Static Test Facility MSFC Saturn S-1

8/4/2019 Static Test Facility MSFC Saturn S-1

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STATIC TEST FACILITYR- -msm lDTMS F

SATURN[General lnformation)

APR I L 15, 1963


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lNTRODUCT lON

T h i s b o o k l e t p r e s e n t s i n f o r m a t i o n o n t ho s e t e s t and g r ou nd s up p o r t f a c i l i t i e sa t t h e M a r s h a l l Space F l i g h t C e nt er o f d i r e c t i n t e r e s t t o C h r y s l e r p e rs on ne lr e s p o n s i b l e f o r t h e c a p t i v e t e s t p ro gra m o f t h e S a tu r n S - 1 and S-1B sta ge s.


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L I S T O F C O N T E N T S

MAP REDSTONE ARSENAL AND HUNTSV ILL E, ALABAMAAE RI AL VIE W OF MSFC TE ST AREA YEAST"PERSPECTIVE DRAWING OF MSFC TEST AREA "EAST"DESCRIPTION OF SATURN I STATIC TEST TOWERARTIST CONCEPTION OF THE STATIC TEST TOWER AFTER MODIFICATIONAR TI ST CUTAWAY OF THE TOWER AND TE ST P O SI T I ON L ES S NEW ANNEXFLOOR PLAN T E S T TOWER ANNEX (F IR ST FLOOR)FLOOR PLAN T E S T TOWER ANNEX (INTE RMEDI ATE MEZZANINE)FLO OR PLAN T E S T TOWER ANNEX (SECOND FLOOR )ST AT IC TE ST TOWER CAPABILI TY DURING NORMAL S TA TI C TE STST AT IC TES T TOWER SUPPORT F AC I L I T I E S (TABULAR FORM)PLAN VIEW OF F AC I L I T I E S SUPPORTING THE STA TIC TES T TOWERPHOTO LI QU ID OXYGEN, GASEOUS NITROGEN STORAGE F A C I L I T I E SSCHEMATIC LOX STORAGE AND TRANSFER SYSTEMSSCHEMATIC NITROGEN SYSTEMSCHEMATIC INDUSTRIAL WATER AND FIREX SYSTEMSPHOTO UNDERGROUND FU E L STORAG?3 F A C I L I T YSCHEMATIC FUEL STORAGE AND TRANSFER SYSTEMSDESCRIPTION OF THE BLOCKHOUSEARTIST CONCEPTION OF THE BLOCKHOUSE AFTER MODIFICATIONPHOTO BLOCKHOUSEFL OOR FLAX BLOCKHOUSE (BASEMENT)FLOOR PLAN BLOCKHOUSE ( F I R S T FLOOR)FLOOR PLAN BLOCKHOUSE (CONTROL ROOM)PHOTO AND D E S C R I P T I O N O F THE PNSTRZTMENTATION EQUIPMENTPHOTO CHECKOUT, CONTROL, AND MI NI TO RI NG CONSOLESPHOTO STAGF, INTJIRFACE TE S T S E T CONSOLESDESCRIPTION OF READY STORAGE AREASPHOTO NITROGEN TRANSF ER, STORAGE, AND CONVERSION F AC I L I T Y


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RE SE RV OIR ADITAN CED DYnAMI CTEST STAND

BOOSTER PUMPSATURN I DYNAMIC

TEST STAND

POWER PLANT NITROGEN STORAGETRANSFER, & CONVERSI

F A C I L I T Y

ST A T I C T E ST

POWER PLANTTE sr sTAND UNDERGROml

STORAGE .

STORAGEM S F C TEST COMPLEX(EAST)


