i i i r i i - dtsc-ssfl. · pdf file4.4.2 stand talkers to move their scba's and class...

02 JUNE 88 ROCKWELL INTERNATIONAL COR PNORTH AMERICAN SPACE OPERATIONS

7-101 R6 of 28

CTL-III, 705 RENOVATION

ROCKETOYNE DIVISION

OPERATING INSTRUCTIONS

5662G/0164 6

TITLE : CTL-III ROTOGENERATOR LASER STAND SETUP PROCEDUR E

WRITTEN/REVISED BY APPROVED BY

LASER SYSTEMS DEV .(631) SYSTEMS SAFETY

SAFETY r

TEST NUMBER TEST DATE

TEST CONDUCTOR DIAGNOSTIC ENGINEE R

MECHANIC MECHANIC

MECHANIC MECHANIC

1 .0 SCOP E

This procedure covers the facility setup requirements for operation

2 .0

of the Rotocoil Laser in the 705 building .done the day before the test .

PRETEST DAY SETUP

Sections 2 to 7 to b e

2 .1 To be done the day before the test :

3 .0 CL2 VAPORIZER SETU P

3 .1 Vaporizer Already ON . If vaporizer is not on, go to Section 4 . 0to 4 .2 .

3 .2 Record vaporizer temperature : OF .

3 .3 Verify temperature is below 185°F .

3 .4 If temperature is AT 165°F, adjust set point to 180°F .

3 .5 If temperature is BELOW 165°F, verify set point is at 165°F .

3 .6 Verify indicating lights correct and level correct :

3 .6 .1 Verify water level is above the black marked minimum level . Ifnot, add water at top .

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02 JUNE 88 ROCKWELL INTERNATIONAL COR PNORTH AMERICAN SPACE OPERATIONS

7-101 R6 of 2 8

ROCKETDYNE DIVISION 56626/0164 6

3 .6 .2 Verify "HTCO indicator" light is OFF .

3 .6 .3 Verify "Heater CTLR On" light is ON .

3 .6 .4 Verify "Heater Light On" is ON if temperature is below 165°F, orOFF if above 185°F .

NOTE : At 165 - 180°F, the heater will vary depending on setpoint .

3 .6 .5 Record temperature and "Heater Light" in Appendix 1 .

4 .0 START UP VAPORIZER

4 .1 At 480 Control Box :

4 .1 .1 Turn main power level to ON .

4 .1 .2 Verify "Main Power On" light is ON .

4 .1 .3 Verify "HTCO Indicator" light ON .

4 .1 .4 Push start button .

4 .1 .5 Verify heater CTLR ON .

4 .1 .6 Push HTCO reset .

4 .1 .7 Verify "Heater On" light is ON .

4 .2 Verify water level is above the black marked minimum level . Ifnot, add water at top .

4 .3 Verify air conditioning 705 system ON and operational and celltemperature is between 65° and 80° . If not, notify engineer .

4 .4 Check general condition of Building 705 for cleanliness . Ifthere are loose papers, rags, or other material lying about,clean up .

4 .4 .1 Verify safety equipment (SCBA's) is ready for use and in properworking order .

4 .4 .2 Stand talkers to move their SCBA's and Class "G" to ControlCenter .

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02 JUNE 88 ROCKWELL INTERNATIONAL CORP 7-101 R6NORTH AMERICAN SPACE OPERATIONS of 2 8

ROCKETDYNE DIVISION 5662G/0164 G

4 .4 .3 Halogens ( fluorine , chlorine , iodine) .

NOTE : Class G

This protective equipment is used when opening ahalogen "K" bottle valve, initiating flow in anysystem , or opening any halogen -type system .

Self-contained breathing equipment ( Scott Air Pack) .

Teflon coated cloth or gray lite cover- all or apron .

Teflon coated cloth or gray lite hood having faceshield .

Neoprene gloves .

Neoprene boots .

4 .5 Sweep out H2O2 and KOH load tank area .

4 .6 Check area for tripping hazards inside and outside Building 705and take appropriate action to remove, if any are found .

4 .7 Check area around chlorine bottles, chlorine tank and KOH,H202 load tanks for cleanliness . Clean up any loose trash .

4.8 Verify all GN2 cascade shutoff valves are OPEN ; #7, #13, #19,#25 .

4.9 Verify GN2 cascade pressure at 4,760 minimum . If not, chargeup GN2 .

4 .9 .1 Verify 10-M9 and 22 -M9 He vessel #137 shutoffs are OPEN .

4.10 Verify 3000 psig GHe area pressure is at 2500 psi minimum . Ifnot, charge up per 7 -105, Section 7 .0 .

4 .11 Place 5 KOH 55-gallon drums at KOH load tank ( Reagent grade byModule I, under tank) .

NOTE : Verify KOH Drum Tops are clean prior to opening . Itis preferred to have all drums from same batch or lot .

4 .12 Ready KOH drums : 1) One in position ( ready to load ), and (2)All five tops are clean .

4 .13 Verify RGA pop-off plastic boots are installed .

4 .14 Record EWR# and amount of NaOH loaded at C12 treatment tankpretest . #

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02 JUNE 88 ROCKWELL INTERNATIONAL CORP 7-101 R6NORTH AMERICAN SPACE OPERATIONS of 28

ROCKETDYNE DIVISION 5662G/0164G

4 .15 Take a Cl2 treatment tank sample per below : Suit up withClass "G" protective clothing and take sample at pump pitcockbleed . See above NOTE in 4 .4 .3 .

