STATIC TEST FACILITYRC-msm

lDT

MSF SATURN
[General lnf or mation)
APRIL 1 , 1963 5

l NTRODUCT l ON

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 on those t e s t and ground s u p p o r t f a c i l i t i e s a t t h e M a r s h a l l Space F l i g h t Center 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 personnel r 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 program o f t h e S a t u r n S-1 and S-1B stages.

L I S T O F CONTENTS

MAP REDSTONE ARSENAL AND HUNTSVILLE, ALABAMA AERIAL VIEW O F MSFC T E S T AREA YEAST" PERSPECTIVE DRAWING OF MSFC TEST AREA "EAST" D E S C R I P T I O N O F SATURN I S T A T I C TEST TOWER A R T I S T CONCEPTION O F THE S T A T I C T E S T TOWER AFTER MODIFICATION A R T I S T CUTAWAY OF THE TOWER AND T E S T P O S I T I O N L E S S NEW ANNEX FLOOR PLAN T E S T TOWER ANNEX ( F I R S T FLOOR) FLOOR PLAN T E S T TOWER ANNEX (INTERMEDIATE MEZZANINE) FLOOR PLAN T E S T TOWER ANNEX (SECOND FLOOR) S T A T I C T E S T TOWER CAPABILITY DURING NORMAL S T A T I C T E S T S T A T I C T E S T TOWER SUPPORT F A C I L I T I E S (TABULAR FORM) PLAN VIEW O F F A C I L I T I E S SUPPORTING THE S T A T I C T E S T TOWER PHOTO L I Q U I D OXYGEN, GASEOUS NITROGEN STORAGE F A C I L I T I E S SCHEMATIC LOX STORAGE AND TRANSFER SYSTEMS SCHEMATIC NITROGEN SYSTEM SCHEMATIC INDUSTRIAL WATER AND F I R E X SYSTEMS PHOTO UNDERGROUND FUEL STORAG?3 F A C I L I T Y SCHEMATIC FUEL STORAGE AND TRANSFER SYSTEMS D E S C R I P T I O N OF THE BLOCKHOUSE A R T I S T CONCEPTION O F THE BLOCKHOUSE AFTER MODIFICATION PHOTO BLOCKHOUSE FLOOR 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 EQUIPMENT PHOTO CHECKOUT, CONTROL, AND MINITORING CONSOLES PHOTO STAGF, INTJIRFACE T E S T S E T CONSOLES D E S C R I P T I O N O F READY STORAGE AREAS PHOTO NITROGEN TRANSFER, STORAGE, AND CONVERSION F A C I L I T Y PHOTO L I Q U I D NITROGEN STORAGE VESSELS FACILITY PHOTO FUEL STORAGE AXD T w S F E R D E S C R I P T I O N O F THE DYNAMIC T E S T STAND PHOTO DYNAMIC STAND D E S C R I P T I O N O F THE POWER PLANT T E S T STAND PHOTO POWER PLANT T E S T STAND PHOTO POWER PLANT T E S T STAND WITH BLOCKHOUSE I N FOREGROUND DESCRIPTION O F THE WATER RESERVOIR AND BOOSTER PUMP STATION PHOTO BOOSTER PUMP STATION AND RESERVOIR

RESERVOIR

ADITAN CED DYnAMI C TEST STAND

BOOSTER PUMP SATURN I DYNAMIC T E S T STAND

POWER PLANT

NITROGEN STORAGE TRANSFER, & CONVERSI FACILITY

STATIC TEST

POWER PLANT TE sr sTAND

UNDERGROml

STORAGE

M S F C TEST COMPLEX (EAST)

