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Reproduced by

PRICES NATIONAL TECHNICAL .SUBJECT W CANGE INFORMATION SERVICE US Department of Commerce .

Springfield, VA. 22151

SpaceDivision * NorthAmericanRockwell 12214 Lakewood Boue",Downey, Cafornia 9

I

SD 71-140-7(MSC-03321)

25 June 1971

PHASE B FINAL REPORTEXPENDABLE SECOND STAGE

REUSABLE SPACE SHUTTLE BOOSTER

Volume VIIPreliminary Design Drawings

Contract NAS9-10960, Exhibit BDRL MSFC -DRL-221, DRL Line Item 6

DRD MA-078-U2

Approved by

\ [ JF B. HelloVice President and General Manager

Space Shuttle Program

Space Division . North American Rockwell 12214 LAKEWOOD BOULEVARD * DOWNEY. CALIFORNIA 90241

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0FOREWORD

The Space Shuttle Phase B studies are directed toward the definitionof an economical space transportation system. In addition to the missionswhich can be satisfied with the shuttle payload capability, the NationalAeronautics and Space Administration has missions planned.that requirespace vehicles to place payloads in excess of 100,000 pounds in earth orbit.To satisfy this requirement, a cost-effective multimission space shuttlesystem with large lift capability is needed. Such a system would utilize areusable shuttle booster and an expendable second stage. The expendablesecond stage would be complementary to the space shuttle system andimpose minimum impact on the reusable booster.

To assist the expendable second stage concept, a two-phase studywas authorized by NASA. Phase A efforts, which ended in December 1970,concentrated on performance, configuration, and basic aerodynamic con-siderations. Basic trade studies were carried out on a relatively largenumber of configurations. At the conclusion of Phase A, the contractorproposed a single configuration. Phase B commenced on February 1, 1971(per Technical Directive Number 503) based on the recommended system.Whereas a large number of payload configurations were considered in theinitial phase, Phase B was begun with specific emphasis placed on threerepresentative payload configurations. The entire Phase B activity has beendirected toward handling the three representative payload configurations inthe mostacceptable manner. Results of this activity are reported in this12-volume Phase B final report.

Executive SummaryTechnical SummaryWind Tunnel Test DataDetail Mass Properties DataOperations and ResourcesInterface Control DrawingsPreliminary Design DrawingsPreliminary CEI Specification - Part 1Preliminary System SpecificationTechnology RequirementsCost and Schedule EstimatesDesign Data Book

SD 71-140-1SD 71-140-2SD 71-140-3SD 71-140-4SD 71-140-5SD 71-140-6SD 71-140-7SD 71-140-8SD 7I-140-9SD 71-140-10SD 71-140-11SD 71-140-12

This document is Volume VII, Preliminary Design Drawings.

- iii -

SD 71-140-7

C.

VolumeVolumeVolumeVolumeVolumeVolumeVolumeVolumeVolumeVolumeVolumeVolume

IIIIIIIVVVIVIIVIIIIXXXIXII

0CONTENTS

Section Page

1.0 INTRODUCTION I... 11. 1 System Concept . . . . 11.2 Selected Vehicles . . . . . . 1

2.0 DRAWING CONTENT AND DRAWING NUMBER SYSTEM 42. 1 Drawing Content . . . . . . . 42. 2 Drawing Number System . . . . . . 4