4 .16 Locate KOH sample bottles (1 for each lot number) .

4 .17 Locate polyurethane hand pump .

4 .18 Rinse hand pump with DI water . ( Dispose of water in waste drumif contaminated . )

4 .19 Suit up with Class L protective clothing (2 mechanics as statedin 26 .21) .

4 .20 Insert KOH hand pump into KOH barrel and draw (from one of thefour drums) sample into sample bottle .

4 .21 Sample each barrel that has a different lot number . (Note,should all be the same lot number) .

4 .22 Rinse KOH pump into waste KOH drum .

4 .23 Secure KOH drums that were sampled .

4 .23 .1 Label each sample as "KOH", with the date, lot number, andCTL-III .

4 .23 .2 Notify Transportation for pick-up of sample bottle(s) and directdelivery to the Chem Lab .

4 .24 The following are required for post test securing .

4 .24 .1 Obtain a clean plastic bucket .

4 .24 .2 Obtain Portable Oxygen Meter for 705 entry posttest .

5 .0 PNEUMATIC CONSOLE PRELIMINARY SETU P

5 .1 Adjust the 705 GN2/pneumatic station per below :

Sta Set Pressure Name

A 2100 - 2200 GN2 Suppl y

B 65 - 75 DI Water Tank Pressure

C 50 - 55 60 Contro l

0 130 - 140 Utility/Crane

E 0 Primary GN2/Cold GN2

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Sta Set Pressure Name

F 90 - 95 100 Control

G 160 -190 C12 Tank Pressurizatio n

H 0

I 0

J

K

L

U

1300 - 1350 1500 Control

135 - 140 150 Contro l

0 Mix Vessel Purge

M 130 - 140 CL2 System Purg e

0 Primary He

5 .2 Adjust Pfaudler 50 psi control, 40 - 45 psig .

5 .3 Verify 2-M14 OPEN, cold GN2 manual shutoff .

5 .4 Verify the GN2 supply #1244 to ejector is CLOSED and itsbypass hand valve is CLOSED .

5 .5 Give instrumentation leadman Appendix II of this procedure .

6 .0 CONTROL CONSOLE PREPARATIO N

6 .1 Check control console to verify all switches are down or inneutral position .

6 .2 Verify the "02 Generator Control" patchboard is installed( Instrumentation Room, Bay 5) .

6 .3 Make announcement :

ATTENTION ALL PERSONNEL . THE CTL-III CONTROL CONSOLE WILL BEACTIVATED . Repeat .

6 .4 Turn ON control console key switch .

7 .0 HYDRAULIC SYSTEM PRETEST SETU P

7 .1 Verify hydraulic mule switch on console is UP .


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7 .2 Verify that the hydraulic pump outlet accumulator (11-Mb) andthe 3 servo valve accumulators (130, 131, and 133) areprecharged to 1800 ± 100 psi with the pump off . If they arenot, recharge them per Paragraphs 7 .2 .2 through 7 .2 .12 .

NOTE : The individual accumulator charge isolation valve isnormally in the OPEN position : 8-Mb, 104, 105, and 106,respectively .

7 .2 .1 If precharge is within limits, go to 7 .3 .

7 .2 .2 GN2 console station 0, adjust for 1800 psi .

7 .2 .3 At the accumulator precharge panel, connect the swing tube tothe GN2 supply .

7 .2.4 Precharge panel manual vent 1242, CLOSE .

7 .2.5 Precharge panel manual inlet 1241, OPEN .

7 .2 .5 Precharge panel manual outlet 1243, OPEN .

7 .2 .7 By means of the Precharge momentary switch, charge accumulatorsuntil audible flow is no longer heard .

7 .2 .8 Verify that the individual accumulators are pressurized to 1800± 100 psi .

7 .2.9 Precharge panel outlet 1243, CLOSE .

7 .2 .10 Precharge panel inlet 1241, CLOSE .

7 .2 .11 Precharge panel vent 1242, OPEN .

7 .2 .12 Disconnect swing tube from GN2 supply, cap fitting, and plugline .

7 .2 .13 GN2 console station 0, adjust for zero psi .

7 .3 Verify hydraulic pump arm switch, ON (RACHL console) .

7 .4 Verify hydraulic pump outlet 1-Mb, OPEN .

7 .5 Verify 705 facility hydraulic isolation 3-Mb, OPEN .

7 .6 Verify hydraulic accumulator supply manifold isolation 142, OPEN .

7 .7 Verify hydraulic pump cooling water supply OPEN and waterflowing from dump line .

7 .8 Hydraulic recirculation pump switch, ON .

7 .9 Hydraulic main pump bypass 8-M21, OPEN .

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7 .10 Hydraulic main pump switch, ON .

7 .11 Hydraulic main pump bypass 8-M21, CLOSE .

7 .12 Verify hydraulic supply pressure reads 2600 - 3000 psi onH-write display .

7 .13 Verify hydraulic mule switch red light on control console comesON . If not, replace lights as needed . If a switch still doesnot have an indicating light on, notify engineer .

8 .0 DI WATER TANK

Verify DI water tank is full per below :

8 .1 Verify DI water tank pressurizing valve (1632) is CLOSED(console) .

8.2 Make announcement : "ATTENTION ALL PERSONNEL . THE DI WATER TANKWILL BE VENTED ." (REPEAT )

8 .3 OPEN DI water tank vent valve 2406 (console) .

8 .4 Verify DI water tank supply valve 2402 is CLOSED (console) .

8 .5 When DI water tank pressure is zero psig according to gage, OPENDI water tank sight gage bottom shutoff valve .

