2003 TABLE OF CONTENTS - NASA7 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

KSC 2003 ANNUAL REPORT

2003ANNUAL REPORTTABLE 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 ....................................................................... 50Economic Impact ............................................................... 51Workforce Diversity ............................................................. 53Procurement Report ........................................................... 54


A MESSAGE FROMTHE CENTER DIRECTOR

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With the loss of STS-107 and the SpaceShuttle Columbia in February 2003, thepublic may have expected NASA andthe Agency’s John F. Kennedy SpaceCenter to stop meeting the challengesof space exploration. However, thechallenge of restoring the Space Shuttleprogram to safe flight serves as theperfect platform for KSC to flourish.

As a Center built upon inspirationalvisions, dedicated workers and anunquenchable thirst for exploration, weaccept unexpected diversions asopportunities to test our strength. Withour mettle now forged by fire, we’llsucceed in the future by overcomingchallenges and leading the world inspace exploration.

Fiscal Year (FY) 2003 was marked byamazing milestones, especially ourworkforce’s dedication to our CoreValues and acceptance of our GuidingPrinciples. This approach is a passion ofmine because a shared vision providesa foundation for future success.

We excel because our inclusive settingnot only respects differences, buttreasures everyone’s unique qualities.We recognize the importance of eachperson’s contribution to the Center andhow their perspective only makes ourresults richer. By avoiding stagnantmanagement, the Center’s leadershipis fluid, serving as a catalyst for endlessnew ideas.

The safety of our workforce, astronautsand public remains our top priority,serving as the Center’s backbone.Whether supporting an awe-inspiring

event or routine task, safety is alwaysthe unifying factor in everything we do.While the Center prompts many specialprofessional and personal bonds, Irealize our families are what are mostimportant in life and I never forget that.

We remain good stewards of theenvironment by protecting the sereneNational Wildlife Refuge. KSC is livingproof our world can continueprogressing while responsibly caring forour resources.

None of these principles are successfulwithout serving our customers withexcellence at all times and relying onteamwork to accomplish this importanttask. Our truly collaborative approachcreates a productive stability.

When my leadership journey with KSCbegan this fiscal year, I joined atremendous heritage. I intend tocontinue this legacy by expecting muchfrom the workforce, thus ensuring wemeet the public’s expectations ofcontinuing our space explorationjourney for the benefit of humankind.

Through remarkable teamwork in FY2003, KSC supported eight ExpendableLaunch Vehicle missions, three SpaceShuttle launches and two landings,International Space Station processing,our reservists fighting the war on terrorand much more. Our future comprisesambitious goals as well, includingreturning our Space Shuttle fleet to safeflight and developing new technologiesand future vehicles supporting the Visionfor Space Exploration.

As KSC continues tirelessly inspiringfuture generations and exploring theuniverse, we should all look forward toKSC’s future impact on our world.

James W. Kennedy

KSC 2003 ANNUAL REPORT 2

KSC 2003 ANNUAL REPORT3 KSC 2003 ANNUAL REPORT

NASA VISION & MISSION

The NASA VisionTo improve life here,To extend life to there,To find life beyond.

The NASA MissionTo 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 theHubble Space Telescope.


THE PRESIDENT’SMANAGEMENT AGENDA

KSC fully embraces the President’sManagement Agenda (PMA) toachieve NASA’s Mission as safely andefficiently as possible. Within the PMAframework are five initiatives used toimprove government performance. KSCcontinues to fully support the Agency’simplementation of these initiatives.

Strategic Management ofHuman CapitolNASA strives to attract and retain thebest and brightest scientists andengineers. KSC is enhancing recruitmentefforts, increasing technology-basedtraining opportunities and establishingand aligning student programs to assurea future “pipeline” of employees. In FY2003, KSC rolled out the Agency’sStrategic Human Capital Plan andhosted expos to discuss new initiativesand demonstrate new human capitaltools to employees. KSC activelyparticipates in the NASA CorporateRecruiting Program, including leadingthe recruiting trip to the University ofPuerto Rico, and spearheadingadditional KSC-specific recruiting trips.Using competency management andtraining and development strategies,KSC is aggressively seeking ways tooptimize its workforce to facilitatestaffing for Return to Flight, Orbital

Space Plane, the NASA EngineeringSafety Center and other Agencypriorities.

Competitive SourcingIn the framework of the NASACompetitive Sourcing initiative, KSC isworking to achieve efficient andeffective competition between publicand private sources, and is meetingcompetitive sourcing goals defined bythe Office of Management and Budget(OMB). The Center completed itsCompetitive Sourcing Plan andexceeded the 15 percent OMBrequirement for FY 2003. Future plans forKSC include providing specific supportfor the upcoming competition for theNASA Shared Services Center, anapproach for consolidating specificNASA business and technical supportservices.

Financial ManagementSignificant achievements includedimplementation of the IntegratedFinancial Management Program’s(IFMP) Core Financial and TravelManager modules in February 2003;supporting the audit of NASA’s FY 2003financial statements by providingfinancial data and analysis toindependent auditors and NASA


KSC 2003 ANNUAL REPORT5

Headquarters; and working with theCompetency Center to support fullcost configuration in Core Financial forFY 2004 operations. Progress continuedin addressing Core Financialstabilization and data issues.

e-GovernmentKSC continued implementation of acommon network infrastructure forNASA e-Gov activities, as well asparticipating in federal e-Govinitiatives. This year, KSC completed itsnetwork infrastructure upgrade plan,designed systems to support the OneNASA portal, and led an Agency-widepilot at seven NASA Centers for theAgency Security Update System. KSCalso leads the One NASA ePresencepilot, and implemented Phase 1 of theNASA Management InformationSystem. In addition, KSC manages theAgency’s Cyber Identity ManagementSystem Project, and leads the Office ofSpace Flight ODIN WebEx pilot.

Integrated Budget andPerformanceKSC prepared for implementation offull cost accounting procedures in FY2004. These included establishing a FullCost Team to implement full costpractices at KSC; delivering a trainingprogram for approximately 200 end-users; and updating and developing afull cost budget submission for FY 2004thru FY 2009. KSC also worked withNASA Headquarters and the IFMPprogram to standardize structures;reconfigure the accounting systemand resolve operational issues; as wellas develop and deploy a program ofChange Management for the Center,which included a “Full Cost 101 RoadShow” offered to all Centeremployees.

Through this framework, KSC realizes itsstrategic goals to assure and advanceaccess to space for exploration,development and use; provide

innovative spacecraft and rangetechnologies for safe space operationsand exploration missions; and provideand assure safe, world-class services.



SIGNIFICANT EVENTS

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10/7/02 –STS-112/Atlantis launches todeliver the S1 Truss to the InternationalSpace Station, and attach it to the S0Truss.

10/17/02 – The Tracking and Data RelaySatellite-J (TDRS-J) arrives at KSC’sShuttle Landing Facility. The TDRS Systemis the primary source of space-to-ground voice, data and telemetry forthe Space Shuttle.

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

11/23/02 – STS-113/Endeavour launchesto transport the Expedition Six crew, anddeliver and attach the Port 1 IntegratedTruss Segment to the ISS.

12/4/02 - NASA’s third TDRS, TDRS-J, liftsoff from Cape Canaveral Air ForceStation (CCAFS), Fla., aboard an AtlasIIA rocket.

12/6/02 – NASA chooses the Delta IIexpendable launch vehicle, providedby Boeing Launch Services, Inc., tolaunch 19 NASA and NASA-sponsoredmedium-class scientific payloadsbetween 2006 and early 2009.

12/7/02 –STS-113/Endeavour lands atKSC.

12/17/02 – Final pieces for the Station’sfootball-field-long backbone arrives atKSC’s Shuttle Landing Facility.

1/12/03 – NASA’s Ice, Cloud and LandElevation satellite and Cosmic HotInterstellar Spectrometer satellite lift offfrom 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 anExtended Duration Orbiter mission.

1/25/03 – NASA’s Solar Radiation andClimate Experiment successfullylaunches aboard a Pegasus XL rocketfrom CCAFS.

2/1/03 – A Space Shuttle contingency isdeclared in Mission Control, Houston, asa result of the loss of communicationwith the Space Shuttle Columbia atapproximately 9 a.m. EST as itdescended toward a KSC landing. Nocommunication and trackinginformation are received in MissionControl after this time. The STS-107 crewmembers and Columbia are lostbecause of a breach in the leftReinforced Carbon Carbon wingleading edge.


2/7/03 – Private KSC employeememorial service occurs honoring thedeparted STS-107 Columbia crew.

2/12/03 – Columbia Accident Investiga-tion Board (CAIB) arrives at KSC.

2/24/03 – First of two Mars ExplorationRovers, MER-2, arrives at Center from theJet Propulsion Laboratory in Pasadena,Calif. The rovers serve as roboticgeologists to seek answers about theevolution of Mars.

2/25/03 – Groundbreaking for thesecond Operations Support Building(OSB II). The site of the new six-story,189,000-square-foot building is in theLaunch Complex 39 area near theVehicle Assembly Building.

3/6/03 – The Space Infrared TelescopeFacility (SIRTF) arrives at KSC for launchpreparations. On Aug. 25, SIRTF isrenamed the Spitzer Space Telescope inhonor of the late Dr. Lyman Spitzer Jr.

4/28/03 – NASA’s Galaxy EvolutionExplorer spacecraft launches from aPegasus XL rocket from CCAFS. Themission features an orbiting telescope toobserve millions of galaxies across 10-billion years of cosmic history.

6/1/03 – A major Stationcomponent, NASA’s Node 2, arrives atthe Center. The European SpaceAgency (ESA) in Italy built Node 2 forNASA.

6/4/03 – A major Station component,the Japanese Experiment Module (JEM),arrives at KSC. The pressurized module isJapan’s primary contribution to theStation.

6/5/03 – KSC’s Web site celebrates itsfirst-time online coverage of anexpendable vehicle mission with the firstMER mission and its associated events.

6/10/03 – MER-A launches aboard aDelta II launch vehicle from CCAFS.

6/18/03 – KSC ceremony highlightsarrival of Node 2 and JEM. The eventincludes official transfer of ownership ofNode 2 between ESA and NASA.

7/7/03 – MER-B launches aboard aDelta II launch vehicle from CCAFS.

7/7/03 – Several days of tours begin forthe workforce and their guests to viewColumbia debris. Experts are availableto provide information and answerquestions.


7/11/03 – NASA spacecraft, designed totest two of Albert Einstein’s Theory ofGeneral Relativity predictions, travels tothe VAFB launch site for the GravityProbe B mission.

7/15/03 – Flight demonstration tests KSC-managed Space-based Telemetry AndRange Safety (STARS) at NASA’s DrydenFlight Research Center demonstrating amore effective, economical trackingand communication technology.

7/28/03 – Two new security gatescomplete the opening of SpaceCommerce Park and a new roadway.This provides an alternate route for thegeneral public between Titusville andMerritt Island, Fla.

8/10/03 – James W. Kennedy becomes8th KSC Director after serving as DeputyDirector since Nov. 2002. Gen. Roy D.Bridges, former KSC Director, becomesDirector of the Agency’s LangleyResearch Center, Hampton, Va.

8/12/03 – The Canadian SpaceAgency’s Scientific Satellite AtmosphericChemistry Experiment launches aboardan Orbital Sciences Pegasus XL at VAFB.

