Facility Handbook For Payload Hazardous Servicing Facility

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K-STSM-14.1.15-REVC-PHSFDecember 1995Revision CFacility Handbook forPayload HazardousServicing FacilityRELEASEDCONTRACT NAS10-11400

DRD CA-4RELEASED

K-STSM-14.1.15December 1995Revision CFACILITY HANDBOOKFORPAYLOAD HAZARDOUS SERVICING FACILITYPREPARED BY:/s/Jan TiberiusJan Tiberius, MDS&DS-KSCAPPROVED:/s/P. Thomas BreakfieldP.Thomas Breakfield III, CSDirector, Payload Flight Operations/s/Bobby G. BrucknerBobby G. Bruckner, CGRELEASED

K-STSM-14.1.15December 1995Revision CDirector, Payload Ground OperationsRELEASED

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K-STSM-14.1.15LIST OF EFFECTIVE PAGESRevision C supersedes the previous publication, dated January 1993.Total number of pages in this publication is 62 consisting of:Page No.i through xiv1-1 through 1-42-1 through 2-43-1 through 3-144-1 through 4-85-1 through 5-46-1 through 6-47-1 through 7-10RELEASEDi

K-STSM-14.1.15RELEASEDii

K-STSM-14.1.15TABLE OF 3.3.113.3.123.3.133.4TitlePageINTRODUCTION .1-1Purpose .1-1Scope .1-1Customer Charge .1-1Facility Accommodations.1-3Emergency Planning and Community Right-to-Know.1-3Hazardous and Controlled Waste .1-3FACILITY DESCRIPTION.2-1Location and Description.2-1Security/Access.2-2Requirements and Special Considerations .2-3PAYLOAD HAZARDOUS SERVICING FACILITY .3-1Description .3-1Access .3-2Mechanical Systems.3-3Material Handling Equipment.3-5Airlock Bridge Crane .3-5Service Bay Bridge Cranes .3-5Electric Towing .3-5Air Bearing Pallet.3-5Electric Fork Lift.3-5Gasoline Fork Lift .3-6Vacuum System .3-6Compressed Air System.3-6Gaseous Helium System.3-7Gaseous Nitrogen System .3-7Heating, Ventilating and Air-Conditioning Systems .3-7Breathing Air System .3-7Hypergol Vent System.3-7Propellant Waste Drain System .3-7Environmental Monitoring System.3-8Krypton Vent System.3-8Emergency Exhaust System .3-8Safety Equipment.3-8Fire Protection Systems .3-9RELEASEDiii

K-STSM-14.1.153.4.1Fire Detection System.3-9RELEASEDiv

K-STSM-14.1.15TABLE OF CONTENTS .24.8.34.8.44.8.5V5.1TitlePageFire Alarm System.3-10Fire Control Equipment .3-10Water Deluge Systems .3-10Electrical Systems .3-10Alternating Current.3-12Illumination.3-12Lightning Protection .3-12Grounding Systems.3-12Power Kill Switch.3-12Back-Up Power .3-13MULTI-OPERATIONS SUPPORT BUILDING .4-1Description .4-1Access .4-3Customer Areas.4-3Office Area .4-3Conference Room .4-4Facility Storage .4-4Mechanical Shop.4-4Break Room .4-4PHE Change Room.4-4Payload Control Rooms .4-4Facility Control Room .4-4Heating, Ventilating and Air-Conditioning Systems.4-5Fire Protection Systems .4-5Fire Detection System.4-5Fire Alarm System.4-6Fire Control Equipment .4-6Safety Equipment .4-6Electrical Systems .4-6Alternating Current.4-6Illumination.4-6Lightning Protection .4-6Grounding Systems.4-7Back-Up Power .4-7SPECIAL SERVICE FACILITIES .5-1RELEASEDFuel Transfer Building .5-1v

.117.127.13Oxidizer Shed.5-2TABLE OF CONTENTS (continued)TitlePageKrypton Storage Building.5-2COMMUNICATIONS AND DATA HANDLING .6-1Communications.6-1Operational Intercommunication System .6-1Closed Circuit Television .6-1Other Communications.6-1Data Handling.6-1Wideband Cable Transmission System .6-1Reradiating Antenna System .6-2Audio Frequency Capability .6-2FACILITY DESCRIPTION SUMMARY.7-1Fire Protection.7-1Floor Space .7-1Ceiling Heights .7-2Equipment Entry (Clear).7-4Cranes .7-5Crane Hook Heights .7-6Pneumatic Systems .7-6Temperature/Humidity .7-6Environment .7-6Electrical Power.7-7Illumination .7-7Communications.7-8Data Handling.7-9RELEASEDvi