8 .6 Record DI water tank liquid level according to sight gage ~ .

8 .7 If the DI water tank is 90% full, proceed . If not, fill perProcedure 7-105, Section 5 .

8 .7 .1 CLOSE sight gage bottom shutoff valve .

9 .0 FIREX SETUP

9 .1 OPEN, or verify OPEN, the following valves at the NE corner of 705 :

9 .1 .1 Both blue shutoffs .

9 .1 .2 Main red firex shutoff .

9 .1 .3 1" Shutoff to the 02 generator .

IMPORTANT : If this valve is CLOSED, do not OPEN until fire hoselines are connected to both spray nozzles to routewater elsewhere . Then OPEN the 1" valve .

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02 JUNE 88 ROCKWELL INTERNATIONAL CORPNORTH AMERICAN SPACE OPERATION S

ROCKETDYNE DIVISION

7-101 R6 of 2856626/01646

10 .0 PRETEST CHECKOUT S

10 .1 Establish headset contact between a man outside and one at th econtrol console .

10 .2 MAKE ANNOUNCEMENT :

"ATTENTION ALL PERSONNEL : THERE WILL BE PRE-SEQUENCE FUNCTIONA LVALVE CHECKS ON THE 705 FACILITY . PLEASE BE AWARE OF VALV EACTUATION ." (REPEAT ANNOUNCEMENT )

10 .3 Functionally operate the following valves by cycling the consol eswitch OFF and ON . Verify operation of each valve by audible flow o fgases or feeling the valve .

Name Location

10 .3 .1 BHP Mix Vessel Light See on TV

10 .3 .2 Try to operate the following 2 valves By CL2 Tankonly once and for a short time .

10 .3 .3 CL2 Sys 6N2 Purge 1635 By CL2 Tank

10 .3 .4 CL2 Tank Slow Vent 2305 By CL2 Tank

10 .3 .5 H2 02 Storage Tank Pump Out Flush 3401 By Load Tank s

10 .3 .6 H202 Storage Tk Drain Line Flush 2420 By Load Tank s

10 .3 .7 H2 02 Load Tank Flush 2409 By Load Tank s

10 .3 .8 H2 02 Load Line Flush 2408 By Load Tank s

10 .3 .9 KOH Load Tank Flush 2410 By Load Tank s

10 .3 .10 KOH Load Line Purge 1609 By Load Tank s

10 .3 .11 KOH Load Line Flush 2411 By Load Tank s

10 .3 .12 Load Tank Emergency Shower and Eyewas h

10 .3 .13 Sparger He DI Water Flush 20 Inside 705 by Generator

10 .3 .14 02 Generator BHP Transfer Line Flush 19 Inside 705 by Generato r

10 .3 .15 Primary GN2 Supply 1702 Inside 705 by Generator

10 .3 .16 He Diluent Supply 1625 Inside 705 by Generato r

10 .3 .l7 02 Generator 6N2 1621 Inside 705 by Generato r

10 .3 .18 02 Generator Vent 3118 Inside 705 by Generator

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02 JUNE 88 ROCKWELL INTERNATIONAL COR PNORTH AMERICAN SPACE OPERATION S

ROCKETDYNE DIVISION

7-101 R 6 of 285662G/0164G

Name Location

10 .3 .19 RGA Sight Gage Flush 3406 Inside 705 by Generato r

10 .3 .20 Transition Duet DI Water Flush 18 Inside 705 by Generato r

10 .3 .21 BHP Relief Transfer Line Flush 3404 Inside 705 by Generato r

10 .3 .22 02 Generator Level Flush 13 Inside 705 by Generato r

10 .3 .23 Sparger He Main 23 Inside 705 by Basement

10 .3 .24 Cold 6N2 5/0 3101

Door

Inside 705 by Basemen t

10 .3 .25 BHP Mix Vessel Sample Valve 3301

Door

Bottom BHP Mix Vesse l

10 .3 .26 Waste Tank 10 In Line Drain 3303 By Waste Tanks

10 .3 .27 BHP Drain Line Flush Valve 3302 Mix Vessel Ladde r

10 .3 .28 Emergency Water Active Switch UP

The following 2 valves will flow firex water; leave OPEN only a shorttime .

10 .3 .29 Waste Tank Emergency Aspirator Under Baker Tan k

10 .3 .30

Supply 2530

CL2 Treat Tank Emergency Aspirator Under Baker Tan k

10 .3 .31

Supply 2541

Emergency Water Active Switch DOWN .

10 .3 .32 Functional Check Baker Tank Emergency Shower and Eyewash .

11 .0 BAKER TANK SETU P

11 .1 At the CL2 treatment Baker tank :

11 .1 .1 Verify NaOH loading to CL2 waste treatment tank complete .

11 .1 .2 Take a CL2 treatment sample, by using a provided sample bottle .

(1) Suit up with Class "G" protective clothing . No SCBArequired .

(2) Take sample from pump pitcock discharge .


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ROCKETOYNE DIVISION 5662G/0164G

NOTE : Class G protective equipment is used when opening ahalogen "K " bottle valve, initiating flow in anysystem, or opening any halogen-type system .

Teflon coated cloth or gray lite cover-all or apron .Teflon coated cloth or gray lite hood having faceshi ld .

'Neoprene g oves .Neoprene boots .

11 .2 Establish headset communication - Baker tanks to control console(Headset Channel #1 or #2 only) .

