NASA

TM-2001-210256

Reducing/Eliminating PYRO Operations

J. Francisco Soriano

ESD Hazards

During

National John

Aeronautics Space

and

Space

Administration Kennedy Space Center, Florida 32899-0001

F. Kennedy

Center,

June

2001

REDUCING/ELIMINATING PYRO

ESD HAZARDS OPERATIONS

Soriano 1 Shuttle

DURING

J. Francisco 1 Aerospace Systems Engineering, Engineer NASA and McNair John Scholar, Space

now at the Space Branch, Center, Florida.

Mechanical Systems

Division,

ET/SRB

& Launch F. Kennedy

Accessories

Pyrotechnics

ABSTRACT Several OPF area the safety safety based concerns have occurred during and pyro operations (ESD). support at 30% These equipment or lower concerns (GSE). at 30% content. charge, located RH in the targeted Two or lower In order of the in

on the increase flight

of electrostatic hardware

discharge ground

of personnel,

proposed methods considered to control ESDs during pyro operations RH are 1) the use of an ionizer blower and 2) to increase the moisture to demonstrate experimental that runs the were ionizer is effective in the in neutralizing Electrostatics static Laboratory conducted

a series

Operations & Checkout (O&C) Building PYRO Systems Engineering representative Dr. Rupert was metal effectiveness plate and angle Lee from NASA KSC blower Failure in charge of performing of the ionizer from initial of attack. 1000 the experiment to 400 volts.

at NASA as well Analysis (Job These as

KSC. I served as the as a laboratory research and Physical Testing

NASA KSC assistant to who The of a charged distance, RH, we did not

Laboratory lapse Since

#: KSC-MSL-0331-2000-00-00). based upon the time were conducted. variables studied:

was evaluated experiment

A full factorial

(2 3 = 8) was

have a statistical analysis program, such manually based on the method of "ANOVA" curve) was not influencialvariable. situations be the would most into the charged increasing OPF ECS currently

SAS available, calculations were done (ANalyis of VAriances), but R 2 (fitness of distance that the as close below 30% was best found to be the major possible combination of and facing rate, second which directly would of

obtained. As conjectured, Therefore, we concluded be to position plate. This during the ionizer pyro blower scenario resulted operations

as possible discharge RH. The

in the quickest

beneficial

method

the moisture content current configuration not planned

in the work environment through a modification of the appeared to be dependent on budget constraints and Finally, some recommendations are discussed such a mockup pyro connector and a PPE to assess the realistic

to be modified.

as to test the ionizer in an actual field experiment with technician with all the NASA KSC Safety-compliant effectiveness of the ionizer blower.

GENERAL

ORDNANCE

OPERATIONS

Mechanical Operation The term "mechanical" refers to all operations where the pyro devices are hand-held, installed/removed as a single unit device or as part of an assembly where no electrical mechanical Uplock pyro connections/disconnections installation Release assemblies, are the Thruster, MPM with are performed. Avionics Bay guillotine/jettison, Faraday Caps Some Firex, of the pyro Strut Band Ku on and devices Thruster, Antenna involving MLG/NLG NLG

guillotine/jettison during installation, location assembly ET). Electrical performed

devices

are not removed

and separation nuts (8 installed and 2 located in the Aft structural

on each SRB/MLP hold down post attachments between the Orbiter &

Operation during open

The

term

"electrical"

refers

to all

operations These

where

electrical are usually of consisting electrical

connections/disconnections

are performed pin (exposed

on pyro devices.

operations

pin to the environment)

during mating/demating

pyro connectors. The pyro system is intimately related to the electrical system of all the wiring, cabling, interconnects, power supply, and additional interfaces.

NASA STANDARD INITIATOR (NSI) The NASA

(EED) used Standard Initiator (NSI) is one Shuttle. of two NSIs types of Electro-Explosive System (ODS) "A" explosive Devices pyros devices. energy, or or damage by the static crew are

in the STS Program. EEDs

This and the Orbiter

Docking

the only approved

for the Space device reaction designed in Orbiters

are category

A category "A" explosive because it initiates a chain to equipment. electricity emergency NSIs contain and escape They are are used systems.

is that which by expenditure of its own of events, causes injury or death to people for for a minimum all pyro probability initiation of initiation except for system

2 electrical

contacts,

which

lead to a bridgewire

that is surrounded

by 0.114

grams of granular mixture transforms electrical energy characteristics: 1) The bridgewire of 0.95 2) 3) 4) 5) 6) 1.05 + 0.10 _. An electrical ignition. current

of Zirconium into explosive diameter

Potassium Perchlorate (ZrKC104). An NSI energy. Specifically, they have the following stainless steel (304 Nilstain) results with a resistance resistance of

is a 0.002"

to 1.15 _2. The bridge

distance

of 0.118"

in a circuit

of 3.5 to 5 amps

will heat the bridgewire Volume.

to 600 F and cause

Output pressure of 650 + 125 psi in a 10cc closed Will not fire if subjected to 1 amp for 5 minutes. Can auto-ignite An airtight shrapnel when if subjected to temperatures steel end closure thin stainless welded

in excess

of 400 F. will contribute

to the cartridge

the NSI detonates.

Although NSIs are used as NSI Detonators, NSI Charges (LSC), they have

mainly Booster enough

for initiating Cartridges, power

other secondary/high explosive pyros such NSI Pressure Cartridges, and Linear Shape alone in some other Orbiter systems

to be used

suchas in the Crew ModuleFirex System,MPM Guillotine, and Aft Gas Samplers. An expended NSI will havea hole in the endwheretheexplosivechargewaslocated,andan unexpended NSI will havea smoothendcapwith no visible hole.
NSI Detonator An NSI Detonator is a category "A" explosive device, and consists of an

NSI threaded into a detonator acts on the detonator's Lead detonator's produce end. boosters, Electrostatic Apollo Cyclotrimethylene a 0.040"-dent

housing containing additional Azide (PbN6) primer/accelerator, Trinitramine block. (RDX) high An unexpended wrench used

explosive which explosive. has

mixtures. The NSI in turn acts on the Detonators a protrusion NSI detonators, and removal. from the will on its NSI

in a steel

detonator is expended.

This protrusion

is not present cartridges in NSIs

after the detonator all have The NSI

and NSI pressure Protection the

fiats for installation today is based

on a design changes

era called

Apollo

Standard

Initiator.

One

of the design

that the NSI in two ways. is electrically

incorporated was electrostatic protection. Electrostatic safety is achieved The NSI utilizes the spark gap/air gap method, and also the ordnance cavity isolated Spark from ground. gaps are located in the electrical connector cavity where arcing

is not dangerous.

The design scheme is to provide as high an internal breakdown voltage in the ordnance area and as low an external spark gap breakdown voltage as possible. Providing a spark gap between the pins and case involves the electrical breakdown of air dielectric. Electrical breakdown in an air gap happens after the onset of voltage on the pins. If voltage order is applied of Ix-seconds, to the pins an ionization process starts and a short time later, in the the spark jumps specification between 500 from pin to case. for the NSI is that it shall withstand the case and the pins shorted The initiator shall at the top surface not ignite an AC voltage nor otherwise of be

The dielectric 200+10 current degraded. in place feature. volts shall

strength not exceed discs

for 60 seconds

together.

The leakage and are secured

Ix-amperes.