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STATIC TEST TOWER

The S t a t i c Test Tower i s a two-pos i t ion f a c i l i t y designed and const ructed tos t a t i c f i r e complete Sat~: rr :- i and 1B Boozter s tages fo r f u l l du ra t i on tes ts o fap pr ox im at el y 140 seconds and 1,504,000 pounds th rus t . The bas ic s t ruc tu r e i sa re in f o rced concre te tower 140 fee t i n he igh t w i th a th ree- leve l re in fo rcedconcrete annex t o the rear. Housed wi th i n the st ru ct ur e are engineer ing of f i ce s,instr ument at ion and co nt ro l termi nal rooms, equipment used i n ve hi cl e preparat i on,f a c i l i t y power system, two eleva tors, access s t ai r s , and an ind us tr ia l water systemf o r the de f l ec to r and f i r e x systems.The s t r u c tu r e s f o r r e s t r a i n i n g t he ve hi c le s d u r i ng ca p t i ve f i r i n g s a r efastened t o th e tower and t o specia l spread foo t in gs beari ng on H-pil es.Lat er a l th ru st loads which occur dur i ng the engine g imbal ing te s t ar e absorbedby but t resses. Each po si t i on has a water-cooled f lame def le ct or and a 170-footlong by 30-foot wide concrete b l as t t rench. Each b l as t t rench i s connectedt o a drainage and waste dispo sal system. Both po si t i on s ar e served by a track-mounted 45-ton gantry crane and a 100-ton r o l l ng overhead crane supported bya tru ss system above the tower, br in gi ng the to ta l tower hei ght t o 186 feet.Each f lame deflector has a co ol an t water f lo wr at e o f approxi mately 46,500 gpm.Tower f i r e p ro tec t io n i s p rov ided by a F i re x system wi th a maximum f l w r a t e o f31,000 gprn. The tower i s l i nk ed t o th e blockhouse by an underground re in fo rc edcon cre te ins tru men tat ion ca bl e tunnel, which als o serves as an emergency escapepassage f o r personnel.Suppo rt ing f a c i l i ies inc lude:

(a) A LOX storage and tr an sf er f a c i l i t y con si st in g o f two 14,000 ga ll on and two28,000 g a l l on double-wal led vacuum in su la te d sto rag e tanks, f ou r 250-gpm400 -fo ot head pumps used f o r tr an sf er and in te rt an ki ng , and two 250-gpm200-foot head pumps a t th e connections f o r unloading r a i l cars o r motor


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BREAK AREA GSHOP AREA

\ /

I M/G ROOM1 I104'- 0"ELEVATOR J r 2 o ! o U w m ,

STATIC TOWER ANNEX


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L ~ ~ ~ ~ .HAFTROX

STATIC TOWER ANNEXl"-12'#SCALE E-


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\O

OFFICE AREA

STATIC TOWER ANNEXSCALE


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STATIC TEST TOWER CAPABILITYDURING NORMAL STATIC TESTOF SATURN S - 1 BLOCK I I STAGES

REQUIRED TIME TO LOAD BOOSTER PROPELLANT TANKSLOX : 1 hour 10 minutes ( af t e r pre-cool)Fuel : (RP- I ) : 1 hour

PROPELLANT FLOWRATES (LOAD NG)LOX : 800 gpmFuel: 585 gpm

LOX BOlLOFF RATE2,500 gal /h r a t 70% Humid i ty, ~o 'F , 29.92 in . Hg Barom etr ic Pressur e

PROPELLANT QUANTITIES (FULL LOAD)LOX : 63,000 galFue l: 41,000 ga l

FLAME DEFLECTOR WATER FLOW DURATION


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STATIC TEST TOWERSUPPORT FACILITIES

v SYSTEML i u id Oxygen

Fuel (RP-1)

Gaseous Ni rogen

He1 ium

I n d u s t r i a lWater--

E l e c t r i c a l

MODEF i 1F i l lD r a i nF i 1D r a i n

F i 1 o rD r a inF i l l o rD r a in

F i 1 1

F i 1 1

CAPAC lTY(2) 28,000 gal(2) 14,000gal

(2 ) 17,000 ga 1

(2) 10,000 ga 1(2) 10,000gal

(35) 35 c u f t@ 5,000 psi

15 c u f tT r a i l e r@ 5,000 psi

(2) 1,000,000ga 1

500 KVA

PUMP RATE(2) 250 gpm(2) 250gpmGravity + 10PS 1(2) 250 gpmGrav i t y

(2) 250 gpm(2) 100 gpm

(7) 10,000gpm

LINESIZE6 i n4 i n10 i n6 i n

2 4 i n

4 i n4 i n2 i n

3 / 4 i no r 1 i n

30 i n

REMARKS

LOX Pi t loc ate dS . W . o f Tower

( ~ u p p lmentarySupport)

Reduced t o 3,000psi on t he Towerand f i l t e r e d t o10 muReduced t o 3,000p s i a t t h et r a i l e r . F i l t e r e don the towert o 10 mu

F ILTRA-TlON

20 mu20 mu

20 mu

20 t o70 mu20 t o70 mu8 0 m u

80 mu

1 / 4 i n c h

L i ne Vol tage4160 V

"