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K-STSM-14.1.15LIST OF -2TitlePageKSC/CCAS Payload Processing Facilities.1-2Aerial Photograph of PHSF Complex .2-1PHSF Complex Site Plan.2-2Payload Hazardous Servicing Facility .3-1PHSF Floor Plan.3-2PHSF Mechanical Systems .3-4PHSF Electrical and Fire Protection Systems .3-11MOSB Floor Plan.4-2Office Area Seating .4-3MOSB Electrical and Fire Protection Systems .4-5Emergency Warning Systems of Fuel Transfer Building & OxidizerShed .5-3PHSF Communication Systems.6-3MOSB Communication Systems.6-3LIST OF TABLESTable3-13-23-34-16-1TitlePagePHSF Room Specifications .3-3Crane Speeds - Meters per Minute.3-6KSC CWA Environmental Requirements.3-9MOSB-South Room Specifications .4-1RF Capability for the PHSF and MOSB.6-2RELEASEDviii

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K-STSM-14.1.15ABBREVIATIONS AND ACRONYMSThe following abbreviations and acronyms are used in this document. A morecomprehensive listing is contained in NASA Reference Publication 1059 Revised,Space Transportation System and Associated Payloads: Glossary, Acronyms, andAbbreviations.AacACMamperealternating currentAccess Control MonitorBIBOCbpsbi-phaseBase Operations Contract(or)bits per second CCCASCCTVCFMCGCSCWAdegrees CelsiusCape Canaveral Air Stationclosed circuit televisionCubic Feet per MinutePayload Ground Operations (NASA)Payload Flight Operations (NASA)clean work areaEGLELVEMSEPDESSelectrical ground lugExpendable Launch VehicleEnvironmental Monitoring SystemEmergency Procedures DocumentElectronic Security System Ff-cFCBdegrees Fahrenheitfoot-candleFacility Control Building (renamed MOSB)GHeGHzGN2GSEgaseous heliumgigahertzgaseous nitrogenground support equipmentHADHEPAhpHPFheat-activated detectorHigh-Efficiency Particle Airhorsepowerhazardous processing facilityRELEASEDx

K-STSM-14.1.15HVACHzHeating, Ventilating and Air-ConditioninghertzABBREVIATIONS AND ACRONYMS (continued)IDASIGPIRIGIntrusion Detection Alarm Systeminstrumentation ground plateInter-range Instrumentation GroupkbpskgKHBKHzKMIKSCkilobits per secondkilogramsKennedy HandbookkilohertzKennedy Management InstructionJohn F. Kennedy Space Centerll/secLCLCClmLPSLSSMliterliters per secondLaunch ComplexLaunch Control CenterlumenLaunch Processing SystemLaunch Site Support azineMulti-Operations Support Building (previously called FCB)Multi-Payload Processing FacilityN2O4NASANEMANRZ-LNitrogen TetroxideNational Aeronautics and Space AdministrationNational Electrical Manufacturers Associationnonreturn to zero levelO&COIS-DOMIOS&YOperations & Checkout Buildingoperational intercommunication system - digitalOperations and Maintenance Instructionoutside stem & yokePAPACASPETSPGOCPHEpublic addressPersonnel Access Control Accountability SystemPayload Environmental Transportation SystemPayload Ground Operations Contract(or)Propellant Handlers EnsembleRELEASEDxi

K-STSM-14.1.15PHSFPKSPayload Hazardous Servicing Facilitypower kill switchRELEASEDxii

K-STSM-14.1.15ABBREVIATIONS AND ACRONYMS (continued)PPFpsigpayload processing facilitypounds per square inch gageRFradio frequencySAAscfmSIDSatellite Accumulation Areastandard cubic feet per minuteStandard Interface DocumentTAATemporary Area l Processing FacilityWBTSWide-Band Transmission SystemRELEASEDxiii