11 .3 Verify operation of the CL2 treatment aspirator manually perbelow :

11 .3 .1 OPEN, or VERIFY OPEN, the ball valve downstream of the pump .

11 .3 .2 OPEN, or VERIFY OPEN, the gate valve downstream of pump andaspirator (valve that goes directly into the Baker tank) .

11 .3 .3 OPEN, or VERIFY OPEN , both ball valves upstream of the pump, oneach side of filter .

11 .3 .4 Prime the motor, using both pitcocks .

11 .3 .5 Verify selection switch on electrical control is in OFF(3 selections - Auto, Manual, and Off) .

11 .3 .6 Place or verify the electrical control ON/OFF knife switch to ON .

11 .3 .7 Turn selection switch to MANUAL to start pump .

11 .3 .8 Check aspirator supply gage . Verify pressure at 100 psig ± 10 .If not, stop pump by turning selection switch to OFF and informtest conductor (check for 3 minutes) .

11 .3 .9 While waiting 3 minutes, verify vacuum gage is below 20 inchesof vacuum . If not, inform test conductor .

11 .3 .10 Turn off pump by placing selection switch to OFF .

11 .3 .11 Place knife switch to OFF .

11 .3 .12 Secure both filter shutoffs upstream of pump (2545 and 2534) .

11 .3 .13 Secure hand valve shutoff at Baker tank entrance .

11 .3 .14 Verify hand valve just downstream of the pump is OPEN (2550) .


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ROCKETOYNE DIVISION 56626/0164 6

11 .4 At the GENERATOR WASTE Baker tank :

11 .4 .1 OPEN, or VERIFY OPEN, the ball valve downstream of the pump .

11 .4 .2 OPEN, or VERIFY OPEN, the gate valve downstream of pump andaspirator (valve that goes directly into the Baker tank) .

11 .4 .3 OPEN, or VERIFY OPEN, both ball valves upstream of the pump, oneach side of filter .


11 .4.5 Verify selection switch on electrical control is in OFF(3 selections - Auto, Manual, and Off) .


11 .4 .7 Turn selection switch to AUTO .

11 .4 .8 On control console, waste tank recirc pump 2537 ON .

11 .4 .9 Check aspirator supply gage . Verify pressure at 100 psig ± 10 .If not, stop pump by turning selection switch to OFF and informtest conductor (check for 3 minutes) .

11 .4 .10 While waiting 3 minutes, verify vacuum gage is below 20 inchesof vacuum . If not, inform test conductor .

NOTE : The waste tank aspirator pump will be secured perProcedure 7-109 .

12 .0 VACUUM LEAK CHECKS

12 .1 Fifty ( 50) minutes before diagnostics ready :

Sign Off :Diagnostics Engineer Initial

12 .2 Start up vacuum pumps per below: -

12 .2 .1 OPEN water trap drain on KT850 (on Vessel V3504) .

12 .2 .2 CLOSE water trap drain after flow is stopped .

12 .2 .3 Slowly OPEN the coolant water supply valve to KT-850 vacuum pumpand verify audible flow .

12 .2 .4 Turn ON KT-850 vacuum pump and verify oil level in sight glass .

12 .2 .5 Verify KT-850 oil purifier inlet and outlet valves OPEN .

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12 .2 .6 Turn ON KT-850 oil purifier and monitor oil purifier pressuregage :

If pressure exceeds 65 psig, turn oil purifier OFF . Turn backON when vacuum pump oil warms up . If oil purifier pressurestill exceeds 65 psig, notify EIC .

12 .2 .7 Notify engineer that pumps are running and ready for vacuumchecks .

12 .2 .8 Perform leak checks per direction from test conductor .

12 .2 .9 When checks are completed as indicated by test conductor, turnOFF vacuum pumps (CLOSE isolation valves first) .

12 .2 .10 Turn OFF oil purifier .

12 .2 .11 CLOSE coolant water supply valve to vacuum pumps .

12 .2 .12 Notify personnel in 705 that sequences will be run .

12 .2 .13 Assist test engineer in sequences .

12 .2 .14 Test Engineer ' s OK to Proceed :

12 .3 RGA Drying Procedure :

12 .3 .1 OPEN RGA vent 3118 .

12 .3 .2 Run Station E to 1300 psig .

12 .3 .3 Diluent heater 2333 ON .

12 .3 .4 OPEN MIV .

12 .3 .5 Verify pop-off valves are seated .

12 .3 .6 OPEN CL2 main 24 .

12 .3 .7 Make announcement :

"ATTENTION ALL PERSONNEL . THERE WILL BE A HIGH VOLUME GN2PURGE THROUGH THE RGA IN ONE MINUTE . THIS PURGE WILL CONTINUEFOR TWO HOURS . PLEASE STAY CLEAR OF THE RGA AND EJECTOR DUCT . "

12 .3 .8 Record time of da y

12 .3 .9 OPEN primary GN2 supply 1625 .

12 .3 .10 OPEN primary GN2 servo to 30% .

12 .3 .11 OPEN RGA drains 3, 5, 7, 1, 2, 4, and 8 .

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12 .3 .12 When RGA drying purge has been on for two hours , continue .

12 .3 .13 CLOSE RGA Drains 3, 5, 7, 1, 2, 4, 6, and 8 .

12 .3 .14 CLOSE 1625 primary GN2 supply .

12 .3 .15 CLOSE primary GN2 servo . Place in STANDBY .

12 .3 .16 CLOSE CL2 main 24 .

12 .3 .17 CLOSE MIV .

12 .3 .18 Diluent heater 2333 OFF .