STORAGE

STATIC TEST T W R O E

The S t a t i c Test Tower i s a t w o - p o s i t i o n f a c i l i t y designed and c o n s t r u c t e d t o s t a t i c f i r e complete Sat~:rr:-i and 1B Boozter stages f o r f u l l d u r a t i o n t e s t s o f approximately 140 seconds and 1,504,000 pounds t h r u s t . The b a s i c s t r u c t u r e i s a r e i n f o r c e d c o n c r e t e tower 140 f e e t i n h e i g h t w i t h a t h r e e - l e v e l r e i n f o r c e d c o n c r e t e annex t o t h e r e a r . Housed w i t h i n t h e s t r u c t u r e a r e engineering o f f i c e s , i n s t r u m e n t a t i o n and c o n t r o l t e r m i n a l rooms, equipment used i n v e h i c l e p r e p a r a t i o n , f a c i l i t y power system, two e l e v a t o r s , access s t a i r s , and an i n d u s t r i a l water system f o r t h e d e f l e c t o r and f i r e x systems.
The s t r u c t u r e s f o r r e s t r a i n i n g t h e v e h i c l e s d u r i n g c a p t i v e f i r i n g s a r e fastened t o t h e tower and t o s p e c i a l spread f o o t i n g s b e a r i n g on H - p i l e s . L a t e r a l t h r u s t loads which occur d u r i n g t h e engine gimbaling t e s t a r e absorbed Each p o s i t i o n has a water-cooled flame d e f l e c t o r and a 170-foot by b u t t r e s s e s . long by 3 0 - f o o t wide c o n c r e t e b l a s t trench. Each b l a s t trench i s connected t o a drainage and waste d i s p o s a l system. Both p o s i t i o n s a r e served by a t r a c k mounted 45-ton g a n t r y crane and a 100-ton r o l l i n g overhead crane supported by a t r u s s system above t h e tower, b r i n g i n g t h e t o t a l tower h e i g h t t o 186 f e e t .

Each flame d e f l e c t o r has a c o o l a n t water f l o w r a t e o f approximately 46,500 gpm. Tower f i r e p r o t e c t i o n i s provided by a F i r e x system w i t h a maximum f l w r a t e o f 31,000 gprn. The tower i s l i n k e d t o t h e blockhouse by an underground r e i n f o r c e d c o n c r e t e i n s t r u m e n t a t i o n c a b l e tunnel, which a l s o serves as an emergency escape passage f o r personnel. Supporting f a c i l i t i e s include: (a) A LOX s t o r a g e 28,000 g a l l o n 400-foot head 200-foot head transports. and t r a n s f e r f a c i l i t y c o n s i s t i n g o f two 14,000 g a l l o n and two double-walled vacuum i n s u l a t e d storage tanks, f o u r 250-gpm pumps used f o r t r a n s f e r and i n t e r t a n k i n g , and two 250-gpm pumps a t t h e connections f o r unloading r a i l cars o r motor

(b)

A 5000 p s i GN2 storage and t r a n s f e r f a c i 1 i t y c o n s i s t i n g o f a b a t t e r y o f t h i r t y - f i v e b o t t l e s o f 35 c u b i c f e e t water volume each. h his f a c i l i t y has common useage s e r v i c i n g o t h e r t e s t f a c i l i t i e s a t t h e MSFC.)
A f u e l s t o r a g e and t r a n s f e r f a c i 1 i t y t o support and supplement t h e f u e l (RP-1) suppl i e d t o t h e t e s t tower from t h e ready storage area. T h i s f a c i 1 i t y c o n s i s t s o f two 20,000-gallon underground s t o r a g e vessels and two 250-gpm t r a n s f e r pumps.

(c)

(d)

5000 p s i He1 ium connections and t r a n s f e r p i p i n g a t t h e t e s t tower f o r hookup t o mob i 1 e s t o r a g e and t r a n s f e r un i t s .

(e)

A water s t o r a g e and t r a n s f e r f ac i 1 i t y cons i s t ing o f two one-mi 1 1 i o n gal l o n s t o r a g e tanks and seven 10,000 gprn d i e s e l - d r i v e n pumps.

A R T I S T CUTAWAY OF THE S T A T I C T E S T TOWER AND EAST T E S T P O S I T I O N WITH THE O R I G I N A L BLOCK HOUSE I N BACKGROUND.