8/20/03 – The Center inaugurates theAgency’s One NASA leader-ledworkshops, helping employees betterunderstand the Agency’s overallstrategy and direction. One NASA is acultural change emphasizing a strongcommitment to teamwork, accessibletools and a greater collaboration acrossthe Agency.

8/25/03 – The Spitzer launches aboard aDelta II launch vehicle from CCAFS.

8/26/03 – CAIB releases its report on theColumbia investigation. NASAAdministrator Sean O’Keefe acceptsCAIB Report recommendations andfindings.

9/17/03 – The Multi-Element IntegratedTest between the JEM and NASA’sNode-2 is successfully completed insidethe Space Station Processing Facility.

9/23/03 – Atlantis continuespreparations for Return to Flight. Someof the work includes reinstallation of theReinforced Carbon-Carbon panels onthe Shuttle’s wing leading edge, wiringinspections, and checks of the Shuttle’sengines in the Orbital ManeuveringSystem.


SAFETY AND HEALTH FIRST

Addressing safety and health concernsand continuously improving employeewellness, the Center tirelessly supports itstop priority and one of KSC’s fourGuiding Principles — Safety and HealthFirst.

After a two-year endeavor, KSCbecame Voluntary Protection Program(VPP) qualified by the OccupationalSafety and Health Administration(OSHA). The Center selected VPP toensure continuous safety and healthprogram enhancements, andcertification as a “Star” site constitutesrecognition as an exemplary safety andhealth program. At least 78 percent ofKSC’s workforce, including two majorcontractors, are VPP Star certified. TheCenter is currently the only federal site inthe region (Florida, Georgia, Mississippiand Alabama) VPP Qualified.

During the VPP certification audit, OSHArepresentatives conducted formal andinformal interviews with civil servants,gauging employee awareness andinvolvement in KSC’s safety and healthprogram. OSHA representatives alsoreviewed safety and healthdocumentation, and inspected worksites verifying consistency andcompliance.

KSC not only complied with approxi-mately 500 OSHA requirements, butseveral areas were also recognized asbest industry practices. These includedthe Center Director’s use of electroniccommunications to the entire workforcehighlighting safety and health aspects,such as employee and management’ssafety and health roles and responsibili-ties, employee rights such as “stop workauthority,” incident and close callreporting, and unannounced monthlyworkplace inspection results.

OSHA also noted the establishment of“RehabWorks” (an on-site occupationalhealth rehabilitation center), employeeawareness and knowledge of VPP, theCenter’s Employee Safety and HealthPocket Guide, and KSC’s Business WorldWeb site with safety and health links.

The annual Spaceport Super Safety andHealth Day increased awareness forpracticing “Safety and Health First” bothin professional and personal activities.More than 120 exhibitors, located atvarious Spaceport locations, offeredsafety and health related information,training sessions and demonstrations.Activities also included astronautappearances, award presentations, ahealth fair and KSC Fitness Centers’open houses.

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Top: Promoting wellness, the annual Spaceport SuperSafety and Health Day included a blood pressurecheck station.Right: Spaceport Super Safety and Health Day offersthe workforce informative presentations and exhibitsto reinforce safe and healthful behaviors.


KSC’s Occupational Health Programcontinuously promoted employeewellness throughout the year withactivities such as Fitness Center events,physical exams, inoculation programs,health education and screeningprograms and the Employee AssistanceProgram (EAP). During the fiscal year,employees made more than 3,000RehabWorks visits and 88,741 KSC FitnessCenter visits. The Fitness Centers offeredmotivational programs such as thePresident’s Adult Active Lifestyle award,which promoted physical fitness.

Screening programs includecardiovascular disease risk reductionand breast and colorectal cancerscreenings. An employee health andfitness day taught employees aboutcommunity health and wellnessprograms and provided healthscreenings, as well as nutrition andexercise counseling. Additionally, theworkforce can receive free flu shots aswell as counseling services through theEAP.

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BUILD RELIANCE ANDTEAMWORK EVERYWHERE

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As we strive for mission success in all ourendeavors, our dependence on oneanother to provide services is critical.Therefore, KSC builds upon its strengthsin reliance and teamwork and commitsto completing opportunities forimprovement consistent with theCenter’s Guiding Principle to BuildReliance and Teamwork Everywhere.These efforts assure future strategicgoals of KSC and the Agency arerealized.

Perhaps the most poignant display ofthe Center coming together in thefiscal year was the STS-107 SpaceShuttle Columbia recovery project. Tocollect debris, 870 KSC civil servantsand contractors helped with the tasksin East Texas. Workers searched aground area corridor 250-miles-long by10-miles-wide. About 38 percent ofColumbia’s dry weight was recovered.Additional in-depth information aboutthe loss of Columbia and its crew canbe found throughout this document.

Last year, the Senior ManagementTeam reviewed the Center-wide KSCReliance and Teamwork Survey;subsequently, a One KSC Team formedto address feedback results. This teaminitially focused on a targetedapproach to achieving One KSC and

making changes to make reliance andteamwork a way of life at the Center.

In addition to One KSC, the Agencyinitiated One NASA, a cultural changeemphasizing a strong commitment toteamwork, accessible tools and agreater collaboration across NASA.Selected by NASA Headquarters, KSChosted the first One NASA leader-ledworkshop Aug. 20, a direct response toworkforce feedback. One NASA alsointroduced key leaders from otherenterprises participating in Centerworkshops. KSC Director JamesKennedy visited the Jet PropulsionLaboratory Oct. 16-17 to participate inits One NASA activities, including a townhall meeting.


NASA worker Joy Huff (right) shows Stafford-CoveyReturn to Flight Task Group members a wing leadingedge subsystem bonded to tile.


U.S. Forest Service members walk a grid during aColumbia Recovery search near the Nacogdoches,Texas site. A space program worker able to identifypotential hazards of Shuttle parts accompanies thegroup.


SATISFY OURCUSTOMERS’ NEEDSANYTIME, ANYWHERE

Integral to KSC’s strategic planning isbuilding and maintaining customersatisfaction through relationshipmanagement. Satisfying Our Customers’Needs Anytime, Anywhere is one ofKSC’s four Guiding Principles. TheCustomer Assurance and Analysis Officeserves as an independent advocate forsystematically managing customerknowledge and feedback to developstrategies for improvement and newopportunities.

The ultimate goal is to ensure acustomer focused culture withcustomers consistently choosing KSC astheir launch site. To achieve this, ourcore customers use customersatisfaction data to drive change andlead continuous improvement. KSC’score customers are Launch ServicesProgram (LSP), Shuttle/InternationalSpace Station (ISS) and SpaceportEngineering and Technology.

The LSP acquires commerciallyavailable ELV launch services for NASAand its customers. LSP ensures missionsuccess, provides low cost services ontime and maximizes customersatisfaction. LSP improvements includea Launch Services Connectionsnewsletter and a new launch servicesmission budget policy. Responding tocustomers’ requests, these additions

facilitate additional communication,thus educating customers on financialregulations, launch services, outreachmaterials and more.

The Shuttle Processing Directorateprepares the Space Shuttle for safe andsuccessful missions. The ISS/PayloadProcessing Directorate identifies andsatisfies ground processing and support,as well as test and integrationrequirements, ensuring a successfulmission. Shuttle/ISS Improvementsinclude updating the DirectorateInformation Technology Policy,publishing a Payload Processing Guide,and documenting standard/nonstandard international customerservices. There is an ongoing effort toupdate customer orientation packagesand establish a single point of contactfor communicating capabilities andrequirements.

The Spaceport Engineering andTechnology Directorate providesinnovative and integrated solutions tocomplex technical problems withcustomer satisfaction as a priority. Newto this effort, the directorate establishedits customer base. The directorate willuse both internal and external customerfeedback to improve processes andcustomer support.


With cables released, the first of two MarsExploration Rovers sits on the floor ofthe Payload Hazardous Servicing Facility.


An owl is heldjust before its release.


ENVIRONMENTALLEADERSHIP

Launch Complex-34 areas werepolluted during the space program’searly history when DNAPLs cleanedApollo rocket parts. Because DNAPLstend to sink to the bottom of the watertable and collect in pools, these solventscan contaminate fresh water sourceswhen left untreated in the ground.

Methods to clear up this potentialproblem are bio-augmentation, whichdegrades some environmentalcontaminants through the addition ofnutrients, and Emulsified Zero-Valent Iron.This approach uses environmentallyfriendly oil and water to neutralizeDNAPLs. Micro-organisms are alsoadded, rendering contaminatingchemicals harmless.

A Florida Power and Light (FPL)alternatively financed project remediedsome of the Center’s inefficient energyoperations. FPL provided a loan for up-front project costs and KSC uses energybill savings generated by the project forfinancing.

Projects in the high bays of the SpaceStation Processing and Operations andCheckout facilities produced significantenergy savings of about $500,000annually. A Payloads/Station Teamreduced heating, ventilation and air

Situated on 140,000 acres, that includea wildlife refuge, the Center continuesto operate in the ultimate marriage ofnature and technology. KSC spent thefiscal year preserving and improvingthat union.

The Merritt Island Spaceflight Trackingand Data Network won the FederalEnergy and Water Management Award.It was chosen by the Department ofEnergy for its long-term efforts toimprove energy efficiency at thetracking and data relay station. Thisgroup saved KSC approximately$100,000 annually in energy bills.

Thousands of sites across the world arecontaminated with dense, non-aqueousphase liquids (DNAPLs). DNAPLscommonly come in the form of cleaningsolvents. KSC implemented new clean-up technologies to help fight this battle.

16KSC 2003 ANNUAL REPORT

Nature thrives with technology as seen in this photoof the Vehicle Assembly Building and surroundinggrounds and water. In the foreground, perched on aplant, is an anhinga—a common Center inhabitant.


conditioning system energy costs to one-tenth the previous levels while improvingtemperature and humidity conditions.The team received a 2002 KSCEnvironmental & Energy Bi-Annual Awardfor their success.

Similarly proactive, KSC’s Energy WorkingGroup provided educationalopportunities, making the workforceknowledgeable about energyefficiency. Included were tours of KSC’slargest mechanical equipment roomand the Central Heat Plant, coveringtopics such as resourcefully maintainingcritical work conditions.

Learning about Earth-friendly personaland professional practices wasstimulated by Environmental and EnergyAwareness Week (EEAW) travelingpresentations, tours, seminars andexhibits.

Dr. Stuart D. Strahl, President/CEO ofAudubon of Florida, spoke at the EEAWOpening Ceremony. Audubon works toensure that conservation becomes acommon interest in Florida rather thanbeing relegated to a special interestgroup. Audience members learned the

importance of discovering andprotecting Florida’s environmentaldiversity.

Supporting environmentally friendlytransportation, employees inspected anAlternative Fueled Vehicle and GlobalElectric Motorcar (GEM). The workforcealso test-drove a Segway HumanTransporter, and discovered using thedevice is as natural as walking.

Providing an opportunity to putknowledge to use, Amnesty Daysallowed KSC workers to dispose ofunwanted government chemicalsexcluding biohazardous, radioactive orexplosive materials. In all, 20,166 poundsof excess materials were collected.