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K-STSM-14.1.15FOREWORDLaunch site payload processing facilities are described in three levels ofdocumentation. These levels and their purposes are:a.Launch Site Accommodations Handbook for Payloads, K-STSM-14.1, provides anoverview of the John F. Kennedy Space Center (KSC) launch and landing siteoperations and each facility.b.Facility handbooks describe a specific facility, its systems, general operatingrules, regulations, and safety systems. Facility handbooks are revised andreissued as needed to maintain the level of usefulness necessary to supportcustomers planning to process their payloads at KSC. The following handbooksare available:Facilities Handbook for Building AEFacilities Handbook for Building AO**Facilities Handbook for Building AM**Facilities Handbook for Hangar S**Facilities Handbook for Explosive Save Area 60A(ESA-60)K-STSM-14.1.7Facilities Handbook for Spacecraft Assembly andEncapsulation Facility - 2 (SAEF-2)K-STSM-14.1.8Facilities Handbook for Radioisotope ThermoelectricGenerator Facility (RTG-F)K-STSM-14.1.9Facilities Handbook for Life Sciences Support Facility Hangar LK-STSM-14.1.10*Payload Accommodations at the Rotating ServiceStructure (RSS)K-STSM-14.1.12Facilities Handbook for Vertical Processing Facility (VPF)K-STSM-14.1.13*Orbiter Processing Facility (OPF) Payload Processingand Support CapabilitiesK-STSM-14.1.14*Operations and Checkout (O&C) Building PayloadProcessing and Support CapabilitiesK-STSM-14.1.15Facilities Handbook for Payload Hazardous ServicingFacility (PHSF)K-STSM-14.1.16Space Station Processing Facility (SSPF) Processing andSupport CapabilitiesK-STSM-14.1.17Facilities Handbook for Multi-Payload Processing 1.3K-STSM-14.1.4K-STSM-14.1.6RELEASEDxv

K-STSM-14.1.15***c.These handbooks are titled differently as the facilities serve functions other thanpayload support. Only the payload accommodations are described in thesedocuments.These handbooks are being phased out and will not be updated; the facilities areno longer available for payload processing activities.Standard Interface Documents (SIDs) - SIDs provide the most detailed informationon facility interfaces for KSC launch site payload processing facilities. WhenSIDs are not available for a payload processing facility, facility handbooks shouldbe used for design interface information and customers should ask for verificationof any areas of concern.The Payload Strongback and the PayloadEnvironmental Transportation System (PETS) Multiuse Container do not havefacility handbooks, and in these cases, only the SIDs will be used. Customersmay obtain copies of any of the following SIDs from their respective Launch SiteSupport Manager (LSSM):SID 79K12170SID 79K16210SID 79K16211SID 79K17644SID 79K18218SID 79K28802SID 79K18745SID 82K00463SID 82K00760SID 82K03223Payload Ground Transportation CanisterVertical Processing FacilityHorizontal Processing Facility (O&C Building)Payload StrongbackLaunch Pad 39ALaunch Pad 39BOrbiter Processing FacilityPayload Environmental Transportation System MultiuseContainerSpace Station Processing FacilityMulti-Payload Processing FacilityRELEASEDxvi

K-STSM-14.1.15SECTION IINTRODUCTION1.1 PURPOSEThis handbook will provide basic information regarding payload processing and supportcapabilities in the Payload Hazardous Servicing Facility (PHSF) at KSC. The locationof the PHSF is shown in Figure 1-1, which follows. The PHSF can be used as apayload processing facility (PPF) and/or a hazardous processing facility (HPF). Whenused as a PPF, the processing flow begins after a payload and its associated groundsupport equipment (GSE) have been received and inspected. The payload isassembled, configured and readied for launch. This may include installation of solarpanels, antennas and other items that have been shipped separately to the launch site.At this stage in processing, initial pressure system tests and payload functional testingwith payload-unique ground checkout equipment are conducted. When used as anHPF, the PHSF accommodates the following: ordnance installation; loading of liquidpropellants (e.g., hypergols); hazardous systems tests and checkout; buildup, andmating of a payload to a solid propellant upper-stage motor; propellant system leaktests; and other potentially explosive or hazardous operations.The KSC LSSM, in conjunction with the Launch Site Support Team and the payloadowner, determine launch site facility utilization assignments. Assignments take intoconsideration the identified payload requirements and space shuttle or NationalAeronautics and Space Administration (NASA)-purchased Expendable Launch Vehicle(ELV) schedules. The handbooks previously identified in the Foreword describe theconfiguration of the Cape Canaveral Air Station (CCAS) and KSC Payload FlightOperations (CS) and Payload Ground Operations (CG) division-controlled PPFs andHPF’s which are available to potential customers.1.2 SCOPEThis handbook is intended to be used as a guide for payload organizations planningpayload activities in the PHSF.This document details the capabilities andstandardized interfaces of the PHSF.1.3 CUSTOMER CHARGEUse of the PHSF for payload processing is considered an optional service.1.4 FACILITY ACCOMMODATIONSRELEASED1-1