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STATIC TEST TOWER CAPABILITY DURING NORMAL STATIC TEST O SATURN S - 1 BLOCK I I STAGES F

REQUIRED TIME TO LOAD BOOSTER PROPELLANT TANKS LOX : 1 hour 10 minutes ( a f t e r p r e - c o o l ) F u e l .: (RP- I ) : 1 hour

PROPELLANT FLOWRATES (LOAD1 NG)

LOX : Fuel: 800 gpm 585 gpm

LOX BOlLOFF RATE 2,500 g a l / h r a t 70% H u m i d i t y , ~o'F, 29.92 i n . Hg B a r o m e t r i c P r e s s u r e

PROPELLANT QUANTITIES (FULL LOAD) LOX : Fuel: 63,000 g a l 41,000 g a l

FLAME DEFLECTOR WATER FLOW DURATION F u l l f l o w (upper and lower d e f l e c t o r ) 13 minutes 7 hours Upper def 1 e c t o r : FLAME DEFLECTOR WATER FLOWRATES F u l l flow: 46,500 gpm Upper d e f l e c t o r : 5,000 gpm
GN7 TOWER PRESSURE

3,000 p s i a f t e r r e d u c t i o n f r o m 5,000 p s i on 2nd l e v e l o f Tower annex

STATIC TEST T W R O E SUPPORT FACILITIES F ILTRATlON 20 mu 20 mu 20 mu

SYSTEM L i qu i d Oxygen

MODE Fi1 1 Fill Drain Fi11 Drain

CAPAC l TY (2) 28,000 g a l (2) 1 4 , 0 0 0 g a l

(2)

17,000 ga 1

PUMP RATE (2) 250 gpm (2) 250gpm Gravity + 10 PS 1 (2) 250 gpm Gravi t y

LINE SIZE 6 in 4 in 10 i n 6 in 24 i n

FROM LOX S t o r a g e LOX S t o r a g e Tower Fuel Storage Tower

TO Tower Tower LOX P i t Tower Fuel Storage Tower Tower

REMARKS

LOX P i t l o c a t e d S.W. o f Tower

F u e l (RP-1)

F i 1 1 o r (2) Drain F i l l o r (2) D r a in Fi1 1

10,000 ga 1 10,000gal

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4 in
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20 70 20 70

to mu to mu

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Industrial Water
--

(2)

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Water Storage & B o o s t e r Pump Tower Sub Stat ion

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3 #

210

FACILITIES SUPPORTING

STTE & W

lndustr~al Water Liquid Ox gen --------- -----------Fuel (RP- ) -----------Gaseous Nitrogen (GN2)---------

I'

GN2 STORAGE

The Blockhouse i s t h e c o n t r o l and d a t a a c q u i s i t i o n c e n t e r f o r f i v e t e s t S t a t i c T e s t Tower E a s t , S t a t i c T e s t Tower West, Power P l a n t positions T e s t Stand, C o l d C a l i b r a t i o n T e s t Stand N o r t h , and t h e Cold C a l i b r a t i o n T e s t Stand South. An underground c a b l e t u n n e l connects t h e f a c i l i t y w i t h t h e S t a t i c T e s t Tower. Underground c a b l e d u c t s connect i t t o t h e o t h e r f a c i l i t i e s mentioned.

--

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 concrete f o r p r o t e c t i o n o f personnel. A c o n c r e t e b l o c k a d d i t i o n has been made on t h e n o r t h e a s t s i d e t o house i n s t r u m e n t maintenance equipment. A second z d d i t i o n now under c o n s t r u c t i o n w i l l add 20,600 square 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 main b u i l d i n g o n t h e West s i d e and 400 f e e t o f c a b l e and escape t u n n e l t o t h e proposed J-2 t e s t s t a n d , and a t u n n e l to t h e proposed advanced Dynamic Test F a c i l i t y .