12 .3 .19 Record time of day


"THE HIGH VOLUME GN2 PURGE ON THE RGA IS COMPLETE . THE 705BUILDING AND RGA ARE NOW SAFE . "

12 .3 .21 Run Station E to 0 psig .

13 .0 SECURING

13 .1 TURN OFF Camera Purge S /O at mix vessel .

13 .2 Record vaporizer temperature . If it is 165°F or below, informtest conductor .

13 .3 End of pretest day securing , use Procedure ( Daily) 7-109 .

14 .0 TEST DAY SETU P

14 .1 To be done first thing in morning of the test .

NOTE : If there are 4 mechanics for test setup, 1 mechanic canstart Section 14 .2, while the other 3 can start atPropellant Load Section, 26 .0 .

14 .2 Verify chlorine vaporizer at 165 or above . Notify testconductor , if not .

14.3 If below 180°F ( approximately 165°F), check set point and resetto 180°F .

14 .4 Record vaporizer temperature in Appendix 1 .

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15 .0 PRELIMINARY STAND PREPARATION

15 .1 Verify air conditioning system ON and operational, Building 705temperature is between 65°F and 71°F . If not, notify engineerand call Maintenance at Extension 5626 .

Record Work Order No .

15 .2 Check general condition of 705 and area for cleanliness . Ifthere are loose papers, rags, or other material lying about,clean up .

15 .3 Notify Propellant Desk (G . McGrath Extension 5123) to notifyBig 3 to Pump GN2 to 5000 psi .

NOTE : Big 3 can be notified directly at 9/346-6906 .

15 .4 Record-initial GN2 bottle bank pressure : Thencharge to 4,800 psi .

15 .5 Record bottle bank pressure in Appendix I .

15 .6 Record GHe area pressure on Vessel 137 :

15 .7 Record pressure in Appendix I .

15 .8 Verify OPEN, or OPEN, firex S/0 at NE corner of 705 ; both blueS/0 and the main (red) .

15 .9 Verify cold GN2 manual supply 2M-14 is OPEN (inside 705, bybasement door) .

15 .10 Verify OPEN 21 -M9 sparger He supply manual S /0 at pneumaticstation inlet .

15 .10 .1 Record BHP drain bucket level on Appendix I .

15 .11 OPEN transition duct drain . Record drain bucket level drainagelevel on Appendix I .

15 .12 CLOSE transition duct drain .

15 .13 Ejector water checks .

15 .13 .1 Check each of three 1/4" ports, on bottom of ejector, for water .

15 .13 .2 Reinstall and cap ports .

15 .13 .3 Inform engineering if water found .


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16 .0 PNEUMATIC CONSOLE PRELIMINARY SETU P

16 .1 Adjust the 705 GN2/Pneumatic station per below . ONLY RUN THE HANDLOADERS UP, NOT DOWN . If they need to be run down, vent down thestation and start again .

Sta Set Pressure

A

C

D

E

F

G

H 0

I 0

J

K

L

U

ROCKWELL INTERNATIONAL CORP 7-101 R6NORTH AMERICAN SPACE OPERATIONS of 2 8


2100 - 2200

65 - 75

50 - 5 5

130 - 140

1275 - 1310

90 - 9 5

160 - 190

Name

GN2 Suppl y

DI Water Tank Pressure

60 Control

Utility/Crane

Primary GN2/Cold GN2

100 Contro l

CL2 Tank Pressur e

1300 - 1350 1500 Control

135 - 140 150 Contro l

19 - 29 Mix Vessel Purg e

M 130 - 135 CL2 System Purge

P 1650 - 1700 H2 Console Suppl y

675 - 700 Primary He

16 .2 Adjust Pfaudler 50 psi control to 40 - 45 psig .


ATTENTION ALL PERSONNEL . THE GN2 SUPPLY TO THE EJECTOR WILLBE TURNED ON AT THIS TIME . REPEAT .

16 .4 OPEN ejector GN2 bypass supply .

16 .4 .1 Allow pressure to equalize .

16 .5 OPEN #1244 GN2 supply to the ejector .

16 .6 CLOSE eject GN2 bypass supply .


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ROCKETDYNE DIVISION 56626/0164 G

17 .0 CONTROL CONSOLE PREPARATION

17 .1 Check control console to verify all switches are DOWN or inNEUTRAL position .

17 .2 Verify the "02 generator control patchboard is installed .


ATTENTION ALL PERSONNEL . THE CTL-III CONTROL CONSOLE WILL BEACTIVATED . REPEAT .

17 .4 Turn ON control console key switch .

17 .5 OPEN 2621 mix vessel vent .

18 .0 HYDRAULIC SYSTEM PRETEST SETUP

Verify hydraulic mule switch is UP on console .

18.1 Verify that the hydraulic pump outlet accumulator ( 11-M6) andthe three servo valve accumulators ( 129, 130, and 133) areprecharged to 1800 ± 100 psi with the pump OFF . If they arenot, recharge them per Paragraphs 18 .1 .1 through 18 .1 .12 .

NOTE : The individual accumulator charge isolation valve isnormally in the OPEN position : 8-M6, 104, 105, and106, respectively .

18 .1 .1 If precharge is within limits , go to 18 .2 .

18 .1 .2 GN2 console station 0 , adjust for 1800 psi .

18 .1 .3 At the accumulator precharge panel , connect the swing tube tothe GN2 supply .

18 .1 .4 Precharge panel manual vent 1242, CLOSE .

18 .1 .5 Precharge panel manual inlet 1241, OPEN .

