Little Joe II Test Launch Vehicle

8/6/2019 Little Joe II Test Launch Vehicle

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MONTHLY PROGRESS REPORTLITTLE JOE II TEST LAUNCH VEHICLE

Report No. 21

10 December 1964

Reference: Par. 3.4.1 of NASA Statement of WorkGDC-62-361 Revised 21 September 1964

NASA CONTRACT NAS 9-492


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CONTENTS

Calendar of Events ...................................SECTION I

A. Contract Status ..............................B. Systems Integration Interface .....................

SECTION HEngineering .................................1. Vehicle ..................................2. Launcher & GSE ............................3. Technical Support ...........................4. Reliability and Quality Control ..................

SE CTION HIManufacturing ................................1. Material .................................2. Tooling .................................3. Fabrication and Assembly .....................

SECTION IVA. Launch Operations ............................

1. Launch Site Operations .......................2. Operations Procedures and Support ..............

B. Logistics ...................................SECTION V

A. Documentation ...............................1. Periodic Reports ...........................2. Other Scheduled Documents ....................3. Unscheduled Documents ......................4. Approved Documents ........................5. December Activity ..........................

iii

33445

8889

13131415

161616162323


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CONTENTS(Continued)

SECTIONVIA. Program Planning andControl ....................1. PERT .................................

2. Schedules ................................3. WSMR Operations ..........................4. Change Control ............................

2828282828

iv


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CALENDAR OF EVENTS

November 5

November 5 - 6

November 11 - 12

November 13

November 16

November 16

November 19

November 23

November 23 - 30

December

December 2 - 3

December 4December 8

Convair personnel attended meeting at WSMR with NASA-MSC on schedule status for Mission A-002 (Little Joe II12-51-1/BP-23}.Messrs. P. S. Jaschke, O. P. Littleton and M. A. Silveira,NASA-MSC, visited Convair for coordination purposes.Mr. M. A. Silveira, NASA-MSC, visited Convair forcoordination purposes.Messrs. T. W. Batson, J. F. Proctor and M. P. Ragusa,NAA-S&ID, visited Convair for interface coordination.Messrs. G. Hyman, L. Riekert and L. T. Morris, GE-ASD,visited Convair to review qualification status and the FRRreport for Mission A-002 (LJII 12-51-1/BP-23}.Mr. George Ratkovic, Aeroject-General Corp./Downey,visited Convair for coordination of the Little Joe H 12-51-2primacord mockup.Convair personnel visited NASA-MSC to attend preliminaryplanning meeting concerning Mission A-004 (Little Joe 1I12 -51-3/AFRM-002}.Convair personnel attended a preliminary readiness re-view {PRR} at NASA-MSC for Mission A-002 (Little Joe II12 -51-1/BP-23}.Mr. E. H. Jones, NASA-WSMR, visited Convair for coordi-nation purposes on Mission A-003 (Little Joe II 12-51-2/BP-22}.

COMING EVENTSConvair personnel to visit NASA-MSC to negotiate contractchanges.Messrs. M. E. Dell and P. S. Jaschke, NASA-MSC, willvisit Convair for the purpose of program review.Convair will attend the FRR at WSMR.Launch of Mission A-002 (Little Joe II 12-51-1/BP-23}.


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SECTION I

A. CONTRACT STATUS

1. Amendment No. 13 dated 9 November 1964 incorporated CCP No. 138,139, 143, 148, 150, 152 through 159, 161 and 162 into the contract at an in-crease in program price of $868,443, including a fixed fee of $52,400. Thisamendment increased total estimated costs to $12,721,679, plus a fixed fee of$815,174, for a total program price of $13,536,853.

2. Amendment No. 14 is being processed by NASA as a result of nego-tiations conducted on 26 and 27 October 1964 and will incorporate specifiedportions of CCP No. 160, 163 and 168 into the contract at an increase in progamprice of $436,040, including a fixed fee of $22,959.

3. During the month of November, 1964, Contract Change AuthorizationNo. 67 through 70 were initiated by NASA.4. Tentative plans were made in October 1964 to negotiate CCP No. 164A

through 171 during the month of November 1964. Negotiations were not accom-plished during November and have now been tentatively rescheduled for the weekof 14 December 1964.