3.0 MATED CONFIGURATIONS . . . 11

4.0 EXPENDABLE SECOND STAGE (ESS-MODIFIED S-Il) . . 15

5.0 BOOSTER . . . . . . . . . . . 57

6.0 OPERATIONS 67

7.0 APPENDIX A. ALTERNATE ESS/BOOSTER CONFIGURATION(EXTERNAL HYDROGEN TANK STUDY) . . . 80

8.0 APPENDIX B. ALTERNATE ESS CONFIGURATION 82

9.0 APPENDIX C. TRADE STUDY REFERENCE DRAWINGS 84

- iv -

SD 71-140-7

0

ILLUSTRATIONS

ESS Study Engineering Drawing Assignment

S080-0001S080-0002S080-0003V080-0001V080-1000V080-1001V080-1002V080-1003V080-1006V080-1007V080-1008

V080-2000V080-Z001V080-2002V080-2003V080-2004V080-2005V080-2006V080-2008V080-2009V080-2010

V080-3000V080-3001V080-7002VX80-001376Z014076Z024076Z024176Z024376Z114076Z1149

B-9U/ESS/RNS Mated Configuration (3-View)B-9U/ESS/Space Station Mated Configuration (3-View)B-9U/ESS/Space Tug Mated Configuration (3-View) .ESS Inboard Profile, Subsystem ArrangementESS Space Allotment, General ArrangementESS Forward Skirt Structure DiagramESS Aft Skirt Structure Diagram . .ESS Thrust Cone Structure Diagram .

ESS Heat Shield Base-Main Engines .

ESS Thermal Protection Subsystem-StructureESS Docking Provision-ESS/SS Orbiter ConfigurationESS Main Propulsion System SchematicESS Propellant Feed Subsystem LayoutESS OMS and APS Tankage Fuel Lines LayoutESS Attitude Control Propulsion Subsystem InstallationESS Engine Servicing Subsystem LayoutESS Pressurization Subsystem ..

ESS Engine Compartment Conditioning System .ESS Auxiliary Propulsion Subsystem SchematicESS Thrust Vector Control Layout . .

ESS Stage/Engine Connect Panel Layout-RecoverableEngine ....

ESS Avionics Subsystem Block Diagram .

ESS Avionics Containers InstallationESS/Payload Separation Subsystem . .

ESS/Payload Adapter-ESS/Space Tug ConfigurationBasic Configuration-B-9U Booster .

Inboard Profile-B-9U BoosterLines and Geometry-B-9U Booster ..

B-9U Booster (3-View) .. .

Basic Configuration-ESS/B-9U BoosterBody Structural Arrangement-ESS Modified

- V_

SD 71-140-7

Figure

2-1

I Drawing

Page

7

1213141617181920212223242527293031444546

4753545556585960616263

0Drawing

76Z122376Z 122576Z 1226S080-5002

VA70-3201

VA70-5510

VA70-5530

VA70 -5540

VA70-5602

76Z 140076Z 140276Z 1403

76Z 140476Z 140576Z1261V080-1009S080-5001

S080-5003V080-0002V080-1004V080-1005V080-700176Z0253

S080-0004V080-0003GD Sketch

Page

Booster/ESS Fixed-Platform Separation System . . 64

Booster/ESS Movable-Platform Separation System . . 65Booster/ESS Tension Links Separation System . . 66ESS Recoverable Hardware-Horizontal/Vertical

Engine Orientation . . . . . . . . 68Midbody Structural Arrangement for Space Shuttle

Orbiter-Configuration 161C . . . . . 69Manipulator Installation for Space Shuttle Orbiter-

Configuration 161C . . . . . . . 71Payload Retention System for Space Shuttle Orbiter-

Configuration 161C (A) . . . . . . . . 72Cargo Transfer Tunnel Installation for Space Shuttle

Orbiter-Configuration 161C . . . . . . 73

Deployment Mechanism Installation for Air-BreathingEngine System . . .. . . . . 74

KSC Maintenance and Checkout Hangar, Floor Plan . 75KSC Maintenance and Checkout Hangar, Sections/Views . 76KSC Maintenance and Checkout Hangar, VAB Mating

Bay . . . . . . . . . . . 77KSC Launch Pads 39A and 39B, Plan . . . . 78KSC Launch Pads 39A and 39B, Plan 4 Section Views . 79Basic Configuration-ESS/B-17E Booster . . . . 81ESS Single Space Shuttle Orbiter, General Arrangement . 83Umbilical Arm Effects-Angular-Positioned ESS/Space

Shuttle Booster . . . . . . . . 85ESS/Booster Belly to Tower-Launch Configuration. . 86ESS Inboard Profile-w-PhaSe B Baseline . . . . 88