Furthermore, KSC is home to some 25threatened and endangered species,both permanent residents and annualmigratory types. The U.S. Fish andWildlife Service manages the Center’sland. Efforts to increase population andhabitat usage included controlledburning, wetlands enhancement andexotic, invasive plant removals. Thesespecies continue to use KSC lands forwintering, spawning and thriving.

17 KSC 2003 ANNUAL REPORT

New methods of environmental cleanup are explained at Launch Complex 34A.


SPACE SHUTTLE PROGRAM

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Although STS-112 (launched 10/07/02)and STS-113 (launched 11/23/02) wereprocessed and launched during FY 03,the tragic loss of Columbia and herseven-member crew prior to landingFeb. 1, 2003, brought Space Shuttlelaunch activities at KSC to a halt. Theloss changed the focus of processingactivities to support the investigation.For the next several months, KSC andcontractor workers were involved inColumbia debris recovery andreconstruction efforts and Columbiaprocessing reviews, and they assistedthe Columbia Accident InvestigationBoard in determining the root cause ofthe accident.

NASA and contractor workersconcentrated on implementing processimprovements, performing upgrades tothe remaining fleet of orbiter vehiclesand developing new processes,hardware and tools to comply with CAIBrecommendations to prepare theorbiters for Return to Flight.

With a renewed emphasis on safety andreliability, a number of new processes

and upgrades were implemented atKSC to support future Space Shuttlemissions.

Shuttle Processing and Return toFlight ActivitiesAs part of Return to Flight activities andin consideration of CAIB recommenda-tions, Non-Destructive Evaluation (NDE)testing was performed on all orbitervehicle Atlantis (OV-104) wing leadingedge Reinforced Carbon Carbon (RCC)panels. Insulator hardware was disas-sembled, and Atlantis’ wing leadingedge RCC panels were shipped toLockheed Martin Missiles and Fire Con-trol Division to re-perform the originalNDE testing and visual inspections. KSCLogistics packed and shipped thepanels, and developed and coordi-nated turnaround schedules to supportthe upcoming launch schedule. Attach-ment hardware for wing leading edgereinstallation and panel reassemblywere identified and procured.

Spaceflight Operations ContractorUnited Space Alliance (USA) and NASA

The afternoon sun casts a shadow on Space ShuttleAtlantis as it launches on its journey to theInternational Space Station (STS-112).


continuously improve risk-managementdecisions regarding ground operations.The latest improvement uses the ProcessFailure Modes and Effects Analysis(PFMEA) tool to analyze a process. Theobjective of PFMEA is to documentpotential failures that could occurduring a particular process and torecommend actions to eliminate thefailure mode or control the hazard. Theanalysis quantifies risks to personnelsafety, flight hardware and scheduledelays. The PFMEA tool was used tocomplete more than 13 assessments thisyear.

KSC Shuttle Processing implemented anupdated electronic logbook (ELOG) todisseminate information betweenShuttle Processing engineering, qualityand operations personnel and otherSpace Shuttle program projects on adaily basis.

ELOG’s future uses include surveillancedatabase modules for Shuttle ProcessingEngineering and Safety & MissionAssurance, closed-loop accounting ofsurveillance plans and generatingsurveillance metric reports.

In conjunction with Agency experts, KSCShuttle Processing successfullycompleted the inspection of MainPropulsion System Propellant Feed LineBall Strut Tie Rod Assembly (BSTRA)components following the observationof a cracked BSTRA ball in Discovery(OV-103). The inspection requireddevelopment of new tools andtechniques at KSC and a multi-Centerfailure analysis investigation. KSCdeveloped new procedures resulting inthe execution of the first-ever removal ofa 17-inch (diameter) liquid oxygenpropellant feed line from Discovery inorder to return it to the vendor for repair.

USA accomplished a substantialprocedural improvement by utilizing theBoeing Delta Mariner facility at PortCanaveral. Starting with the delivery ofExternal Tank (ET)-119, the ET Barge,

temporarily moored at the facility, istransported up the Banana River to thenewly developed temporary mooringsite at the Vehicle Assembly Buildingbasin, allowing for easy ET offload.During launches, the barge is moved tothe VAB turn basin, eliminating the needfor towing back to Port Canaveral andreturning after launch. The combineduse of the Boeing Delta Mariner facilityand the temporary VAB mooring siteresulted in savings of more than $40,000on each delivery.

A team of KSC engineers andtechnicians and the Cryogenics TestLaboratory developed a safe andreliable technique to isolate a column ofliquid oxygen behind a plug of frozenliquid precision-cleaning agent (Freon).The technique permitted successfulreplacement of a cracked gasket in aliquid oxygen block valve at ShuttleLaunch Pad 39A without draining (andpotentially wasting) thousands of gallonsof liquid oxygen. The technique willundergo further development for use onlarger line sizes with different fluids. A U.S.patent is pending.

UpgradesA new Space Shuttle Main Engine(SSME) horizontal handling truck arrivedto supplement the single truck in servicesince the beginning of the program. Thenew truck features an updated design,increased capabilities and improvedportability for support of SSME removal inthe event of a Trans-Atlantic Landing.

During performance of normalrefurbishment programs on CrawlerTransporters 1 and 2, failed bearingswere found on the jacking and levelingcylinder bearings. USA groundoperations engineering removed andreplaced 64 bearings on each of 32cylinders, which weighed 10,000 poundseach. Extensive modifications to theCrawler Transporter 2 cab and exhaustsystem were also completed during thewindow provided by Return to Flightactivities.


Workers in the Orbiter ProcessingFacility remove one of two OrbiterManeuvering System pods fromEndeavour.


Infrastructure Improvementsand ModificationsFPL and the Shuttle Program completedthe largest energy conservation projectin KSC history with no up-front cost tothe taxpayer. The project, which in totaladdresses $3.2 million worth of energyefficient upgrades and revitalization,was financed by FPL with loanpayments repaid completely from theaccrued savings. The project earnedKSC the Department of Energy’s“Energy Champion” award as NASA’smost outstanding initiative for the year.

For the first time in KSC history, adetailed account of energy transferredin the form of chilled and hot water is onthe horizon. A Center-wide project,begun this year, will provide instrumentreadings (in BTUs) from KSC’s north andsouth ends. Installation of ultrasonic flowmeasurements at key locations will tiethem into the Kennedy ComplexControl System (KCCS) through theEthernet. Completion of thismeasurement project, in conjunctionwith ongoing KCCS installations, willplace KSC at the forefront of all NASACenters in network-based facilitymanagement.

KSC recruited nationally recognizedtechnical experts from the Departmentof Energy to develop projects for energysavings opportunities. These audits, aswell as those performed in-house by theShuttle Program and FPL, form the basisfor future energy reduction initiatives.Future projects may include additionalLaunch Complex 39-area generationcapability and software-based loadcontrol.

Following the loss of Columbia,infrastructure modifications continuedat Launch Pads 39A and 39B. Pad Aprojects included upgrades to thefollowing:• Orbiter Mid-body Umbilical Unit

Support System,

• Corrosion Control and PneumaticTubing Replacement,

• Slidewire System CableReplacement, and Rotating ServiceStructure Elevator Control SystemUpgrade,

• Payload Ground HandlingMechanism EnhancementModification including Stem StrainModification, and

• Engine Service Platforms “Frog” Railsrepair.

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 testingand validation.

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INTERNATIONALSPACE STATION AND

PAYLOAD PROCESSING

KSC’s Space Station Processing Facility(SSPF) is one of the world’s most uniqueprocessing resources. It is home to allStation elements prior to launch fromKSC on their journey to the InternationalSpace Station (ISS). It is inside this facilitythat Station assembly components fromU.S. and international partners arereceived, tested, integrated andvalidated, in preparation for their finaldestination. Reflight carrier elements,which are required for logistics andscience resupply and return-to-earth,are processed here. In addition, theSSPF supports the final integration andcheckout of ISS science prior to flight.

KSC currently houses 10 Stationelements, in various processing andtesting stages. As NASA looks forward toReturn to Flight in 2004, planning andprocessing for the third phase of Stationassembly has begun.

During the fiscal year, the Centercompleted its third Multi-ElementIntegration Test (MEIT 3), which includedthe European-built Node 2 module, theJapanese Experiment Module (JEM)Kibo Pressurized Module and an ISSsimulator. MEIT 3 required assembly of anintegrated international and multi-Center/contractors team at KSC, andproved the hardware/software

relationships of these elements metrequirements.

To accomplish the test, multiple cableswere connected between the twomodules and the on-orbit Stationemulator, providing electrical power,data, command, and cooling tovalidate the compatibility of the systems.Test results confirmed that both moduleswould interact properly when deliveredand attached to the Station. On futureISS missions, Node 2 will be attached tothe 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 wascompleted successfully. This includedemulating the Space Station on-orbitconfiguration, testing the command andtracking systems that support the audioand video systems on-orbit, and thecaution and warning systems thatmonitor life support systems in themodule.

Additional significant ISS elementsprocessed for ISS missions included:

• Starboard 1 Integrated Truss segmentfor Mission STS-112

• Port 1 Integrated Truss segment forMission STS-113


Astronaut Soichi Noguchi (left), with the JapaneseAerospace Exploration Agency, examines data duringa Multi-Element Integrated Test of the U.S. Node 2and the Japanese Experiment Module in the SpaceStation Processing Facility.


STS-113 astronauts Michael Lopez (red stripe)and John Herrington service the newly installedInternational Space Station Port One truss


• Starboard 6 Truss segment, finalsections of the Station’s truss system,arrived at the SSPF for testing andvalidation for a future Station mission.

Columbia Recovery SupportThe ISS and Payloads Processing teamsupported the recovery andreconstruction of Columbia. At the KSCColumbia debris hangar, experiencedpayload engineers combed throughdebris to separate and identify payloadand experiment hardware. Amidst thepayload debris, the team found intactexperiment samples that containedvaluable science.

The Biological Research in Canisters(BRIC) experiments still contained livingworms and moss growth. The ZeoliteCrystal Growth Furnace (ZCG)contained crystal samples, and theCommercial ITA, Inc. BiomedicalExperiment (CIBX) still held samples ofan experiment that might yield newanti-cancer drug delivery systems.

The BRIC experiment yielded twosurviving types of samples. First, living C.Elegan worms were recovered fromcanisters on April 28, 2003. Since theworms have only a seven to ten day life

cycle, it was determined they werefourth or fifth generation descendants ofthe worms launched on STS-107.Second, researchers found moss intactwith growth patterns that will enableresearchers to learn how gravity andlight affect cell organization. BRIC wasable to download temperature datarecorded on three data loggers,including temperatures recorded whileon the ground in Texas.

Liquid was extracted from the ZCGFurnace autoclaves thought to stillcontain Zeolite crystals flown in zerogravity that could be recovered later inthe lab. The durable and complexcrystals are known for their highadsorption properties and are oftenused as catalysts in petroleum andpharmaceutical industries.

Samples recovered from the CIBX-2,that studied developing technology fordrug delivery systems to combatcancerous tumors and cancermetastasis, revealedmicroencapsulation. The drug deliverytechnology uses co-encapsulation ofantibodies and immune stimulants intomicron microcapsules.


Technicians supervise the transfer of the Integrated Equipment Assembly, a major component of theInternational Space Station’s Starboard 6 truss segment.


FUTURE LAUNCHOPERATION


The Center workforce looked forward thisyear and positioned KSC for futurelaunch operations.

