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N72-71709 _|NASA-CR- 126236) APOLLO SYSTEMS ENGINEERING NgNUAL: SE}IVICE I_ODULE AND A DAPT_R ST_UCTUHE (North AmeEican Aviation, Inc.) 19 Feb. 196_ 370 p

6O/99

Unclas 15610

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7"65".12132

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Accession

No.

55566-64

Copy No.

SID 64-206 (DIM-9)

APOLLO SYSTEMS ENGINEERING MANUAL Service Module and
J.',

Adapter Structure
CONTRACT NASg-150

":_,._

19'_,February 1964

Exhibit

I,

Paragraph

5.2

7

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NORTH
SPACE and

AMERICAN
INFORMATION

AVIATION,
SYSTEMS

INC.
DIVISION ° i
• %

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_0 "AS _"_°QuA_TERs o.t_

NORTH SPACE and

AMERICAN INFORMATION

AVIATION, SYSTEIV_

INC. DIVISION

V°lume:DEM-9 Section: Page: Date: Rev. Date: ii 2-19-64

FOREWORD

This i through

manual is 18) which

one in a series of special Apollo Engineering Manuals (Dli4's furnish a contemporary source of desigm and system in[orm,jspacecraft. This i!lustrations_ on manual_ DIM-9, the components contains of the

tion_ and descriptions for the Apollo basic information, by use of text and service module and adapter structures.

Illustrations include: a. over-all configuration control drawings of' both service module (S/M) and adapter; b. detail drawings of component parts; c. installation drawings; d. interface control drawings_ when available. The structural components of the service module operate within desio_n limftations while subjected NASA Exhibit "B" Technical and the adapter to environmental Part are designed restricI, dated

to

tions imposed by the 3 January 1963.

Specification,

A final manual can not be consummated at this time. Expanding, dynamic, and involved technology of the subject matter permits the issuance only of pertinent information on an as-known basis. When relevant data appear_ revisions will be in order. The service module but not limited to_ Chairman: and the adapter structures Manual following personnel: Review Board is composed

of,

J.R. Cole, Chief Service Module Design To be To be determined determined representatives) Chief Structural Chief Systems

696-420

Alternate: Recorder: Members:

(Or their H.S. Oder, Spacecraft J.W. Gibb, Propellant

696-230 Analysis 696-320

D.I. Champaign_ Chief Electrical Power R.E. Field, Chief Propulsion Engines M.E. Stelzriede, Chief Environmental Control System

697-810

696-310

696-510

SID

64-206

I

SPACE NORTI-I

and

INFORMATION AlVlERICAN

SY_STEMS AV'IATION,

DIVISION INC.

S e cti on. --_ Page: iii Volume: DIM-9__ Date: ___ Rev. Date:

answers

The following to_ technical H. W. Myers Robison Stecki

lead engineers can give more definite information questions in their areas of specialization: LI_M Adapter

on_

and

- Spacecraft - S/M - S-I

D. M. E. T. K. G.

Structure Adapter; Mounting Provisions Main for Tanks Control and S/M and Adapter

Bucuvalas C. Dullea

- Service

Propulsion

System_

- Mounting Provisions for Electrical Power Systems

Environmental

B. F.

Glienke

- Mounting Provisions for Reaction Control Propulsion and Pressurization Systems

System,

Service

Cole,Chie
Apollo Service Module Design

SID

64-206

/

NORTH
SPACE and

AMERICAN
INFORMATION

AVIATION,
SYSTEMS

INC.
DIVISION

Volume= Section: Page:

DIM- 9

iv

Date: _-19-64 Rev. Date:

CONTENTS

Section 1.0 I_YfRODUCTION i.i General 1.2 2.0 Reliability MODULE STRUCTURE Function - Component Design

Page i-i i-i I-i 2-1 2-1 2-1

SERVICE 2.1 2.2 2.3 2.4 2.5

General and Configuration Component Description and Operating Conditions

2-17
2-17

Characteristics and Criteria Test Requirements

2-17
3-1 3-1 3-I 3-6 Criteria - Component 3-6 3-6

3.0

ADAPTER STRUCTURE ...... 3.1 General and Configuration 3.2 Component Description 3.3 Operating Conditions 3.4 3.5 Design Characteristics Desig_ Test Requirements SYSTEM and

4.0

SERVICE PROPULSION 4.1 General 4.2 4.3 4.4 4.5

TANK

STRUCTURES

Configuration and Function Operating Conditions Design Characteristics and Test Requirements PROVISIONS Provisions Provisions Provisions Provisions Provisions

4-1 4-1 4-1 .

Criteria

4-8 4-8 4-8
5-1

5.0

SYST_HS MOUNTING 5.1 General 5.2 5.3 5.4 5.5 5.6 ECS RCS SPS EPS T.S. Mounting Mounting Mounting Mounting Hounting

Configuration Configuration Configuration Configuration Configuration

5-1 5-1 5-1
5-7

5-20
p -_u 6-1 6-1 6-1 7-1 7-1 7-1

6.0

THERMAL CONTROL STRUCTURES 6.1 Aft Heat Shield 6.2 Service Module Insulation SIGNIFICANT INTERFACES 7.1 General 7.2 External Interfaces 7.3 Internal Interfaces 7.4 Test Requirements REFERENCES

7.0

7-8 7-8
8-1

8.0

S!D

64-206

NORTH
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AM.FRICAN
INFORMATION

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SYSTEMS

INC.
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Volume: Section: Page: Date: Rev. Date:

DIM-9

v 2-!9-64

ILLUSTRATIONS Page Servlce Servmce Service Servmce Servlce Service Service Service Module Nomenclature (V17-933200) Module: General Assembly (V17-000002) . Module: Structural Assembly (V17-320001-I) Module: Structural Assembly (V17-320001-2) Module: Structural Assembly (V17-320001-3) Module: Structural Assembly (V17-320001-4) Module: Structural Assembly (V17-320001-5) Module: Structural Assembly (V17-320001-6) 1-2 1-3 2-2 2-3 2-4 2-5 2-6 2-7

Figure i-i 1-2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 •2-10 2-11 2-12