Isomica

are installed

of the propellant

with an epoxy impregnated washer or sealing tape as an electrically insulating The metal disk welded in place across the output end is for hermetic sealing. dielectric compromise safety specifications the design at the calling for no breakdown pins to case of the external spark gap and thus time adding nothing to functional

As a design consideration to 1500 volts AC can compromise reliability Electrostatic charged electrostatic

while

same

over the 500 volts DC specifications. specifications volts state that the EED from shall not function pins to case. when a 500-pF on capacitor is the

to 25,000

is discharged

A human

average

equivalent of 300 pF. NSIs are designed with a "no fire current" and "no fire power". That requirement specifies that all NSIs will not fire nor be degraded with 1 amp/1 watt applied Firing appeared for 5 minutes. System that the NSI-1 fast enough. According with required to Test NSI-I's -40 Report on TR82-106 Appendage of energy "Verification 2" dated to fire, July provided of Electrical 22, 1982, it this energy Compatibility

millijoules

was delivered

A typical Capacitance value 16,000 known Failure

energy

analysis

for a human human result have is 300 which

follows: pF. Maximum energy human allowable to produce of energy voltage is 350 volts A calculated At is of 18.3 _t-joules.

of an average volts ignited in which Static Failure Voltage Technician Technician spark current

during pyro operations, of 16,300 volts to have mode 1. 2. 3. 4. 5. 6. a human

in a calculated the same

is required would an NSI.

for an average

40 millijoules.

amount

that as a minimum

an NSI would defect generation potential

fire are: with the NSI spark the NSI at a level to dissipate way does NSIs. not static. touch the connector one backshell of the pins when and the gap. >16,000 volts.

A manufacturing

around

of the wriststat in some reaches

not measured

with a volt scanner.

connecting/disconnecting goes from

to the NSI in a way pin through bridge

to touch wire

then to ground.

SAFETY

PROCEDURES AND REQUIREMENTS ELECTRICAL PYRO OPEERATIONS

USED

DURING

NSIs are designed two NSI connector

to be relatively insensitive to static electricity and RF radiation (the pins may act as antenna to RF energy) as compared to other EEDs, if a high enough cause NSIs to be NASA/KSC

however they can still be initiated by either of these forms of energy level exists. Incorrect usage of meters or other energy sources may inadvertently safety practices initiated. Therefore, during pyro operations the and procedures must be followed.

following

KHB

1710.2

KENNEDY

SPACE

CENTER

SAFETY

PRACTICES

HANDBOOK

This is the governing document Revision D dated November requirements during design,

for safety at NASA/KSC. This 1998, establishes and specifies and maintenance activities under KSC. and property the completion

handbook, which is safety policies and at NASA Kennedy

operations

Space Center and areas of jurisdiction minimize the hazards to personnel operations. It is intended to assure manner with maximum efficiency. This manual is divided control films areas, into seven operational tapes contains

These requirements identify and associated with daily industrial of the task to the safest possible

chapters safety,

ranging unique

from hazardous

general

information, areas.

weather, and

personnel,

facilities

requirements,

use of plastic The safety remainder KSC policy

and adhesive

in Space eleven

Shuttle/Payload annexes dealing

Processing with OSHA Electric Code, others. there

of this manual safety and for pressure

requirements, and NASA

NASA

requirements vessels

document,

National systems,

and pressurized to Pyro Systems

among

Of specific

interest

applicable

and Pyro operations,

are two main

annexes: Annex D. KSC Supplement to NFPA 70--National Electric Code This section discusses all sources of static electricity discharges situations. tools, phase power It outlines connections. should handling wear EEDs cables should grounding when stand devices Caps when handling When surface. specific procedures grounding for grounding during hoisting equipment, materials,

controls

to avoid flight and

unsafe three-

of personnel, of flight

hardware,

hardware,

All personnel open grain, firing shoes,

or working using legstats

within

5 ft of

Faraday on

or Shorting

Plugs

are removed, checks

also when shall be

line extension personnel

are connected

to EEDs.

or conductive

a conductive

Resistance

performed The upon Orbiter arrival

prior to operations. shall be grounded explosives and wheels chocked fluids inside the OPF platforms. to facility Payloads ground

or canisters

containing

or hazardous mechanism.

shall be grounded

at the facility/handling

Pneumatictools usedon hardwarecontaining EEDs, within 10 ft of open grain, or in petroleum/oil/lubricant areas shall be fitted with a conductive air supply hose or connected to facility ground. All materialsin contactwith open grain shall be grounded. Conductiveplastic sheeting(velostat)shall be groundedto common groundwith railcar prior to installation.
Annex F. KSC Supplement Propellants_ and Pyrotechnics This section discusses the requirements. Relative operations. Humidity When (RH) The RH shall be recorded is not prior to start and every 4 hrs during devices then to NSS-1740.12-NASA Humidity Safety (RH) Standard for and Explosives, Explosive

Relative

requirements

RI-I_50%,

if personnel

wearing

grounding

personnel should during operations into the work and segments,

be verified and every When with EEDs

AV<350 volts, and electrostatic time new equipment, personnel, RH<30%, Faraday operations Caps removed involving

scanning shall be done <lhr or hardware are introduced open grain except exposed, SRB shall circuits

area.

or firing

not be permitted. For SRB at 10-min segment intervals processing if propellant when RH=30%-10%: Electrostatic interval scanning if propellant case shall be done is covered. of segments

is exposed,

and 30-min

Operations shall not continue if AV>350 with propellant or equipment and personnel When segment has end rings with shipping

volts measured on segment within 5 ft of open grain. covers installed; if electrostatic

scan

readings

>lkv then stop operations (do not continue unless readings <1 kv). If scan readings on case of covered propellant > 4kv then notify safety and evacuate personnel from area at least 500-ft radius. If RH<10% then SRB segment processing shall not be permitted. General Explosives Requirements EEDs must be classified as category by certified personnel only, For operations requirements, connection/disconnection be in effect Plugs during these of pyro devices.

A or category

B, handled

only in approved

areas

and

and under control of the explosive storage facility doors and openings shall be closed Controlled the switching removal operations or during of Faraday

area supervisor. during electrical shall also Caps/Shorting

of pyro devices.

and RF silence

RF Transmission Cell phones and pagers in VHF & UHF shall not transmit or equipment containing EEDs. Mobile, KSC-controlled transmit S&As For safing within Rotation devices pin removal, of the 2 firing S&As inhibits during shall remain testing when and removing processing an S&A shall be pin. Rotation ground 50 ft. Unapproved radios shall not transmit within 20 fl of flight radio transceivers within 600 ft. hardware shall not

S&A

performedwith the ETA or CDF disconnected from the S&A or at the point of terminus. All the rotationtesting shall be doneprior to firing circuit electricalconnection. If firing circuits must be connectedduring rotation test, safety assessment shall be provided to assureno hazardous condition exists. Rotation testingof S&As (exceptSRB ignition) with only the initiators electricallyconnectedshall be donewith a minimum clearance of 10ft. SRB ignition S&As shall not be rotatedin the VAB. S&A rotation during Phase1 or 2 lightning warnings shall be prohibited. FaradayCaps shall remain on EEDs when installing/removingthe S&A.
Orbiter Hatch T-Handle explosives and TAL lock shall A the lock

The pyro activation T-handle enclosure lock shall be available at each landing site and shall be installed ASAP after Fwd Assessment Team inspection. The not be removed pyro engineer during processing until the T-6 BDA enclosure clear shall control the T-handle whenever is unlocked unless

for the start of ET tanking.

is removed and transported to an approved explosive storage facility. Whenever the Thandle enclosure is unlocked, safety pip pins shall remain installed in the hatch and cabin vent T-handles. The through following and launch: OMI $5009 Part I, all vehicle Safety CDF, and GSE explosive Ignition items, S&A except control the Range cables, shall SSV safeguard (Orbiter, ET/SRB, and shall be Orbiter-installed followed from Payload) OMI $5009, explosive Part I,

operations

requirements

1)

During

Safety initiators, be connected. 2)

Range

and the SRM

Prior to any explosive PIC circuits.

connection,

functional

tests shall be performed

on critical

MEC

3)

After completion of the functional tests, the MEC Critical Commands disabled and the SSV and GSE PIC racks shall be powered down. In parallel with the subsequent pad clear, the active version of TCS sequence

shall

be

4)

VFC81

shall be replaced with a dummy version (Rev. 0) in the C10 console and any hot spare console that is loaded with C10 software. Console dumps shall be performed to verify 5) After that VFC81 Rev. 0 is loaded tests, After in both consoles. shall be remotely powered-down. The MECs

the PIC resistance

the SRBs

shall be powered-down 6) After the SRBs

SCO ingress. the following safeguards shall be in effect:

are powered-down,

VFC81 Rev. 0 shall remain loaded at C10 and the hot spare(s). MEC Critical Commands shall remain disabled. GOAL programs capable of firing PICs, except SRSS PICs, shall not be activated.