Tower

FROMLOX Sto ra geLOX St or ag eTowerFuel StorageTower

ReadyStorageReadyStorageHighPressureSto rageB a t t e r yT r a i l e r A t -

tachmen tne ar GN2s t o r a g e

WaterStorage &Booster Pump

3 # 210

TOTowerTowerLOX P i tTowerFuelStorageTowerTower

Tower

Tower

TowerDe f 1 ec tor5& F i ex

Tower SubS t a t o n


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FACILITIES SUPPORTINGS T T E & W

lndus tr~al WaterLiquid Ox gen --------- ------------Fuel (RP- ) ------------Gaseous Nitrogen (GN2)--------- GN 2 fSTORAGE


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Th e B lo ckho use i s t h e co n t ro l a nd da ta a cq u i s i t i o n ce n te r f o r f i v e t e s tp o s i t i o n s -- S t a t i c Test Tower East, S t a t i c Test Tower West, Power Pl an tTe s t S ta nd , Co l d Ca l i b ra t i o n Te s t S t a n d Nor th , and the Cold Ca l ib r a t ionTest Stand South. An underground cab le tunnel connects the f a c i l i t yw i t h the S ta t ic Test Tower. Underground cab le ducts connect i t t o t h e o t h e rf a c i l i t i e s m e n t i o n e d .O r i g i n a l c o n s t r u c t i o n i s o f r e i n f o r c e d c o nc r e te f o r p r o t e c t i o n o f p er so nn el .A concr e te b l oc k a dd i t i o n has been made on the nor the ast s ide t o houseinstr ument maintenance equipment. A second z d d i t io n now under co ns tr uc t i onw i l l add 20,600 s qu ar e f e e t o f b l a s t - r e s i s t a n t c o n s t r u c t i o n o t t h e mainbu i l d i ng on the West s i de and 400 f ee t o f cab le and escape tunne l t o t heproposed J-2 t e s t stand, and a tunne l to the proposed advanced DynamicT es t F a c i l i t y .


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ARTIST CONCEPmON OF MOD IF I ED BIQGKHOUSE WI21.I MODIFIED STATIC T.EST TOG.JER IN BAQEGROUL\JD


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PATC Ll LBAD CELL F IRE DE~ECT IONC P A N E L ~ 4 1 1 6 . NI T 5YSTE.WI- = - ---I - - - F- ,-y~ T R T T C ~ F ~ P ~ ~ T- - - ,TL- - - -. - - _- 3 I- r-' -- S - T U ~ ~ZAART-1 I_ STRIP _CHART 1 - 1

-1

TUNNEL TOSTAT1C


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Ii ry----::-::- 1 -----%-I I - - - - - , r -II I TAPE SY3. - TAPE 3YS . I,--- --.-7 I 1- _ _ _ _ I I ' RESTI I , - - ---I Kcc _sGA 'I r 1 ILLISADIC~ I ROOMI I ITA PE ROOMI I I i ROOM IL i lpql -- - - - - - I- A I_ -1 -_1 fi

-- I r 4PATCH LHARMONIC

PANEL' 4NAt.yzER

RECORDER ROOM 1 1I 1 1


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/-COLDC A L I B P A T ~ O ~T E S T S T A ~ D~ 0 ~ 5 0 1 ~ 5


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READY STORAGE AREAS

T he Ready S t o r a g e A re a c o n s i s t s o f a l i q u i d n i t r o g e n s t o r a g e and t r a n s f e rf a c i l i t y and a l i q u i d f u e l s t o r ag e and t r a n s f e r f a c i l i t y .The n i t r o g e n f a c i l i t y c o n s i s t s o f f i v e 12 ,0 00 -g al lo n, o ne 1 4 , 00 0- ga llo na nd tw o 7 , 0 0 0 -g a l lo n vacuum i n s u l a t e d d o u b l e -w a l le d c y l i n d r i c a ls t o r ag e ta nk s f o r s t o r i n g 1 i q u i d n i r o g e n a t - 32 5 '~ . T he o t h e r co mp on en tso f t h e n i t r o g e n r e a dy s t o r a g e a r ea i n c l u d e t wo s te am h e a t e d 2 5 ,0 0 0- sc f/h r v a p o r i z e r s a t 3,0 00 p s i o u t l e t p re s s ur e , t wo 2 5 ,0 0 0- sc f/ hr t r a n s f e rpumps, two 250-gpm un lo ad in g pumps, tw o 250-gpm t r a n s f e r pumps, and t h r e ef a n - b lo w n a m b i en t a i r t e m p e r a t u r e 4 ,8 0 0- sc f/ rn in v a p o r i z e r s a t 5,00 0 p s io u t l e t p r e s s u r e. T he se t h r e e v a p o r i z e r s p r o v i d e t h e g ase ou s n i t r o g e n u se da t t h e S t a t i c T e s t Tow er and t h e P ower P l a n t T e s t S ta nd .T h e s ec on d g r o u p o f e q u i p m e nt c o n s i s t s o f f o u r 1 0 ,0 0 0 -g a ll o n u n d e rg r o un ds t o r a g e t a n k s f o r h y d ro c a rb o n f u e l s . T r a n s f e r eq uip m en t i n c l u d e s tw o250-gpm 2 5 0 - f o o t h ea d t r a n s f e r pumps w i t h f i l t e r s an d m e t e r s , a nd t wo125-gpm i n t e r t a n k t r a n s f e r pumps. T r a n s f e r l i n e s c o nn e ct t h e f a c i l i t yt o t h e S t a t i c T e s t Tow er, Power P l a n t T e s t S ta nd , and o t h e r f a c i l i t i e s .