2-13
2-14 3-1 3-2 3-3 3-4 4-i 4-2

Complete Interior Arrangement of Service Module (V17-935561-I) Complete Interior Arrangement of Service Module (V17-935561-2) Installation of Forward Bulkhead (V17-320101) • • Assembly of Aft Bulkhead, Station X S 200 (V17-320201-I) Assembly of Aft Bulkhead, Station X S 200 (V17-320201-2) Assembly of Aft Bulkhead, Station X S 200 (V17-320201-3) Assembly of Aft Bulkhead, Station X S 200 (V17-320201-4) Assembly of Radial Beam 2 (V17-322001) Adapter - GeneralAssembly (VI$-000002). Design Study - Configuration - S-IV B Adapter (V2¼-932002)

2-8
2-9 2-11 2-12 2-13

2-14 2-15
2-16 3-2 3-3 3-4

4-3 4-4 4-5
4-6 4-7

Manufacturing Assembly Breakdown of S-I Adapter (SK-015129) Skin Panel Splice for Adapter Plate (1718-300011) . Installation of Main Propellant Tank, Service Module (VI7- 340001 ) Tank Assembly Complete: Main Propellant, Oxidizer (V17-342001) Tank Assembly Complete: Main Propellant, Fuel (V17-34;001) Tank Tank Assembly: Assembly: Main Main Propellant, Propellant, Oxidizer (V17-342002) Fuel (V17-343002) Helium Oxidizer (V17-347002) Tank _V17-3 4.02 _ 2 P)i Control Control Control System

3-5
4-2 4-3 4-4 4-5 4-6 4-7 4-9 5-2

Tank Assembly: Assembly of UpperMain Propellant, Skirt Support, Mounting Provisions, Environmental Installations (V17-331717-I) Mounting Provisions, Environmental Installations (V17-331717-2) Mounting Provisions, Environmental

5-i
5-2

System

5-3
System •

5-3
5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11

Installations(V!7-3317!7-3) . • . Assembly of Oxyoen Tank Shelf Support (V17-331667) • Module Installation of Reaction Control System (V17-332000). Panel Assembly Complete, Panel Assembly Complete, Panel Assembly, Reaction Panel Assembly, Reaction Housing Assembly, Reaction Longitudinal Heat Shield System (V17-331525)

Reaction Control System (V17-332001-I) Reaction Control System (V17-332001-2) Control System (V17-332002-I) Control System (V17-332002-2) Control System (V17-332010) Installation, Reaction Control

5-4 5-5 5-6 5-8 5-9 5-1o 5-ii 5-12
• 5-13

SID

64-206

e
Figure 5-12

NORTH
SPACE and

AMERICAN
INFORMATION

AVIATION,
SYSTEMS

INC,
DIVISION

Volume: Section: Page: Date: Rev. Date:

DIH- 9

vi 2-19-64

Page Lateral Heat Shield Installation, Reaction Control Tanks_ Control System 5-15 Reaction Tanks_ Control 5-16 Reaction System 5-14

(v17-3316N) 5-13
5-14 5-15 Insulation Installation for Reaction (V17-332046) End Mounting Assembly of Propellant System (V17-332041) Mounting Assembly, Propellant Control System (V17-332042) Installation of Engine (V!7-327!01-I) . Installation of Engine (V17-327101-2) . Mounting Provisions (V17-331000) Mount_ Mount, and

Pressure

5-17
Service Service Propulsion Propulsion System

5-16
5-17

• 5-18
System

5-19
Service Propulsion System

5-18 5-19 5-20 5-£1 5-22 5-23
5-24

Installation,

5-£0 5-21 5-23 5-24 • 5-25 5-26
5-27 Lines Lines Lines Shield_ Shield, Station Station Suppoz_t, Support_ Support, Sectors Sectors X S 200 6-4 Shie!d_ XS 200 Electrical 5-28 Electrical

Mounting Provisions Installation, Service Propulsion Pressurization System (V17-331100). Mounting Provisions, Electrical Power System (V17-331552-!) Mounting Provisions, Electrical Power System (V!7-331552-2) Installation of Fuel-Cell Mounting, Stabilized (V17-331524) Assembly of Support Shelf_ Upper Hydrogen Tank Control Layout One and Four - Electrical (V17-933074) Power System Web . "(V17-331566) Sectors Shear

Radiators_

5-25
5-26

Installation Provisions_ Fluid Power System (V17-331553-i) Installation Provisions_ Fluid Power System (V17-331553-2) Installation Provisions_ Fluid Power System (V!7-331553-3) Outer and Inner and Shell Assemb!y_ Aft Heat Five (V17-331944) • Shell Assembly, Aft Heat Five (V17-331700) Shield_

5-29
Electrical 5-30 Three_ Three_ Four_ 6-2 Four, 6-3

5-27
6-1 6-2 6-3 6-4

Installation of Aft Heat (V17-331689-I) Installation of Aft Heat (vr(-331689-2) . Insulation Installation (V17-331562-I) Insulation Installation (V17-331562-2)

6-5
Provisions_ Provisions_ Service Service • for Module 6-7 Module • Specimen Test 6-9 7-2 7-3 to Command Module 7-4

6-5
6-6 6-7 7-1 7-2 7-3

6-8

Complete Assembly of Thermal Simulator (DTT-6600) Installation of Fairing V17-310001-I) Installation of Fairing V17-310001-2) Fairing Panel Assembly_ Service Module

(WT-311ool).