18 .1 .6 Precharge panel manual outlet 1243, OPEN .

18 .1 .7 By means of the precharge momentary switch, charge accumulatorsuntil audible flow is no longer heard .

18 .1 .8 Verify that the individual accumulators are pressurized to 1800± 100 psi .

18 .1 .9 Precharge panel outlet 1243, CLOSE .

18 .1 .10 Precharge panel inlet 1241, CLOSE .

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18 .1 .11 Precharge panel vent 1242, OPEN .

18 .1 .12 Disconnect swing tube from GN2 supply , cap fitting, and plugline .

18 .1 .13 GN2 console station 0, adjust for zero psi .

18 .2 Verify hydraulic pump arm switch, ON (RACHL console)

18 .3 Verify hydraulic pump outlet 1-M6, OPEN .

18 .4 Verify 705 facility hydraulic isolation 3-M6, OPEN _

18 .5 Verify hydraulic accumulator supply manifold isolation 142, OPEN .

18 .6 Verify hydraulic pump cooling water supply OPEN and waterflowing from dump line .

18 .7 Hydraulic recirculation pump switch, ON .

18 .8 Hydraulic main pump bypass 8-M21, OPEN .

18 .9 Hydraulic main pump switch, ON .

18 .10 Hydraulic main pump bypass 8-M21, CLOSE .

18 .11 Verify hydraulic supply pressure reads 2600 - 3000 psi onH-write display .

18 .12 Verify hydraulic mule switch light on control console comes ON .If not, replace lights as needed . If a switch still does nothave an indicating light on, notify engineer .

19 .0 DI WATER TANK

Verify DI water tank is full per below :

19 .1 Verify DI water tank pressurizing valve (1632) is CLOSED(console) .


"ATTENTION ALL PERSONNEL . DI WATER TANK WILL BE VENTED ."(REPEAT )

19 .3 OPEN DI water tank vent valve 2406 (console) .

19 .4 OPEN, or VERIFY OPEN, DI water tank supply valve 2402 (console) .

19 .5 Use special made block to block OPEN DI water tank supply (placeunder stem) .

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19 .6 When DI water tank pressure is zero psig according to gage, OPENDI water tank sight gage bottom shutoff valve .

19 .7 Determine and record DI water tank liquid level according tosight gage % .

19 .7 .1 CLOSE sight gage bottom shutoff valve .

19 .8 If the DI water tank is 90% full, proceed . If not, fill perProcedure 7-105, Section 5 .

19 .9 Have DI water trailer moved out of chlorine area ( blocks TVcoverage) .

20 .0 INSTRUMENTATION SETU P

20 .1 Verify 02 generator patchboard interlock red light is ON (Rack12) .

20 .2 Have EIC bring up IBM PC data system with H2O2 load tankweight displayed .

21 .0 C02 SETU P

21 .1 OPEN 2802 C02 tank S/O .

21 .2 Record tank pressure: If pressure is not 267psi, notify test conductor.

21 .3 Record tank pressure in Appendix 1 .

21 .4 Record tank level : X1000 lbs.

21 .5 Record tank level in Appendix I .

22 .0 MIX VESSEL SETU P

22 .1 OPEN camera and light purge manual S/0 .

23 .0 BAKER TANK SETU P

23 .1 Verify console operator available to start pump remotely at the BHPwaste Baker tanks :

23 .1 .1 Mechanic to put on faceshield and neoprene gloves .

23 .1 .2 OPEN, or VERIFY OPEN , the ball valve downstream of the pump .


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23 .1 .3 OPEN , or VERIFY OPEN, the gate valve downstream of pump andaspirator ( valve that goes directly into the Baker tank) .

23 .1 .4 OPEN , or VERIFY OPEN , both ball valves upstream of the pump, oneach side of filter .

23 .1 .5 Prime the motor , using both pitcocks .

23 .1 .6 Verify selection switch on electrical control is in OFF( 3 selections - AUTO, HAND , and OFF) .

23 .1 .7 Place, or verify, the electrical control ON/OFF knife switch toON .


23 .1 .9 Open 2537 BHP waste tank pump to START pump .

23 .1 .10 Check aspirator supply gage . Verify pressure at 80 psig ±10 .If not , stop pump by turning selection switch to OFF and informtest conductor (check for 3 minutes) .

23 .1 .11 While waiting 3 minutes . Verify vacuum gage is below 20 inchesof Hg . If not, inform test conductor .

23 .1 .12 Continue with procedure .

23 .2 Start CL2 treatment aspirator per below .

24 .0 BAKER TANK SETUP

24 .1 At the CL2 treatment Baker tanks :

24 .1 .1 OPEN, or verify OPEN, the ball valve downstream of the pump .

24 .1 .2 OPEN , or verify OPEN , the gate valve downstream of pump andaspirator (valve that goes directly into the Baker tank) .

24 .1 .3 OPEN, or verify OPEN , both ball valves upstream of the pump, oneach side of filter .


24 .1 .5 Verify selection switch on electrical control is in OFF( 3 selections - AUTO, MANUAL, and Off) .



24 .1 .8 Open 2548 CL2 treatment tank pump, to start pump .


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24 .1 .9 Check aspirator supply gage . Verify pressure at 100 psigminimum . If not, stop pump by turning selection switch to OFFand inform test conductor (check for 3 minutes) .

24 .1 .10 While waiting 3 minutes, verify vacuum gage also goes below20 inches of HG . If not, inform test conductor .

24 .1 .11 Continue with procedure .