ESS Interbody Fairing-ESS/Booster Attachment . . 89

ESS Separable Aft Skirt Alternate Concept . . . 90

Platform Concept-ESS/Booster Separation . . 91ESS/Booster Fixed-Platform Separation SystemConcept . . . . . . . . . . . 92

B-9U/161C/ESS Mated Comparison .. 93

ESS Initial Phase B Baseline Configuration . . . 94

ESS/B-9U Booster Interface Concept . . . . . 95

- vi-

SD 71-140-7

1.0 INTRODUCTION

01.0 INTRODUCTION

1.1 SYSTEM CONCEPT

The prime objective of the Expendable Second Stage (ESS) study was todetermine the feasibility and cost-effectiveness of and to produce a preliminarydesign for a system suitable for a wide variety of advanced space missionsbeginning in the last half of 1979. The overall system is intended to meetevolving NASA/DOD system requirements through the most economical useof shuttle/ESS system elements.

The space shuttle orbiter's cargo bay is 15 feet in diameter and60 feet in length. Payloads larger than this bay can be accommodated byusing the ESS mounted on the reusable booster. In addition to the capabilityof placing large payloads in orbit, the expendable second stage constitutesan element of a larger shuttle mission. To reduce cost, it has been assumedthat a space shuttle orbiter will be available after it has completed itsprimary up-mission. By performing a rendezvous and docking maneuverwith the ESS, the orbiter could remove high-value components from the ESSby means of a manipulator arm arrangement on the orbiter. After thecomponents are placed in the cargo bay of the orbiter, the orbiter wouldreturn to the launch site. The recovered components would be refurbishedand made available for use in subsequent ESS flights. In this concept, theESS must have provisions for docking with the orbiter and means to facilitateremoval (minimum EVA) of the components. Following the removal of com-ponents, the ESS will deorbit to a safe impact area.

ESS preliminary design drawings are provided to illustrate thefeatures of this concept.

1.2 SELECTED VEHICLES

1. 2. 1 Expendable Second Stage Vehicle

Phase B activity on the expendable second stage has been directedtoward selecting a baseline system based on a derivative of the Saturn S-IIstage, shown on Drawing V080-0002, Zone 33, in Appendix C. The ESS isequipped with two space shuttle orbiter engines. The hydrogen tank volumeis reduced from the basic S-II stage by the deletion of one hydrogen ring(approximately 99 inches). Other features of the selected ESS include theuse of shuttle orbiter auxiliary propulsion system elements for the orbitmaneuvering system and the attitude control propulsion system. In addition,

-SD 71-140-7SD 71-140-7

0the design features the use of orbiter avionics elements. To preclude theneed for jettisoning hardware from the reusable booster at staging -toachieve an all-azimuth launch capability -the ESS incorporates a modifiedS-II aft skirt. The selected ESS vehicle is shown on NR Drawing No. V080-0001, Inboard Profile General Arrangement. The features mentioned hereare shown in the various preliminary design drawings included in thisvolume.

1. 2.2 B-9U Booster Vehicle

The Space Shuttle Phase B Study has resulted in the selection of areusable booster with a mission gross weight of approximately 4. 2 millionpounds. This booster (designated the GDC B-9U) features 12 engines, eachproducing 550,000 pounds of thrust at sea level. It is designed to launch anorbiter weighing approximately 859,000 pounds. Although a modified attach-ment system has been defined to accommodate the ESS, the system can beinstalled for an ESS flight and removed following the flight with only minimaleffect on the booster in terms of accommodating an orbiter launch.

The preliminary design drawings included in this volume emphasizebooster modifications that have been defined to permit the booster to launchboth the space shuttle orbiter and an expendable second stage with the threespecified payloads. Also included are preliminary design drawings thatreflect launch operations at KSC.

Complete details of the booster are included in SD 71-114-2(3),Booster Vehicle Definition. In addition to the information referenced above,this volume contains the following basic drawings: B-9U Booster InboardProfile (General Dynamics Drawing No. 76Z0240), Booster Lines (GDDrawing No. 76Z0Z41), and Booster 3-View (GD Drawing No. 76Z0243).The B-9U/ESS Booster Basic Configuration is shown on General DynamicsDrawing No. 76Z1140.