SiD

64-206

NORTH SPACE

and

'AMERICAN INFOR_ATION

AVIATION, SYSTEMS

INC. DIVISION

Volume:_ Section: Page: vii

Date: 2-19-64 Rev. Date:

Figure

Page Fairing Assembly Complete_ Command Module to Service Module Umbilical (V17-331771) Assembly of Support - Command Module to Service Module and Fly Away Umbilical (V17-331913) Strap-Tension Tie_ Service Module to Adapter (V18-300005) Control Layout for Servicing and Umbilical Locations (V17-933401)

7-4 7-5
7-6 7-7

7-5 7-6 7-7 7-9

SID

64-206

NORTH SPACE and

AMERICAN INFORMATION

AVIATION, SYSTEMS

INC. DIVISION

Volume: Section: Page: Date: Rev. Date:

DIM-9 _2L__ i 2-19-64

1.0 i.i i.i.i

INTRODUCTION General

The Apollo service module is pictured in the layout V17-933200, "Service Module Nomenclature 'f (Figure i-i). This layout provides names and basic details of the S/M_ the fairing_ and the adapter. Drawing V17-000002 (Figure 1-2) is a perspective of the S/M general assembly. This design information manual (D_) presents the structure of the S/M, the adapters, the tanks of the service propulsion system (SPS), the mounting provisions of the S/M systems, the significant interfaces. The systems of the S/M for which mounting provisions must be designed are: the SPS, including the S/M aft heat shield; the reaction control system (RCS) plus its heat shields; the environmental control system the telecommunication system (I!S). (ECS); system the electrical power system (EPS); (T.S.); and the internal insulation

I.i.2

1.1.3

1.2 1.2.1

Reliability Information this manual reliability obtained by furnished by the Reliability Engineering Group for is classified, but DIM-9 is unclassified. Hence, information_ advice, or completed studies may be contacting Department 643-50.

SID

64-206

NORTH
SPACE and

AMERICAN
INFORMATION

AVIATION,
SYSTEMS

INC.
DIVISION

Volume: Section: Page: Date: Rev. Date:

DIM-9 2 ] 2-19-64

2.0 2.1 2.1.!

SERVICE General

MODULE and

STRUCTURE

Configuration

The service module structure consists of the outer shell_ radial beams_ forward and aft bulkheads, and inner web. (See 7.2.1 for analysis of the fairing.) Drawing V17-320001 (Figures 2-1 through 2-6) depicts the structural assembly of the S/M. The definition of the present S/M configuration required studies in space allotment for its systems and equipment. Design criteria were the factors of access_ removal_ Both structural design and choice of materials exigencies of space environment. and servicing. were based on the

2.1.2

2.1.3

The

S,/M is 155

inches

long

and

154

inches

in diameter.

The

outer

shell is made of one-inch aluminum honeycomb sandwich; the radial beams of aluminum plate are made by numerically controlled machining_ followed by chem-milling; forward and aft bulkheads are fabricated from aluminum honeycomb; and the inner web is made of aluminum sheet. 2.1.4 The six radial beams divide the interior of the S/M into three pairs of diametrically opposed sectors which are unevenly sized. Desigm layout V17-93556! (Figures 2-7 through 2-8) illustrates the complete interior arrangement of the S/M. A center section which is 44 inches in diameter extends the length of the S/M. The function of the S/M is threefold: a) support of the main engine of the SPS; b) housing of the SPS propellant tanks; c) housing of all other systems not contained in the command module (C/M) but required for the spacecraft (S/C) mission. Component Description and Function

2.1.5

2.2 2.2.1

The outer shell of the S/M is formed by bonded one-inch aluminum honeycomb sandwich panels. This material was chosen for fabrication of the outer shell because it provides the greatest amotunt of strength and rigidity for the least amount of weight. In addition_ its simplified structure reduces the number of parts needed_ handling_ and inspection. Also_ reliability is increased.. The outer shell of the S/M contains the space radiators (ECS and EPS) which form an integral part of the outer face sheets of the aluminum honeycomb sandwich panels. It also supports the four RCS modmles. It distributes the C/H and S/M equipment loadings from the radial beams into the S/C booster. In addition_ it resists aerodynamic pressures_ provides a clean aerodynamic shape_ and protects the S/M interior from external environment.

2.2.2

SID

64-206

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2.2.3 2.2.4

NORTH SPACE and

AMERICAN INFORMATION

AVIATION, SYSTEMS

INC. DIVISION

Volume: Section: Page: Date: Rev. Date:

DIM-9 2 !0 2-19-64

Panels sheet

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form inch

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center

shell The

or web web

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structures

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The function of the center webs is twofold: a) to aid as stabilizers for the six radial beams; b) to distribute the weight of the helium bottles and the engine mou_ts which are located in Sectors One_ Four, Six and Three.

2.2.5

The aft bulkhead is made of bonded aluminum honeycomb sandwich three inches thick and 154 inches in diameter. The center opening coincides with the inner caps of the vertical beams and is 44 inches in diameter. The forward bulkhead is made of the same type of material_ has the same size of center opening_ but is only one inch thick. See drawing V17-320101 (Figure 2-9) for the forward bulkhead_ and drawing V!7-320201 (Figures 2-10 through 2-13) for the aft buli_head.

2.2.6

Both bulkheads distribute shell. The aft bulkhead

the radial per se acts

beams' loading into as support structure

the outer for the

SPS main tanks_ the SPS engine and gimbal mount_ the radial beams_ the EPS fuel cel!s_ the cryogenic hydrogen tank_ the aft heat shield_ the high-gain antenna_ hard lines_ electrical wiring_ etc. The aft bulkhead also serves as a heat barrier between the SPS engine and the S/M interior. lateral support for the upper 2.2.7 The forward ends of the bulkhead SPS main provides tanks.

All radial beams have similar configurations. Each beam is a rectangular structure machined and chem-milled from 2.5-inch aluminum-plate stock. Each has a minimum web .0iS-inch thick and stiffeners .06-inch thick. The vertical distances between stiffeners vary between figuration_ see drawing (Figure 2-14). 6 and 19 inches. For V17-320001_ "Assembly a typical of Radial beam Beam con2"

2.2.8

Criteria which governed the choice of radial besom configuration were: a) the length of the main SPS tanks in their final configuration; b) accessibility to these tanks; c) weight and fabrication savings through the use of numerically controlled machining and chem-milling instead of the use of more conventional methods including welding of structures.

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64-206

NORTH SPACE and

AMERICAN INFORMATION

AVIATION, SYSTEMS

INC. DIVISION

Volume: Section: Page: Date: Rev. Date:

D]2vb 9 2 17 2-19-64 _

2.2.9

Functions of the radial beams are five: a) supporting structures for the C/M; b) transfer fraznes for propellant loads from the aft bu]_khead to the S/M shell; c) transfer framework for SPS loads to the S/M and C/M; d) support structhres for aumi!iary equipment pertaining to S/M systems; e) adjuncts to the outer shell for the distribution of pressure loads. O_eratin_ Conditions

In normal launch mission> the S/M with all its systems_ including the SPS and RCS engines_ will successfully perform all of the maneuvers required of the spacecraft (S/C) between lift-off and reentry. Among these maneuvers are the following: earth orbit with in-flight and ground-directed checks; injection into lunar trajectory; transpositional docking with LEM; mid-course correction; translunar flight; f'free-turn _' trajectory; lunar orbit; transpositional 2.3.2 docking; and earth trajectory.