The Space-Based Telemetry And RangeSafety (STARS) project demonstrated aspace-based platform’s Range Safetyand Range User capabilities for variouslaunch vehicles. Range Safety includesflight-termination processing from bothspace and ground resources andvehicle tracking using the GlobalPositioning System satellites. Range Userincludes high-return link data rates forvoice, video and vehicle data. The brainof STARS, is known as the Command andData Handler. Estimates show that thesenew methods could reduce costs by upto $40 million per year.

Much of the STARS hardware was put tothe test during the fiscal year. The trialsexercised the equipment as it will beused during flights. These tests preparedfor Flight Demonstration 1, whichanalyzed different functions, capabilitiesand environments. This was a “highdynamics” flight with STARS hardwareand antennas located in an F-15Baircraft. At NASA’s Dryden FlightResearch Center in California, theaircraft performed the dynamicmaneuvers to determine antennacoverage.

The latest in ground-based operations,launch and payload check-outautomation systems were demonstratedas well, using a combination of flightqualification and ground hardware. The

Advanced Checkout, Control andMaintenance System (ACCMS)optimizes ground resources andprocesses needed to meet possibleReusable Launch Vehicle (RLV)turnaround goals, safety standards andefficiency objectives.

This technology will help alleviate thecomplexity of many time-consumingpersonnel tasks, automate routine tasksand reduce organization supportrequirements. Most significant for RLVoperations, ACCMS will reduce risk andtime associated with unplannedmaintenance activities.

Additionally, Sierra Lobo, Inc., acontractor supporting KSC’s efforts, wonNASA’s Small Disadvantaged BusinessPrime Contractor Award. The Ohio-based company was recognized for itsDensified Propellant ManagementSystem contract work. The densifiedpropellants project is considered an“enabling technology” for some RLVsbecause it can decrease vehicle mass.

Another KSC effort is the OperationsConcept Development (OCD). The OCDturns operational concepts intotransportation elements. It clarifiessystem operations, requirements, ideasand boundaries. KSC’s significant OCDexpertise included pre-launchprocessing, launch operations, landingoperations and system design.

KSC also supported the Lessons LearnedDatabase. This key development

KSC 2003 ANNUAL REPORT 26KSC 2003 ANNUAL REPORT

Members of the Space-based Telemetry and Range Safety project support a flight demonstration, which testedhardware on an F-15B aircraft.

captures knowledge from previous andexisting human space flight programsand dozens of space flight experts.

To maximize industry’s creativity andtechnical proficiency, NASA definednecessary capabilities for a potential,new transportation system. KSC alsoprovided technical leadership. TheCenter assessed these requirements thatwill ensure final contractor productshave the integrity needed to progress.

KSC completed seven trade studies todetermine feasibility of future operationrequirements, supported a SystemsRequirements Review milestone,compared various spacecraftconcepts, and provided data for thefuture evaluation of contractorproposals. The Center also began twotrade studies analyzing facility, launchsite and control center requirements.

KSC also supported a Marshall SpaceFlight Center acquisition project bycontributing Ground Operations,Ground Processing Systems, IntegratedLogistics Support, and GroundOperations Training sections for theAlabama-based Center’s draftingprocess.

The Launch Services Program (LSP) isintegrally involved in these efforts, aswell. LSP workers, including contractors,provided and analyzed ELV datasupporting concept developmentefforts. The LSP also evaluatedmodifications required for existing ELVdesigns and launch complexes.Additionally, the LSP is participating inhuman and risk analyses and continuingdevelopment of independent andreliable ELV modeling capabilities.

KSC 2003 ANNUAL REPORTKSC 2003 ANNUAL REPORT29

International Space Station elements areprocessed for future Space Shuttle flights.The JEM pressurized module and theU.S. Node 2 are a few of the elementsthat line the SSPF’s high bay walls.


PAYLOAD CARRIERS

Program ImprovementsThe Payload Carriers Program continuedefforts to improve carrier support forInternational Space Station payloadsand initiated structural rework of theLightweight Multi-Purpose ExperimentSupport Structure to provide requiredsupport for Return to Flight activities.

A study by Kansas State University todetermine the useful life of payloadcarriers was expanded to document allpayload carriers throughout NASA. Thedatabase expansion provides corporatememory to future generations of thescience community for delivery systems.It also provides life expectancy analysiscapability for each individual carrier, aswell as the fleet. These analyses allowinformed carrier selection and costestimation decisions.

The NASA/Boeing Launch ServicesSimulation and Analysis Laboratory(LSSAT) team developed an innovativestrategy and integration tool used toanalyze payloads and achieve the bestuse of carrier space for payloads to beinstalled in the Shuttle. The tool

incorporates precise 3-D modeling andreal-time simulation.

KSC’s LSSAT was recently recognized bythe National Systems TrainingAssociation as the best application in2002 for Modeling and SimulationAnalysis. The tool has the potential forfuture applications in other programsincluding ELVs.

Mission SupportPayload processing support wasprovided for mission STS-107. Experimentssupported by payload carriers in theShuttle’s payload bay included the FastReaction Experiments Enabling Science,Technology, Applications and Research(FREESTAR) Hitchhiker, which comprisedsix experiments.

The program supported the CAIB byproviding flight hardware identification,flight documentation support andpersonnel interviews during debrisrecovery and reconstruction efforts.

The U.S. Node 2 moves toward a workstand in theSpace Station Processing Facility. The Italian-builtcomponent is the second of three ISS connectingmodules.


LAUNCH SERVICESPROGRAM

During the year, LSP managed thelaunch of eight missions, including twopowerful new Mars Exploration Rovers(MER) that traveled to the red planetaboard Delta II launch vehicles. MER-A“Spirit” launched June 10, 2003, andMER-B “Opportunity” launched July 7,2003. The identical rovers reached Marsin January 2004 and are exploringdifferent areas of the planet’s surface insearch of evidence of water that mayhave been present in the planet’s past.

TDRS-J, the second TDRS of three,launched aboard an Atlas IIA launchvehicle Dec. 4, 2002. TDRS-J will provideimproved communications to the SpaceShuttle, ISS, Hubble Space Telescopeand other Earth-orbiting satellites wellinto the 21st century.

NASA’s Ice, Cloud and land ElevationSatellite (ICESat) and Cosmic Hot Inter-stellar Plasma Spectrometer (CHIPSat)launched Jan. 12, 2003, aboard a DeltaII. ICESat is the benchmark Earth Observ-ing System mission for measuring icesheet mass balance, cloud and aerosolheights, as well as land topography andvegetation characteristics. CHIPSat, aUniversity-Class Explorer mission fundedby NASA, will use spectroscopy to studyvery hot plasma believed to fill the localinterstellar bubble.

The first time a spacecraft was mated atKSC to an ELV occurred inside the Multi-Payload Processing Facility Jan. 15,2003. The Solar Radiation and ClimateExperiment (SORCE) vehicle was matedto the Pegasus XL during pre-launchprocessing. A successful launch aboardPegasus Jan. 25 sent SORCE to orbit theEarth and provide accuratemeasurements of solar energy.

NASA’s Galaxy Evolution Explorer(GALEX) launched April 28, 2003, from aPegasus XL vehicle. GALEX, anultraviolet imaging and spectroscopicsurveyor, will map the global history andprobe the causes of star formations andtheir evolution.

Scientific Satellite AtmosphericChemistry Experiment (SCISAT-1/ACE),the first Canadian scientific smallsatellite in more than 30 years, launchedaboard a Pegasus XL vehicle Aug. 12,2003, from VAFB. SCISAT’s two-yearmission will monitor and collectinformation about Earth’s ozoneproviding improved measurements andunderstanding of the chemicalprocesses that control the distribution ofozone in the Earth’s atmosphere,particularly at high altitudes.


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 MarsExploration Rover mission.


Another milestone was reached whenthe Spitzer Space Telescope (formerlySIRTF) launched on a Delta II ELV Aug.25, 2003. Spitzer, named for Dr. LymanSpitzer Jr., one of the 20th century’s mostdistinguished scientists, is the largestinfrared telescope ever launched intospace and the last of four missions inNASA’s Great Observatories Program.Previous missions included the HubbleSpace Telescope, the ComptonGamma-Ray Observatory and theChandra X-Ray Observatory.

At any given time, KSC’s LSP manages30 to 40 current and future ELV missions.The LSP team works with other NASACenters—Jet Propulsion Laboratory:Marshall Space Flight Center inHuntsville, Ala.; and Goddard SpaceFlight Center in Greenbelt, Md.—to planand process NASA’s scientific, researchand communications spacecraft forlaunch on ELVs.

Missions involve multi-year planning anddevelopment between KSC’s programoffice and NASA Centers. GroundOperations, Payload Safety and MissionIntegration Working Groups are involvedin planning and processing for alllaunches. Facilities at KSC and VAFB inCalif. are used to process payloads andlaunch vehicles. Facilities outside NASA,such as Astrotech in Titusville, Fla. andSpaceport System International inLompoc, Calif. are sometimes used toprocess payloads.

As the year winds down, the LaunchServices team prepares for futureEastern and Western Range launches.Mission Integration and GroundOperations Working Groups continue tomonitor planning and processing ofvehicles and spacecraft. Among futurescientific missions are Aura, NASA’sfollow-up mission to Aqua and a keypart of the Earth Observing System;SWIFT, a mission that will study the“afterglow” of gamma ray bursts; andthe Geostationary OperationalEnvironmental Satellite (GOES-N) that

will launch aboard NASA’s first flight ofBoeing’s Delta IV launch vehicle.

Future planetary missions include theMErcury Surface Space ENvironmentGEochemistry Ranging (MESSENGER)spacecraft that will fly by and then orbitthe planet Mercury to conduct the firststudy of the planet; and Deep Impact,a mission that will use an infraredspectrometer to study a comet.

31


SPACEPORTAND RANGE

TECHNOLOGIES


Continuously electrifying NASA’stechnology efforts, KSC made severalcontributions this year in areas ofapplied research & development,engineering development andlaboratory services.

R&D Magazine selected a KSCresearcher as the recipient of theprestigious “R&D 100 Award” for theproduct, “Flexible AerogelSuperinsulation.” R&D considered thecreation to be one of the mosttechnologically significant products ofthe year. This is the first such award wonby KSC.

Water intrusion into Space ShuttleThermal Protection System tile is an oldproblem. During ascent, water can flashoff, potentially causing tile damage.Due to this concern, for many yearsheat lamps were used for hours on endto dry out tiles in case an orbiter wasexposed to rain. Rectifying this tedioustask, KSC developed a method todetect water intrusion in tile, as well as amethod for water removal using a smallvacuum system attached to existingwaterproofing holes.

KSC laboratories provided criticalsupport to the CAIB. This includedworking in both the hangar and thelaboratories providing real-time failure

analysis, metallurgical and chemicalsupport. Activities included developingan X-ray dot map of slag harvestedfrom Reinforced Carbon Carbonleading edge wing debris using ascanning electron microscope andenergy dispersive X-ray spectrometer, aswell as development of lexan wingmodels for display of the RCC debris.