B. SYSTEMS INTEGRATION/INTERFACE

1. North American Aviation - Space and Information Systems Divisioncontinued coordination of spacecraft/launch vehicle electrical interface forBP-22. Design of spacecraft umbilical, launcher changes and BP-22 type dis-connect set testing is proceeding on schedule, with test starting in December.

2. Aerojet General Corporation - Coordinated configuration of nozzlecomponents in support of BP-23 and reviewed shaped charge installation withthe associated test program in support of BP-22.

3. Thiokol - Routine coordination in support of the Little Joe II programcontinued.


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2. Launcher and GSEa. Launcher

Design of the upper mast modification and umbilical installationfor BP-22 and AFRM-002 has been completed. Liaison on themast fabrication and drawing maintenance continued on an as-needed basis.

b. GSE

Design of the umbilical rigging fixture for BP-22 and AFRM-002has been completed and design for the range safety system in-stallation platform for BP-22 has been started.

Activity for DecemberTesting of the umbilical retract mechanism using actual discon-nect equipment will be started in mid-December and completedearly in January.

3. Technical Support

a. Control Dynamics

Trajectory dispersion studies were completed for Mission J(Apollo A-002), delineating the effects on mission performanceof such factors as thrust, drag, wind, hinge moment, pitchcommand time constant, and pitch-up timing.The integrated control system-vehicle development tests havebeen reported by GDC-64-332, Integrated Attitude Control Sys-tem Tests, 30 November 1964.

A special five-degree-of-freedom digital program was formulatedto explore the pitch-up maneuver cross-coupling at angles ofattack which were beyond the range of the MSC analog simulation.The effects of unsymmetrical control gains were explored andfound to be within acceptable limits for a satisfactory mission.

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Activity

b. Weight AnalysisMonthly Weight andBalanceReport No. 30was published. Re-port No. 31, incorporating the final weight statement for vehicle12-51-1 andaddingvehicle 12-51-3, has beenprepared.for DecemberA memo report on Mission J (A-002} trajectory dispersionstudies will be published. Results of the interaxis couplingstudies (five-degree-of-freedom) for Mission J will be reported.Analog anddigital simulations of Mission N (A-003) andP (A-004)will be conductedto establish ballast requirements, RCSre-quirements (or not), andpreliminary gains for autopilot controlandpitch command.

4. Reliability andQuality Controla. DesignReview andMonitoring

Convair andvendor drawings and functional test andoperationcheckoutprocedures are continually reviewed for adequacyofquality control and reliability assurance provisions. A total of39 Convair andvendor drawings or drawing changeswere re-viewed during the month.Datadocumentsfrom 27vendors were reviewed. Data require-ments include drawings; specification, reliability failure modeanalysis, reliability predictions; service experience data;qualifications test reports; status, operating, and checkoutdata;andquality-control program data.

b. ComponentSelection andVendor Monitoring ProgramDuring the month, emphasiscontinuedon selection of reliablecomponents. A total of 67 advancebills of material (ABMs)were reviewed to ensure that vendors wouldbe required to com-ply with adequatereliability andquality control provisions.A total of 46 purchaseorders were reviewed. Only vendors withdemonstrated ability to produce reliable componentsof the typedesired were awardedpurchaseorders.


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c. Failure AnalysisStatus of all failure analyses reports (FARs) is summarized asfollows:

Total FARs initiated during reporting period 16Total FARs initiated to date 164FARs closed to date 132FARs remaining open 32All inspection reports requiring material review andaction aresummarized eachmonth in the Monthly Quality Report.

d. Reliability Analysis andMeasurement ProgramUpdatedfailure analysis and reliability estimates are includedin theQuarterly Reliability StatusReport.

e. Test Activities(1) The Repcocommandreceiver has successfully completedqualification testing at Convair.(2) The Gultonbattery to be usedwith the WSMRcommanddestruct system is continuing in qualification testing.

(3) The hydraulic actuator assembly qualification testing hasbeensuccessfully completed.(4) Partial re-qualification testing of the American Wianckorate gyro packagehasbeen initiated. This testing is theresult of packageredesign by American Wianeko.(5) Qualification testing of the Beckman and Whitely destructors

has been completed. Both high energy and low energy unitsexhibited failures during the high temperature tests, sandand dusts tests, and humidity tests. A high energy unitfailed to ignite the primer after bridgewire burn-out duringthe locked rotor test.