1.2.3 Specified Payloads

The Phase B design activity has been oriented to accommodate threeNASA-specified payload configurations, which cover the spectrum (weightand size envelope) of anticipated payloads. Payload variables include weight,size, and shape.

1.2.3.1 ESS/Booster /Space Station

The heaviest of the three payloads is the MDAC space station, whichweighs 176,960 pounds. The mated configuration is shown on NR DrawingNo. S080-0002.

-2

SD 71-140-7

01.2.3.2 ESS/Booster/RNS

The largest aerodynamic shape and the lightest payload are combinedin the NR reusable nuclear stage (RNS) without engine. The RNS weighs83,000 pounds. The mated configuration of the ESS/booster/RNS is shownon NR Drawing S080-0001.

1.2.3.3 ESS/Booster/Space Tug

The smallest aerodynamic shape and medium-weight payload is theNR space tug, with a designated weight of 107,180 pounds. However, sincethe payload is less than 33 feet in diameter (diameter of ESS vehicle), itrequires an adapter between the payload (15-foot diamneter) and the ESS.

A potential shape is shown on NR Drawing No. VX80-0013. The matedconfiguration for the ESS/booster/space tug is shown on NR Drawing

No. S080-0003.

- 3 -

SD 71-140-7

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2.1 DRAWING CONTENT

The preliminary design drawings in this volume clearly identify thepayloads for each of the combinations shown. Also, the physical propertiesof the three payloads are indicated in the three mated-configuration prelim-inary design drawings. The main body of this volume contains preliminarydesign drawings of the selected system; several alternate configurationsare shown in the Appendixes. The selected expendable second stage isshown with the booster selected for the Orbiter External Hydrogen Tankstudy (the selected ESS is shown with an alternate main engine arrangement).In addition, the selected ESS (with one shuttle orbiter engine) is shown incombination with the baseline B-9U booster.

2. 2 DRAWING NUMBER SYSTEM

The following drawing number system was used in the ExpendableSecond Stage study for all drawings submitted with the final report. Forthis study, the basic 080 designation was used.

The Phase B drawings, except those of General Dynamics, are sub-mitted for the selected configuration with the drawing prefix and groupnumber, as shown below:

X80 -XXXX

T --- ~Group Number

Prefix Number

2.2.1 Drawing Prefix Usage

The following prefixes are applicable:

V080 - Expendable Second Stage (ESS) Vehicle Drawings

FS80 - ESS Field-Installed Support Equipment Drawings

G080 - ESS Support Equipment Drawings

-4 -SD 71-140-7

0M080 - ESS Manufacturing Drawings

R080 - ESS Model and Mockup Drawings

S080 - ESS Combined-Vehicle Drawings

VX81 - ESS Payload Drawings

2.2.2 Group Number Usage

A four-digit group number is ued, with the first digit designating thevarious functional activities and the remaining digits assigned sequentially.