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N I T R E S ? TRAhTSF!iB, STORAOE,UD Gij?TV;.;RSICFl FACIUTP - CafVGNE?UTTS TEST FACI TTY I!$ BALli3RCUfJn


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DYNAM IC TEST STAND

M e c h a n i c a l t e s t s o n m u l t i s t a g e v e h i c l e s a r e p e r fo rm e d o n t h e D yna mic T e s tStand. T h i s f a c i l i t y a l l o w s f o r t h e c he ck ou t o f m ec ha nic al m a t i n g f e a t u r e s ,t h e d e t e r m i n a t i o n o f n a t u r a l b e n di ng c h a r a c t e r i s t i c s b o t h o n la u nc h armsa nd u n d er s i m u l a t e d f r e e f l i g h t . T he D yna mic T e s t St an d p r o v i d e s a d d i t i o n a lc a p a c i t y f o r t h e t r a i n i n g o f p er so nn el i n t h e d e t a i l s o f s t a g e ha n d l i n ga nd la u n c h p r e p a r a t i o n . G ro un d s u p p o r t e q ui pm e n t s u ch as h y d r a u l i c sy s te m s ,p n e um a ti c sy s te m s , e l e c t r i c a l c o n n e c t io n s , a nd l a u n c h e r s u p p o r t s c an b ec he ck ed o u t u n de r s i m u l a t e d l a u n ch c o n d i t i o n s .Th e t e s t s t a n d c o n s i s t s o f a h e a v i l y r e i n f o r c e d c o n c r e t e fo u n d a t i o n and a2 0 4 - f o o t s t e e l t o w e r . T h e f o u n d a t i o n acco mm od ates t h e same l a u n c h s u p p o r t st h a t a r e u se d a t Cape C an av era l and w i l l s u p p o rt t h e e n t i r e v e h i c l e i n t h ef u l l y f u e l e d c o n d i t i o n . T he s t e e l to we r s t r u c t u r e has a cce ss s t a i r s anda n e l e va t o r, w o rk i ng p l a t fo r m s , w i n d p r o t e c t i o n , v e h i c l e s u p p o rt s f o r f r e ef l i g h t c o n d i t i o n s , l a t e r a l s u p p o rt s , s u p p o rt f o r u m b i l i c a l arm s and co nn ec-t i o n s , and s u pp o r t f o r a 7 5 -to n s t i f f - l e g d e r r i c k w i t h an 8 0 - f o o t boom.T he d e r r i c k a nd a s ec on da ry j i b h o i s t a r e u sed t o i n s t a l l and a ss em ble t h ev a r i o u s v e h i c l e s t a ge s i n th e f a c i l i t y . The e n t i r e s t r u c t u r e w i t h c ra n em a st i n s t a l l e d i s ab o u t 2 60 f e e t a b o ve t h e gr ou n d l e v e l .F a c i l i t y i n s t r u m e n t a t io n i s p r ov id e d b y t h e c o n t r o l c e n t e r l o c a te d t o t h ee a s t o f t h e D yn am ic T ow e r.I n t h e p r e s e n t S a t u r n t e s t i n g p ro gr am , 103,320 g a l l o n s o f d e i o n i z e d w a te ri s u se d t o s i m u l a t e p r o p e l l a n t w e i g ht s on bo ard t h e f i r s t s ta g e , Thep r o p e l l a n t w e ig h ts i n t h e S - I V s t a g e a r e s i m u l a t e d b y 1 6,7 50 p ou nd s o f2 - i n c h d i a m e t e r p o l y e t h y l e n e b a l l s i n t h e h yd ro g en ta n k s an d 6 95 ,0 00 g a l l o n so f w at e r t o s i m u l a t e t h e w e i g h t o f l i q u i d o xy ge n. T he v e h i c l e s a r e su sp en de d