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f. TrainingConvair Training Section conducted108hours of instruction forNASAsoldering certificates during the month.

g. First-Article InspectionOnefirst-article inspection was conductedthis month.

h. Quality Performance AuditsQuality program procedures, test instructions, process specifi-cations and certifications are being audited, and corrective andpreventive action is initiated as required. These audits ensurethat procedures are being followed.

i. Vendor Quality ControlA total of 8 supplier facility evaluation surveys were conductedandapprovedto ensure that suppliers are meeting Convairquality assurance requirements.

j. Process ControlA total of 256 solution control analyses were performed on59tanks that are available for all production programs. A calibra-tion survey of 5 ovensandfurnaces was conducted. A total of25 incoming material evaluation tests were performed.

k. Fabrication InspectionDetailed inspection results are being submitted as a part of theMonthly Quality Report.

1. Surveillance

A weekly surveillance of all inspection and factory areas, includ-ing segregatedstockrooms for Little Joe II material, for con-formance to Inspection CheckLists is continuing. Corrective andpreventive action is being initiated as required.


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SECTIONIIIA. MANUFACTURING

1. MaterialAn all-out effort is continuing in support of Vehicle 12-51-1 at WSMR.As of this date, all production material/parts havebeenshippedandare avail-able at the base. There are a few spare items still duebut they are expectedto be shippedby 4 December 1964.The majority of items required for Vehicle 12-51-2 havebeenre-leasedandpurchaseorders placed. Substantial quantities of parts havebeenreceived andare being received daily. All material is being handledon anexpeditebasis. A complete report of all items released hasbeenprepared by

Engineering Work Order packagefor follow-up and schedulingpurposes.It is anticipated that the shortage countwill be high for a time, butwill decrease rapidly to a point where a small number of items will fall in theproblem category. Generally, parts released for 12-51-2 are electricalhardware type with short lead times. There still are someproblems on de-livery of certain hydraulic componentssuch as the Randall actuator and the

Markite potentiometer but sufficient quantities of these items are expectedby9 December 1964.2. Tooling

The planning required to rebuild "Little WSMR"has beenreleased.Provisions have also beenmade in the system to maintain "Little WSMR"com-patible with "Big WSMR".Planning for the 12-51-2 vehicle, the launcher andthe GSEis beingprocessed in accordancewith program schedules. Premium time is being re-quired in boththe mechanicaland the electrical planning sections to maintainschedulerequirements.

DecemberActivityPlanningwill continueto support the schedule requirements for12-51-1 and12-51-2 firings. It is expectedthat premium time will be requiredfor both theprocessing of the engineering releases and in support of the factoryliaison.


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The engineering releases for the rigging fixture have been received.The fabrication task is expected to be completed in time to support Dept. 131in mating the rigging fixture and the new launcher masts.

3. Fabrication and AssemblyVehicles 12-50-3 and 12-50-4 In storage at San Diego.Vehicle 12-51-1 In launch operations at WSMR.

Factory support available on anexpedited basis as required.

Vehicle 12-51-2 In work in Final Assembly. Anall-out effort is being made to meetthe present schedule. This includesa very close liaison with Engineer-ing and material groups, and anextended work week.

Vehicle 12-51-3 In Final Assembly to latest firingconfiguration.

Vehicle 12-51-4 Fore and aft bodies complete.Held in fixture pending mating andFinal Assembly.

Launcher No. 2 Mast rework for NAA umbilical andupdating of launcher to 12-51-2firing configuration in work.

San Diego operational facilities are being modified and updated toaccurately simulate the launch operations facilities at WSMR.

GSEThe manufacture of the new dual and RF Command Consoles is in

work. Modification of the consoles at WSMR will be accomplished after12-51-1 firing.


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N o'rE AIR CONDITIONING OUTLET ADAPTERATTACHES IN DOOR i OPENING.

PAYLOADUMBILICAL

UMBILICALARM

LAUNCH ESCAPEASSEMBLY

_-_ COMMAND MODULE

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BP SERVICEMODULE

STATION O

SUPPORT ARMUIPMENT AREA ACCESS DOOR(3)

(SEE NOTE)

FOREBODY

STATION 227.0

AIR CONDITIONING ADAPTER DOOR

ALGOLNOZZLE.

