Department of

Defense, Environmental Protection

Agency, and GeoSyntec, Inc. created

the innovative solution, which is

described further in the Environmental

Leadership section.

Through a patent license, Pacific

Instruments, Inc.’s (Concord, Calif.)

Signal Conditioning Amplifier Recorder

(SCAmpR) provides signal conditioning,

amplifying and recording capabilities in

a single circuit board. SCAmpR

significantly improves reliability, reduces

cost and provides more flexibility than

pre-existing systems used during Space
35 KSC 2003 ANNUAL REPORT KSC 2003 ANNUAL REPORT

Shuttle launches. A Space Act

Agreement for co-development of

SCAmpR and KSC’s use of client-server

software for SCAmpR supports the

agreement.

NASA provided TABER Industries in North

Tonawanda, N.Y., with a patent license

to develop and commercialize the

Multi-Sensor Array pressure transducer.

Working with sensors around Space

Shuttle launch pads, it records physical

phenomena. The technology enables

sensor clusters to uniquely monitor their

own health and estimate their own

remaining lifespan.

The patent license with Armor Holdings

Forensics in Jacksonville, Fla., supports

the manufacturing and sale of a scaling

device and accompanying software.

KSC engineers developed the device to

assess Space Shuttle external tank

damage following hailstorms. When a

photograph is taken, a pattern,

projected by lasers, appears with the

investigated object’s image, allowing

the viewer to quantify the size of the

object. Accompanying software

calibrates the pattern in the photo

image and computes the distance

scale for the entire image, saving

valuable time in establishing and

documenting measurements.

A reimbursable Space Act Agreement

with Phoenix Systems International

supports development of a Nitrogen

Oxides (NOx) emissions reducer in fossil

fuel-burning power plants. This effort is a

continuation of previous KSC

developments. Previously, Phoenix

obtained exclusive rights for all

commercial applications of the KSC

NOx technologies, which reduced costs

and elimination of hazardous waste

streams. Additionally, this development

could directly apply to the Space

Shuttle launch pad NOx scrubbers and

Center boiler plants. Participation under

this Agreement demonstrates NASA’s

commitment to environmental

stewardship.

Due to the Center’s proximity to the

Atlantic Ocean, KSC is a corrosive

environment. Cortec Corporation in St.

Paul, Minn., licensed a NASA-developed

corrosion inhibiting technology—a

Galvanic Liquid Applied Coating

System—for concrete structures. This

inorganic coating slows or stops

corrosion of reinforcing steel inside

concrete structures, thus protecting

launch support structures, highway

bridges and KSC buildings.

Detcon, Inc. in The Woodlands, Texas,

signed an Exclusive Patent License

agreement for the UV/IR Hydrogen

Flame Detector (U.S. Patent No.

5,625,342). The ultraviolet/infrared

hydrogen flame detector reduces false

alarms due to reflections from a known

flame source or from non-flame sources

that emit UV, such as lightning or

welding arcs. The company is tailoring

the technology to meet the needs of

their commercial market through a nonreimbursable Space Act Agreement

with KSC.

A meeting with Circuit Avenue

Netrepreneurs, in Camden N.J., at the

National Design Engineer Show (March

2002) led to a partially exclusive license

for the Advanced Data Acquisition

System (ADAS) in the fields of chemicals,

pharmaceuticals and biotechnology. A

minority owned business, it will use ADAS

to develop their command, control and

monitoring system, which collects data

from telemetry-enabled instruments and

makes command decisions.

Via a Space Act Agreement, the Open

Channel Foundation and KSC offer the

public software for researching NASAKSC technologies at http://

www.openchannelfoundation.org/

cosmic/. The download is free for any

U.S. citizen or U.S.-owned company, and

returns the taxpayer’s investment to the

U.S. economy. Each technology’s

forum, providing outlets for user

comments, is monitored by the

innovators themselves, allowing users
KSC 2003 ANNUAL REPORT 36

direct contact with the NASA expert for

that particular technology. A minimum

of nine technologies totaling 64

transactions of KSC-developed software

have been downloaded.

Also enhancing KSC’s technology base

through industry partnerships is the Small

Business Innovation Research (SBIR)/

Small Business Technology Transfer (STTR)

program managed by KSC’s

Technology Transfer Office. In 2003, the

Office managed 50 SBIR/STTR contracts

valued at $18.1million.

SBIR/STTR funds early-stage research

and technology development designed

to address future mission needs. In 2003,

four SBIR/STTR funded projects were

successfully implemented at KSC and

are described below.

KSC engineers employed Optimal

Engineering Solution’s P.I. EXPERT,

ensuring Shuttle maintenance

operations run efficiently. Recognizing a

need for versatile statistical software,

three former university professors

developed a prototype integrating

traditional statistical quality assurance

tools with robust optimization techniques

in a user-friendly format that is also

visually compelling. With SBIR/STTR

funding, the company in Daytona

Beach, Fla., created the process

improvement technology, which is

critical to businesses looking to

restructure or accelerate operations in

order to gain a competitive edge.

Orbital Technologies Corporation

(ORBITEC) in Madison, Wis., partnered

with Utah State University to develop a

Temperature and Moisture Acquisition

System (TMAS) under the SBIR program.

The TMAS measures moisture in small

root modules used for plant research in

microgravity and can be used wherever

pinpoint moisture readings are desired.