A KSC research and developmentteam used a new hazardous gasdetection system to study Costa Ricanvolcanic emissions. The new prototypesystem, Aircraft-based Volcanic EmissionMass Spectrometer (AVEMS), alsoapplies to the Space Shuttle program. Itis a step toward an advanced systemthat detects toxic gas leaks andemissions in Space Shuttle engine andcrew compartments, providing anadded level of protection. From air andthe volcano’s crater, the team analyzedgases vented from Costa Rica’sTurrialba volcano. The study was the firstto sample and quantitatively analyzefresh volcanic gases in their naturalstate. The new system showscommercial promise and could be usedfor breath, blood and workplace airquality analyses.

NASA, the National Oceanic andAtmospheric Administration (NOAA)

Dr. Richard Arkin records data as thehazardous gas detection systemAircraft-based Volcanic EmissionMass Spectrometer analyzes the toxicgases produced by Costa Rica’sTurrialba volcano. The system detectstoxic gas leaks and emissions in theShuttle.


NASA, the National Oceanic andAtmospheric Administration (NOAA)and other ocean scientists studied andmapped deep-sea corals off CapeCanaveral’s shore. A multi-beam sonarsystem provided the first high-resolution,3-D map of the Oculina Banks. Formedby a single species of coral, OculinaBanks’ deep coral reefs occur no whereelse on Earth.

NASA, NOAA, the Navy, the CoastGuard, and the Florida Fish & WildlifeCommission performed underwateracoustic research involving sensortechnology demonstrations studyingfields ranging from marine biologicalresearch to homeland security. The workalso served as a pilot project assessingthe agencies’ cooperation.

This is the fourth consecutive year KSCearned more Space Act Award dollarsthan any other NASA center. The fiscalyear 2003 award amount of $195,700 isproportionately divided among awardareas.

More than 100 inventors receivedrecognition at the Sixth Annual KSCSpace Act Awards Luncheon. Thewinners individually collected $500 to$21,000. NASA retiree and exceptionalSpace Act Award recipient, AdamKissiah, not only received praise forinventing the cochlear implant 25 yearsago, but also accepted $21,000—thelargest award to a single inventor in KSChistory.

Aside from recognizing and grantingmonetary awards for inventions andother scientific and technicalcontributions that support NASA’saeronautical and space goals, theSpace Act Awards program stimulatesand encourages creation and reportingof similar contributions in the future.

KSC’s Technology CommercializationOffice received 128 New TechnologyReports for innovations developed atKSC. These include patent andcopyright licenses, cooperativeagreements, and Space ActAgreements. Some of KSC’s recentpatent and license awards and licenseofferings include the Advanced Self-Calibrating, Self-Repairing DataAcquisition System, the MultipurposeThermal Insulation Test Apparatus, andthe Cable and Line InspectionMechanism.

Technology Successes

NASA-KSC’s Technology Transfer Officetransfers developed technologies toindustry for commercial use as spinoffsand leverages industry partnerships tocreate “spin-ins.” Spinoffs typically arelicense agreements with companies,while spin-ins are performed primarilythrough Space Act Agreements. TheKSC Technology Transfer Office identifiespartners for both and facilitatesagreement negotiations with industrypartners. Occasionally, a companylicenses a NASA technology forcommercial use and that companypartners with NASA to advance thattechnology to better meet KSC’s needsthrough a Space Act Agreement. In2003, NASA-KSC signed seventechnology license agreements and fivetechnology Space Act Agreements,listed below.

KSC’s patent license with Toxicologicaland Environmental Associates, Inc.,Baton Rouge, La., prompts the use andsale of Emulsified Zero-Valent Iron.

Dr. Grant Gilmore sits alongside undersea expeditionequipment used to characterize the condition of thedeep-sea coral reefs and reef fish populations in theOculina Banks, a marine protected area, 20 milesoffshore of the east coast of Florida.


and other ocean scientists studied andmapped deep-sea corals off CapeCanaveral’s shore. A multi-beam sonarsystem provided the first high-resolution,3-D map of the Oculina Banks. Formedby a single species of coral, OculinaBanks’ deep coral reefs occur nowhereelse on Earth.

NASA, NOAA, the Navy, the CoastGuard and the Florida Fish & WildlifeCommission performed underwateracoustic research involving sensortechnology demonstrations, studyingfields ranging from marine biologicalresearch to homeland security. The workalso served as a pilot project assessingthe agencies’ cooperation.

This is the fourth consecutive year KSCearned more Space Act Award dollarsthan any other NASA Center. The fiscalyear 2003 award amount of $195,700 isproportionately divided among awardareas.

More than 100 inventors receivedrecognition at the Sixth Annual KSCSpace Act Awards Luncheon. Thewinners individually collected $500 to$21,000. NASA retiree and exceptionalSpace Act Award recipient AdamKissiah not only received praise forinventing the cochlear implant 25 yearsago, but also accepted $21,000—thelargest award to a single inventor in KSChistory.

Aside from recognizing and grantingmonetary awards for inventions andother scientific and technicalcontributions that support NASA’saeronautical and space goals, theSpace Act Awards program stimulatesand encourages creation and reportingof similar contributions in the future.

KSC’s Technology CommercializationOffice received 128 New TechnologyReports for innovations developed atKSC. These include patent andcopyright licenses, cooperativeagreements and Space Act

Agreements. Some of KSC’s recentpatent and license awards and licenseofferings include the Advanced Self-Calibrating, Self-Repairing DataAcquisition System, the MultipurposeThermal Insulation Test Apparatus, andthe Cable and Line InspectionMechanism.

Technology SuccessesKSC’s Technology Transfer Officetransfers developed technologies toindustry for commercial use as spinoffsand leverages industry partnerships tocreate “spin-ins.” Spinoffs typically arelicense agreements with companies,while spin-ins are performed primarilythrough Space Act Agreements. TheKSC Technology Transfer Office identifiespartners for both and facilitatesagreement negotiations with industrypartners. Occasionally, a companylicenses a NASA technology forcommercial use and that companypartners with NASA to advance thattechnology to better meet KSC’s needsthrough a Space Act Agreement. In2003, KSC signed seven technologylicense agreements and five technologySpace Act Agreements, listed below.

KSC’s patent license with Toxicologicaland Environmental Associates, Inc., inBaton Rouge, La., prompts the use andsale of Emulsified Zero-Valent Iron.NASA, University of Central Florida,Department of Energy, Department ofDefense, Environmental ProtectionAgency, and GeoSyntec, Inc. createdthe innovative solution, which isdescribed further in the EnvironmentalLeadership section.

Through a patent license, PacificInstruments, Inc.’s (Concord, Calif.)Signal Conditioning Amplifier Recorder(SCAmpR) provides signal conditioning,amplifying and recording capabilities ina single circuit board. SCAmpRsignificantly improves reliability, reducescost and provides more flexibility thanpre-existing systems used during Space


Shuttle launches. A Space ActAgreement for co-development ofSCAmpR and KSC’s use of client-serversoftware for SCAmpR supports theagreement.

NASA provided TABER Industries in NorthTonawanda, N.Y., with a patent licenseto develop and commercialize theMulti-Sensor Array pressure transducer.Working with sensors around SpaceShuttle launch pads, it records physicalphenomena. The technology enablessensor clusters to uniquely monitor theirown health and estimate their ownremaining lifespan.

The patent license with Armor HoldingsForensics in Jacksonville, Fla., supportsthe manufacturing and sale of a scalingdevice and accompanying software.KSC engineers developed the device toassess Space Shuttle external tankdamage following hailstorms. When aphotograph is taken, a pattern,projected by lasers, appears with theinvestigated object’s image, allowingthe viewer to quantify the size of theobject. Accompanying softwarecalibrates the pattern in the photoimage and computes the distancescale for the entire image, savingvaluable time in establishing anddocumenting measurements.

A reimbursable Space Act Agreementwith Phoenix Systems Internationalsupports development of a NitrogenOxides (NOx) emissions reducer in fossilfuel-burning power plants. This effort is acontinuation of previous KSCdevelopments. Previously, Phoenixobtained exclusive rights for allcommercial applications of the KSCNOx technologies, which reduced costsand elimination of hazardous wastestreams. Additionally, this developmentcould directly apply to the SpaceShuttle launch pad NOx scrubbers andCenter boiler plants. Participation underthis Agreement demonstrates NASA’scommitment to environmentalstewardship.

Due to the Center’s proximity to theAtlantic Ocean, KSC is a corrosiveenvironment. Cortec Corporation in St.Paul, Minn., licensed a NASA-developedcorrosion inhibiting technology—aGalvanic Liquid Applied CoatingSystem—for concrete structures. Thisinorganic coating slows or stopscorrosion of reinforcing steel insideconcrete structures, thus protectinglaunch support structures, highwaybridges and KSC buildings.

Detcon, Inc. in The Woodlands, Texas,signed an Exclusive Patent Licenseagreement for the UV/IR HydrogenFlame Detector (U.S. Patent No.5,625,342). The ultraviolet/infraredhydrogen flame detector reduces falsealarms due to reflections from a knownflame source or from non-flame sourcesthat emit UV, such as lightning orwelding arcs. The company is tailoringthe technology to meet the needs oftheir commercial market through a non-reimbursable Space Act Agreementwith KSC.

A meeting with Circuit AvenueNetrepreneurs, in Camden N.J., at theNational Design Engineer Show (March2002) led to a partially exclusive licensefor the Advanced Data AcquisitionSystem (ADAS) in the fields of chemicals,pharmaceuticals and biotechnology. Aminority owned business, it will use ADASto develop their command, control andmonitoring system, which collects datafrom telemetry-enabled instruments andmakes command decisions.

Via a Space Act Agreement, the OpenChannel Foundation and KSC offer thepublic software for researching NASA-KSC technologies at http://www.openchannelfoundation.org/cosmic/. The download is free for anyU.S. citizen or U.S.-owned company, andreturns the taxpayer’s investment to theU.S. economy. Each technology’sforum, providing outlets for usercomments, is monitored by theinnovators themselves, allowing users


direct contact with the NASA expert forthat particular technology. A minimumof nine technologies totaling 64transactions of KSC-developed softwarehave been downloaded.

Also enhancing KSC’s technology basethrough industry partnerships is the SmallBusiness Innovation Research (SBIR)/Small Business Technology Transfer (STTR)program managed by KSC’sTechnology Transfer Office. In 2003, theOffice managed 50 SBIR/STTR contractsvalued at $18.1million.

SBIR/STTR funds early-stage researchand technology development designedto address future mission needs. In 2003,four SBIR/STTR funded projects weresuccessfully implemented at KSC andare described below.

KSC engineers employed OptimalEngineering Solution’s P.I. EXPERT,ensuring Shuttle maintenanceoperations run efficiently. Recognizing aneed for versatile statistical software,three former university professorsdeveloped a prototype integratingtraditional statistical quality assurancetools with robust optimization techniquesin a user-friendly format that is alsovisually compelling. With SBIR/STTRfunding, the company in DaytonaBeach, Fla., created the processimprovement technology, which iscritical to businesses looking torestructure or accelerate operations inorder to gain a competitive edge.

Orbital Technologies Corporation(ORBITEC) in Madison, Wis., partneredwith Utah State University to develop aTemperature and Moisture AcquisitionSystem (TMAS) under the SBIR program.The TMAS measures moisture in smallroot modules used for plant research inmicrogravity and can be used whereverpinpoint moisture readings are desired.TMAS is the moisture sensor chosen foruse in ORBITEC’s Plant Research Unit(PRU)—a plant growth facility underdevelopment by NASA’s Space StationBiological Research Program for SpaceStation experiments. TMAS alsocomplements ORBITEC’s other biomassproduction systems, previously used byNASA Ames Research Center.