SRB power shall be applied for instrumentationreadsonly, except in OMI S0024. Pre-launch Propellant Loading, OMI $5009 Part II, and OMI S007 Launch Countdown. 7) OMI $5009,PartII, shallbe performedin the following sequence:
8) SSV Closed SRBs, SRM powered Loop up for the Range Test. power CDF, removed, power off stray S&A voltage checks cables performed, NSIs, S&A SRSS sating and SRM Ignition control connected. Safety Open Loop Test, flight code insertion and the

ET, OV, and MEC Ignition

and the SRSS

pins removed. tests performed. position. SCO ingress. to verify loaded they are in the safe position. the following disabled. except SRSS PICs, shall not be activated. safeguards shall be in effect: at C10 and the hot spare(s).

SSV and GSE PIC resistance All S&As SRBs MECs S&As After VFC81 MEC GOAL rotated to the armed powered-down. After inspected remotely physically the SRBs Critical

powered-down,

are powered-down, Commands capable

Rev. 0 shall remain

shall remain of tiring PICs,

programs

SRB power Pre-launch Countdown. OMI SSV Closed SRBs, SRM SSV SRBs MECs $5009, powered Loop

shall be applied for instrumentation Propellant Loading, OMI $5009

reads only, except in OMI S0024. Part II, and OMI S007 Launch

9)

Part II, shall be performed up for the Range Test. power CDF, Safety

in the following Open Loop Test,

sequence: flight code insertion checks cables and the

ET, OV, and MEC NSIs, S&A SRSS safing Ignition

removed, and SRM

power Ignition

off stray S&A

voltage

performed,

and the SRSS

control

connected.

pins removed. tests performed. position. SCO ingress. and ET/IT doors

and GSE PIC resistance rotated to the armed powered-down. After remotely

All S&As

powered-down,

S&As physically inspected to verify they are in the safe position. 10) After completion of explosives Part II (S&A hookup), the fwd skirts shall be controlled.

11)After SRB final power-down in OMI $5009 Part II, the following restrictions shall be in effect in addition to those in effect for Part I: 12) GOAL Ignition SRSS programs vehicle capable of arming/tiring off. the restrictions for Parts I and II shall SRSS PICs, or arming SRSS S&A devices, power shall not be activated. shall remain

safeguard or SRM

If OMI $5009,

Part III is performed,

apply.

13) The Orbiter 14) Orbiter the Orbiter

shall be powered power-down electrical or system.

down

for disconnection switching

of live drag chute is not

explosives. when from

controlled are made

required or isolated

connections/disconnections

to pyro circuits

that are shorted

GSOP

5400

USA GROUND

SAFETY

OPERATING

PROCEDURES

Vol.

HANDBOOK This document, which is a Revision C dated January 20, 2000, written per KHB 1710.2

Kennedy Space Center Safety Practices Handbook, is intended to identify the hazards associated with ground processing and integration operations. provides the requirements for safety of USA operations KSC. It outlines the applicability, responsibilities, safety of safety GSOP payload involving where reconnected responsibilities. 5400 Section 2.10 where except pyros ODS paragraph EED SRB are firing 2.10.1 processing, electrically where requires are an RH>30% exposed. More At for

and minimize This document of

personnel in designated areas monitoring, and implementation

general

STS

and

operations explosives, NSIs and

circuits

RH<30% for

operations all operations testing, or

will cease. disconnected,

specific,

or exposed

will not be permitted

RH<30%.

Appendix G_ Space Shuttle Vehicle This section discusses the safeguards and safety information exactly Lightning procedures provided to prevent by this appendix,

(SSV) Ordnance Operations and Safe_,uards governing the installation, connection, verification, inadvertent firing of SSV ordnance. around The specific is and pertaining handbook. 5400 for major hazardous operations such as to pyro devices the SSV

the same outlined policy

in the previous

as it is outlined

in GSOP

ordnance operations shall be terminated

for phase 1, shall and secured.

not begin,

and for phase

2, if already

in progress

10

ELECTRICAL For electrical pyro initiation operations, work or failure

PYRO the proper with pyros

OPERATING safety is the controls most

PROCEDURES must hazardous time be established and depends the greatly per WAD most critical. upon the

procedures. Inadvertent quality For

Electrical

of initiation of a pyro task. operations, The when team

at the proper

of work

in this portion portions a pre-task This to safety person interaction personnel QC/QA. the task, operations.

all hazardous to give given of each All including

of pyro briefing. issues,

the task

task team should and

leader

(Pyro briefings

Engineer) cannot with expected specific

is be

required coverage duties

importance the concerns, should

of pre-task paper

overemphasized.

is the point within

be summarized status. Team stage should

hardware

Also,

the task is extremely

be reviewed. at this early task

communication safe for the

and professional operation. briefing Prior

important

in a successful, be present

involved

in the

commencing

to initiating electrical

all non-essential Also,

personnel

must be cleared this clear applies work around only). Personnel

from

a 10-ft radius pyro box strut interrupt uplocks,

of pyro

if applicable,

to the affected

device if it's in an area different connectors require clear of middeck thruster, flame and retardant Fwd Sep Bolt). radios All coveralls safety Also, to be on or nomex

from the electrical along with clears essential bunny personnel suits (clean

(i.e. pyro Ku, gear

are required room of 20 ft away

to wear RF silence from are

blue-collar is required the electrical to be no lightning

in OPF bay and connectors. notified advisories Prior

are to be kept a minimum and Emergency operation. Medical

Fire/Rescue standby

required

for the pyro

As part

of RF silence,

can be in effect

prior to starting. of pyros, all possible sources of energy must be verified

to any electrical

connection

to be isolated or turned off (controlled hardware from inadvertent initiation. power must be off, or an interruption

switching). To ensure in the pyro

This protects both personnel and the no energy source is on, either orbiter circuit is required prior to reaching the separation verification provides bolt connection). of being isolated or controlled protection that would to send

PIC circuitry (i.e. pyro interrupt boxes installed for forward Each task involving electrical connections will call for some from energy sources. is required. and hardware to the pyro device For any pyro Power while disconnection, or controlled no accidental are working power switching personnel energy down personnel

down

is required

switching in that area.

in that it ensures

test configuration

A second verification of no stray energy source in the pyro circuitry, voltage test is performed prior to any and all pyro NSI and ODS pyro test requires minutes allowable to connection, use of a stray another stray voltage voltage test meter. test should This test should of the planned actual connection to the NSI.

a power-off connections. within is longer

stray This five prior

be performed For NSI's,

If the time duration pyros,

be performed. For ODS

the maximum allowable than 100 times devices.