In a normal launch abort mission the S/H will use either or both of its propulsion systems in operations designed to successfully keep the S/C within orbit_ or return it to the earth. Characteristics and Criteria - Component Design

The S/H outer shell_ fairing_ and radial beam structures will withstand the aerodynamic heating during boost. The internal structure of the S/M is designed for a temperature range between -200 and +300 F_ although temperature and load conditions are not always concurrent. The S/M structure is designed to withstand hazards imposed by the environment as described by the environmental requirements listed in the NASA Exhibit B. Technical Specification_ Part !> dated 3 January 1963. These requirements include resistance to the following: a) acoustics_ vibration_ and flight loads; b) extremes of humidity and temperature; c) high a!titudes_ ground handling, and transportation; meteoritic d) saltand in-air_ ground radiation. 2.4.2 Other design Manual and more winds> storm conditions_ storms_

technical

criteria

which

have

been

used

to

fix

the

of the S/H components (ARM) -6_ "Structural

are found Loads and

in the.Apollo Criteria."

Requirements

2.5 2.5.1

Test

Requirements

Test requirements for the S,/M outer shell_ fairing_ radial beams_ and other internal sti_uctural components including mountingprovisions structures are specifically called out in SID 62-109-2, "General Test Plan_ Research and Development for Project Apollo Spacecraft - Individual System Test."

SID

64-206

NORTH SPACE

and

AMERICAN INFORMATION

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INC. DIVISION

Volume: Section: Page:

DIM-9 2 18

Date: 2-!9-64 Rev. Date:

2.5.2

Tests which have been completed and for which (ATR's) have been released are listed here: ATR NO. NAME OF TEST

Apollo

Test

Reports

301-7 301-9 301-IO 301-12

Joint - S/M to Adapter Circumferential Edge Member Longitudinal Edge Member Structural Component Test - S/M Outer Shell Pane!_ Blind Rivet Joint Tests Structural Component Test Aluminum Honeycomb Sandwich S/M Honeycomb Attac_hment Test S/MMeteroid Shielding S/M Aft Bulkhead Structural Components Test S/M Aft Bulkhead Structural Components Test_ Bulkhead Splice and Shear Panel Tie but for which no reports have

301-14 301-17

303(213) 3o4 3o4-t

2.5.3

Tests which have been completed been written are these: ATR NO. 301-i 301-3 S/M S/M S/M NAME OF TEST

301-5 2.5.4
Scheduled ATR NO.

- Outer Shell Panel Test Simulated Aft Bulkhead Test Radial Shear Web Test as yet uncompleted are these:

tests

NAME

OF TEST

3OO 301-6 304-2

S/M with Adapter Static Test Fittings - C/H Support Aft Bu_head Component Test - S/M Combined Module Static Structural Test_ has not been

2.5.5

ATR 600_ l%_q.

S!D

64-206

NORTH SPACE and

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Volume: Section: Page: Date: Rev Date:

DZM-9 3 ] 2-1q-64

3.0 3-i

ADAPTER General

STRUCTURE and Configuration

3.1.1

Two S_ and the General Drawing the S-5

adapter structures are in preparation: the S-1 adapter S-5 or S/C L_ adapter. Drawing V18-000002, "Adapter Assembly" (Figure 3-i) shows the S-I configuration. V24-932002 (Figure 3-2) pictures a design proposed for adapter.

3.1.2

Each adapter is a connecting structure between the S/M and the instrument package. Each serves as an enclosure for the lower portion of the main SPS engine and its attached cone_ the aft heat shield below Station X S 200_ and the high-gain antenna in stowed position. Each adapter is made of aluminum honeycomb panels spliced together with pairs of longitudinal splice plates of aluminum. Each adapter structure is equipped with shapedcharge explosives for separation.

3.1.3

The S-I adapter is a cylindrical structure formed of four equally sized rectangular panels which have a uniform thickness of two inches. Location of the S-I adapter is between Stations X D 200 and X D 084. Drawing SK-015129 (Figure 3-3) is the manufacturing assembly breakdown for this adapter.

3.1.4

The S-5 adapter is a truncated conic structure with a conic angle of approximately nine degrees. Its panels vary in thickness. In addition to enclosing the same kinds of items mentioned in 3.1.2_ the S-5 houses and supports the lunar excursion module (L_). Component Description adapters are made of bonded aluwas chosen for the same reasons

3.2 3.2.1

The panels of both S-I and S-5 minum honeycomb. This material as those given in 2.2.1.

3.2.2

Four pairs of longitudinal splice plates made of sheet aluminum O.06-inch thick are used to bind the panels of the S-I adapter together. Drawing V18-300011, "Skin Panel Splice for Adapter Plate" (Figure 3-4)_ displays details of the splice-plate configuration. The function of the shell splice plates in both the structure as formed by the use of the S-I and S-5 adapters is as follows:

3.2.3

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64-206

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a) to protect the equipment noted in 3.1.2 and 3.1.4 from the effects of environmental forces; b) to distribute the body loads in both booster. C/M and S/H; c) to distribute the S/C loading to the

3.2.4

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In normal launch and abort missions_ the S-! adapter structure will function until the adapter panels are separated from the S/C by explosive charges %o allow SPS-engine operation. In normal launch and abort of the spacecraft LEM adapter_ only the portion above the LEM attach points is separated by explosive charges into four hinged panels. The latter open out to permit the removal of the LEMwhich withdraws from the booster and leaves it behind. No detrimental dynamic pressures nor structural be permitted to strike the aft face at Station equipment within the confines of the adapters. Design Characteristics and Criteria the - Component of the shrapnel will XS 200 or any

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to

Test requirements for the S-I adapter components are specifically stated in SiD 62-I09-2_ "General Test P!an_ Research and Dpv_Tnpm_ ................ f_ Project Apollo _y__ ....... _ _ - _....... _n_zvz_ua± System Test." 3.5.2 Tests ATR completed and N_ME covered OF TEST by released ATR's are these:

NO.