TMAS is the moisture sensor chosen for

use in ORBITEC’s Plant Research Unit

(PRU)—a plant growth facility under

development by NASA’s Space Station

Biological Research Program for Space

Station experiments. TMAS also

complements ORBITEC’s other biomass

production systems, previously used by

NASA Ames Research Center.

A SBIR success model, NASA highlighted

a unique software system, jointly

developed with SENTEL Corp. in

Alexandria, Va. The Electronic Portable

Information Collection system (EPIC) is

the first paperless procedure system

used to launch rockets into space. EPIC

recently supported two Atlas V

launches. SENTEL developed EPIC to

record and maintain hundreds of

mission-critical procedures that must be

completed before each launch. To

manage those resources, EPIC offers a

wireless network that communicates a

series of work authorization procedures

almost in real time.

Researchers conduct underwater acoustic research in

the Launch Complex 39 area turn basin.
KSC 2003 ANNUAL REPORT

PARTNERSHIPS

37

The Center’s capabilities and research

potential endlessly grows through its

relationships with pioneering

organizations.

KSC, the Air Force, the Secretary of

Defense office and the Federal Aviation

Administration addressed space launch

needs associated with low-cost, routine

and safe space access. As a result, the

Future Interagency Range and

Spaceport Technology Program (FIRST)

emerged. FIRST develops key

technologies to achieve global,

interoperable spaceports and ranges.

Agency, Dynamac Corp., Bionetics and

University of Florida researchers and

scientists moved to the 100,000 squarefoot Space Life Sciences (SLS)

Laboratory located at the International

Space Research Park (ISRP). This facility

serves as a research hub for plant

growth experiments, resource recovery

and microbiology/microbial ecology

studies. Built by the state of Florida and

NASA, the laboratory also contains

analytical chemistry labs, space flight

experiment facilities and a flight

hardware development growth

chamber.

After SLS Lab completion, a developing

320-acre tract outside the KSC security

zone will expand the ISRP for access by

academic and commercial tenants

supporting NASA’s mission. The

collaborative NASA and Florida Space

Authority effort provides sites for

commercially-developed research,

technology and academic facilities. The

year’s major focus was the

Environmental Impact Statement and

related analysis. This investigation

helped NASA determine facility

locations and provide Florida a longterm lease of the site. The park will

accommodate up to 2 million square

feet of development over a 20-year

period.

The Center, Dynamac Corp., 45th

Space Wing, Jet Propulsion Laboratory,

the National Oceanic and Atmospheric

Administration, and National Marine

Fisheries Service developed a passive

acoustic monitoring systems prototype.

These systems monitor vital fishery life

history activities such as reproduction

and human activity. The Naval

Undersea Warfare Center and U.S.

Coast Guard Research and

Development Center may deploy these

technologies for Cape Canaveral

homeland security endeavors.

The system can distinguish between

marine life and possible human and/or

underwater craft movements. If marine

life is observed, it can tell the type of fish

and how many. It can even hear shrimp

walking around and clicking their claws.

If human, it can tell if the noise is a diver,

a small submarine, etc.

KSC, GeoSyntec Environmental

Consultants, the DoD and U.S. Navy

tested the NASA-developed Emulsified

Zero-Valent Iron environmental cleanup

technique. This technology is described

further in the Environmental Leadership

section.

KSC and Phoenix Systems International,

Inc. developed an application of the

Center’s oxidizer scrubber technology

for use at coal- and oil-fired electric

power plants. The new system should be
KSC 2003 ANNUAL REPORT 38

more cost effective, reduce nitrous

oxide emissions and extend the nation’s

coal reserves.

NASA’s Office of Space Science

selected KSC, Cornell University, Florida

Institute of Technology, University of

Arkansas at Little Rock, and Arctic Slope

Regional Corp. to develop a Mars dust

particle analyzer for future landers or

rovers. Meeting stringent size, weight

and power guidelines, this miniaturized

instrument intends to perform real-time,

simultaneous measurements of Mars

dust particles.

Since the mid-1960s, the partnership

between KSC and the U.S. Air Force’s

45th Space Wing has highlighted the

vast array of facilities, infrastructure,

processes and intellectual talent both

groups share. During the fiscal year, the

partnership grew and evolved as KSC

adapted to the Return to Flight

environment.

Relying on the NASA/USAF Cape

Canaveral Spaceport Planning and

Customer Service Office, some key

developments progressed through the

relationship. The Advanced Technology

Development Center provides a

demonstration and testing environment

closely resembling a launch facility. The

Space Exploration Technologies

(SpaceX) launch system is a privately

funded commercial space launch

company. The Underwater Technology

Development Program and its Passive

Acoustical Monitoring System supports

research.

Hundreds of guests attend a ribbon cutting ceremony officially opening the U.S. Astronaut Hall of Fame as part

of the KSC Visitor Complex.
KSC 2003 ANNUAL REPORT

KSC RESERVISTS CALLED

TO SERVE

While orbiter processing and Columbia

investigation work continued at KSC,

world events called many KSC civil

servants and contractor workers away

from families, friends and the Space

Coast. Nearly 100 dedicated men and

women were called to serve and

defend our country as reservists in the

nation’s armed services.

As they serve in the Air Force, Army,

Coast Guard or Navy, they carry with

them the spirit, hope and determination

of their “space” family at KSC.

Though some have returned home,

many KSC reservists are still serving

today.