DC or AC voltage

is 50 millivolts.

the maximum

DC or AC voltage is 20 millivolts. lower than the minimum "All-Fire"

These allowable voltages are more voltage level required to initiate these

11

Also, to ensure the flight connection will be properly shielded from RF energy, verification is also madewith the stray voltage meter in the way of a shield-to-ground check. The shieldingof all pyro wires is terminatedat eachRF connectorbackshell. The shield-to-ground test requires less than one ohm resistancebetween the connector backshell and orbiter structure. After all verifications, the stray voltage meter is disconnected from the orbiterconnector. Next, in preparationfor handlinga live NSI (or ODS) pyro connector,don a wriststat. Connectthe wriststat ground clip to orbiter structureor an adjacentorbiter connector backshell. Next,perform a resistance checkusing a SimpsonDVOM betweenthe wearer and wriststat groundclip or orbiter structure. The resistancebetweenthe wearerand wriststatgroundclip/orbiter structuremust be between101_ and 1 MK2(10,000g2 and
1,000,000 within voltage DVOM and ODS After the if2). wriststat The limits from purpose between is high. the area. the energy of the the After current This meter wriststat and is to alleviate connector. level turn any The voltage resistor the where potential/electrostatic potential pyros charge difference wearer the pyro verification,

to a non-harmful has the ability touched

in a case

this wriststat

off the Simpson or degrade leads. technician cables or wire with the NSI's

and remove

to initiate

if the conductors is fully any The with one ready open hand

are accidentally and everyone pin and pyro technician remove

with the meter only tiring the Cap

the task team to handle to EEDs. backshell hand. Holding

is in position, including should the ensures hold Faraday

a grounded line pyro connector plug ground

is allowed connected harness other twisting addition

device

extension

grounded

or sating obviously another

the connector/backshell harness, between the technician

two things: this provides

this prevents path (in any

of a connector/wire to the wriststat)

and secondly

and the pyro device,

thus preventing

electrostatic deformations, cushion. normal wear

discharge. Once the pyro no bent pins, no contamination, exists (usually and tear when pins and sockets

pins are exposed, inspect to verify no and o-ring is in place at bottom of rubber from gold plating being removed brush as and are mated/demated), use an acid

If contamination

originating

compressed air to remove contaminants. minute waiting time is required to allow Next, after inspections Verify good connections connector required barrel-locking any longer (unless

Isopropyl alcohol can also be used but a 20all alcohol to flash off prior to final connections.

of the connectors to be mated are complete, mate the connectors. by identifying three bayonet-locking pins are visible through the ring. other Once mated, the pyro is safed and the wriststat made). is not Before pyro connections in same area are being

leaving this connection, inspect wires to verify no damage or defects, verify backshell and strain relief tang are not loose, and verify wire routing is such that no tight bends or interference with other hardware exists. In some electrical connections, an "upstream" break point test location is used to verify

downstream Separation mated

connections are correct and intact. For example, after Bolt pyros are connected, a resistance check is made "upstream" boxes Fwd to measure Sep Bolt, resistance and across down the through NSI the ship harness, Typical bridgewire.

the Forward at the FLCA connector resistance just is

pyro interrupt at the

12

approximately 1.25 to 1.75 _. To perform a resistancecheck on NSI

bridgewires, energy these even pyros. only Other to fire checks The one type is more meters meter than such Valhalla is allowed 100 times as the meters have for use: lower the Valhalla than the "All Keithly energy 4314A. fire" 580, output of this meter other model

or ODS The level

pyro output for and

energy when

Simpson

DVOM, sufficient

Honeywell,

number

measuring

resistance resistance connections.

orbiter electro-explosive devices (EEDs). The safety controls for are the same as described earlier in this section for electrical safety clear area location includes both the circuit location from around where the pyro device test "break" in the pyro the resistance

being tested, and the will be made.

SAFETY Orbiter Required (within without energy Power when "black power source Down mating boxes"). down that could live pyro

TERMS

AND

DEFINITIONS

connectors - All pyros Boxes

unless

circuit from

is isolated FLCAs pyro have The from purpose

from

PIC

card any to

EXAMPLE if Pyro cause Interrupt

isolated away

may be connected is to keep energy device sufficient connectors.

are installed. connector

inadvertent

initiation

EXAMPLE - Energized initiate EED if contacted Controlled The purpose Switchin_ is the same

black box next to pyro with connector. (or Power Down)

could

as outlined

in the previous

term.

EXAMPLE

- Test

Operations

switch throws requiring FLCAs/MECs may affect circuits that energize PIC cards/pyro initiation. Controlled Switching definition - No flight vehicle/element or GSE commands issued, connected unless no switches or circuit elements. breakers Safety operated on flight in previous elements example. or GSE live pyro electrically connectors to the flight is isolated requirement for demating

circuit

from PIC card as outlined

RF Silence The purpose is to prevent the two NSI connector pins from acting energy. Energy from handheld radios or other RF transmitters inadvertent Beacon pyro initiation. equipment Doors closed. Hand-held irons) within radios in OPF Bays 1 and 2. No beepers. No AC powered electrical as an antenna to RF can be enough for OPF bay. pyros. RF motors (i.e. fans)

off within

or heat producing Wriststats Don attach wearer Resistor Resistance should Wriststat ground and

(i.e. soldering

10 ft of open connector

verify

resistance

between is to remove

wearer

and

wriststat and verify potential

ground between

clip.

Then between

clip to designated

structural Wriststats

ground will bleed

location any voltage current between verification

resistance electrostatic

and structure. in wriststat between

The purpose

personnel energy.

and orbiter

pyro connectors.

off any unwanted dissipation. wearer

will limit the static wearer 10kg2 and and ground 1 M_.

electricity clip, Wriststat and

and

orbiter every

structure step where

be between

precedes

13

pyro

connectors where

are

mated/demated

or Faraday

Caps/Shorting

Plugs

are

removed

(all

operations Clear Area

pyro pins are exposed).

A 5 to Expanded

10-ft areas

clear

area

is typically required

required around

in the

area

of where

electrical inadvertent

connections. activation - Drag chute and floor area walls, ceilings,

are sometimes

the envelope

of a pyro system could cause injury to other personnel. EXAMPLE electrical connections require clear area of entire rotating swing platforms to OPF exterior door (per GP-1098). 10-ft clears do not go through floors, or platforms.

CURRENT

PROBLEMS

WITH ECS EQUIPMENT AMBIENT CONDITIONS FACILITY ENVIRONMENTAL (OPF ECS)

DURING

LOW

RH

ORBITER

PROCESSING

CONTROL

SYSTEM

The OPF ECS is used primarily for Space Shuttle Orbiter purge operations. ECS consists of four individual airflow ducts that are connected to the Forward,

The OPF Payload

Bay, Aft, and Cabin interface ducts of the Orbiter. The OPF ECS allows for the operator to control flow rate and air temperature through these ducts. The air entering the ducts is de-humidified Carbon filters. A typical OPF and filtered with a High Efficiency Particle Accumulator (HEPA) and

ECS

air process

starts

with

outside

ambient

air entering

the OPF

ECS

through an inlet filter. The air is drawn through this filter via a centrifugal compressor blower, which compresses and moves the air. Then the air goes through the cooling coil were the air is de-humidified to no more than 37 grains of moisture/lb of dry air per OPF ECS ICD requirements. After the air is de-humidified, chamber were it is mixed and distributed to the four purge Cabin. Then each circuit controls the purge airflow it enters the mixing/manifold ducts: FWD, PLB, AFT, and Finally, the

rate and temperature.