K-STSM-14.1.15The PHSF is designed to accommodate a variety of NASA and NASA customerpayloads. In some instances, payload elements may be processed simultaneously,and customers must be aware during design development of the possibility of sharingRELEASED1-2

K-STSM-14.1.15RELEASED1-3

K-STSM-14.1.15the facility with other payload elements. Each payload customer is required tocoordinate closely with the KSC LSSM to ensure that support can be provided whenneeded.The PHSF is considered a customer-operated facility; customers are responsible for allday-to-day operations. Customers are required to schedule a pre-operational cranecheck through the NASA LSSM or Facility Manager prior to crane’s first use daily.Customers must also be familiar with the Payload Customer Emergency AwarenessHandbook for the PHSF, Operations and Maintenance Instruction (OMI) Nos. S9931A,Emergency Procedures Document (EPD) - PHSF, KCA-013 and E3517, Water DelugeSystem Operation - PHSF.1.5 EMERGENCY PLANNING AND COMMUNITY RIGHT-TO-KNOWThe Emergency Planning and Community Right-to-Know Act, Title III of the SuperfundAmendments and Reauthorization Act of 1986, requires persons to report the amountand location of hazardous chemicals produced, stored, used, or released to theenvironment each year. Customers are required to complete KSC form 28-185,Environmental Health Protection Program Toxic Substance Registry System (TSRS)Inventory and provide Material Safety Data Sheets (MSDS) for each chemical broughtonto KSC. All forms must be sent to the LSSM 90 days prior to customer arrival.1.6 HAZARDOUS AND CONTROLLED WASTEAll waste generated at KSC must be managed in accordance with the requirements ofKennedy Handbook (KHB) 8800.7, Hazardous Waste Management. Before arrival,customers will complete KSC Form 26-551, Process Waste Questionnaire which willidentify any potential hazardous and/or controlled waste the customer expects togenerate during processing.A satellite accumulation area (SAA) will be established in facility areas which havebeen identified as waste generation sites. SAA’s will comply with the intent of theResource Conservation and Recovery Act of 1976 (RCRA), which established anationwide program to regulate the generation, storage, transportation, treatment, anddisposal of hazardous and controlled waste. Regulations for the generation, controland disposal of waste at the launch site are strictly enforced, and customers will berequired to coordinate any waste operations or problems with their assigned LSSM.RELEASED1-4

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K-STSM-14.1.15SECTION IIFACILITY DESCRIPTION2.1 LOCATION AND DESCRIPTIONThe PHSF complex is located off E Avenue, south of the Operations and Checkout(O&C) building in the KSC Industrial Area (see figures 2-1 and 2-2). The complex hasthree main structures: 1) the PHSF which contains a hazardous operations service bayand airlocks; 2) the Multi-Operations Support Building (MOSB) M7-1357 which containsan office area, support rooms and payload control rooms for the PHSF and MultiPayload Processing Facility (MPPF) customers; and 3) the transporter storage building.The complex also has a fuel transfer building, an oxidizer shed and a krypton storagebuilding.Figure 2-1. Aerial Photograph of PHSF ComplexNASA built the PHSF and the Facility Control Building (FCB) in 1987. The FCB wasthen modified in 1994, and renamed the MOSB. The MOSB south end supports PHSFcustomers, and MOSB north end supports MPPF customers. This document willaddress the PHSF-related facilities only. MPPF requirements are documentedseparately in K-STSM-14.1.17, Facilities Handbook for Multi-Payload ProcessingFacility, Rev Basic dated May 1995.RELEASED2-1

K-STSM-14.1.15Figure 2-2. PHSF Complex Site Plan2.2 SECURITY/ACCESSThe PHSF complex is a secured area enclosed by a 3.1 m (10 ft) chain-link fence.Vehicles and personnel must enter the site through an 8.2 m (27 ft) wide gate locatedoff E Avenue at the east end of the PHSF complex. A guard post is located west of theMOSB on the perimeter road, but is manned only during dynamic hazardousoperations.A KSC Industrial Area security patrol conducts random inspections of the PHSFcomplex on a 24-hour basis. All doors with access to the outside of the PHSF are leadsealed nightly. Each door is alarmed and monitored by an Intrusion Detection AlarmSystem (IDAS). If a breach of security occurs, alarms sound at KSC’s ProtectiveServices Control Center in the Launch Control Center (LCC) room 1P10. BaseOperations Contractor (BOC) security personnel monitor the IDAS 24-hours a day. Agraphic display indicates the exact location of the alarm, the alarm is logged and apatrol unit is dispatched. A minimum of five officers are available to respond to securityevents at the PHSF within 10 minutes.The NASA Site Manager controls the IDAS alarm status. During first-shift operations,the NASA Site Manager is responsible for changing the IDAS “alarm” status to“access.” The access mode enables BOC to monitor the number of door openings atthe facility and instructs console operators not to dispatch security/emergency services.RELEASED2-2