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and

D

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64-206

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3.5.3

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tests

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Date: ___4 Rev. Date:

4.0 4.1 4.1.1

SERVICE General There

PROPULSION

SYSTEM

-

TANK

STRUCTURES

are

six

SPS tanks

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each

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three

types).

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designed for storage of fuel_ oxidizer_ and pressurant. The fuel and oxidizer tanks are domed cylinders; the pressurant tanks are spheres. An over-all view of these tanks is found in drawing V!7-340001 4.1.2 (Figure 4-1). items. Allison_ and oxidizer tanks. pressurant tanks.

The SPS tamks are the only major subcontracted !nd is_apo!is_ Indiana is fabricating the fuel Airite_ Los Amgeles_ California is m_king the All three (6AI-4V). coordinate

4.1.3

pairs of tanks are constructed of titanium, alloy NAA drawings (See 4.2.1 and 2 below) are used to and control fabrication processes. in the S/M will be governed dated 4 March 1963_ and of Apollo SPS Tanks." by

4.1.4

Actual installation of these tamks Process Specification MA 0310-0007, entitled "Fitting and Installation Configuration and Function

D

Drawing V17-342001 (Figure 4-2) describes the main oxidizer tank assembly, including the door. Drawing V17-343001 (Figure 4-3) does the same thing for the main fuel tank and its door. Drawings V17-342002 (Figure 4-4) and V!7-34_002 (Figure 4-5_ depict details for fabrication of the oxidizer In the latter two drawings the 4.2.2 Dra_ng V17-347002 the main pressurant (Figure tanks. 4-6) and door sets fuel tanks, respectively. is not included. forth fabrication details for

4.2.3

These six ta__ks of the SPS f1_ction vessels for the fuel and oxidizing tion feed the main SPS engine.

as the storage and provision agent which under pressuriza-

4.2.4

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Date: 2-19-64 Rev. Date:

4.2.5

The weight pounds and of each is

and volume capacity of each 19 cubic feet, respectively. about 41 inches.

pressurant tank are 390 The outside diameter

4.2.6

Drawing V17-342025, Tank"_igure 4-7),

"Assembly of Upper Skirt Support, Oxidizer presents typical support details of these

large oxidizer and fuel tanks at the forward bulkhead. Support details for these same tanks at the aft bulkhead are found in Figures 2-10 through 2-13. Operatin_ Conditions

In a normal launch mission, the SPS tanks will store (without loss of contents) and supply under pressure the necessary fuel and oxidizing agent to the SPS engine for all maneuvers between transpositional docking and earth trajectory. A temperature range of 40-80 F will be maintained. 4.3.2 In a launch abort mission, the SPS tanks will provide sufficient fuel and oxidizer under necessary pressure to enable SPS engine operation for bringing the C/M successfully into earth reentry. Design Characteristics and Criteria of SPS components of tank structures

Criteria useful in design may be found in ARM-6. 4.4.2

The environmental requirements equally valid for the SPS tank Test Rezuirements

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NO.

OF TEST of Tank Skirt

301-4 301-8 301-13
302-1

Test

SPS Main Propellant Tank Cover Door Seal Test - S/M, Main Propellant Manhole Door Pressure Vessel Tests - S/M Pressurant and Propellant Tanks S/M Fuel and Oxidizer Tank Fastener Tests

3o5

SID

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Date: __79_64 IRev. Date:

4.5.3

Particular fabrication test requirements for the subcontractors of the SPS tanks are called out in SID 62-1259 (reissued 12 February 1963), "Statement of Work for Testing of Pressurant and Propellant Tanks_ Project Apollo."

SiD

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Volume: Section: Page: Date: ___ Rev. Date:

DIM-9 5 i

5.0 5.1 5.1.i

SYSTEMS General

MOUNTING

PROVISIONS

Mounting provisions (or the following systems: a. b. c. d. e.

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Environmental control system Reaction control system Service propulsion system Electrical power system Telecommunication system of this section of DIM- 9 is supported by drawings. confined to con-

5.1.2

The subject matter figuration details

5.1.3

The function of systems-support structures is self-explanatory. Any variables in the treatment of the environmental requirements other than those found in 2.4.1 will be stated. Again, operating conditions for these mounting provisions differ in no way from the conditions imposed on the structures supported by them. Likewise, design characteristics and criteria for component configuration are also given in ARM-6. Finally_ only one test requirement exists for the testing of systems-mounting provisions. It is ATR 301-i1, "Fittings and Equipment Support," and it is yet unwritten, pending completion o£ test. ECS Mounting Provisions Configuration Control configura-

Drawing V17-331717, "Mounting Provisions, Environmental Systems Installations" (Figures 5-i through 5-3) shows tion details for supporting structures of this system. 5.2.2 Particular details concerning the L02 tles are found in drawing V!7-33!667, Shelf Support" (Figure 5-4).

supercritical storage bot"Assembly of Oxygen Tank

5.2.3 which these 5.2.4 special support structures are in preparation. need design. The drawings for

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Volume: Section: Page: Date: Rev. Date:

D!M-9 5 7 2-19-64

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Complete Reaction Control System" (Figures 5-6 through 5-7) show the over-all configuration o£ the RCS mounting provisions. Drawing _±7-332002 (Figures 5-8 through 5-9) gives details of the panel per se. the RCS is shown in drawing V!7-332010 are used for mounting the assembly.

5.3.2

The housing assembly of (Figure 5-10). Brackets

5.3.3

The engines of the RCS are supported on panels which form part of the outer shell of the S/H. Hinges, attached by screws to the shell, allow the RCS panels to be swung out for access or replacement. Heat shields which protect the outer shell of the S/H from RCSengine-flame impingement are shown, with their mountings, in two drawings: V17-331525 (Figure 5-11) for the longitudinal installation, and V17-331611 (Figure 5-12) for the lateral installation. The insulation for the RCS panels is depicted in drawing V!7-332046 (Figure 5-13). The RCS engine installation requires a cluster of three tanks in each of its four locations. The complete assembly of the fuel, oxidizer, and pressurant tanks which are mounted as a cluster is exhibited in drawings V!7-332041 (Figure 5-14) and V17-332042 (Figure 5-15). Mounting Mounting SPS Mountin_ of valves of the RCS Provisions for the RCS is done has by brackets been and a panel. yet.