purge air is filtered and exits the OPF ECS via the ECS duct system. This filtered air enters the Orbiter through the LO2 T-0 for the FWD, PLB, and AFT circuits and through the white room for the Cabin circuit. Based on the current from be 29% design and thus assuming prohibit ambient pgro conditions of 50 F and Orbiter Pad The ECS 50% RH, is similar it in

can be calculated F would

psychrometric

equations

that the delivered operations. for one circuits, major which

purge

air at 65 ECS and

RH and

design and operation to the OPF ECS except have humidifiers in the AFT, PLB, and Cabin allow Before pyro operations during low ambient

difference: will raise

The Pads the humidity

humidity

days. cage" type RH monitoring device

1996, the RH level

was measured

by a "squirrel

that measured measurements inside the area

the OPF Bay humidity were misleading since within the Orbiter

for pyro operations they did not reflect pyro operations

in the OPF. However, these accurately the actual RH value were performed. Typically the

where

14

OPF when would

High the

Bay humidity first the hand-held RH level

is above RH inside

30% the

RH. were work

It was not until used. area and At that

the

1996-1997 around 30%. of personnel Dept 1998, 5532 1999, and of pyro be affected, 11, 1999

time pyro

frame was

meters the High

time,

a discrepancy

discovered:

specifically was above safety December 1997, interruption would

devices,

drop below to prevent during a Safety Currently

30% although possible pyro there Variance TOPs

Bay RH level

In order hardware submitted 31, 2000. in which Some when lengthy launch. The

mission Request have been were

delays

and to assess was from requested: V5032.003, were the

and

flight

operations,

USA Pyro (the latest 4 variances request situation and major V5032.002,

Engineering

USK-251 to January and 2000) V5032.005. operations and including

the affected impacts

V5032.004, and flight

of the RH<30% delays

discussed

in the

producing in the order

a hazardous of weeks

for personnel milestones

hardware,

requests

were

approved

for

pyro

operations

for RH<30%

and

specified

that

the

potential rationales: common personnel performed

hazards remained Nomex/Blue-collar with wearer of increased intervals,

at an "acceptable level of risk" based coveralls and wriststats shall be used clip/Orbiter at Low structure, RH levels, within electrostatic a 5-ft radius

on the following and verified to be shall brief shall be to disconnect scanning prior

and ground hazards tools

Pyro Engineering/TTL

on all personnel,

and equipment operations

and at 10-minute

and finally,

shall stop if RI-_10%.

ELECTROSTATIC

DISCHARGE (ESD) PRINCIPLES INFORMATION on surfaces ESD can materials, can result cause cause damage in uncontrolled of solid

AND BACKGROUND

High energy

electrical associated

potentials with

ESD. propellants,

The dissipation explosives of electronic

of and

ignition

flammable/combustible

to or inadvertent Shock or flight

actuation

devices/systems, and shock involuntary muscle reaction, damage.

experienced which can

by personnel. result in injury

to personnel causes hardware/equipment

When an insulated person is charged, the charge will distribute itself all points on the person have the same voltage with respect to ground. the charge who will be densely leaning located against on areas a wall, close to the ground. distance For is not actually the shortest

in such a way This implies a standing the soles

that that and

person of the or the

is through

the floor covering. Consequently, most of the charge will be located on the soles feet and by induction bind an equally large, opposite charge in a conducting layer floor. The capacitance of a person can be determined C= ( ereo)A/d Where: er is the relative e0 = 8.85 permittivity or dielectric is the vacuum constant of the insulator. which is a fundamental by using equation:

x 10 -z2 (F)(m-l),

permittivity,

constant.

15

A is the area of the soles. d is the effective For a typical thickness person, of about person, and of the soles plus the insulating floor Er
=

covering. 4 to 10. This leads to a

A _= 300 cm 2, d = 5 to 10 mm, 100 to 300 pF. If the parameters 60 to 70% if the capacitance be about is also measured

capacitance for a given this fraction Under charged by being are formed Ionization

A, d and er are actually directly, the value value, of the measured

determined estimated that

by this equation

will normally

indicating

of the total charge circumstances, or insulating to the charged

is on the feet. atmospheric body body air is considered slowly its charge. very few charged neutralize a good when particles insulator, surrounded or ions, and which air ions a

normal insulated attracted

will lose its charge might

by air.

The reason

for this is that air, as a rule, contains primarily causes by radioactive an electron radiation.

The "natural"

to be knocked

off an air molecule,

02 or N2,

leaving

the

molecule as a singly, positively charged elementary ion, which within second will attract 10 to 15 molecules, mostly HEO, forming a molecular positive air ion. will almost elementary immediately ion. attach to an uncharged elementary oxygen

a fraction of a cluster called a

The electron form

molecule attract

and thus about 8 to

a negative

The negative

ion will also

12 H20 molecules to form a negative air ion. This ionization process will create, under normal circumstances, only a small number of ion pairs (about 5 to 10 ion pairs per cm 3 per sec.), pressure When but the production a critical has the value the electron gets rate will increase value, the breakdown very markedly strength, if the electric Eb, which field strength in the air exceeds field at atmospheric

of Eb -= 3 x 10 6 v/m. knocked off a neutral molecule by natural ionization, and if this a

happens in an electric field strength exceeds kinetic energy ionization by collision.

field, the electron Eb, the electron large The to enable process

will move and be accelerated. may, before it collides with it to ionize place the molecule. in the whole discharge will take

If the accelerating a molecule, gain is called the field a transport where words,

sufficiently

This process region

strength exceeds Eb and will give rise to an electrical of charge by the ions being moved by the field. Many vapor-air of the static electric discharge problems are connected creating

in other

with

a charged hazard

person when

and

the

possibility

of spark mixtures

from the person

an ignition

explosive

may be present

in the working only,

environment. estimate If a body an acceptable voltage transfer upper

If we consider limit tolerated, maximum walking

charging across

by walking or decay a floor

we can easily for the person. Rm is given by

for the grounding acceptable

resistance resistance

Vm can be Aq (C), the

with a step rate n (sl),

and a charge

grounding

Rm = V,,,/ nLlq

16

The maximum permissible value Vm

environment. known voltage Ves. If for instance, ignition figure In the minimum energy

of the

body contains graphs

voltage

depends than

upon the voltage walking

the

working with and an

the atmosphere that follows, two

explosive show

mixtures

of vapors buildup across

Wmin, Vm has

to be smaller

explosion-safe

a typical

dissipation (charging/discharging) in two different scenarios, one insulated floor (top graph) and the other standing still (bottom graph).

" !-'.

............ _

............... T................... ]- ..................

t ea

',.I

Types There

of diseharees are three types

of electrical Spark discharge

discharges Discharge between

such as Corona is the best-known two conductors

Discharge, type

Brush of electric

Discharge, discharge In a

and Spark Discharge. Out of these three types, and is reserved for the

at different

potentials.

spark, ionization takes place between the two conductors. between by the conductors potential is C and their

along and the charge is transferred In this channel most of the If the partial is V, the energy W dissipated

through a narrow channel energy stored in the field of the two conductors in the discharge is given

will be dissipated. difference

capacitance

I,I1= (1/2) CV 2 Because the most gas/vapor The human the discharge density incendive channel (ability is very narrow and short and the discharge making as a whole or explosion very in a

fast, the energy

of a spark discharge of an electrical of all types mixture)

can be very high, discharge of discharges. discharge

the spark

discharge

to start an ignition

or dust/vapor body

can precipitate discharges

an electrostatic

hazard

when

the

material

is

initiated

by electrical

less than 0.015 joules.