25 .0 START CL2 RUN TANK JACKET HEAT EXCHANGE R

25 .1 Perform Section 4 of Procedure 7-105 . Set temperature to 50°F .

26 LIQUID PROPELLANT LOAD SECTIO N

NOTE : This section requires 3 mechanics ; 2 for loading and 1 onthe control console ( on headset) .

26 .1 Set H202 tank failwet preset 2556 switch UP (verify greenlight comes ON) .

26 .2 Set KOH tank failwet preset 2522 switch UP (verify green lightcomes ON) .

26 .3 Set both firex handles to failwet (both near load tanks) .

26 .4 OPEN DI water tank supply 2402 .

26 .5 Verify H202 and KOH berm drain valves CLOSED and berm freeof debris .

Zero/Empty KOH and H 202 Tank s

26 .6 OPEN 1807 KOH tank drain to empty (on console) .

26 .7 OPEN 2223 H202 tank drain to empty .

26 .8 Suit up with protective clothing Class "L" . See 26 .21 .

26 .9 Verify KOH load tank empty (visual) .

26 .10 Verify H202 load tank empty ( visual) .

26 .11 CLOSE 2223 H202 tank drain (on console) .

26 .12 CLOSE 1807 KOH tank drain .

26 .13 Zero outside tank weight indicator on both weigh scales (local) .

26 .14 Record actual reading : KOH : , and H202

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26 .15 Have instrumentation mechanic calibrate panel meters 10 and 12 .

26 .16 Verify that the readings are 0 ± 2 on the console panel meters .

26 .17 Verify 2223 H202 tank drain is CLOSED (on console) .

26 .18 Verify 2232 H202 pump drain is CLOSED .

26 .19 OPEN 2213 H202 storage tank pump outlet .

26 .20 Turn ON water hose and leave running near H2O2 storage tankoutside of berm .

26 .21 This Section requires 2 mechanics in protective clothing per A-105,Section "L . "

Section "L"

This protective equipment shall be used for clean-up andtransfer of peroxides (H202 and KOH) of 30% and above .

Self-contained breathing equipment (Scott Air Pack) requiredwhen working within closed area or building .

Face shield .

Neoprene or gray-lite aprons .

Neoprene gloves and boots .

26 .22 Clear area for transfer per below :


"ATTENTION ALL PERSONNEL . PROPELLANT LOADING TO THE KOH LOADTANK AND THE H202 LOAD TANK WILL BEGIN AT THIS TIME . ONLYPERSONNEL INVOLVED IN THE PROPELLANT LOADING PROCESS WILL BEALLOWED IN THE LOAD TANK AREA ." (REPEAT )

26 .22 .2 Turn on Hyp RED LIGHTS .

26 .22 .3 Verify area near load tanks is clear .

26 .22 .4 OPEN 2204 H202 storage tank supply .

26 .23 Transfer H202 .

NOTE : Will take approximately 45 minutes .

26 .24 Set H202 pump selector switch to AUTO .

26 .25 Prep H202 PUMP -. Depress "MANUAL" start button .


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26 .26 Console operator to verify load tank area clear of personnel andload crew near gorilla cage and on headset .

26 .27 Console operator to start H292 pump #2202 .

26 .28 Check load tank temperature . If temperature is below 122°F andno temperature increase above outside air temperature, thencontinue . If not, go to Emergency H 202 Transfer step .

26 .29 Wait 5 minutes .

26 .30 Console operator to continuously monitor H202 load tanktemperature .

26 .31 Transfer lbs of H202 to load tanks (use panel meter) .

NOTE : To STOP transfer, go to H202 Securing, 26 .57 .

26 .32 Console operator to monitor H202 load tank temperature onpanel meter . If temperature increases above outside airtemperature, the propellant load crew is to clear the load tankarea and close 2202 to STOP the pump .

26 .33 Transfer KOH .

NOTE : Will take approximately 1-1/2 hours .

NOTE : Can run the H202 pump at the same time .

26 .34 Wash pump inlet with DI water .

26 .35 Place pump inlet to KOH barrel .

26 .36 Turn ON KOH pump (slow at first, fast after 5 minutes) .

26 .37 Transfer lbs of KOH to load tank (4 barrels, plus partof the 5th) .

NOTE : To STOP transfer, go to KOH Securing, 26 .51 .

********************************* *

26 .38 * EMERGENCY H202 TRANSFER STO P* *********************************

26 .39 Turn OFF pump 2202 .

26 .40 CLOSE valve 2204 H202 storage tank supply .

If temperature starts to rise :


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26 .41 Have load crew move away and clear the load tank area .

If temperature reaches 122°F :

26 .42 OPEN 2409 H202 load tank flush .

26 .43 OPEN 2223 H202 load tank drain .

26 .44 OPEN 2232 H202 storage tank pump inlet dump .

25 .45 After 5 minutes, continue .

25 .46 CLOSE 2232, 2223, and 2409 .

25 .47 Proceed to H202 securing and inform engineering .

26 .48 Turn OFF pump .

26 .49 TO SECURE FROM LOADING PROPELLANTS

26 .50 KOH Secure

26 .51 Turn off pump .

26 .52 Remove pump inlet line from drums .

26 .53 Wash pump inlet line with DI water .

26 .54 Secure KOH drums .

26 .55 Cap off/secure pump inlet line as required .

26 .56 H2O2 Secure

26 .57 Turn off pump 2202 .

26 .58 Selector switch to OFF .

26 .59 Manual motor start to OFF .

26 .60 CLOSE 2204 H202 storage tank supply .