A SBIR success model, NASA highlighteda unique software system, jointlydeveloped with SENTEL Corp. inAlexandria, Va. The Electronic PortableInformation Collection system (EPIC) isthe first paperless procedure systemused to launch rockets into space. EPICrecently supported two Atlas Vlaunches. SENTEL developed EPIC torecord and maintain hundreds ofmission-critical procedures that must becompleted before each launch. Tomanage those resources, EPIC offers awireless network that communicates aseries of work authorization proceduresalmost in real time.

Researchers conduct underwater acoustic research inthe Launch Complex 39 area turn basin.


PARTNERSHIPS

37

The Center’s capabilities and researchpotential endlessly grows through itsrelationships with pioneeringorganizations.

KSC, the Air Force, the Secretary ofDefense office and the Federal AviationAdministration addressed space launchneeds associated with low-cost, routineand safe space access. As a result, theFuture Interagency Range andSpaceport Technology Program (FIRST)emerged. FIRST develops keytechnologies to achieve global,interoperable spaceports and ranges.

Agency, Dynamac Corp., Bionetics andUniversity of Florida researchers andscientists moved to the 100,000 square-foot Space Life Sciences (SLS)Laboratory located at the InternationalSpace Research Park (ISRP). This facilityserves as a research hub for plantgrowth experiments, resource recoveryand microbiology/microbial ecologystudies. Built by the state of Florida andNASA, the laboratory also containsanalytical chemistry labs, space flightexperiment facilities and a flighthardware development growthchamber.

After SLS Lab completion, a developing320-acre tract outside the KSC securityzone will expand the ISRP for access by

academic and commercial tenantssupporting NASA’s mission. Thecollaborative NASA and Florida SpaceAuthority effort provides sites forcommercially-developed research,technology and academic facilities. Theyear’s major focus was theEnvironmental Impact Statement andrelated analysis. This investigationhelped NASA determine facilitylocations and provide Florida a long-term lease of the site. The park willaccommodate up to 2 million squarefeet of development over a 20-yearperiod.

The Center, Dynamac Corp., 45thSpace Wing, Jet Propulsion Laboratory,the National Oceanic and AtmosphericAdministration, and National MarineFisheries Service developed a passiveacoustic monitoring systems prototype.These systems monitor vital fishery lifehistory activities such as reproductionand human activity. The NavalUndersea Warfare Center and U.S.Coast Guard Research andDevelopment Center may deploy thesetechnologies for Cape Canaveralhomeland security endeavors.

The system can distinguish betweenmarine life and possible human and/orunderwater craft movements. If marinelife is observed, it can tell the type of fishand how many. It can even hear shrimpwalking around and clicking their claws.If human, it can tell if the noise is a diver,a small submarine, etc.

KSC, GeoSyntec EnvironmentalConsultants, the DoD and U.S. Navytested the NASA-developed EmulsifiedZero-Valent Iron environmental cleanuptechnique. This technology is describedfurther in the Environmental Leadershipsection.

KSC and Phoenix Systems International,Inc. developed an application of theCenter’s oxidizer scrubber technologyfor use at coal- and oil-fired electricpower plants. The new system should be


more cost effective, reduce nitrousoxide emissions and extend the nation’scoal reserves.

NASA’s Office of Space Scienceselected KSC, Cornell University, FloridaInstitute of Technology, University ofArkansas at Little Rock, and Arctic SlopeRegional Corp. to develop a Mars dustparticle analyzer for future landers orrovers. Meeting stringent size, weightand power guidelines, this miniaturizedinstrument intends to perform real-time,simultaneous measurements of Marsdust particles.

Since the mid-1960s, the partnershipbetween KSC and the U.S. Air Force’s45th Space Wing has highlighted thevast array of facilities, infrastructure,processes and intellectual talent bothgroups share. During the fiscal year, thepartnership grew and evolved as KSC

adapted to the Return to Flightenvironment.

Relying on the NASA/USAF CapeCanaveral Spaceport Planning andCustomer Service Office, some keydevelopments progressed through therelationship. The Advanced TechnologyDevelopment Center provides ademonstration and testing environmentclosely resembling a launch facility. TheSpace Exploration Technologies(SpaceX) launch system is a privatelyfunded commercial space launchcompany. The Underwater TechnologyDevelopment Program and its PassiveAcoustical Monitoring System supportsresearch.

Hundreds of guests attend a ribbon cutting ceremony officially opening the U.S. Astronaut Hall of Fame as partof the KSC Visitor Complex.


KSC RESERVISTS CALLEDTO SERVE

While orbiter processing and Columbiainvestigation work continued at KSC,world events called many KSC civilservants and contractor workers awayfrom families, friends and the SpaceCoast. Nearly 100 dedicated men andwomen were called to serve anddefend our country as reservists in thenation’s armed services.

As they serve in the Air Force, Army,Coast Guard or Navy, they carry withthem the spirit, hope and determinationof their “space” family at KSC.

Though some have returned home,many KSC reservists are still servingtoday.

KSC honors these brave men andwomen as they continue to defend ourcountry and work to ensure liberty andjustice for all, whether at home or onforeign soil.


THE COLUMBIARECOVERY AND

RECONSTRUCTION

KSC Assists in ColumbiaRecovery EffortsKSC civil servants and contractorworkers went to Texas, Feb. 1, 2003, asthe result of the Columbia (OV-102/STS-107) tragedy. The first Rapid ResponseTeam (RRT), comprising about 40 NASAand contractor personnel, traveled toBarksdale Air Force Base, La., within 10hours of the accident. Within 72 hours,120 USA managers and employees weredeployed to Texas and Louisiana.

Upon arrival at Barksdale AFB, the RRTset up a command center to manageresources and establish theinfrastructure necessary to support sucha large-scale effort. NASA coordinatedthe overall effort, along with USA andother contractors, the FederalEmergency Management Agency,Environmental Protection Agency, theTexas Forestry Service and other assisting

agencies, eventually encompassing16,500 workers at all debris recoverysites. USA quickly pulled together thenecessary communications supporteffort by Feb. 2 and provided computerworkstations and laptops withconnectivity to the NASA sites atBarksdale AFB, and Texas locations inNacogdoches, Hemphill, San Augustine,Lufkin and Palestine. By the conclusionof debris recovery efforts, more than 800KSC employees were at 16 locations insix states. Search efforts wereconducted on land, by air and at sea.

Columbia Reconstructionat KSCIn the first days following the accident, ateam formed to plan Columbia’sreconstruction. The state’s ReusableLaunch Vehicle hangar at the ShuttleLanding Facility was selected as theoptimal reconstruction facility, based onits size, available technical workforce,access to the vehicle ground-processing infrastructure and itsproximity to materials sciencelaboratories. The facility became knownas the Columbia ReconstructionHangar.

40

Workers place the final piece of the STS-107 missionpatch on the outside of the hangar, where pieces ofColumbia debris were collected and identified.


The Reconstruction Team establishedseveral critical processes for safehandling and management of thedebris, which included receiving,handling, decontamination, tracking,identification, cleaning and assessmentof the debris, with an emphasis onevidence preservation. The teamcomprised engineers, technicians,inspectors and managers from NASA,USA, Boeing and the NationalTransportation Safety Board.

The reconstruction effort spanned fivemonths, during which 27 truckloads ofColumbia debris arrived at theColumbia Reconstruction Hangar fromBarksdale AFB. The debris recoveryworkers collected an estimated 38percent of the orbiter’s dry weight, orapproximately 84,900 poundscomprising 83,900 items. The majority ofitems were no larger than half a squarefoot. More than 40,000 items could notbe positively identified. The remainingbalance of debris was instrumental insteering the investigation toward a rootcause—with 876 pieces associated withColumbia’s left wing as the most critical.

Initially, a two-dimensionalreconstruction of the orbiter outer moldline was developed to facilitateassessment of the debris. As debris waspositively identified, the left wingleading edge became theinvestigation’s main focus area. Thisinitiated a three-dimensionalreconstruction of panels one through 13of the left wing leading edge.

Technicians used virtual reconstructionto create a replica of the orbiter leftwing leading edge. A full-scale left wingwas also built on tables to display lowersurface thermal protection tiles andstructure. These reconstructiontechniques, used in conjunction withmaterial sampling and failure analyses,allowed investigators to extract thegreatest amount of information possiblefrom the debris.

During Columbia’s reconstruction,systems experts hosted more than 60guided tours of the ColumbiaReconstruction Hangar and LaunchComplex 39 Shuttle processing facilities,provided presentations and leddiscussions for the CAIB, the media,visiting Center personnel and otherinterested officials. At the completion ofthe CAIB’s investigation, groundoperations personnel supported aColumbia Reconstruction Hangar walk-through for more than 11,000 KSCworkers and their families during six daysin July 2003.

Workers inventoried, packed andmoved Columbia debris to the Long-Term Storage Facility in the VehicalAssembly Building. Parts of the vehiclewill be available to scientific, research,academic and governmentalorganizations for hypersonic studies anddesign of future aircraft and spacecraft.

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Large items of Columbia debris seem to lay in anendless line.


NASA Administrator Sean O’Keefe (left) looks overColumbia debris with Shuttle Test Director SteveAltemus, also a Columbia Reconstruction ProjectTeam member.


EDUCATION

The Education Programs and UniversityResearch Division assists NASA ininspiring and motivating students topursue careers in science, technology,engineering and mathematics; andengaging the public in shaping andsharing the experience of explorationand discovery. Education Programs(EP) is one of 18 NASA Themes.

This year, the Division supported thedevelopment and implementation ofNASA’s Educator Astronaut Program.Nearly 9,000 nominations generatedfrom the Center’s service area. KSCcontinues to follow the selectionprocess and interacts with manyapplicants offering guidance andsupport.

KSC also helped implement a secondnew Agency initiative—the NASAExplorer Schools Program. Five KSCregional service area schools areparticipating to acquire new teachingresources and technology tools for theirfifth to eighth grade classes. The Centerwelcomed 22 Florida and Georgiaeducators for an intensive, hands-onsummer workshop including a Stationlink-up to interact with Expedition 7crew members. The KSC Educationoffice is in the process of strengtheningthese relationships by visiting all five

schools chosen from our regional servicearea.

Educators and students depend on theCenter continuously for on- and off-sitespace-related workshops that providecurriculum material and classroomtechniques. The office hosted 498 K-12schools, 46,004 K-12 students and 15,406K-12 teachers.

This year, the Division strengthened itsactivity with the Workforce and DiversityManagement Office to integrate effortsfor the NASA Corporate Recruitingactivity. This partnership strengthenedNASA’s recruiting and hiring of studentswho competently fill gaps, andprepared for existing employeeretirements. It also funneled EPparticipants into KSC vacancies.

In the research area, the Divisionworked closely with the SpaceportEngineering and Technology directorateto identify KSC’s top technologyrequirements. With KSC’s TechnologyPlanning Team, Education identifiedpotential technology research projects.Adhering to the Team’s guidelines,participating faculty and studentsacquired projects supporting one of sixCenter Strategic TechnologyDevelopment Initiatives.