KSC honors these brave men and

women as they continue to defend our

country and work to ensure liberty and

justice for all, whether at home or on

foreign soil.
KSC 2003 ANNUAL REPORT

THE COLUMBIA

RECOVERY AND

RECONSTRUCTION

KSC Assists in Columbia

Recovery Efforts

KSC civil servants and contractor

workers went to Texas, Feb. 1, 2003, as

the result of the Columbia (OV-102/STS107) tragedy. The first Rapid Response

Team (RRT), comprising about 40 NASA

and contractor personnel, traveled to

Barksdale Air Force Base, La., within 10

hours of the accident. Within 72 hours,

120 USA managers and employees were

deployed to Texas and Louisiana.

Upon arrival at Barksdale AFB, the RRT

set up a command center to manage

resources and establish the

infrastructure necessary to support such

a large-scale effort. NASA coordinated

the overall effort, along with USA and

other contractors, the Federal

Emergency Management Agency,

Environmental Protection Agency, the

Texas Forestry Service and other assisting

agencies, eventually encompassing

16,500 workers at all debris recovery

sites. USA quickly pulled together the

necessary communications support

effort by Feb. 2 and provided computer

workstations and laptops with

connectivity to the NASA sites at

Barksdale AFB, and Texas locations in

Nacogdoches, Hemphill, San Augustine,

Lufkin and Palestine. By the conclusion

of debris recovery efforts, more than 800

KSC employees were at 16 locations in

six states. Search efforts were

conducted on land, by air and at sea.

Columbia Reconstruction

at KSC

In the first days following the accident, a

team formed to plan Columbia’s

reconstruction. The state’s Reusable

Launch Vehicle hangar at the Shuttle

Landing Facility was selected as the

optimal reconstruction facility, based on

its size, available technical workforce,

access to the vehicle groundprocessing infrastructure and its

proximity to materials science

laboratories. The facility became known

as the Columbia Reconstruction

Hangar.

40

Workers place the final piece of the STS-107 mission

patch on the outside of the hangar, where pieces of

Columbia debris were collected and identified.
KSC 2003 ANNUAL REPORT

The Reconstruction Team established

several critical processes for safe

handling and management of the

debris, which included receiving,

handling, decontamination, tracking,

identification, cleaning and assessment

of the debris, with an emphasis on

evidence preservation. The team

comprised engineers, technicians,

inspectors and managers from NASA,

USA, Boeing and the National

Transportation Safety Board.

The reconstruction effort spanned five

months, during which 27 truckloads of

Columbia debris arrived at the

Columbia Reconstruction Hangar from

Barksdale AFB. The debris recovery

workers collected an estimated 38

percent of the orbiter’s dry weight, or

approximately 84,900 pounds

comprising 83,900 items. The majority of

items were no larger than half a square

foot. More than 40,000 items could not

be positively identified. The remaining

balance of debris was instrumental in

steering the investigation toward a root

cause—with 876 pieces associated with

Columbia’s left wing as the most critical.

Initially, a two-dimensional

reconstruction of the orbiter outer mold

line was developed to facilitate

assessment of the debris. As debris was

positively identified, the left wing

leading edge became the

investigation’s main focus area. This

initiated a three-dimensional

reconstruction of panels one through 13

of the left wing leading edge.

Technicians used virtual reconstruction

to create a replica of the orbiter left

wing leading edge. A full-scale left wing

was also built on tables to display lower

surface thermal protection tiles and

structure. These reconstruction

techniques, used in conjunction with

material sampling and failure analyses,

allowed investigators to extract the

greatest amount of information possible

from the debris.

During Columbia’s reconstruction,

systems experts hosted more than 60

guided tours of the Columbia

Reconstruction Hangar and Launch

Complex 39 Shuttle processing facilities,

provided presentations and led

discussions for the CAIB, the media,

visiting Center personnel and other

interested officials. At the completion of

the CAIB’s investigation, ground

operations personnel supported a

Columbia Reconstruction Hangar walkthrough for more than 11,000 KSC

workers and their families during six days

in July 2003.

Workers inventoried, packed and

moved Columbia debris to the LongTerm Storage Facility in the Vehical

Assembly Building. Parts of the vehicle

will be available to scientific, research,

academic and governmental

organizations for hypersonic studies and

design of future aircraft and spacecraft.

41

Large items of Columbia debris seem to lay in an

endless line.
KSC 2003 ANNUAL REPORT

NASA Administrator Sean O’Keefe (left) looks over

Columbia debris with Shuttle Test Director Steve

Altemus, also a Columbia Reconstruction Project

Team member.
KSC 2003 ANNUAL REPORT

EDUCATION

The Education Programs and University

Research Division assists NASA in

inspiring and motivating students to

pursue careers in science, technology,

engineering and mathematics; and

engaging the public in shaping and

sharing the experience of exploration

and discovery. Education Programs

(EP) is one of 18 NASA Themes.

This year, the Division supported the

development and implementation of

NASA’s Educator Astronaut Program.

Nearly 9,000 nominations generated

from the Center’s service area. KSC

continues to follow the selection

process and interacts with many

applicants offering guidance and

support.

KSC also helped implement a second

new Agency initiative—the NASA

Explorer Schools Program. Five KSC

regional service area schools are

participating to acquire new teaching

resources and technology tools for their

fifth to eighth grade classes. The Center

welcomed 22 Florida and Georgia

educators for an intensive, hands-on

summer workshop including a Station

link-up to interact with Expedition 7

crew members. The KSC Education

office is in the process of strengthening

these relationships by visiting all five

schools chosen from our regional service

area.