XXXX

~~~~T ~Sequential Number

Function Designation (seeParagraph 2.2.3)

2. 2.3 Function Designation Usage

The functions are designated as follows:

Function No. Function Name

0XXX General

Structure

Propulsion

Avioni c s

Vehicle Support

Mechanical

Examples

Configuration Control,3 -View

Thrust Structure,Forward Skirt

OMS, ACPS

Avionics GeneralArrangement

Electric and HydraulicPower

Separation Mechanism

-5-

SD 71-140-7

1 XXX

2XXX

3XXX

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5XXX

02.2.4 Drawing Control

Except those for Manufacturing, all drawings were monitored,approved, controlled, and maintained by the Structure and Mechanismsgroup. These responsibilities included the following:

1. Assignment of all drawing numbers for drawings to be includedin the final report.

2. Approval of all drawings before distribution.

3. Preparation and maintenance of a drawing list that identifies alldrawings applicable to each prefix (including General Dynamicsdrawings).

4. Maintenance of a program file of all drawings and revisions(including General Dynamics drawings).

2. 2. 5 General Dynamics Drawings

General Dynamics drawings applicable only to the ESS program wereprepared in accordance with the General Dynamics format, using a specificprefix to indicate the ESS usage - i. e. , space shuttle drawings are76Z0XXX and ESS drawings are 76ZlXXX.

General Dynamics drawings include the ESS separation system,booster, and launch facility modifications. Other related General Dynamicsbooster drawings are referenced to the NR report SD-71-128-Z, DesignEvaluation Drawings for a Space Shuttle System, Volume II, Booster.

2. 2. 6 ESS/WBS Numbers Relationship

Figure 2-1, ESS Study Engineering Drawing Assignment, shows therelationship of the preliminary design drawing numbering system to theWBS numbering system.

2. 2. 7 ESS Vehicle Drawing Numbers

Following is the list of ESS vehicle drawing numbers for the selectedsystem. A complete list of drawings is presented in the front of thisvolume under Illustrations.

Number Description

S080-0001 ESS/B-9U/RNS-3-View Mated Configuration

-6-SD 71-140-7

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Configuration

Expendable Second Stage Recoverable

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Expendable Second Stage Inboard

Profile, Phase B Baseline

Expendable Second Stage Space

Allotment, General Arrangement

Expendable Second Stage Forward SkirtStructure Diagram

Expendable Second Stage Aft SkirtStructure Diagram

Expendable Second Stage Thrust Cone

Structure Diagram

Expendable Second Stage Heat Shield

Base-Main Engines

Expendable Second Stage Thermal

Protection Subsystem-Structure

Expendable Second Stage Docking

Provision-ESS/SS Orbiter Configuration

Expendable Second Stage Main Propulsion

System Schematic

Expendable Second Stage Propellant Feed

Subsystem Layout

- 8 -SD 71-140-7

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V080-2002

V080-2003

V080-2004

V080-2005

V080-2006

V080-2008

V080-2009

V080-Z2010

V080 -3000

V080-3001

VX80-0013

Expendable Second Stage Orbit Maneuver-ing System and APS Tankage Fuel LinesLayout

Expendable Second Stage Installation-Attitude Control Propulsion Subsystem

Expendable Second Stage EngineServicing Subsystem

Expendable Second Stage PressurizationSubsystem

Expendable Second Stage Engine Compart-ment Conditioning System

Expendable Second Stage Auxiliary Pro-pulsion Subsystem Schematic

Expendable Second Stage Thrust VectorControl Layout

Expendable Second Stage/Engine ConnectPanel-Recoverable Engine

Expendable Second Stage Avionics Sub-system Block Diagram

Expendable Second Stage AvionicsContainers Installation

Expendable Second Stage PayloadAdapter-ESS/Space Tug Configuration

- 9 -

SD 71-140-7

Numb e r

0

02. 2.8 S-II Applicable Drawing Numbers

Following is a list of S-II major assembly drawings which may be

used for the ESS vehicle without structural or functional revisions. Detail

drawing breakouts are not included but may be structured from the major

assemblies.

Number De s c ription

V7-316002 Systems Tunnel

(V7-332142 LH 2 Forward Bulkhead

V7-332242 LH 2 Cylinder No. 6

V7-332442 LH 2 Cylinder No. 4

V7-332542 LH 2 Cylinder No. 3

V7-332742 LH 2 Cylinder No. 1

V7-333102 Common Bulkhead

V7-333202 Aft LO 2 Bulkhead

V7-490004 LO2 Tank Vent

V7-490007 LH 2 Tank Vent

V7-480008 L0 2 and LH 2 Fill and Drain Lines

Drawings for the other major assemblies required are not included

because they entail structural or functional revisions to be compatible with

the ESS vehicle system.

- 10 -

SD 71-140-7

C-)3.0 MATED CONFIGURATIONS OzZGC

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03.0 MATED CONFIGURATIONS

- 11 -

SD 71-140-7

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- 15 -

SD 71-140-7

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