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

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READY STORAGE AREAS

The Ready S t o r a g e Area 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 r f a c i l i t y and a l i q u i d f u e l s t o r a g 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 12,000-gallon, one 14,000-gallon and two 7,000-gallon vacuum i n s u l a t e d double-walled c y l i n d r i c a l The o t h e r components s t o r a g e tanks f o r s t o r i n g 1 i q u i d n i t r o g e n a t -325'~. o f t h e n i t r o g e n ready s t o r a g e area i n c l u d e two steam heated 25,000-scf/ h r v a p o r i z e r s a t 3,000 p s i o u t l e t pressure, two 25,000-scf/hr t r a n s f e r pumps, two 250-gpm u n l o a d i n g pumps, two 250-gpm t r a n s f e r pumps, and t h r e e fan-blown ambient a i r temperature 4,800-scf/rnin v a p o r i z e r s a t 5,000 p s i o u t l e t pressure. These 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 gaseous n i t r o g e n used a t t h e S t a t i c T e s t Tower and t h e Power P l a n t T e s t Stand. The second group o f equipment c o n s i s t s o f f o u r 10,000-gallon underground s t o r a g e tanks f o r hydrocarbon f u e l s . T r a n s f e r equipment i n c l u d e s two 250-gpm 250-foot head t r a n s f e r pumps w i t h f i l t e r s and meters, and two 125-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 connect t h e f a c i l i t y t o t h e S t a t i c T e s t Tower, Power P l a n t T e s t Stand, and o t h e r f a c i l i t i e s .

N I T R E S ? TRAhTSF!iB, STORAOE,UD Gij?TV;.;RSICFl FACIUTP

- CafVGNE?UTTS TEST FACILTTY I!$ BALli3RCUfJn

DYNAM IC TEST STAND Mechanical t e s t s on m u l t i s t a g e v e h i c l e s a r e performed on t h e Dynamic T e s t Stand. T h i s f a c i l i t y a l l o w s f o r t h e checkout o f mechanical 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 bending c h a r a c t e r i s t i c s b o t h on launch arms and under s i m u l a t e d f r e e f l i g h t . The Dynamic T e s t Stand p r o v i d e s a d d i t i o n a l c a p a c i t y f o r t h e t r a i n i n g o f personnel i n t h e d e t a i l s o f s t a g e h a n d l i n g and launch p r e p a r a t i o n . Ground s u p p o r t equipment such as h y d r a u l i c systems, pneumatic systems, e l e c t r i c a l connections, and launcher s u p p o r t s can b e checked o u t under s i m u l a t e d launch c o n d i t i o n s . The 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 f o u n d a t i o n and a 2 0 4 - f o o t s t e e l tower. The f o u n d a t i o n accommodates t h e same launch supports t h a t a r e used a t Cape Canaveral and w i l l s u p p o r t t h e e n t i r e v e h i c l e i n t h e f u l l y fueled condition. The s t e e l tower s t r u c t u r e has access s t a i r s and an e l e v a t o r , w o r k i n g p l a t f o 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 r t s f o r f r e e f 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 r t s , s u p p o r t f o r u m b i l i c a l arms and connect i o n s , and s u p p o r t f o r a 75-ton 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. The d e r r i c k and a secondary j i b h o i s t a r e used t o i n s t a l l and assemble t h e v a r i o u s v e h i c l e stages i n t h 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 r a n e mast i n s t a l l e d i s about 260 f e e t above t h e ground 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 i o n i s p r o v i d e d by t h e c o n t r o l c e n t e r l o c a t e d t o t h e e a s t o f t h e Dynamic Tower. 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 program, 103,320 g a l l o n s o f d e i o n i z e d water i s used t o s i m u l a t e p r o p e l l a n t w e i g h t s onboard t h e f i r s t stage, The p r o p e l l a n t w e i g h t s 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 by 16,750 pounds o f 2 - i n c h diameter p o l y e t h y l e n e b a l l s i n t h e hydrogen tanks and 695,000 g a l l o n s o f water 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 oxygen. The v e h i c l e s a r e suspended by c a b l e s t o a c h i e v e t h e f r e e f l i g h t e f f e c t . The v e h i c l e i s r a i s e d about one i n c h o f f i t s s u p p o r t s p r e v i o u s t o shaking. The w e i g h t s of t h e v e h i c l e s i n t h e p r e s e n t s e r i e s o f t e s t s d u r i n g t h e s h a k i n g p r o c e d u r e i s a p p r o x i m a t e l y one m i l l i o n , one hundred and twenty thousand pounds. D e f l e c t i o n s o f t h e l o n g i t u d i n a l a x i s i n t h e b o o s t e r s e c t i o n a r e i n t h e area o f 13 t o 2 inches.