Educators and students depend on the

Center continuously for on- and off-site

space-related workshops that provide

curriculum material and classroom

techniques. The office hosted 498 K-12

schools, 46,004 K-12 students and 15,406

K-12 teachers.

This year, the Division strengthened its

activity with the Workforce and Diversity

Management Office to integrate efforts

for the NASA Corporate Recruiting

activity. This partnership strengthened

NASA’s recruiting and hiring of students

who competently fill gaps, and

prepared for existing employee

retirements. It also funneled EP

participants into KSC vacancies.

In the research area, the Division

worked closely with the Spaceport

Engineering and Technology directorate

to identify KSC’s top technology

requirements. With KSC’s Technology

Planning Team, Education identified

potential technology research projects.

Adhering to the Team’s guidelines,

participating faculty and students

acquired projects supporting one of six

Center Strategic Technology

Development Initiatives.

Students place flowers at the Space

Mirror Memorial to honor the fallen

crew of Space Shuttle Columbia.

43
KSC 2003 ANNUAL REPORT

Following the Columbia tragedy,

countless students encouraged the

Center and NASA family with letters,

pictures and other sympathetic

expressions.

Columbia Elementary School’s (Palm

Bay) sixth graders greeted Kirstie

McCool Chadwick, STS-107 Pilot William

“Willie” McCool’s sister, attended

science demonstrations and placed

carnations at the Space Mirror

Memorial. Gifted fourth and fifth graders

contributed a memorial quilt and wrote

letters to the Astronaut families,

President Bush, NASA employees and

Administrator Sean O’Keefe. A Sanford

school created an STS-107 Memorial

Garden. Education and KSC’s ISS and

Payloads Processing Directorate

collaborated with the Japanese

Aerospace Exploration Association to

welcome a group of Japanese high

school students whose experiments flew

on STS-107. They honored the Columbia

crew with a floral tribute at Spacehab’s

STS-107 memorial stone in Cape

Canaveral.

By working with elementary and

secondary students and teachers, the

Division will keep improving the public’s

understanding and appreciation of

NASA’s missions, and promote

awareness of NASA EP’s vital role in

supporting the nation’s education

efforts.

44

Students pause during work on their experiments that flew on Space Shuttle Columbia. STS-107 launched

experiments designed and developed by students from six different countries.
45 KSC 2003 ANNUAL REPORT

OUTREACH TO

THE WORLD

Kennedy Space Center Visitor

Complex

Kennedy Space Center Visitor Complex

(KSCVC) helped spread NASA’s

message to more than 1.4 million guests

from all over the world in 2003. The

number is expected to grow steadily

through the continuous additions of new

attractions, exhibits and tour stops.

The addition of the Astronaut Hall of

Fame as part of the KSCVC experience

perfectly compliments the existing

exhibits and attractions. Balanced

against the machines and hardware

that make space exploration a reality,

the Astronaut Hall of Fame tells the other

side of the story, the human side. It

focuses on the astronauts who took

those first brave steps into space,

offering a glimpse at the formative years

of these pioneers, and a first-hand look

at the NASA training that molded them

into heroes.

Space Camp facilities opened more

opportunities for the public to

participate in learning about human

space flight. New programs, such as

Astronaut Training (ATX), allow visitors to

engage in a hands-on Shuttle launch

and mission.

Astronauts Sally Ride, Dan Brandenstein,

Story Musgrave and Robert “Hoot”

Gibson were inducted into the

Astronaut Hall of Fame, June 21, 2003.

The event garnered extensive media

coverage. ABC’s Good Morning

America broadcasted live from the

Astronaut Hall of Fame and featured

interviews with both the new inductees

as well as those honored in prior years.

CNN broadcast the ceremonies live

nationally.

A new retail store opened mid-year at

the Orlando International Airport. Its

success provides daily evidence of the

public’s respect for NASA and reminds

those visiting Central Florida how close

the Visitor Complex is to Orlando. The

store serves as a NASA icon to the more

than 13.5 million visitors passing through

the airport annually.

KSCVC education programs continued

to expand in 2003. The summer day

camp program had a record year with

more than 900 participants. An

extremely successful patch program

day designed exclusively for homeschooled students attracted more than

1,500 students and parents. In

November, the Visitor Complex

KSC 2003 ANNUAL REPORT

This aerial view of the KSC Visitor Complex shows full-scale solid rocket

boosters and external tank in the foreground, a full-scale model of a Space

Shuttle orbiter behind them, the Launch Status Dome to the right, and the

Astronauts Memorial Space Mirror next to the pond.
KSC 2003 ANNUAL REPORT 46

partnered with NASA, the Brevard

County School Board and the National

Space Club to host every Brevard

County sixth grade student at KSCVC for

a day of hands-on learning.

Government Relations

KSC’s Government Relations Office

arranged several significant meetings

and events, including Florida Space Day

in Tallahassee, March 27. Former Center

Director Roy Bridges and industry

partners met with Florida Gov. Jeb Bush,

Lt. Gov. Toni Jennings, Secretary of State

Glenda Hood, Senate President Jim King

and Speaker of the House Johnnie Byrd

to reinforce NASA’s Vision and KSC’s

mission. The NASA contingent

emphasized the many economic,

research and technological benefits

that the Space Program brings to

Florida.