5.3.4

5.3.5

5.3.6 5.3.7 5.4 5.4.1

control

unit

not

designed

Configuration

Drawing V17-327101, Propulsion System" mounting provisions

"Installation of Engine Mount, Service (Figures 5-16 through 5-17), breaks down for the SPS main engine.

the

A propellant distribution system of valving, hard lines; and electrical harnesses carry fuel and electricity to the SPS main engine. Drawing V!7-33!000 (Figure 5-18) depicts mounting provisions for this distribution system. 5.4.3 Support provisions for the pressurization system which assures a constant flow of fuel and oxidizer to the main engine are shown in drawing V17-331!00 (Figure 5-19). Included in these provisions are a control panel, line supports, and mounting brackets. Drawings V!7-33!I01 and V17-331102 which exhibit supports for the panel assembly of the pressurization-system module are not available and therefore not included.

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Volume: Section: Page:

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Date: 2-19-64 Rev. Date:

EPS

Mountin_

Provisions

Configuration

The over-all view of the EPS mounting provisions for the installation of the fuel cells and related equipment is the purpose of drawing V17-331552 (Figures 5-20 through 5-21). Sheet one of this drawing is a perspective of the installation. The fuel cell itself is mounted by means of a stabilized shear web as seen in drawing V17-331524 (Figure 5-22).

5.5.2

Both the LH 2 and L02 bottles in Sector One serve the EPS. The manner of mounting the L02 bottles is stated in 5.2.2. Hounting of the upper LH 2 tank is shown in drawing V17-331566 (Figure 5-23). See Figures 2-10 through 2-13 for provisions made for the lower LH 2 tank. of the EPS is depicted

5.5.3

Proposed mounting of the space radiators in layout V17-933074 (Figure 5-24).

5.5.4

Hard lines and valves which supply liquid oxygen and liquid hydrogen to the fuel cells are mounted in Sector Four as illustrated by drawing V!7-331553 (Figures 5-25 through 5-27). Supports for other lines which supply glycol fill to the EPS radiators clips. include blocks, line mountings, saddle clamps, and

5.5.5

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5.5.6

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blocks,

clips,

Configuration the telecommunica-

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Volume: Section: Page: Date: Rev. Date:

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_

6.0 6.1 6.i.i

THERMAL Aft Heat

CONTROL Shield

STRUCTURES

There are two means of thermal control of the S/H structures: a) the aft heat shield below the aft bulkhead at Station KS 200; and b) the service module insulation. (Note: Insulation of the RCS heat shields is mentioned in 5.3.4.) The aft heat shield is fabricated from nickel_ Fiberglas_ quartz fiber_ and aluminized Hylar. Nickel 0.005 to O.!5-inch thick forms the outer shell. Drawing V$,7-331944 (Figure 6-1) depicts the outer shell assembly [typical) for Sectors Three, Four and Five. Fiberglas which varies in thickness between 0.03 and 0.06 inch makes up the inner shell as illustrated for Sectors Three, Four, and Five in drawing V17-331700 (Figure 6-2). Quartz fiber l.O-inch thick is used as an interlining between the outer and inner shells, while aluminized Mylar about 0.25-inch thick on the inboard side of the inner shell supplies the last layer of the aft heat shield. Differential pressure between the S/M and the adapter during prelaunch GN 2 purge and boost blow-down is relieved by five valves _laced in the outer shell of the aft heat shield. Drawing V17-331889 (Figures 6-3 through 6-4) shows installation details for the heat shield.

6.1.2

6.1.3

The aft heat shield and the flexible boot protect the tanks_ propellant distribution systems, and electrical from SPS engine heating.

main SPS wiring

6.1.4

Criteria which influenced the configuration of the aft heat shield were these: a) provision of sufficient clearance space for fuel lines, valves_ tanks, engine gimbal, and high-gain antenna below the aft bulkhead; b) provision of an interface between the engine and the fuel tanks; c) choice of materials for weight and the best thermal protection. On either the normal launch mission or the normal launch abort

6.1.5

mission the aft heat shield will fully protect the SPS tanks, valving, and distribution lines from engine radiation temperatures in excess of 2000 F. 6.1.6 Other and more technical criteria the design of the aft heat shield No tests are planned test requirements. Service Hodule for the aft which have been used to are found in the ARM-6. heat shield, hence there set

6.1.7

are

no

Insulation

Crinkled, aluminized Hylar is the insulation material used in all sectors of the service module and in the space between the service module and the command module. One-half inch of space SID 64-206

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2-iO-64

has been allotted for insulation, even though the total thickness of the Mylar layers uncompressed will be only 0.25 inch. Installation accessories are hollow aluminum rods, nylon buttons, cords, and thread; spring clamps; and reflecting pressuresensitive tape. Drawing V17-331562 (Figures 6-5 through 6-6) shows the perspective of the insulation-installation provisions. 6.2.2 The function heat shield of this insulation in the dissipation system of heat is to supplement from any source the aft and to

keep the SPS tanks, propellants, and other equipment at an even, nondestructive, proper, operative temperature. The insulation system also prevents loss of heat in the cold environment of space. 6.2.3 Criteria which governed the choice of aluminized Mylar (NRC-2) as insulation material are these: a) it is the best reported insulation value per pound; b) it has the ability to withstand high compression of large g loads while maintaining initial insulation effectiveness; c) its low bulk density is needed to achieve thermal equilibrium with a minimum loss of cryogenic fluids; d) by its use a high vacuum can be obtained; e) it is easy to apply to complex shapes; f) a minimum effect is obtained from thermal short circuiting. During the normal launch mission or the normal launch abort mission the thermal insulation system will protect the SPS tanks and internal equipment of the S/M from environmental temperature extremes generated externally. The insulation will maintain the temperature range of 80 through 40 F for the propellant during the mission. Test requirements for the thermal insulation system are stated in SID 62-109-2, "General Test Plan, Research and Development for Project Apollo Spacecraft, Individual System Test." ATR 306, "Thermodynamic Analysis of the Typically Insulated S/M Propellant Sextant," has not been completed since the test has not been run. However, design work has begun on the thermal simulator - test specimen. Drawing DTT-6600 (Figure 6-7) gives details ol _ae SPS tank-insulation assembly. If additional information is desired, contact can be made with Department 696-210.