3Y?IM:IC
SATU,W BOOSTER

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P W R PLANT TEST STAND O E

S i n g l e engines 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 s t Stand. T h i s f 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 engine used i n t h e S a t u r n S - 1 b o o s t e r . The H-1 engine has a t h r u s t o f 188,000 pounds w i t h a 160 second (maximum) d u r a t i o n . A1 1 engine c h a r a c t e r i s t i c s can b e measured and t e s t s made f o r b o t h i n b o a r d and o u t b o 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 and s u c t i o n l i n e systems. 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 e S - 1 s t a t i c t e s t program and f o r hardware development t e s t i n g i n c o n n e c t i o n w i t h t h e S-1 s t a g e p r o d u c t improvement program. The w a t e r c o o l e d d e f l e c t o r has a f l o w o f 5,000 t o 6,000 gpm. The s t a i n l e s s s t e e l p r o p e l l a n t tankage assembly has c a p a c i t y f o r 9,000 g a l l o n s o f LOX The Power P l a n t T e s t Stand r e c e i v e s i t s f u e l and 6,000 g a l l o n s o f RP-1. and n i t r o g e n s u p p l y f r o m t h e Ready Storage Area. The f a c i l i t y has w i t h i n i t s complex a LOX s t o r a g e and t r a n s f e r system o f 21,000 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 underground connections t o t h e blockhouse.

H-1 POlnlER PLANT T B T STAND (EAST OTEd)

WATER RESERVO l R

l n d u s t r i a l w a t e r f o r t e s t a r e a use i s s t o r e d i n two i n t e r c o n n e c t e d covered s t e e l (90 f e e t i n d i a m e t e r and 22 f e e t h i g h ) tanks o f one m i l l i o n g a l l o n s c a p a c i t y s u p p o r t e d by r e i n f o r c e d c o n c r e t e f o u n d a t i o n s . The d i f f e r e n c e i n e l e v a t i o n o f t h e r e s e r v o i r s bases and b o o s t e r pumps a l l o w s a minimum s t a t i c head o f 22 f e e t a t t h e b o o s t e r pumps. The maximum l i n e p r e s s u r e a t t h e pomp house i s 210 p s i . A 10-inch f i l l l i n e connected t o t h e Redstone A r s e n a l l n d u s t r i a l Water System and an a u t o m a t i c v a l v e system m a i n t a i n t h e r e s e r v o i r f u l l and ready f o r use. Two 3 0 - i n c h s t e e l l i n e s connect t h e West r e s e r v o i r t o t h e b o o s t e r pump s t a t i o n . Nominal s t o r a g e c a p a c i t y i s two m i l l i o n g a l l o n s . The maximum d e p l e t i o n r a t e i s 70,000 gpm and t h e maximum r e p l e n i s h i n g r a t e i s 4,000 gpm.

BOOSTER P M STAT lO U P N The B o o s t e r Pump S t a t i o n houses t h e pumps f o r t h e i n d u s t r i a l w a t e r s u p p l y system. Pumping f a c i l i t i e s i n c l u d e one 1500-gpm e l e c t r i c a l l y - d r i v e n pump, 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 i e s e l - d r iven pumps. The w a t e r d i s t r i b u t i o n system c o n s i s t s o f a 1 6 - i n c h c a s t i r o n p i p e l o o p t h r o u g h t h e a r e a and a 3 0 - i n c h s t e e l p i p e l o o p t o t h e Power P l a n t T e s t Stand and t o t h e S t a t i c T e s t Tower. Flowmeters a r e p r o v i d e d i n both lines. Pressure r e g u l a t o r s l i m i t pressure i n t h e 16-inch l i n e t o 150 p s i g a t t h e pump s t a t i o n . Maximum d e l i v e r y p r e s s u r e t o t h e 3 0 - i n c h l i n e i s 200 t o 210 p s i g .