The Office hosted visits to KSC by U.S.

Sen. Bill Nelson, U.S. Reps. Dave Weldon

and Tom Feeney, and Congressmen

Tom Delay (Texas) and Mike Ross (Ark.).

The Office provided input to the Web

site myregion.org project, which

promotes regional cooperation and

development, and assisted KSC

management with presentations to the

Brevard County Commission.

KSC Web site and Webcasting

Expanded capabilities and new features

on both KSC’s Web site and KSC Direct!

highlights the year. Several new Web site

features were added, including the KSC

Hall of Honor Web site, which allows

former and current employees to add

career summary information, and a new

KSC 45th Anniversary site full of

informative text, photos and videos.

Earlier this year, KSC assumed Agencywide responsibility for the content and

management of the “Mission” section of

the newly revised NASA Portal. Mission

timeline information, feature articles and

NASA Direct! video features about Earth

Observation, Shuttle and ISS, Solar

System, Deep Space, Science and

Technology, and Research Aircraft

KSC 2003 ANNUAL REPORT

Employees produce a KSC Direct! Web broadcast.
KSC 2003 ANNUAL REPORT

missions are added regularly. Since

assuming this responsibility in June 2003,

the Mission section has been the most

frequented of the Portal’s four public

feature sections.

Multimedia Gallery search capabilities

were improved, and archived video

on-demand capabilities now enhance

the site.

New ELV mission Web sites, live launch

and NASA Direct! Web broadcasts

were introduced this year to provide

up-to-the-minute launch countdown

updates, extensive mission information,

and interactive question and answer

sessions with program experts. This new

programming began with the MER-A

“Spirit” (June 10), followed by MER-B

“Opportunity” (July 7) and SIRTF (Aug.

25) launches.

The first live launch Web coverage from

Vandenberg Air Force Base occurred

during the SCISAT launch, Aug. 12.

A redesigned KSC Site Survey now

allows for better public feedback. To

keep the public informed and updated

on important NASA news, our Weekly

News Briefs now feature a two-anchor

format in English, as well as a new

Spanish version.

Live Space Shuttle launch coverage

Web sites and Web broadcasts were

also created for Missions STS-112

(October), STS-113 (November) and STS107 (February).

Development and launch of a Shuttle

Columbia Tribute/Information site on

Feb. 3 kept the public informed with the

latest information. Updated daily

throughout the CAIB efforts, the site

included press briefings, hearings,

reports, memorials, transcripts and

general information.

During the year, KSC’s Web site, live

mission coverage and KSC Direct!

programming reached more than 10

million people. U.S. visitors accounted

for approximately 80 percent of those

accessing the site throughout the year.

An average of 859,000 visits were made

to the site per month.

Exhibits

The exhibits team took the NASA

message on the road to 39 events and

reached more than 509,000 people—

double those reached last year—across

47 KSC 2003 ANNUAL REPORT

Young women sign a Columbia tribute poster at the Sally Ride Science Festival. Held at the University of

Central Florida, Orlando, Fla., the event encourages girls to pursue science, math and technology career paths.
KSC 2003 ANNUAL REPORT

the country and beyond. From the

National Association for the

Advancement of Colored People

(NAACP) Convention in Miami, Fla., to

the Centennial of Flight in Dayton, Ohio,

to the National Space Symposium in

Colorado Springs, Colo., KSC’s road

show explained NASA’s exciting space

flight history, education programs, and

new science and technology programs.

Exhibits included graphic displays of

NASA-wide programs (Space Shuttle, ISS

and LSP), spaceport technology, the

benefits of space, spinoffs, NASA’s

mission and vision statement, and

focused on the One NASA theme

throughout the year.

KSC worked closely with the Jet

Propulsion Laboratory to educate the

public on the importance and safety

concerns of the Mars missions. One of

KSC’s guiding principles, the

environment, was showcased at the

Environment Convention in San Diego,

Calif.

Other events included exhibits in

Georgia, New York, North Carolina,

Texas and Utah. Beyond our own shores,

KSC also took the message to the Paris

Air Show at the request of the state of

Florida, and to a Lisbon, Portugal

workshop.

Speakers Bureau

Over the years, the demand for

speakers has grown and this year was

no different. KSC sent speakers to 566

events, reaching approximately 300,000

people throughout Florida and Georgia,

other U.S. states, along with the Virgin

Islands, England, Holland and Canada.

The number of events represents

approximately a 20 percent increase

over last year.

KSC’s Speakers Bureau supported 12

international events and 40 national

events. These included the Florida State

Native American Youth Program

sponsored by the Governor’s Office,

National Space Day, and the

dedication of many Columbia

Memorials throughout Florida, Georgia

and Puerto Rico.

A group of 25 astronauts and many

others brought the NASA message to a

broad base of diverse events and

organizations, including the Women in

Law Enforcement Conference, the

Florida Department of Transportation

KSC 2003 ANNUAL REPORT 48

Col. Everett Thomas (left), 45th Space Wing, presents a framed memento to astronaut John Herrington, the

world’s first Native American astronaut.
KSC 2003 ANNUAL REPORT

Conference, aviation associations,

aerospace clubs, Boys Scouts, Girl

Scouts and Florida Library programs.