6.2.4

6.2.5

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7.0 7.1 7.1.1

SIGNIFICANT General By the

INTERFACES

term

"interface"

is meant

the

common

boundary

between of contact_ to assure

two or more systems or subsystems. At their points matching or accommodation must be properly achieved compatibility and successful functioning. 7.1.2

Significant interfaces are divided into two categories: a) those which are external, affecting structures; b) those which are internal, affecting such things as mechanics, hydrau!ics_ pyrotechnics, and things electrical. Some of the external interfaces are in the study stage. studies crystallize into designs, the resultant drawings be added to later editions of this manual. All of the systems-mounting However_ these provisions 5.0. External Interfaces As the will

7.1.3

7.1.4

provisions are really interfaces. are separately treated under heading

The fairing_ an important part of the S/C is one of the chief aerodynamic interfaces between the S/M and the C/M. It is made of six equally sized panels fabricated from bonded aluminumhoneycomb sandwich one-inch thick. Installation drawing V!7-3!0001 (Figures 7-1 through 7-2) and panel assembly drawing V17-3!!001 (Figure 7-3) depict the fairing interface. The function of the fairing is twofold: a) to shield from atmospheric pressure certain equipment essential to the smooth functioning of the S/M and C/M; b) to prevent rapid evacuation of air from the S/M interior. 7.2.2 The C/M to S/Mumbi!ical with its own fairing is the second vital interface. This fairing is located in Sector One on the outer shell of the S/M - C/M f_i_g. D_T_ V17-_q1771 (Figure 7-4) shows configuration details of the fairing. Drawing V17-331913 (Figure 7-5) depicts these details for the fly away umbilical. One criterion by which an external structure was added to the otherwise smooth surface of the S/M was the imperative necessity of finding a route for the umbilical - hard lines and electrical wiring - such that it would not penetrate the ablative material of the C/M. A third significant interface exists between the S/M and the S-I adapter. The chief feature is a strap-tension tie which also carries the shaped charges used to separate the S-! adapter panels from the S/C. See drawing T18-300005 (Figure _ £_ • I-u}

7.2.3

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Volume: Section: Page: Date: Rev. Date:

DIM-9 7 3 2-19-64

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Volume: Section: Page: Date: Rev. Date:

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S ecti on: 7 Volume:D!M-9 Page: Date: Rev. Date: 7 2-19-64

Figure 7-6. Service Module

Strap-Tension Tie, to Adapter (V18-300005)

szD 64-2o6

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Volume:_ Section: Page: 7 8

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7.2.4

A fourth external interface concerns the S/M and Adapter-toLaunch Complex or the GSE umbilicals. Drawing V17-933401 (Figure 7-7) presents the control layout for the servicing and umbilical locations. The latter are blown away hydraulically from their respective structures at time of blast-off. (S-I configuration only; S-5 configuration now in design study. ) Design studies interfaces: a. b. c. d. are now in progress for the following external

7.2.5

S/M to SLA; SLA to Saturn instrument S-IV B adapter to L_; S-I Adapter to S-IV B. Interfaces

package;

7.3 7.3.1

Internal

One of the two internal EPS. Drawing V17-331549 mounting which binds

interfaces is between the ECS and the (not included) exhibits a bracket of each is between system. the SPS and the EPS.

members

7.3.2

A

second

internal

interface

Drawing mounting Test

V17-331501 (not for members of

included.) likewise shows each respective system.

a bracket

Requirements for separation given below is 0nly the

Tests for interfaces have been scheduled chiefly systems involving the modules. The test schedule included in this manual for information purposes. first three tests have been completed. 7.4.2 ATR NO. NAME OF TEST System: System: C/M from S/M S,/M to S-!VB

i00 A i01 i01-i i01 I01 A

Separation Separation Adapter S/M Adapter Supplement S/M to S-IV Separation Adapter

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64-206

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,

Date: ____4 Rev. Date:

REFERENCES* IOL AE-I-62-313, dated 5 December to Apollo Engineering Management_ NASA Exhibit "B" Technical £or 1962, from on subject Fart C.H. Feltz, Department of Apollo Engineering I. 3 January III_ Design 1963. Procedure_ 695-i00_ Manuals.

Specification_ Flight Vehicles_

Composite Construction MiL Handbook 23.

Part

8.4

Apollo 1963.

Test

Requirements

Status

and

Coordination

List.

NAA

S&ID_

17

July

8.5

Command Module and Launch Escape System Engineering Manual. NAA S&ID, 7 August

Structures. 1963.

DIM-8_

Apollo

Systems

8.6

General Test P!an_ Research and Development for Individual System Test. NAA S&ID_ S!D 62-109-2.

Project

Apollo

Spacecraft,

*Add in

all the

current list

control_

perspective_ for this

and nomenclature manual.

drawings

as called SID

out

of illustrations

64-206

ILLUSTRATION LOG
PROJECT SECTION REQUESTOR I D FIGg NO. I-i i-2 2-1 2-2 2-3 2-4 2-5 Service Service Module M_ule: Nomenclature General (V17-933200) (Vl?-O00002) (9-17-320001-1) (VI?-320001-2) (V17-320001-3) (V17-320001-4) z .;7-2/i. Z F INAL REPORT NO. -DESIGN INFORMATION MANUAL DIM-9

Assembly

Service Module: Service Module: Service Module: Service Module: Service Module:

Structural Structural Structural Structural Struc t_-al

Assembly Assembly Assembly Assembly

As sembly_ (V17-320001-5) of Service Module of Service Rodule (V17-_20101) (_17-320201-i)

C_mplete Interior Complete Interior Installation Assembly 2- t_1, _2 _,'/3 Assembly Assembly Assembly

Arrangement Arrangement

(V17-935561-I)

of Forward

Bulkhead

z-._/
l/.,L

of Aft Bulkhead, of Aft Bulkhead, of Aft Bulkhead, of Aft Bulkhead,

Statiom _. 200 Station _

200 (V17-320201-2)

Z-I-_ _ - /V 2_ -',/'b-

Station XB 200 (_17-320201-3) Station _ 200 (n7-320201-4)

2-14

Assembly Adapter:

of Radial Beam 2 (V17-322001) General Assembly (V18-OOOOO2)

2 -/_, _-2..