K-STSM-14.1.15The Payload Ground Operations Contractor (PGOC) maintains security within thefacilities as required by the customer. Access requirements to the facility after 4:45p.m. on weekdays, weekends or holidays must be arranged with PGOC Security at theAccess Control Monitor (ACM) station located in the O&C (room 1245). The ACMstation can be reached 24-hours a day at 867-7664. Additional security is optional,and may be arranged by the payload organization/customer assigned to the facility.Personnel who require access to KSC must be issued a NASA/ESMC picture badge ormachine pass. To access the PHSF, individuals must possess a valid KSC-area permitor Temporary Area Authorization (TAA). Those with a “to be escorted” TAA must beescorted by a properly badged individual at all times and may only enter the facilitywith an escort. Access to the PHSF is controlled by a Personnel Access ControlAccountability System (PACAS). PACAS monitors and logs each person who entersthe facility; the time of entrance and the time of exit. PACAS cards are issued throughthe NASA Launch Site Support Office. Access to the PHSF Service Bay (room 116) iscontrolled by PACAS and cipher-locked areas.2.3 REQUIREMENTS AND SPECIAL CONSIDERATIONSBecause much of the work performed at the PHSF is hazardous, safety restrictions,strict security and personnel controls are enforced. A badge exchange board within thefacility allows identification of personnel in the PHSF Hazardous Operations ServiceBay. During hazardous operations, a guard restricts vehicle access to the site complexand an amber beacon flashes at the east side of the MOSB entrance. Fire protectionsystems, sensors and warning devices are used to alert personnel in the eventhazardous conditions arise.The amount of explosives and propellants that can be housed within the PHSFHazardous Operations Service Bay is limited. Therefore, the NASA Safety Office mustapprove the quantity of propellant used by each payload before payload processingactivities begin in the PHSF. Customers are advised to contact their LSSM’s as earlyas possible to ensure the payload processing requirements can be met.RELEASED2-3

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K-STSM-14.1.15SECTION IIIPAYLOAD HAZARDOUS SERVICING FACILITY3.1 DESCRIPTIONThe PHSF (M7-1354) is a steel frame building covered with insulated metal sidingwhich contains a Hazardous Operations Service Bay (hereafter called the service bay)and airlock (see figure 3-1). The service bay meets the requirements of a level 4, class100,000 clean work area (CWA). The airlocks meet a level 5, class 300,000 CWA perK-STSM-14.2.1, KSC Payload Facility Contamination Control/Requirements Plan.Figure 3-1. Payload Hazardous Servicing FacilityA one-story, concrete block structure is connected to the southwest wall of the PHSFand contains the equipment airlock (room 101), an air shower (room 108), the utilities &operations control room (room 114), the electrical/mechanical room (room 115), andseveral support rooms. Another one-story, concrete block structure is connected to thenorth wall of the PHSF’s service bay and contains the communication room (room 119).Figure 3-2, which follows, provides the floor plan for the PHSF.RELEASED3-1

K-STSM-14.1.15Figure 3-2. PHSF Floor Plan3.2 ACCESSSince many areas in the PHSF are classified as CWA’s, access to the facility is limitedto specific entrances. Personnel may enter the service bay through the air shower(room 108) or the airlock (room 117) located on the south side of the PHSF.Equipment may be brought through the equipment airlock (room 101) located on thesouthwest side of the building or through the large, double-door entrance to the airlock(room 117) on the east side of the facility. Room specifications are listed in table 3-1.Specific CWA environmental requirements and the environmental monitoring system(EMS) are discussed in detail in section 3.3.10.Personnel entering the PHSF must use the PACAS card reader located on the southside of the PHSF inside the door of room 1

K-STSM-14.1.1 Facilities Handbook for Building AE K-STSM-14.1.2 Facilities Handbook for Building AO K-STSM-14.1.3 **Facilities Handbook for Building AM K-STSM-14.1.4 **Facilities Handbook for Hangar S K-STSM-14.1.6 **Facilities Handbook for Explosive Save Area 60A (ESA-60) K-STSM-14.1.7 Facilit

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