Speakers also presented to the Hispanic

Heritage Celebration in Tampa, Fla., the

Hispanic Conference in Puerto Rico;

American Society of Engineers of Indian

Origin; Youth Leadership Program for

Hispanic Students in Orlando; Society of

Women Engineers; Brevard County Parks

and Recreation Summer Day Camps for

disadvantaged youths; and the

Governor’s Council on Indian Affairs.

Topics ranged from general to specific

aspects of NASA’s space flight

programs.

Media Outreach

During a Space Shuttle launch and

landing, special event, or just the dayto-day business of doing what KSC does

best, the KSC News Center hosts

hundreds of local, national and

international media representatives,

dignitaries, photographers and film

crews. Stories generated at the Press

Site result in millions of people around

the world learning more about

America’s Space program.

The KSC News Center team produced a

wealth of print, audio and video

material, and photographic images

ensuring requests were fulfilled with

current information. During the year, the

Press Site provided 134 news releases,

2,548 interviews, 492 audio tapes, 3,833

videotapes, 161,042 photographs, and

bi-weekly issues of Spaceport News.

Media support was provided during

Missions STS-112, STS-113 and STS-107.

Topics included Space Shuttle

processing, rollout, crew pre-flight

training and activities, and Space

Shuttle launches and landings. The News

Center also provided media support to

the LSP for ELV launches, which included

TDRS-J, ICESat/CHIPSat, SORCE, GALEX,

SCISAT, SIRTF, and MER-A and MER-B.

The News Center also coordinated

requests from production and

documentary companies, television,

radio and print news reporters from the

U.S., Spain, Switzerland, Latin America,

England, Hungary, Italy, Japan, the

Netherlands, France, Russia and

Belgium. During the year, the Press Site

arranged access for and escorted 34

production companies and 20 television

news crews to various locations around

the Center, provided support for 31 KSC

special events, and coordinated and

accompanied 46 print journalists during

assignments.

Among the many significant projects

supported were The History Channel/

Greystone filming of a one-hour

documentary on lightning; NASA TV

coverage for the ISS elements Node 2

and JEM arrival ceremony; and Mars

Rover viewing; also, the IMAX White

Mountain Productions shoot for a movie

titled, “Mars”; interviews for The

Discovery Channel; and a Kazakhstan,

Russia TV crew for a series of TV

magazine programs.

49 KSC 2003 ANNUAL REPORT

At Launch Complex 39B, media representatives are

briefed on the improved tracking cameras that will

capture ascent imagery during future Space Shuttle

flights.
KSC 2003 ANNUAL REPORT 50

KSC BUSINESS REPORT

Financial Highlights

Financially, FY 2003 included significant

changes for the Agency and the

Center. The new IFMP replaced the

legacy financial systems used for more

than 20 years. In February 2003, KSC

began recording transactions in the

new Agency-wide Core Finance system.

During that time, a new Travel Manager

system was also initiated as part of the

integrated system to manage all Center

travel-planning and expenses.

Additional financial activities included

preparation and planning for future

modules of the integrated system,

including Budget Formulation, Asset

Management, E-Payroll and E-Travel.

Another significant change was the

implementation of the Full Cost Initiative

beginning in FY 2004. The Full Cost

Initiative ties direct and indirect costs to

NASA’s major programs, projects and

institutional activities. KSC’s institutional

and infrastructure costs, such as civil

service salaries and the use of facilities

and support services, are now linked to

the Center’s programs and projects.

The work performed at KSC, whether it

be an Agency program or external work

on a cost reimbursement basis, will

include the full range of costs required

to perform the activity. Full Cost

principles will be used to formulate

future annual budgets. Financial

operations under this practice began in

October.

Both the IFMP implementation and Full

Cost Initiative support the

Administration’s “President’s

Management Agenda,” focusing on

improving performance and

demonstrating results.

KSC successfully maintained and

increased its share of the NASA budget

(see accompanying chart). The FY 2003

KSC-managed budget totaled $1.760

billion, which including the JSCmanaged Space Flight Operations

Contract, with 5,000 workers located at

KSC. While this budget level essentially

remained constant with FY 2002 levels,

the Center projects an increase to more

than $2 billion for FY 2004.

This funding fuels the local economies of

Brevard County and Central Florida,

with the resulting economic impact

measured, analyzed and published

annually. While FY 2003 results are

incomplete to date, they are

summarized and projected in the next

section.

FY 2003 was a productive year that will

pay significant future dividends for the

Agency, the KSC workforce and the

local economy.

KSC 2003 ANNUAL REPORT
KSC 2003 ANNUAL REPORT

Just as the sights and sounds of a rocket

launch brings excitement to the lives of

many Central Floridians, the enormous

operation that is required to make the

launches possible releases a powerful

blast of economic activity that flows

through the businesses and households

of Brevard County, the Central Florida

region and other areas of the state.

While the thrill of the launch is relatively

short-lived, the economic effects of

NASA operations in Florida are

continuous and sustained. In FY 2003, of

the $15 billion NASA budget, NASA-KSC

and other NASA centers injected over

$1.4 billion into Florida’s local and state

economies. This spending prompted a

cycle of economic transactions that

flowed throughout many sectors of

these economies and created a

multiplied level of total economic

activity that far exceeded NASA’s initial

injection.

To conduct its exploration of space,

NASA requires an extraordinary range

of commodities including fuel, missile

engines, computers and photographic

equipment. The range of services it

purchases is just as wide, including

communications, laboratory testing,

Space Shuttle processing, payload

integration and testing, expendable

launch services and university research.