17

Electrical Properties of ionized air In any solid or liquid material, the charge, carriers are constant at constant temperature

mobility,

and concentration

of possible

charge

as long as electrical

breakdown

does not take

place. In a metallic conductor, the charge carriers are characteristic for the metal in question; in a semiconductor the careers (Unit are always there to yield a current, when is _'2-1m -1) _' = nqk where ascribed charges n is the charge a constant carrier value concentration, the decay. Gases q is the charge, However, inherently

electrons with a concentration the carriers may be holes. But The conductivity _'

a field is applied.

and k is the mobility, is not simple a net current. no or very

can be when Gases ions, a

during

the situation contain field to cause

gas is the current-carrying that can be moved

medium.

few non-paired

independently

by an electric

in general and, more specifically, atmospheric however, differ from the charge carriers in other The concentration recombination out (deposition of air ions will change with other, of airborne oppositely particulates

air can be ionized. Atmospheric media in several ways. because with by of processes particles, an electric process may field)

with time and location ions, combination or aided by diffusion

like on

charged

and plate deplete

surfaces, or simply because the actual field-induced neutralization the air of ions faster than they are re-supplied by the ionizing device. Explosive Mixtures of Gases and Powders Explosions may occur not only in vapor-gas powders. The minimum ignition and concentrations of the vapor Whereas mixtures of vapors

mixtures,

but

also,

in clouds

of dusts

or

energy for a vapor-gas mixture depends and the gas, but it is more complicated and gases in closed environments

on the nature for powders. are normally

homogeneous with the vapor concentration being the same throughout the concentration of powder particles in a cloud may vary from point determination The ignition of minimum energy depends ignition energy size very difficult. involved.

the whole mixture, to point, making the

on grain

of the powder

Generally,

it takes

more energy to start an explosion in a cloud of powders than in an explosive vapor-gas mixture. The minimum ignition energies for vapors in atmospheric air are lower than 1 mJ, but powders We can assume will require that any a minimum electrical For of 10 to 100 rnJ to start combustion. discharge a capacitive voltage
Ves "- (2

disseminating system Ves is given

I/2

less by

than

0.2

mJ

in the of 300

atmosphere

is not incendive.

with a typical

capacitance

pF, this means

that an "explosion-safe"

Wmin/C)

So Ves --- 1100 explosion risks. often considerably voltage cannot

to 1200

v.

It should

be stressed

that this safe-voltage

level

refers

only

to are as

When dealing lower. This

with electronic ESD problems, the acceptable levels safe-voltage level only applies to insulated conductors, determined for an insulating material.

be meaningfully

18

MEANS To reduce personnel materials. eliminated, the potential must understand Non-conductive properly selected

OF CONTROLLING proper bonding

ESD AT RH<30% and grounding must be employed and

for ESD,

bonding/grounding materials (i.e., or be treated

reduces voltage potentials wood, paper, glass, plastics, application and

on conductive etc.) must be use. Voltage but can be

for the particular

potentials on surfaces are commonly induced from friction (rubbing reduced by the simple act of separating two dissimilar materials. ESD is not normally bleeder, of about do not a concern when RH>50%. potentials in ESD. will not Moisture in the

or sliding)

air will

act as a high

resistance to a level however, RH>50%

dissipating voltage 350 volts and result absorb moisture, where require be avoided RH<50% assessed

on the surface A few materials bleed-off readily

before they can build up (i.e., Teflon, vinyl, etc.), even in environments

and should where

ESD is a concern. special when attention. possible. resistor going before Operations Voltages, (100k_ direct where especially to 1 M_) to ground. RH<30% on large in series

Environments should surfaces, should

be carefully wire

and avoided using

be dissipated

a high resistance is eliminated

with the ground Grounding The basic become charged

until the charge

of conductors rule of fighting or exposed which

electricity can produce

is to ground from energetic other spark

all conductors charged objects, discharges. machinery and fixed as all occurs.

that

might such

possibly

charged conductors,

to induction

as insulated

The grounding including each direct connection interconnected,

must include part of piping, to the

all conducting tubing system, is not differences

objects, containers, or bonding

and main and moving conducting

structures parts. A parts are

ground

necessary

as long

so that no voltage

Grounding people Due to the insulating

properties

of footwear

and floor

coverings,

a person

may

constitute

a capacitive system, with with a leakage resistance This problem might be wriststats Blue-collar

his/her own capacitance in the range ranging from almost zero to maybe resolved by use of protective

of a few hundred pF and 10 a4 to 1015 _2 or more. coveralls and

fire-retardant

or other type of clothing. Coveralls/Nomex Coveralls

(Safety requirement per GP-1098). Both Personal Protective Equipment (PPE) are used at NASA KSC and provide excellent resistance to static electricity buildup. Cotton in blue-collar coveralls retains moisture and does not allow static buildup. Nomex coveralls have similar characteristics and are used for clean-room type environments. They provide protection against momentary flashes of high heat or fire. are made out of 100% cotton cloth impregnated with a proprietary the cloth to meet NASA KSC flammability requirements. Blue-collar coveralls chemical that allows Westex Corporation

19

manufactures

the particular

cloth under

the trade

names

Proban flash testing

and Indura.

It is used

for

civilian industry for protection Both Proban and Indura have Laboratory clothing just means heat source Wriststats This device consists of plastic a band and consistently such as the blue-collar that the clothing is removed.

against short duration undergone extensive ESD and flammability does not mean within self-extinguish coveralls

fires and electrical arcing. by the NASA KSC Test Flame time limit retardant it the when will not burn;

satisfy will

requirements. that the clothing a specified

or

chain

made wire.

of

metal

similar the strap

to

an

expandable either made of a series

watchband, of solid safety while There contact much resistor being are with body

and conductive

plastic

or fibers,

connected from

to ground accidentally

by a strap, includes touching

conductive

or of multistrand via the strap. associated with

Normally

of 1 Mg2 for minimizing tied to ground

the shock

a live wire

some

problems

the

wrist

straps

though,

intermittent

skin

loose-fitting bands, bad skin contact caused by excessively dry skin or too hair, or sluffing of the band material, resulting in contamination of

components. Ioni_ation: moved charged Removal of ions from the Air structure where and hence and consequently cease has a limited lifetime. with It may be it may be neutralized. It may combine Or a small oppositely

An air ion is an unstable to some surface ions or particles

to exist as an ion.

ion may combine

with aerosol particles and then either be neutralized or become a large ion; in both cases it again no longer exists as a small ion. The rate of combination is proportional to the concentration particle of the species involved. The inverse relation between level conductivity in the air. and concentration can be used as an indicator of the particle

loni_ers Any ionization molecule. The particle methods or from

process in air starts with the removal of an electron from a neutral necessary energy may be delivered to the molecule from a colliding a quantum of electromagnetic use: radioactive radiation ionization energy. Only two ionization technical and field ionization. will move in the field free path characteristic the energy and for

are in practical

In Field Ionization, collide with neutral the ions. However, the end of their mean Controlled strength field in front

if air is exposed to an electric field, ions molecules after having traveled the mean even at the highest possible field strengths, free path is not high enough is normally achieved electrodes to release by

of the ions at

an electron. the necessary high field

ionization

creating form

of a set of conducting

in the

of sharp

points

or thin

wires, by keeping the electrodes at a high potential (-_-2-20 kv) with respect to some suitable counter electrode, which may even be the walls of the room. Discharge conditions necessary are different negative for positives under voltage. given and negative voltages. conditions The is about positive 30% voltage than to start ionization geometrical higher

the corresponding

20

Types of loni_ers Ionizers for neutralizing printing, parallel and plastic with and at a short

static

charges In most from

were cases

first

put ionizers sheets

to practical of material. ionizer,

use

in the

textile,

industries.

these

were bar shaped There radioactive

and mounted are several ionizer, ion

distance

charged

types of ionizers: ionizer bars, blower, whole-room ionization, Radioactive ioniiers In a radioactive ionizer with an extremely material. hard-to-reach When such that the radiation dealing places,

passive ionizer, electrical and unipolar ionizer.

the radioactive layer, is directed with radioactive

source often low

is placed made levels

upon

a base

material ionizer and in front

and covered is mounted at of the charged specifically

thin protective

out of gold. immediately of static

The

towards ionizers

the space are very

relatively

charges

handy.