Students place flowers at the SpaceMirror Memorial to honor the fallencrew of Space Shuttle Columbia.

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Following the Columbia tragedy,countless students encouraged theCenter and NASA family with letters,pictures and other sympatheticexpressions.

Columbia Elementary School’s (PalmBay) sixth graders greeted KirstieMcCool Chadwick, STS-107 Pilot William“Willie” McCool’s sister, attendedscience demonstrations and placedcarnations at the Space MirrorMemorial. Gifted fourth and fifth graderscontributed a memorial quilt and wroteletters to the Astronaut families,President Bush, NASA employees andAdministrator Sean O’Keefe. A Sanfordschool created an STS-107 MemorialGarden. Education and KSC’s ISS andPayloads Processing Directorate

collaborated with the JapaneseAerospace Exploration Association towelcome a group of Japanese highschool students whose experiments flewon STS-107. They honored the Columbiacrew with a floral tribute at Spacehab’sSTS-107 memorial stone in CapeCanaveral.

By working with elementary andsecondary students and teachers, theDivision will keep improving the public’sunderstanding and appreciation ofNASA’s missions, and promoteawareness of NASA EP’s vital role insupporting the nation’s educationefforts.

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Students pause during work on their experiments that flew on Space Shuttle Columbia. STS-107 launchedexperiments designed and developed by students from six different countries.


OUTREACH TOTHE WORLD

Kennedy Space Center VisitorComplexKennedy Space Center Visitor Complex(KSCVC) helped spread NASA’smessage to more than 1.4 million guestsfrom all over the world in 2003. Thenumber is expected to grow steadilythrough the continuous additions of newattractions, exhibits and tour stops.

The addition of the Astronaut Hall ofFame as part of the KSCVC experienceperfectly compliments the existingexhibits and attractions. Balancedagainst the machines and hardwarethat make space exploration a reality,the Astronaut Hall of Fame tells the otherside of the story, the human side. Itfocuses on the astronauts who tookthose first brave steps into space,offering a glimpse at the formative yearsof these pioneers, and a first-hand lookat the NASA training that molded theminto heroes.

Space Camp facilities opened moreopportunities for the public toparticipate in learning about humanspace flight. New programs, such asAstronaut Training (ATX), allow visitors toengage in a hands-on Shuttle launchand mission.

Astronauts Sally Ride, Dan Brandenstein,Story Musgrave and Robert “Hoot”Gibson were inducted into theAstronaut Hall of Fame, June 21, 2003.The event garnered extensive mediacoverage. ABC’s Good MorningAmerica broadcasted live from theAstronaut Hall of Fame and featuredinterviews with both the new inducteesas well as those honored in prior years.CNN broadcast the ceremonies livenationally.

A new retail store opened mid-year atthe Orlando International Airport. Itssuccess provides daily evidence of thepublic’s respect for NASA and remindsthose visiting Central Florida how closethe Visitor Complex is to Orlando. Thestore serves as a NASA icon to the morethan 13.5 million visitors passing throughthe airport annually.

KSCVC education programs continuedto expand in 2003. The summer daycamp program had a record year withmore than 900 participants. Anextremely successful patch programday designed exclusively for home-schooled students attracted more than1,500 students and parents. InNovember, the Visitor Complex


This aerial view of the KSC Visitor Complex shows full-scale solid rocketboosters and external tank in the foreground, a full-scale model of a SpaceShuttle orbiter behind them, the Launch Status Dome to the right, and theAstronauts Memorial Space Mirror next to the pond.


partnered with NASA, the BrevardCounty School Board and the NationalSpace Club to host every BrevardCounty sixth grade student at KSCVC fora day of hands-on learning.

Government RelationsKSC’s Government Relations Officearranged several significant meetingsand events, including Florida Space Dayin Tallahassee, March 27. Former CenterDirector Roy Bridges and industrypartners met with Florida Gov. Jeb Bush,Lt. Gov. Toni Jennings, Secretary of StateGlenda Hood, Senate President Jim Kingand Speaker of the House Johnnie Byrdto reinforce NASA’s Vision and KSC’smission. The NASA contingentemphasized the many economic,research and technological benefitsthat the Space Program brings toFlorida.

The Office hosted visits to KSC by U.S.Sen. Bill Nelson, U.S. Reps. Dave Weldonand Tom Feeney, and CongressmenTom Delay (Texas) and Mike Ross (Ark.).

The Office provided input to the Website myregion.org project, whichpromotes regional cooperation anddevelopment, and assisted KSCmanagement with presentations to theBrevard County Commission.

KSC Web site and WebcastingExpanded capabilities and new featureson both KSC’s Web site and KSC Direct!highlights the year. Several new Web sitefeatures were added, including the KSCHall of Honor Web site, which allowsformer and current employees to addcareer summary information, and a newKSC 45th Anniversary site full ofinformative text, photos and videos.

Earlier this year, KSC assumed Agency-wide responsibility for the content andmanagement of the “Mission” section ofthe newly revised NASA Portal. Missiontimeline information, feature articles andNASA Direct! video features about EarthObservation, Shuttle and ISS, SolarSystem, Deep Space, Science andTechnology, and Research Aircraft


Employees produce a KSC Direct! Web broadcast.


missions are added regularly. Sinceassuming this responsibility in June 2003,the Mission section has been the mostfrequented of the Portal’s four publicfeature sections.

Multimedia Gallery search capabilitieswere improved, and archived videoon-demand capabilities now enhancethe site.

New ELV mission Web sites, live launchand NASA Direct! Web broadcastswere introduced this year to provideup-to-the-minute launch countdownupdates, extensive mission information,and interactive question and answersessions with program experts. This newprogramming 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 fromVandenberg Air Force Base occurredduring the SCISAT launch, Aug. 12.

A redesigned KSC Site Survey nowallows for better public feedback. Tokeep the public informed and updatedon important NASA news, our WeeklyNews Briefs now feature a two-anchor

format in English, as well as a newSpanish version.

Live Space Shuttle launch coverageWeb sites and Web broadcasts werealso created for Missions STS-112(October), STS-113 (November) and STS-107 (February).

Development and launch of a ShuttleColumbia Tribute/Information site onFeb. 3 kept the public informed with thelatest information. Updated dailythroughout the CAIB efforts, the siteincluded press briefings, hearings,reports, memorials, transcripts andgeneral information.

During the year, KSC’s Web site, livemission coverage and KSC Direct!programming reached more than 10million people. U.S. visitors accountedfor approximately 80 percent of thoseaccessing the site throughout the year.An average of 859,000 visits were madeto the site per month.

ExhibitsThe exhibits team took the NASAmessage on the road to 39 events andreached more than 509,000 people—double those reached last year—across


Young women sign a Columbia tribute poster at the Sally Ride Science Festival. Held at the University ofCentral Florida, Orlando, Fla., the event encourages girls to pursue science, math and technology career paths.


the country and beyond. From theNational Association for theAdvancement of Colored People(NAACP) Convention in Miami, Fla., tothe Centennial of Flight in Dayton, Ohio,to the National Space Symposium inColorado Springs, Colo., KSC’s roadshow explained NASA’s exciting spaceflight history, education programs, andnew science and technology programs.

Exhibits included graphic displays ofNASA-wide programs (Space Shuttle, ISSand LSP), spaceport technology, thebenefits of space, spinoffs, NASA’smission and vision statement, andfocused on the One NASA themethroughout the year.

KSC worked closely with the JetPropulsion Laboratory to educate thepublic on the importance and safetyconcerns of the Mars missions. One ofKSC’s guiding principles, theenvironment, was showcased at theEnvironment Convention in San Diego,Calif.

Other events included exhibits inGeorgia, 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 ofFlorida, and to a Lisbon, Portugalworkshop.

Speakers BureauOver the years, the demand forspeakers has grown and this year wasno different. KSC sent speakers to 566events, reaching approximately 300,000people throughout Florida and Georgia,other U.S. states, along with the VirginIslands, England, Holland and Canada.The number of events representsapproximately a 20 percent increaseover last year.

KSC’s Speakers Bureau supported 12international events and 40 nationalevents. These included the Florida StateNative American Youth Programsponsored by the Governor’s Office,National Space Day, and thededication of many ColumbiaMemorials throughout Florida, Georgiaand Puerto Rico.

A group of 25 astronauts and manyothers brought the NASA message to abroad base of diverse events andorganizations, including the Women inLaw Enforcement Conference, theFlorida Department of Transportation


Col. Everett Thomas (left), 45th Space Wing, presents a framed memento to astronaut John Herrington, theworld’s first Native American astronaut.


Conference, aviation associations,aerospace clubs, Boys Scouts, GirlScouts and Florida Library programs.

Speakers also presented to the HispanicHeritage Celebration in Tampa, Fla., theHispanic Conference in Puerto Rico;American Society of Engineers of IndianOrigin; Youth Leadership Program forHispanic Students in Orlando; Society ofWomen Engineers; Brevard County Parksand Recreation Summer Day Camps fordisadvantaged youths; and theGovernor’s Council on Indian Affairs.

Topics ranged from general to specificaspects of NASA’s space flightprograms.

Media OutreachDuring a Space Shuttle launch andlanding, special event, or just the day-to-day business of doing what KSC doesbest, the KSC News Center hostshundreds of local, national andinternational media representatives,dignitaries, photographers and filmcrews. Stories generated at the PressSite result in millions of people aroundthe world learning more aboutAmerica’s Space program.

The KSC News Center team produced awealth of print, audio and videomaterial, and photographic imagesensuring requests were fulfilled withcurrent information. During the year, thePress Site provided 134 news releases,2,548 interviews, 492 audio tapes, 3,833videotapes, 161,042 photographs, andbi-weekly issues of Spaceport News.Media support was provided duringMissions STS-112, STS-113 and STS-107.Topics included Space Shuttleprocessing, rollout, crew pre-flighttraining and activities, and SpaceShuttle launches and landings. The NewsCenter also provided media support tothe LSP for ELV launches, which includedTDRS-J, ICESat/CHIPSat, SORCE, GALEX,SCISAT, SIRTF, and MER-A and MER-B.

The News Center also coordinatedrequests from production anddocumentary companies, television,radio and print news reporters from theU.S., Spain, Switzerland, Latin America,England, Hungary, Italy, Japan, theNetherlands, France, Russia andBelgium. During the year, the Press Sitearranged access for and escorted 34production companies and 20 televisionnews crews to various locations aroundthe Center, provided support for 31 KSCspecial events, and coordinated andaccompanied 46 print journalists duringassignments.

Among the many significant projectssupported were The History Channel/Greystone filming of a one-hourdocumentary on lightning; NASA TVcoverage for the ISS elements Node 2and JEM arrival ceremony; and MarsRover viewing; also, the IMAX WhiteMountain Productions shoot for a movietitled, “Mars”; interviews for TheDiscovery Channel; and a Kazakhstan,Russia TV crew for a series of TVmagazine programs.


At Launch Complex 39B, media representatives arebriefed on the improved tracking cameras that willcapture ascent imagery during future Space Shuttleflights.


KSC BUSINESS REPORT

Financial HighlightsFinancially, FY 2003 included significantchanges for the Agency and theCenter. The new IFMP replaced thelegacy financial systems used for morethan 20 years. In February 2003, KSCbegan recording transactions in thenew Agency-wide Core Finance system.During that time, a new Travel Managersystem was also initiated as part of theintegrated system to manage all Centertravel-planning and expenses.