To meet NASA’s demand for these

goods and services, local contractors

employ workers, fund payrolls and

generate output. These workers and

contractors generate additional

impacts as they spend their incomes

and place orders with other regional

firms for materials and services. Each

round of spending recirculates NASA’s

initial demand among Florida’s

businesses and households, multiplying

the direct impact on the economy.

There are a number of other activities

directly associated with NASA that also

add to its total economic impact in

Florida. These include the local travel

expenditures of out-of-state business

and government personnel that travel

to KSC to conduct business and the KSC

Visitor Complex sales to out-of-state

visitors.

51

KSC BUDGET AUTHORITY SUMMARY

FY 2002 THRU FY 2004 (DOLLARS IN MILLIONS)

KSC 2003 ANNUAL REPORT

ECONOMIC IMPACT
KSC 2003 ANNUAL REPORT

DIRECT PURCHASES FROM CONTRACTORS AND PAYMENTS TO HOUSEHOLDS BY

KSC AND OTHER NASA CENTERS IN FLORIDA IN FY 2003 (Preliminary)

THE TOTAL ECONOMIC IMPACT OF ALL NASA ACTIVITIES AT KSC IN FLORIDA BY

GEOGRAPHIC AREA FY 2003 (Preliminary)

KSC 2003 ANNUAL REPORT 52

KSC annually conducts an Economic

Impact Analysis to measure NASA’s

effect on the economy at the local,

regional and state levels. The University

of Central Florida conducted the 2002

report. The 2003 report is not yet

completed, but estimates for 2003 are

provided.
53 KSC 2003 ANNUAL REPORT

WORKFORCE DIVERSITY

KSC is the most broadly based, complex

and successful launch center in the

world. Through NASA, KSC acts as a

premier national landmark capable of

showcasing the United States’ prowess

in science and technology. KSC is able

to help the nation achieve its objectives

in Space due primarily in part to the

dedication of its workforce, which not

only includes civil service employees,

but also a large number of contractor

employees. Together they are essential

in making KSC’s vision a success.

Kennedy Space Center Workforce

On-Duty Full Time Civil Servants 1,748

On-Duty Other-than-Full Time Civil Servants 91

Total Civil Servants 1,839

Civil Servant Skill Mix

Scientific & Engineering 59.2%

Administrative 25.7%

Technical 8.3%

Clerical 6.9%

On-Site Contractor Employees 9,738

Off-Site Contractor Employees 753

Total Contractor Employees 10,491

Total Construction Employees 379

Total Tenants 1,303

TOTAL KSC POPULATION 14,012

To accomplish the various missions

expected of the Space Center,

employees carry out a multitude of

tasks. At the end of each year, the

Center takes a “snapshot” of its

workforce. This picture includes all

federal and contract employees

chartered to work for KSC. Other

organizations, such as the European

Space Agency and Patrick Air Force

Base, have roles here, but are not

reflected in these numbers. As of Sept.

30, 2003, the KSC workforce was as

follows:
KSC 2003 ANNUAL REPORT 54

PROCUREMENT REPORT

Industry Partners at a Glance

The companies listed below were KSC’s

top business contractors (in terms of

obligations) for FY 2003. The following

briefly describes their work for the

Center:

Space Gateway Support (SGS)

SGS, a joint venture (with Northrop

Grumman, Shaw and Wackenhut)

provides base operations support for

KSC, CCAFS and PAFB, including roads

and grounds maintenance, facilities

maintenance, custodial, fire, security,

calibrations and propellants handling.

They held one contract valued at $2.7

billion over the life of the contract.

United Space Alliance (USA),

Limited Liability Corp.

USA is the prime contractor for the

Space Flight Operations Contract

(SFOC) whose primary purpose is to

ensure mission success (including

meeting the manifest) for the Space

Shuttle Program. KSC is the primary point

of responsibility for launch and landing

of the Space Shuttle, and supports

Ground Operations and Orbiter Logistics

elements of the Space Shuttle Program.

KSC partnered $100 million in FY 2003 on

the SFOC contract. USA performs at

KSC, JSC, MSFC, SSC, DFRC, White Sands

and worldwide Trans Atlantic Landing

sites. The SFOC has a total award value

of $12.7 billion.

Boeing Space Operations

Company

Boeing Space Operations Company is

the prime contractor for the Checkout,

Assembly and Payload Processing

Services (CAPPS) contract. Its primary

purpose is to support payload

processing for the ISS, Space Shuttle,

ELVs and other payload programs.

Boeing performs all aspects of payload

processing, including the planning and

receiving of payloads, payload

processing, maintenance of associated

payload ground systems, integration of

payloads with the Space Shuttle, launch

support and Space Shuttle post-landing

payload activities. CAPPS is a cost-plus

performance/award fee contract with a

basic four-year period of

performance and options to extend the

contract for an additional six years. The

value of the contract for the initial four

year period is $332 million. Work is

performed at the Center, CCAFS, VAFB,

Space Shuttle landing sites and at

various payload associated work

locations within and outside the U.S.
55 KSC 2003 ANNUAL REPORT

Delta Launch Services Inc.

Delta Launch Services Inc., the Boeing

Company, is the prime contractor for

one of two existing NASA Launch

Services (NLS) multiple award Indefinite

Delivery Indefinite Quantity (IDIQ) task

order contracts. Principal work location

for the Delta II vehicle assembly is

Decatur, Ala. Launches occur from

CCAFS and VAFB.