26 .61 CLOSE 2213 H2O2 storage tank pump outlet .

26 .62 Place hose so water flows near outlet of 2232 pump dump, buthose is not in the berm .

26 .63 Verify sump area is clear .

26 .64 Have stand talker watch outlet of 2232 .

26 .65 OPEN 2232 H202 storage tank pump inlet dump .

26 .66 OPEN 2213 pump outlet .


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26 .67 After no more H202 is dumped , continue .

26 .68 CLOSE 2213 .

26 .69 OPEN DI water flush valve 3401 for 10 seconds after flow i s

26 .70

detected, then CLOSE .

CLOSE 2232 pump inlet dump .

26 .71 Place running hose near H202 load tank berm outlet ( outsid e

26 .72

of berm) .

OPEN berm outlet valve .

26 .73 When berm is empty, wash down berm with the running hose .

26 .74 Turn OFF hose .

26 .75 Record final H202 weight and KOH weight from panel meter i n

26 .76

Appendix I .

Record final H2O2 weight from local weight scale i n

27 . 0

27 .1

FINAL

Veri fspeci

Appendix I .

PNEUMATIC CONSOLE SETU P

y pneumatic stations are per below . Adjust UP only . If out offication , inform test conductor .

SettingWig) Sta Set Pressure Name

A 2100 - 2200 GN2 Suppl y

B 65 - 75 DI Water Tank Pressure

C 50 - 55 60 Control

D 130 - 140 Utility/Crane

E 1275 - 1310 Primary GN2 /Cold GN 2

F 90 - 95 100 Contro l

G 160 - 190 CL2 Tank Pressurizatio n

H 0

I 0

3 1300 - 1350 1500 Contro l

K 135 - 140 150 Control

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Settingsi Sta Set Pressure Name

L 19 - 29 Mix Vessel Purge

M 130 - 135 CL2 System Purge

P 1650 - 1700 Console He

U 675 - 700 Primary He

Vacuum Pump Start-up

27 .2 OPEN water trap drain on the KT-850 vacuum pump ( on Vessel 3504) .

27 .3 CLOSE water trap drain after flow stops .

27 .4 Slowly OPEN the coolant water supply valve to KT-850 vacuum pumpand verify audible flow .

27 .5 Turn ON KT-850 vacuum pump and verify oil level in sight glass .

27 .6 Verify KT-850 oil purifier inlet and outlet valves OPEN .

27 .7 Turn ON KT-850 oil purifier and monitor oil purifier pressuregage .

If pressure exceeds 65 psig , turn oil purifier OFF . Turn backON when vacuum pump oil warms up . If oil purifier pressurestill exceeds 65 prig, notify EIC .

27 .8 Leave a headset plugged in an operational condition at the 705pneumatic console to listen for relief valve going off . Set toChannel 1 . Place a second " ready" headset by the 705 main door,set to Channel 2 .

27 .9 VERIFY with test conductor that the wind direction is from thenortheast on the wind velocity meter ( 3 MPH minimum ) ±135° .

27 .10 Set 02 generator failwet preset 2588 , switch UP (verify greenlight comes ON) .

27 .11 Set 02 generator firex handle to failwet ( northeast corner of705) .

27 .12 Verify both Red and Green lights are now indicated on 02generator failwet preset .

27 .13 Verify 02 generator deluge manual S/0 3405 valve is OPEN .

27 .14 Verify the 4 RGA pop-off relief valves are in place and bootsinstalled .

27 .15 Turn on Module Ills safe air supply .


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27 .16 Record CL2 vaporizer test temperature in Appendix I(Step 28 .10) .

27 .17 Return procedure to test conductor .

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APPENDIX I

28 .0 RECORD LEVELS, PRESSURE , AND TEMPERATURE S

28 .1 OF CL2 vaporizer pretest day temperature .

28 .2 Vaporizer " Heater On " light ( OFF or ON) pretestday temperature .

28 .3 % DI water tank level .

28 .4 psig 5K GN2 supply pressure .

28 .5 psig 3K He supply pressure .

28 .6 Lbs Final KOH weight scale reading ( local) .

28 .7 Lbs Final KOH weight scale reading ( panel meter) .

28 .8 OF CL2 vaporizer test day morning temperature .

28 .9 OF Vaporizer " Heater On " light ( OFF or ON) morningtest day temperature .

28 .10 OF CL2 vaporizer test temperature .

28 .11 OF Vaporizer " Heater On" light ( OFF or ON) testtemperature .

28 .12 psig C02 tank pressure .

28 .13 Lbs C02 storage tank level .

28 .14 BHP drain level pail initial recording .

28 .15 BHP drain level pail drainage level .

28 .16 Lbs Final H202 weight panel meter reading .

28 .17 Lbs Final H202 weight local weight scale reading .


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APPENDIX I I

29 .0 +28 VDC CONTROL SYSTEM SETU P

NOTE : The following procedure to be done before sequences the daybefore the test and test day before the area is cleared in themorning .

Verify the following 28 VDC rectifiers are ON and set to +27 .9 to ± .4VDC :

29 .1 Control console .

29 .2 705 Facility ( behind HPOL) .

Verify all circuit breakers are not tripped in the following controlboxes :Pretest Test CircuitDay Day Name Location Breakers

A In 705 (Under Steps) 100

B On 705 Valve Deck Air Lock 100

B1 C12 Tank 2

B2 By 10" Water Ejector 4

B3 By H202 Storage Tank 3

NOTE : If any are tripped, the circuit breaker is to be reset andthe test conductor notified .


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