FM2 PPSR RCS Pressure Test Leak Check1 UCB, March 16, 2006 THEMIS PROBE FM2 PRE-ENVIRONMENTAL REVIEW RCS MEOP TEST/LEAK CHECK Michael Sholl Berkeley RCS Lead Engineer University of California - Berkeley
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FM2 PPSR RCS Pressure Test Leak Check1 UCB, March 16, 2006
THEMIS PROBE
FM2 PRE-ENVIRONMENTAL REVIEW
RCS MEOP TEST/LEAK CHECKMichael Sholl
Berkeley RCS Lead Engineer
University of California - Berkeley
FM2 PPSR RCS Pressure Test Leak Check2 UCB, March 16, 2006
Overview
MEOP tests and leak checks are scheduled to verify RCS system survived environmental testing
Performed after thermal vacuum, vibration and shock testing
Tests to be performed in Building 179 (magnetics)
Test is identical to RCS MEOP/leak check performed March 6-7 2006 in Berkeley
Primary hazards during test are helium asphyxiation and tank pressurization
FM2 PPSR RCS Pressure Test Leak Check3 UCB, March 16, 2006
P
P
GHe
N2H4 N2H4
15 µm
40 µm 40 µm
15 µm
20 µm
20 µm
20 µm
20 µm
20 µm 20 µm 20 µm
SV2SV3
Pressurant P/V Valve SV4
Ullage P/V Valve SV1
COPV Pressurant Tank
High Side Pressure Transducer0 to 200psi
Pyro Valve
Filter
Dual Seat Solenoid Isolation Valve
low Side Pressure Transducer0 to 500psi
Propellant Tanks
F/D Valves
Filter
Latch OrificeLatch
Filter
Dual SeatThruster Valves
Test SequenceSV1 Manifold Tests
• Isolation Valve Cycle Test• (SV1 manifold to 400psia)• Forward Leakage Test (decay test)
using panel gauge• SV1 Leakage Test using pipette• (depressurize SV1 manifold))
Cycling tests on latch and thruster valves • LV Cycle Test• Thruster Valve Cycle Test
Low Pressure Transducer / Propellant Tank MEOP Test
• Low Pressure Transducer Output Test• (pressurize tanks to 400psia)• Propellant tank MEOP Test
Latch, thruster and SV2 & SV3 leak tests• Latch Valve Forward Leak Test • Thruster Valve Forward Leak Test • Low Pressure Service Valves (SV2 &
SV3) Leak Test• (depressurize tanks to 50psia)
High Pressure Transducer / Pressurant Tank MEOP Test
• High Pressure Transducer Output Test• (pressurize COPV to 1750psia)• Pressurant Tank MEOP Test
High Pressure Service Valve Functional Test• High Pressure Service Valve Leak Test • (depressurize COPV to 50psia)
FM2 PPSR RCS Pressure Test Leak Check4 UCB, March 16, 2006
GSE
• 2TE35610-301 (Low Pressure Test Panel)
• TE35610-301 (High Pressure Test Panel)
• Thruster enable test set
• Pipettes (1ml) for valve leak checks• Service Valves
• Latch Valves
• Thruster Valves
• Interfaces to s/c via nozzle throat plugs and Tygon tubing
• Droplet of H2O injected with syringe
• Helium K-bottle
• Blast Shield• 1/2in thick polycarbonate
FM2 PPSR RCS Pressure Test Leak Check5 UCB, March 16, 2006
G13000 PSI 1000 PSI
G21000 PSI
G3
G1SHUTOFF
VALVE
G2SHUTOFF
VALVE
G3SHUTOFF
VALVE
R1
REGULATOR
TOVENT
V1 V2V3
RV2RV1
PORT 1
PORT1
PORT2
LOW PRESSURE TEST PANEL2TE35610-301
BOTTLEREGULATOR
SHUTOFF
BOTTLEISOLATION
VALVE
RB
GAUGEPRESSURE
BOTTLE
GAUGEREGULATOR
BOTTLE
2TE35610-301 (Low Pressure Test Panel)
FM2 PPSR RCS Pressure Test Leak Check6 UCB, March 16, 2006
TE35610-301 (High Pressure Test Panel)
VENT
G1SHUTOFF
VALVE
5000 PSI
SHUTOFF
RV1
TO
REGULATOR
VALVE
R1
V1
PORT1 2
PORT
RV2
V2
G13000 PSI
G2
G2
PORT 1
HIGH PRESSURE TEST PANELTE35610-301
REGULATOR
VALVESHUTOFF
BOTTLE
REGULATOR
VALVE
BOTTLESHUTOFF RB
BOTTLE
REGULATORPRESSUREGAUGE GAUGE
BOTTLE BOTTLE
FM2 PPSR RCS Pressure Test Leak Check7 UCB, March 16, 2006
Thruster Enable Test Set
•Allows actuation of thruster valves• Both seats simultaneously (cross-strapped)• Individual seats
•Low-current mode to hold thrusters open during test
•LEDs indicate thruster firing
SW1 SW2 SW3 SW4
PB1U PB1D PB2U PB2D PB3U PB3D PB4U PB4D
J1U J1D J2U J2D J3U J3D J4U J4D
REA 1 REA 2 REA 3 REA 4
L1U L1D L2U J2D L3U L3D L4U L4D
RCS J4 - THRUSTER ENABLE TEST SET
FM2 PPSR RCS Pressure Test Leak Check8 UCB, March 16, 2006
Nozzle Throat Plugs
FM2 PPSR RCS Pressure Test Leak Check9 UCB, March 16, 2006
Safety/MA Considerations
• 1.5x proof test on both panels and lines (tags will be in place by time of test)
• Only required personnel in test facility
• Blast shield and PPE (face shield/goggles) in use
• O2 alarm and placarding in place
• Temperature and humidity
• Safety signoff at beginning and end of haz. proc.
• ESD per THM-SYS-014 EDS Control Plan
• Temperature: 65-75ºF
• Humidity: 25-60%
FM2 PPSR RCS Pressure Test Leak Check10 UCB, March 16, 2006
Summary
MEOP tests and leak checks are scheduled to verify RCS system survived environmental testing
Procedure has been run, and is well-understood
Safety precautions in place
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