Additional financial activities includedpreparation and planning for futuremodules of the integrated system,including Budget Formulation, AssetManagement, E-Payroll and E-Travel.Another significant change was theimplementation of the Full Cost Initiativebeginning in FY 2004. The Full CostInitiative ties direct and indirect costs toNASA’s major programs, projects andinstitutional activities. KSC’s institutionaland infrastructure costs, such as civilservice salaries and the use of facilitiesand support services, are now linked tothe Center’s programs and projects.

The work performed at KSC, whether itbe an Agency program or external workon a cost reimbursement basis, willinclude the full range of costs requiredto perform the activity. Full Cost

principles will be used to formulatefuture annual budgets. Financialoperations under this practice began inOctober.

Both the IFMP implementation and FullCost Initiative support theAdministration’s “President’sManagement Agenda,” focusing onimproving performance anddemonstrating results.

KSC successfully maintained andincreased its share of the NASA budget(see accompanying chart). The FY 2003KSC-managed budget totaled $1.760billion, which including the JSC-managed Space Flight OperationsContract, with 5,000 workers located atKSC. While this budget level essentiallyremained constant with FY 2002 levels,the Center projects an increase to morethan $2 billion for FY 2004.

This funding fuels the local economies ofBrevard County and Central Florida,with the resulting economic impactmeasured, analyzed and publishedannually. While FY 2003 results areincomplete to date, they aresummarized and projected in the nextsection.

FY 2003 was a productive year that willpay significant future dividends for theAgency, the KSC workforce and thelocal economy.



Just as the sights and sounds of a rocketlaunch brings excitement to the lives ofmany Central Floridians, the enormousoperation that is required to make thelaunches possible releases a powerfulblast of economic activity that flowsthrough the businesses and householdsof Brevard County, the Central Floridaregion and other areas of the state.While the thrill of the launch is relativelyshort-lived, the economic effects ofNASA operations in Florida arecontinuous and sustained. In FY 2003, ofthe $15 billion NASA budget, NASA-KSCand other NASA centers injected over$1.4 billion into Florida’s local and stateeconomies. This spending prompted acycle of economic transactions thatflowed throughout many sectors of

these economies and created amultiplied level of total economicactivity that far exceeded NASA’s initialinjection.

To conduct its exploration of space,NASA requires an extraordinary rangeof commodities including fuel, missileengines, computers and photographicequipment. The range of services itpurchases is just as wide, includingcommunications, laboratory testing,Space Shuttle processing, payloadintegration and testing, expendablelaunch services and university research.To meet NASA’s demand for thesegoods and services, local contractorsemploy workers, fund payrolls andgenerate output. These workers andcontractors generate additionalimpacts as they spend their incomesand place orders with other regionalfirms for materials and services. Eachround of spending recirculates NASA’sinitial demand among Florida’sbusinesses and households, multiplyingthe direct impact on the economy.

There are a number of other activitiesdirectly associated with NASA that alsoadd to its total economic impact inFlorida. These include the local travelexpenditures of out-of-state businessand government personnel that travelto KSC to conduct business and the KSCVisitor Complex sales to out-of-statevisitors.

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KSC BUDGET AUTHORITY SUMMARYFY 2002 THRU FY 2004 (DOLLARS IN MILLIONS)


ECONOMIC IMPACT


DIRECT PURCHASES FROM CONTRACTORS AND PAYMENTS TO HOUSEHOLDS BYKSC AND OTHER NASA CENTERS IN FLORIDA IN FY 2003 (Preliminary)

THE TOTAL ECONOMIC IMPACT OF ALL NASA ACTIVITIES AT KSC IN FLORIDA BYGEOGRAPHIC AREA FY 2003 (Preliminary)


KSC annually conducts an EconomicImpact Analysis to measure NASA’seffect on the economy at the local,regional and state levels. The Universityof Central Florida conducted the 2002

report. The 2003 report is not yetcompleted, but estimates for 2003 areprovided.


WORKFORCE DIVERSITY

KSC is the most broadly based, complexand successful launch center in theworld. Through NASA, KSC acts as apremier national landmark capable ofshowcasing the United States’ prowessin science and technology. KSC is ableto help the nation achieve its objectivesin Space due primarily in part to thededication of its workforce, which notonly includes civil service employees,but also a large number of contractoremployees. Together they are essentialin making KSC’s vision a success.

Kennedy Space Center Workforce

On-Duty Full Time Civil Servants 1,748On-Duty Other-than-Full Time Civil Servants 91

Total Civil Servants 1,839

Civil Servant Skill MixScientific & Engineering 59.2%Administrative 25.7%Technical 8.3%Clerical 6.9%

On-Site Contractor Employees 9,738Off-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 missionsexpected of the Space Center,employees carry out a multitude oftasks. At the end of each year, theCenter takes a “snapshot” of itsworkforce. This picture includes allfederal and contract employeeschartered to work for KSC. Otherorganizations, such as the EuropeanSpace Agency and Patrick Air ForceBase, have roles here, but are notreflected in these numbers. As of Sept.30, 2003, the KSC workforce was asfollows:


PROCUREMENT REPORT

Industry Partners at a GlanceThe companies listed below were KSC’stop business contractors (in terms ofobligations) for FY 2003. The followingbriefly describes their work for theCenter:

Space Gateway Support (SGS)SGS, a joint venture (with NorthropGrumman, Shaw and Wackenhut)provides base operations support forKSC, CCAFS and PAFB, including roadsand grounds maintenance, facilitiesmaintenance, custodial, fire, security,calibrations and propellants handling.They held one contract valued at $2.7billion over the life of the contract.

United Space Alliance (USA),Limited Liability Corp.USA is the prime contractor for theSpace Flight Operations Contract(SFOC) whose primary purpose is toensure mission success (includingmeeting the manifest) for the SpaceShuttle Program. KSC is the primary pointof responsibility for launch and landingof the Space Shuttle, and supportsGround Operations and Orbiter Logisticselements of the Space Shuttle Program.KSC partnered $100 million in FY 2003 onthe SFOC contract. USA performs atKSC, JSC, MSFC, SSC, DFRC, White Sands

and worldwide Trans Atlantic Landingsites. The SFOC has a total award valueof $12.7 billion.

Boeing Space OperationsCompanyBoeing Space Operations Company isthe prime contractor for the Checkout,Assembly and Payload ProcessingServices (CAPPS) contract. Its primarypurpose is to support payloadprocessing for the ISS, Space Shuttle,ELVs and other payload programs.Boeing performs all aspects of payloadprocessing, including the planning andreceiving of payloads, payloadprocessing, maintenance of associatedpayload ground systems, integration ofpayloads with the Space Shuttle, launchsupport and Space Shuttle post-landingpayload activities. CAPPS is a cost-plusperformance/award fee contract with abasic four-year period ofperformance and options to extend thecontract for an additional six years. Thevalue of the contract for the initial fouryear period is $332 million. Work isperformed at the Center, CCAFS, VAFB,Space Shuttle landing sites and atvarious payload associated worklocations within and outside the U.S.


Delta Launch Services Inc.Delta Launch Services Inc., the BoeingCompany, is the prime contractor forone of two existing NASA LaunchServices (NLS) multiple award IndefiniteDelivery Indefinite Quantity (IDIQ) taskorder contracts. Principal work locationfor the Delta II vehicle assembly isDecatur, Ala. Launches occur fromCCAFS and VAFB.

Lockheed Martin CommercialLaunch Services Inc.Lockheed Martin Commercial LaunchServices, Inc. is the prime contractor forone of two existing NLS multiple awardIDIQ task order contracts. Principal worklocation for the Atlas vehicle assembly isDenver, Colo. Launches occur fromCCAFS and VAFB.

The Artic Slope Research Corp.(ASRC) AerospaceASRC Aerospace provides research andengineering services and technicalsupport to the KSC SpaceportEngineering and Technologyorganization and other Centeroperational customers. The supportranges in scope from providingresearch, engineering development,management of complex research anddevelopment and technology projects

to engineering and technical support ofvarious KSC laboratories and test beds.ASRC Aerospace utilizes a consortium ofaffiliated universities in performingapplied research and technologydevelopment efforts. ASRC Aerospacealso provides technology outreach tofoster awareness and utilization of KSCunique capabilities.

Orbital Sciences Corp.Orbital Sciences provides small ELVservices for the Agency, using thePegasus and Taurus small ELVs launchedfrom CCAFS, VAFB, Wallops FlightFacility, Va., and equatorial launchranges.

Dynamac Corp.The Life Sciences Services Contractprovides a broad range of life sciencesservices to NASA. These include medicaloperations for Shuttle and Stationprograms, environmental complianceand stewardship, life sciences payloadoperations, support to the AgencyOccupational Health Program Office,biological science, life sciences payloaddevelopment, workforce protection,fitness and musculoskeletalrehabilitation, and education outreach.

KSC 2003 ANNUAL REPORTKSC 2003 ANNUAL REPORT

-

-

DISTRIBUTION OF FISCAL YEAR ‘03 OBLIGATIONS BY BUSINESS TYPE(IN MILLIONS)

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Analex Inc.Analex is the prime contractor on theELV Integrated Support contract. Thecontractor is responsible for performingand integrating the overallprogrammatic ELV business andadministrative functions, includingprogram/project planning, riskmanagement, evaluation andinformation technology. Servicesprovided include the management,operation, maintenance and sustainingengineering of the NASA ELV telemetrystations located at CCAFS and VAFB;engineering services/studies andtechnical services for various ground/flight ELV systems and payloads and;management, operation, maintenanceand sustaining engineering of theassigned NASA facilities, systems andequipment at VAFB. Services areprovided at KSC, CCAFS, VAFB andother launch sites and launch serviceprovider facilities.

Supporting Small BusinessSupporting small business is a NASApriority. During the fiscal year, KSCobligated $127.2 million dollars to smallbusinesses, achieving 141.33 percent ofthe small business goal of $90 million. Thiswas a significant increase from the$102.9 million dollars in small businessawards made in FY 2002.


GEOGRAPHICAL DISTRIBUTION BY STATE(FISCAL YEAR 2003 OBLIGATIONS)

State Total ($k)

Alabama 543Arizona 11,741California 81,737Colorado 2,397Connecticut 7,027District of Columbia 99Florida 720,020Georgia 2,790Hawaii 93Illinois 411Kansas 139Kentucky 1,340Louisiana 345Massachusetts 3,554Maryland 3,022Michigan 241Minnesota 825Mississippi 99North Carolina 382North Dakota 27New Hampshire 301New Jersey 288New Mexico 3,813New York 2,509Ohio 2,597Oklahoma 362Pennsylvania 661Rhode Island 52South Carolina 455Texas 4,853Virginia 2,907Washington 131Wisconsin 295Wyoming 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 theU.S. in support of the NASA mission. As indicated by the chart below, 34 differentstates received procurement dollars from KSC.


Contractor Number of DollarsObligated 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 6,507Inc.

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 Contractrecorded $690 million managed by the KSC ProcurementWorkforce in FY 2003.



Attached underneath the L-1011 aircraft is thePegasus XL rocket, containing NASA’s SolarRadiation and Climate Experiment.

Documents

2003 TABLE OF CONTENTS - NASA7 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