ELEVATION CONTROLSCREWJACK

MAIN JUNCTION

ELECTRICAL

TO CABLE TRENCH

(6)

-VEHICLE SUPPORT PAD (6)

FIN (4)

ION POSITIONTRANSMITTER

)N (4)

PLUG-INREMOTE CONTROLLER

IDLERTRUCK(2)

AZIMUTH POSITIONTRANSMI I NNER RAIL OUTER RAIL

Figure 1. Launch Vehicle 12-51-1 Launcher

DRIVE TRUCK (2)

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sTA 0,00STA 15.50STA 33.40TIE- DOWNS

STA 84.34STA 92.09

LAUNCH SUPPORT FITTINGACCESS DOOR

ANTENNA

AIR CONDITION DOOR

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/Q ALGOL ID MOTORS

_ RECRUIT

BALLAST

Figure 2. Vehicle 12-51-1 Attltude Control

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8 VEHICLES 2 LAUNCHERS

GO-AHEAD/CONTRACT NAS 9-492

DELIVERIES ON SITELAUNCHERGROUND SUPPORT EQUIPMENTFFVEHICLE

INTO STORAGE - S AN DIEGOACFVEHICLE

GO-AHEADENGINEERINGMATERIALTOOLINGSUBCONTRACTFACTORY NO. I

FABRICATION _l_ASSEMBLY I qMAJOR ITEM ASSEMBLY //OPERATIONAL CHECKOUT / I/

FACTORY COMPLETE IGROUND SUPPORT EQUIPMENT II

DOCUMENTATION-GENERAL ILAUNCH OPERATIONS (BY MISSION) Ii

TEST FACILITY OCCUPANCY INiLAUNCHER CHECKOUT IPROPULSION SYSTEM (GFP) Ii

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ALL SYSTEMS TEST/EVALUATION |

FL IGHT REPORT L

CCA NO. 18T[ CONTRAScT I

STATUS CUT-OFF DATE: NOVEMBER 30, 19641964 1965

TO CONTRACTI

NO. 4

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SCHEDULEACTUALLATE TO SCHEDULEAHEAD OF SCHEDULERE-SCHEDULEATTITUDE CONTROL FINFIXED FINREACTION CONTROL SYS

NOTE: ATTITUDE CONTROL VEHICLES 2, 3,4, DESIGNATEDWITH AN ASTERISK (*) ARE THE SCHEDULED OPERATIONALCHECKOUT/FACTORY COMPLETE DATES PRIOR TO THESTORAGE PERIOD.SUBSEQUENT SCHEDULED DATE FOR THESE VEHICLESDESIGNATES OPERATIONAL CHECKOUT/FACTORY COMPLETEAFTER THE STORAGE PERIOD.

LAUNCHER NO. 2 IS IN PROCESS OF MODIFICATIONAND UPDATING TO BE COMPATIBLE WITH VER 12-51-2.

Figure 3. Milestones (Continued)

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8,4008,2008,0007,8007,6007,4007,2007,0006,8006,6006,4006,2006,0005,8005,6005,4005,2005,0005,8004,600

FORECAST EXPENDITURES

FORECAST EXPENDITURES

EXPENDITURE_MANPOWER

JULY AUG SEPT OCT NOV DEC1963

FEB MAR APR MAY JUNEJULY AUG SEPT OCT NOV DEC1964

MEN3OO2802602402202001801601401201008O6O402O0

Figure 4. Expenditures by Month

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SECTION VI

A. PROGRAM PLANNING AND CONTROL

1. PERT

PERT update reports, analysis reports, and current Networkmasters were submitted as stated in Section V.

Network 57C has been completed and will be implemented into theNASA PERT system on 11 December 1964.

2. Schedules

Affected Program Schedules have been revised to reflect NASAdirected changes for delivery of Vehicles 12-51-2 and 12-51-3 to WSMR, perCCA No. 49, and storage of Vehicle 12-50-4 at the Convair plant in San Diego,per CCA No. 57.

3. WSMR Operations

Daily PERT Status Reports are being received from the ConvairOperation at WSMR relating progress on Vehicle 12-51-1. Daily reportingwill continue, from WSMR, to support the bi-weekly PERT Report to MSC,Houston until launch of the Vehicle.

4. Change ControlContract Change Proposals No. 172 through 176 were submitted to

NASA. These CCP's covered design changes to vehicles 12-51-2 and 3 re-quired to perform their assigned missions and also cover related changes tothe launcher facility and GSE; current changes to vehicle 12-51-1 Range SafetySystem, vehicle checkout procedures at WSMR; and reductions in documentationdistribution.

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