3-3

Manufacturing

Assembly

Breakdown

of _

Adapter

(_E-015129)

-;; -,+

3-4 > 4-s

Skin Panel Splice for Adapter Plate (V18-300011) Installation of Maim Propellant Tank, Service Module (V17-340001) _-z.: _ Assembly Complete: Main Propellant, Oxidizer (VlT-3_l_O01J _ '_¢ Tank Assembly Complete: Main ProPellant _ Fuel Main Propellant, Oxidiser (IF17-343001) _/"_¢ _ 5"

_-4 _-5 4,.-6

Tank Assembly: Tank Assembly, Tank Assembly: A_sembly of

(_17-342002)

Main Propellant, Fuel

(V17-343002) (V17-347002) Tank (VlT-342025)

Main Propellam%,. _elium Skirt .Suppert, Oxidizer

Upper

ILLUSTRATION LOG
PROJECT SECTION REQUESTOR I NO. P- 7_. t_.a_st 3503, .4 REPORT NO. DZ'!;I_-N I._'_(,=.:'.,;,TI','_'! DIM"2_2._7AL 9

FINAL

Mo_mting _-2 5-9 5-4 5-5 5-6 5-7 5-8 5-9 ....... _-!O 5-11 Mounting Molmting :-m_,_mb._ Nodule

Provisions, Provisions, Provisions, of Oxygen

Znvir:m.'_enta! 3ontrc! Environmental Environmemtal Control Control

System System System

Instal]s.ticns

(7].7-.55;71 7-"I /

_nst,_.!]stions (_J!7-3-,J ! 7-.2

I

Installations

(V3.7-_17

7":_.)

!;"

Tar_: Shelf

Support

(V17-331667) System (V17-322000)
. ...... (v17-33.2001-I)

InstalPation

of Reaction

Control

Panel Assembly Panel Asse_b!y

3omplete, Comolete,

"9 ,. ,_4- " (_ ,_e_._ _l.m Control

System System

_*4c.n Control Ccntro!

Control System ._yst_m

(I_,-..j2001-_)

Pa_e]. Assemb2.y_ Peacticn Panel Assemb_!y_ Peaction Housin_ Assembly,

(F17-332002-I) (V17:_.2OO2-2)

_ .... _ o Control. ......_ .n +

Sys+.,_m (V!7-332010) System
r.,O (7]..7-33: ,_

Longitudinal

He_t Shield

Instal].stion, .qe_ction Control Reaction Control

5-].2 Lateral 5-]3 5-1,/+

H_o.t Shield

Installation,

_vstem

(VI7-_°_n]

Insulation

Imstallation

for Reaction of Prooellant

Control Tanks,

Systen,. (V17-3_2046) Cen,<ro! System C_t_o_ (7].5 0f:l)

End M.ounti.-gAssembTy

Reaction Tanks,

5-].5 Motu_ting Assembly, 2ystem 5-16 5-17 (V!7-332042)

Pro;._ellant and Pressure

Re cL_on

Installation Installation

of _ _" _ngxne of Engine

Mount, No,mr,

Service _er_ce ""

Propulsion . _. _o,_ulsion

* .... oy_,,e_ . ..... Sv_t.__

( V!7-3:_7101-I (U!7-327!01-2)

5-18. Mountin_ 5-19

Provisions

Installation,

Service Service

Propu!sJen

Svst,_m (,l_-__.100()

}"..ounting _:'ovisions Installation, System (717-331100)

Pronu_--ion. _"_ssuriza1:.ion _.,_

--]

__;ou/uti_ Provisions, Mounting
FORM 930- R-1

Electrical Electrical

Power System Power System

(V17-351552-I) (V17-931552-2)

Provisions,
l

ILLUSTRATIONLOG
PROJECT SECTION REQUESTOR P. B. gaist. 3503. 4 _IGN INFORMATION MANUAL DIM9
| , It i

REPORT NO,

NO. Insta/lation Assembly Control Four of Fuel-Cell M_antlq, Stabilised Tank Shear Web (VI?-33152_) (VI?-331566) Seet_rs 0he and _-" Fluid Lines Support, Electrical Power _"

FINAL

of Support Shelf, Upper R_rogen Layout - Electrical

Power System Radiators,

(V17-933074} Previsions,

Installation _ystem

(_i?-331553-I) Provisions, Fluid Lines Support, Elee%rioal Power

Installation System Installation

(VI?-331553-2) Provisions, Fluid Lines _ppert, _ee_ieal E_wer

Systen

(v'z?-33z553.:.3)

0uter S_ell Assembly,

Aft Heat Shleld,

Seekers

Three

F_Ar

and Five

Inner ShellAssembly,

A_

Heat Shield,

Se@ters

Three

and Fi_

)
Installation. of InstaAlation Insulation Insulation Complete Aft Heat Shield, Station 200 200 Mule (T17-331689-I) (V17-331689-2) _rI?-331562-1) (_17-33156_-2) Test _TT-6600)

of Aft Heat Shield, Statian Installa_zon _,stalla_Ion Pr_isions, Provisions, Servlse

Ser_Ise M_le for Speoi_en

Assembly

of Thermal Simulator (VI?-310001-1) (_I?-31000_-2) Serviee M_ule C_ma_

Installation Installation Fairing Fairiag

of Fairing of Fairing

7-

2_

7-9
te Comad _ule (V17-311001)

Panel Assembly, Assembly

Complete,

M_ule

to Series

R_4_I_ U_billeal

Strap-Tension

Tie, Service _ule

to _dapter

(V18-300_05)

_-7

,o,. ,30 7

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