They do not require electrical discharges. use impractically Usually year. remain radioactive Thus unchecked

electrical installation and they cannot cause potential harmful Their limitation lies in the fact that at high charge levels, one has to activities utilize or the neutralization an a-active of time. nuclide process with intervals, will take too long. half a

high (radio) ionizers material for extended

a half-life and

of about

the active

is replaced periods

at regular

the device

does

not

21

INVESTIGATION

OF PROPOSED

MEANS RH<30% between

OF CONTROLLING

ESD

AT

On February Laboratory

16, 1999,

there

was a meeting USA Pyro

NASA

Safety, and

NASA NASA

Materials Pyro

Test

representatives,

Engineering,

Systems

Engineering. In that connections/disconnections discussion, the Separation the NASA decision Pyro perform worst-case scenario,

meeting it was with NSIs that a Safety i.e.SSV on

proposed the use during conditions Hazard the Pad Analysis and

of ionizers during ordnance of RH<30%. During that should be performed initiation of assuming the Aft

it was identified

inadvertent

Bolts with personnel in the Orbiter Material Test Laboratory should be made taking on the proposed an action item ionizer

Aft compartment. It was concluded that conduct tests with the ionizer before a concept. The meeting resulted Material with USA Test Lab to task the NASA

could

Engineering the ionizer

to formally

test in conditions

of less than 30 % RH. of the pyro operations in to add to the required

Even though and around

variance approvals have been implemented in most the Orbiter, two extra avenues can be considered

"safety umbrella" even to increase the moisture use of a radioactive 1. Post-flight to PIC work. 2. 3. 4. 5. 6. 7. 8.

when RH<30%, and perhaps as low as RH__10%. One avenue is content in the air and the other is to ionize the surrounding air by combination where proceed as outlined in the following pyros and guidelines: is required, connecting connector and NSIs in

ionizer-blower pyro sating may

the verification Caps with and/or an area

of expended Shorting ionizer Plugs directed

removal/installation cabling

of Faraday

at the

NSI operations involving pin probes, and adapter Russian category EED operations with Faraday exposed shall not be permitted. All personnel shall wear clean, and long legs. All personnel resistance. within 5 ft shall wear wriststats nomex

cabling shall not be permitted. Caps removed or tiring circuits coveralls reading with 10k_ long to sleeves of

or blue-collar

1 Mff2

Work-related paperwork should remain 5 ft from work area. Personnel should avoid activities that produce static charges. Electrostatic of the work area within 5 ft of the EED will maximum allowable of 350 volts at all times.

be performed

with

22

IONIZER The experiment the 2 nd Floor managed by Dr. was of the conducted Operations I. Calle arranged

EXPERIMENT/TEST Laboratory Building H. Gompf. Lee from located at NASA Mr. KSC in Room KSC, Failure Douglas 2275 which Kraft Analysis on is

at the Electrostatics & Checkout and Dr. (O&C) Raymond

Carlos

from

USA Pyro Engineering

for Dr. Rupert

NASA

and Physical Testing Laboratory to be in charge KSC-MSL-0331-2000-00-00. Title: "ESD Testing demonstrate NASA assistant KSC that the ionizer Systems Lee. INSTRUMENTATION Charged A charged Lyndonville, composed attached Plexiglas plate
TM

of performing the experiment (Job #: of Nuclear Ionizers". Description: To static as well charge). I served as the research as a laboratory

is effective Engineering

in neutralizing representative

PYRO

to Dr. Rupert

AND 268A-1

EQUIPMENT

Plate/Probe plate NY

Assembly Model will 14098)

Model be used

analyzer

268A-1

(manufactured to conduct the

by

Monroe The and was

Electronics The assembly top part placed

Inc. is a

experiment.

of two separate contains box. To separate

components

connected portion

by a 10-ft cable. of the instrument we released

with the inside latches

the field meter

the two components,

the two over-center

near the rear of the unit and lifted A _A-20-threaded mounting. Two elevate a unit the front

at the rear of the top section. for convenient of the control The Switches control tripod unit to panel is

receptacle is provided inside of the top section foldout legs are provided underneath the bottom of the cabinet 6.3/4' to permit wide, easy viewing of the meters. weighs 5 lbs. and 9 1/2" and

of 6 3/4" high,

on the front

panel are alternate action push-push type with the exception of the three used for "plate control". These are mechanically interlocked so that only one function can be selected at a time. Controls "PLATE lower condition "POLARITY" are center of grouped of the the by panel function. relate labeled The "HV" relate switch Three to meter "PLATE control pushbutton range knobs, and CONTROL" the switches function. affect "HV directly Three the ON" beneath switches the at the and the

VOLTAGE" plate.

meter

charge/discharge indicator charge

pushbutton

to the polarity

and magnitude

of the initial

voltage on the plate. The "TIMER LIMIT" switch sets the start/stop the timer. The "OUTPUT" BNC connector on the back panel allows recorder to be connected to the output of the field meter. The signal the actual switches. The charged 10% supply isolated voltage on the plate regardless of the settings of the meter

voltage limits for an oscilloscope or here is 1/1000 th of range and function

plate

is a standard test circuit within +7500

tripod

mount below

plate

of 6" X 6" with a capacitance The plate self-discharge volts at 25 C. volts.

rated

for

a total discharge

in the plate 5 minutes volts from

of 20 + 2pF. output,

is less than charging of

of set voltage is concerned,

RH = 50%

As far as the power

maximum

_+1000 volts/+5000

plate available,

adjustable

< +1000

to > +5000

23

Ionmaster" The equipped a reliable four small

Ionizer

NRD

Model Number:

4060 SN36330) blower from NRD is a lightweight unit

Ionmaster"

(Serial

with an articulated arm and a bracket for attachment to the blower, compact and source of ions for static control. The blower bracket contains four slots were metallic grill-like (sealed cartridge) plates (Model containing closure. 2U500, manufactured on NY 14072) by a plastic the radioactive material

May, 2000 by NRD, Inc. Grand Island, 500uCi Po210 sit and are held in position This unit is designed grounding continuous is contained calibration. The radiation methods. balance safely to remove by the unit's in the sealed static

charge

that cannot balanced poses source. annually. element

be controlled air. The The

by conductive ions are kept source, and requires

or in no

This apparatus

delivers internal cartridges,

ionized

a-energy

o_-energy

which

no risk to personnel,

The Polonium emitted

210 source the rays

is replaced 210

from Alpha

Polonium travel through

is called

o_ radiation

and

is of

harmless

externally.

air very rapidly

to a maximum

distance

24

1 3/oa' in still air, but have U.S. receives millirems ionization, ionization an average from occurs man-made

no power sources.

to penetrate As the

the skin. rays travel

In general, through static

each person air, they

in the 100 produce

of 80 millirems air is the

of radiation one that

from natural sources charges.

and about

and this ionized

dissipates

The greatest

at the end of their path.

Plexiglas" the charge 31" high, mounted installed supplying

Test plate

Chamber
TM

A transparent

Plexiglas

box was used as the test chamber and the relative high, 31" wide, humidity used and 72" probe. is usually

that housed

the ionizer Physics meter going

blower, long, valve inside testbed

analyzer,

The Plexiglas" It has a flow with tubing humidity.

box 62"

31" deep,

and 5/8" thick

as an electromagnetic long table.

on top of a 33"

on the outside near the test entrance and outfitted compressed breathing air (dm/dt) to regulate relative

25

Digital

C_ Omega" ) Omega"

Thermo-Hygrometer Thermo-Hygrometer with probe was used to record the required The probe was contacting any

A Digital

percentage of relative humidity and temperature inside the test chamber. attached to the ionizer's movable arm away from the blower and without metallic or non-metallic parts.

EXPERIMENTAL/TEST For the purposes during experimental The sequence for the of studying

PROCEDURE alternate objective methods to eliminate ESD the

one of the two proposed which is the main sequence: the ionizer reading

pyro operations procedure started

at RH<30%,

of this f'mal project,

took the following by verifying that

would and

work

under

the the

conditions operator's

required

experiment.