Lockheed Martin Commercial

Launch Services Inc.

Lockheed Martin Commercial Launch

Services, Inc. is the prime contractor for

one of two existing NLS multiple award

IDIQ task order contracts. Principal work

location for the Atlas vehicle assembly is

Denver, Colo. Launches occur from

CCAFS and VAFB.

The Artic Slope Research Corp.

(ASRC) Aerospace

ASRC Aerospace provides research and

engineering services and technical

support to the KSC Spaceport

Engineering and Technology

organization and other Center

operational customers. The support

ranges in scope from providing

research, engineering development,

management of complex research and

development and technology projects

to engineering and technical support of

various KSC laboratories and test beds.

ASRC Aerospace utilizes a consortium of

affiliated universities in performing

applied research and technology

development efforts. ASRC Aerospace

also provides technology outreach to

foster awareness and utilization of KSC

unique capabilities.

Orbital Sciences Corp.

Orbital Sciences provides small ELV

services for the Agency, using the

Pegasus and Taurus small ELVs launched

from CCAFS, VAFB, Wallops Flight

Facility, Va., and equatorial launch

ranges.

Dynamac Corp.

The Life Sciences Services Contract

provides a broad range of life sciences

services to NASA. These include medical

operations for Shuttle and Station

programs, environmental compliance

and stewardship, life sciences payload

operations, support to the Agency

Occupational Health Program Office,

biological science, life sciences payload

development, workforce protection,

fitness and musculoskeletal

rehabilitation, and education outreach.
KSC 2003 ANNUAL REPORT

-

-

DISTRIBUTION OF FISCAL YEAR ‘03 OBLIGATIONS BY BUSINESS TYPE

(IN MILLIONS)

56

Analex Inc.

Analex is the prime contractor on the

ELV Integrated Support contract. The

contractor is responsible for performing

and integrating the overall

programmatic ELV business and

administrative functions, including

program/project planning, risk

management, evaluation and

information technology. Services

provided include the management,

operation, maintenance and sustaining

engineering of the NASA ELV telemetry

stations located at CCAFS and VAFB;

engineering services/studies and

technical services for various ground/

flight ELV systems and payloads and;

management, operation, maintenance

and sustaining engineering of the

assigned NASA facilities, systems and

equipment at VAFB. Services are

provided at KSC, CCAFS, VAFB and

other launch sites and launch service

provider facilities.

Supporting Small Business

Supporting small business is a NASA

priority. During the fiscal year, KSC

obligated $127.2 million dollars to small

businesses, achieving 141.33 percent of

the small business goal of $90 million. This

was a significant increase from the

$102.9 million dollars in small business

awards made in FY 2002.
57 KSC 2003 ANNUAL REPORT

GEOGRAPHICAL DISTRIBUTION BY STATE

(FISCAL YEAR 2003 OBLIGATIONS)

State Total ($k)

Alabama 543

Arizona 11,741

California 81,737

Colorado 2,397

Connecticut 7,027

District of Columbia 99

Florida 720,020

Georgia 2,790

Hawaii 93

Illinois 411

Kansas 139

Kentucky 1,340

Louisiana 345

Massachusetts 3,554

Maryland 3,022

Michigan 241

Minnesota 825

Mississippi 99

North Carolina 382

North Dakota 27

New Hampshire 301

New Jersey 288

New Mexico 3,813

New York 2,509

Ohio 2,597

Oklahoma 362

Pennsylvania 661

Rhode Island 52

South Carolina 455

Texas 4,853

Virginia 2,907

Washington 131

Wisconsin 295

Wyoming 225

Total: * $856,281

YOUR PROCUREMENT DOLLARS AT WORK

* Includes Intragovernmental, Grants, Agreements and Bank Card Transactions.

During the fiscal year, the Center obligated approximately $856 million within the

U.S. in support of the NASA mission. As indicated by the chart below, 34 different

states received procurement dollars from KSC.
KSC 2003 ANNUAL REPORT

Contractor Number of Dollars

Obligated Contracts (in Thousands)

Space Gateway Support 1 297,222

The Boeing Company 8 162,728

Delta Launch Service Inc. 1 107,127

Lockheed Martin Integrated 3 33,878

 Systems Inc.

Boland David A Inc. 1 23,989

Analex Inc. 1 17,406

A S R C Aerospace Corp. 1 16,868

Dynamac Corp. 4 14,439

Orbital Sciences Corp. 1 11,422

O A O Corp. 1 10,711

Air Liquide America Corp. 2 9,592

Praxair Inc. 5 8,258

Dynacs Engineering Company 1 6,507

Inc.

Air Products & Chemicals Inc. 2 5,213

Military Construction Corp. 9 4,843

Johnson Controls World Services 1 4,115

Advanced Electrical Installation 4 2,528

Telephonic Corp. 1 2,364

All Points Logistics Inc. 4 2,257

Jones Edmunds & Associates 17 2,209

TOTAL: 68 $741,467

TOP 20 KSC BUSINESS CONTRACTORS FOR FISCAL YEAR 2003

* Note: The JSC managed Space Flight Operations Contract

recorded $690 million managed by the KSC Procurement

Workforce in FY 2003.

KSC 2003 ANNUAL REPORT 58
KSC 2003 ANNUAL REPORT

Attached underneath the L-1011 aircraft is the

Pegasus XL rocket, containing NASA’s Solar

Radiation and Climate Experiment.