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POWER PLANT TEST STAND

S i n g l e en g in e s a r e s t a t i c f i r e d a t t h e Power P l a n t T e st S tan d. T h i sf a c i l i t y i s c a p a b l e o f f i r i n g t h e H - 1 e n g i ne use d i n t h e S a t u r n S - 1b o o s t e r . T he H -1 e n g i n e ha s a t h r u s t o f 1 88 ,0 00 p ou nd s w i t h a 160 s e co n d(maximum) d u ra t i o n . A1 1 e n g i n e c h a r a c t e r i s t i c s c an b e m ea su re d and t e s t smade f o r b o t h i n b o ar d and o u t bo a r d c o n f i g u r a t i o n s o f t h e S a t u r n e n g i n e a nds u c t i o n l i n e sy s tem s. The f a c i l i t y w i l l b e a v a i l a b l e f o r s u p p o r t o f t h eS - 1 s t a t i c t e s t p r og ra m and f o r h ar dw ar e d ev elo pm en t t e s t i n g i n c o n n e c t i o nw i t h t h e S-1 s t a g e p r o d u c t i m pr ov e m en t p ro g ra m .T he w a t e r c o o l e d d e f l e c t o r h as a f l o w o f 5,0 00 t o 6 ,0 00 gpm. T he s t a i n l e s ss t e e l p r o p e l l a n t t an k a ge a ss em bly h as c a p a c i t y f o r 9 ,0 00 g a l l o n s o f LOXa nd 6 ,0 00 g a l l o n s o f RP - 1 . T he Power P l a n t T e s t S t an d r e c e i v e s i t s f u e la nd n i t r o g e n s u p p l y f r o m t h e Ready S t o r a g e A re a . The f a c i l i t y has w i t h i ni t s c om ple x a LOX s t o r a g e and t r a n s f e r s y s te m o f 2 1,0 00 g a l l o n s .I n s t r u m e n t a t i o n and c o n t r o l a r e p r o v i d e d by u n d er g ro u n d c o n n e c t i o n s t ot h e b l o c k h o u s e .


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WATER RESERVO lR

l n du s t r i a l wa t e r f o r t es t a r ea use i s s t o r ed i n two i n t e rconnec t ed cove reds t ee l (90 f e e t i n d iam et e r and 22 f e e t h i g h) t an ks o f one m i l l i o n g a l l o n scapa c i t y suppor ted by r e in f o r ced conc r e t e f ounda t ions . The d i f f e r e nc e i ne l ev at io n of the re se rv oi rs bases and booster pumps a l lo ws a minimums t a t i c head o f 22 f e e t a t th e booster pumps. The maximum l i n e pressure a tth e pomp house i s 210 p s i . A 10- inch f i l l l i n e connec ted t o the Reds toneArsenal l nd us t r i a l Water System and an automat ic va l ve system mai nta in th ere se rvo i r f u l l and ready f o r use . Two 30- inch s te e l l i ne s connect theWest reservoi r t o the boos te r pump s t a t on.

Nominal s to ra ge capa c i t y i s two m i l l i o n ga l l ons . The maximum dep le t ionr a t e i s 70,000 gpm and th e maximum re pl en is hi ng r a t e i s 4,000 gpm.

BOOSTER PUMP STAT lONThe Boos ter Pump S ta t i o n houses the pumps fo r th e i n d u s tr i a l water su pplysys tem. Pumping f a c i l i t i e s inc lude one 1500-gpm e l ec t r ic a l ly -d r i ve npump, t h r e e 3250-gpm e l e c t r i c a l l y - d r i v e n pumps, and seven 10,000-gpm,d iese l -d r i en pumps.The wa t e r d i s t r i bu t i on sys tem cons i s t s o f a 16 -inch cas t i r on p ipe l oopthrough th e area and a 30- inch s te el p ip e loop t o the Power Pla ntTest Stand and t o the S t a t i c Test Tower. F lowmeters ar e prov i ded i nbo t h l i ne s . P r essur e r egu la t o r s l i m i t p re s su r e i n t h e 1 6 - in ch l i n et o 150 ps ig a t th e pump s t a t io n . Maximum de l i ve ry p res sure t o the3 0 -i n ch l i n e i s 200 t o 210 p s i g .


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Static Test Facility MSFC Saturn S-1

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