Aider carefully

understanding

manuals for both the replacement of ion cartridges into the ionizer blower and the charged plate analyzer section respectively, we conducted a set of four experimental runs. We measured the distance between the charged plate and ionizer blower, recorded the relative ionizer (inspected 21.4% humidity blower. 02) needed and temperature, Also, we identified and contained to achieve and oriented the charged plate with the time and amount of compressed spec: SES-0073-6.3-29 relative humidity. and its polarity When running was maintained 1000-100 at volt respect to the breathing air with a purity of

by SGS

in "K" Bottles,

the desired cleaned

The charged "+" setting

plate was wiped as specified

with Isopropanol manual.

in the operator's

in the

regime, the decay rate (timing) stopped the 5000 - 500-volt range where the reached 3000 volts. Also, indefinitely in the order of-200 contact Monroe Electronics Inc. charged plate behavior at those set up the voltage

below 300 volts. The same situation decay rate stopped at 1.7 sec when of 1000-100 volts, the decay rate

occurred in the voltage continued

in the region

sec. These occurrences on August 17, 2000 at regimes.

prompted Dr. Rupert Lee to 11:00 AM EST to report the we decided to arbitrarily

voltage

For that reason

to 1000 - 400 v and 1000 - 300 v.

26

The the was

opening remaining observed

of an existing plate, ionizer ion with some rates pairs

orifice in

for venting and stands the test runs.

and the installation to a common chamber, was after Also, ground which placing to speed

of grounding was done produced a

wire

for

the charge

blower,

to neutralize longer as it achieved

charging/discharging 25 TM 16 Units it was verified Two ionizer flow, allowed depended plate

indicating experimental

that equilibrium

not completely

4 Engelhard/Desiccite up the drying process,

Type I desiccant bags into the test chamber that the decay rate was shorter as expected. were high used, direct remained distances impingement (charged at a fixed (near and

orientations flow,

(charged plate position

plate

perpendicular to ionizer plate

to was

blower low 0). to move

90 ) and horizontal blower

parallel while

blower which

The ionizer freely

the charge

at different

far as we denoted

them),

on the size of the experimental

chamber. RESULTS experimental properly position runs working inside to verify at the the following voltage range ionizer

EXPERIMENT/TEST As stated parameters: specified earlier, the we conducted charged plate 4 preliminary control RH meter panel probe

by the manufacturer,

the test chamber,

blower positioning and minimum/maximum chamber. During these experimental runs, inside the chamber after each equilibrium conditions to re-establish, situation, all stands and metallic parts plate obtain was wiped-clean with Isopropanol, rates. faster charging/discharging

distance from charged plate inside the test it was noticed that some air ion pairs remained session and did not permit

charging/discharging

producing longer rates. In order to correct this were grounded to a common ground, the charged and venting of the chamber was achieved to

Once all the experimental setup was properly were conducted whose results are shown below:

chosen,

a total

of 21 experimental

runs

27

Ionizer Experiment for August 18, 2000 Position = Direct Impingement ( 90 ) Distance = 33.02 cm / 13 in _elative Humidity RH = 30% Temperature = 21 C 170 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 2.0 sec Exp. Run# 1 2 3 4 5 6 7 8 9 10 Decay Rate (sec) 2 2 2 2 2 2 2 2 2 2

Ionizer Experiment for August 21_ 2000 Position = Direct Impingement ( 90 ) Distance = 33.02 cm / 13 in _elative Humidity RH = 20% Temperature = 21 C 1 70 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 2.5 sec Exp. Run# 1 2 3 4 5 6 7 8 9 10 Decay Rate (sec) 2 2 2 3 3 2 3 3 3 2

Ionizer Experiment for August 28, 2000 Position = Direct Impingement ( 90 ) )istance = 33.02 cm / 13 in Relative Humidity RH = 10% temperature = 22 C / 72 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 2.2 sec Exp. Run# Decay Rate (sec) 1 2 2 2 3 2 4 2 5 6 7 8 9 10 2 2 2 3 2

Ionizer Experiment for August 16, 2000 Position = Direct Impingement ( 90 ) )istance = 33.02 cm / 13 in Relative Humidity RH = 31% - 29% temperature = 22 C 172 F Voltage Setup (v) = 1000 - 500 Average Decay Rate = 3.4 sec Decay Rate(sec) Exp. Run#

3 4 5 6 7 8 9 10

4 4 3 3 3 3 3

28

onizer Experiment for August 16, 2000 Position = Direct Impingement ( 90 ) Distance = 33.02 cm / 13 in F_elative Humidity RH - 31% - 29% Temperature = 22 C / 72 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 11.6 sec Exp. Run# Decay Rate (sec) 1 2 2 14 3 4 5 6 7 8 9 10 22 15 16 13 10 9 8 7

Ionizer Experiment for August 28, 2000 Position = Direct Impingement ( 90 ) Distance - 55.88 cm / 22 in Relative Humidity RH = 10% Temperature = 22 C ! 72 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 6.1 sec Exp. Run# Decay Rate (sec) 1 6 2 6 3 4 5 6 7 8 9 10 6 6 8 6 6 5 6 6

Ionizer Experiment for August 30, 2000 Position = Direct Impingement ( 90 ) Distance = 55.88 cm / 22 in Relative Humidity RH = 30% Temperature = 21 C / 70 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 7.1 sec Exp. Run# Decay Rate (sec) 1 8 2 9 3 6 4 6 5 6 6 7 7 8 8 8 9 10 7 6

Ionizer Experiment for August 30, 2000 Position = Direct Impingement ( 90 ) Distance = 55.88 cm / 22 in Relative Humidity RH = 30% Temperature ---21 C 1 70 F Voltage Setup (v) = 1000 - 300 Average Decay Rate = 12.2 sec Exp. Run# Decay Rate (sec) 1 13 2 9 3 9 4 10 5 8 6 11 7 16 8 16 9 10 11 13

29

Ionizer Experiment for August 18, 2000 Position = Horizontal Position ( 0 ) Distance = 33.02 cm / 13 in Relative Humidity RH --.30% Temperature = 21 C ! 70 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 3.6 sec Exp. Run# Decay Rate (sec) 1 4 2 3 3 3 4 4 5 6 7 8 9 10 4 4 4 3 3 4

Ionizer Experiment for August 29, 2000 Position = Horizontal Position ( 0 ) Distance = 33.02 cm / 13 in Relative Humidity RH -- 20% Temperature = 22 C / 72 F Voltage Setup (v) -- 1000 - 400 Average Decay Rate = 3.6 sec Exp. Run# 1 2 3 4 5 6 7 8 9 10 Decay Rate (sec) 3 4 3 4 4 4 3 4 4

Ionizer Experiment for August 28, 2000 Position = Horizontal Position ( 0 ) Distance = 55.88 cm / 22 in Relative Humidity RH = 10% Temperature = 22 C / 72 F Voltage Setup (v) = 1000 - 300 Average Decay Rate = 21.9 sec Exp. Run# Decay Rate (sec) 1 23 2 20 3 4 5 6 7 8 9 10 21 27 22 22 22 27 16 19

Ionizer Experiment for August 30, 2000 Position = Horizontal Position ( 0 ) Distance = 55.88 cm 1 22 in Relative Humidity RH = 30% Temperature = 21 C / 70 F Voltage Setup (v) - 1000- 400 Average Decay Rate = 7.6 sec Exp. Run# Decay Rate (sec) 1 6 2 8 3 4 9 5 6 7 8 9 10 9 6 8 7 8 7

3O

IonizerExperiment for August 29, 2000 Position = Horizontal Position ( 0) Distance = 33.02 cm / 13 in
Relative Humidity RH = 20% Temperature = 22 C / 72 F Voltage Setup (v) = 1000 - 300 Average Decay Rate = 4.9 sec Exp. Run# Decay Rate (sec) 1 4 2 5 3 4 5 6 7 8 9 10 4 5 5

Ionizer Experiment for August 29, 2000 Position -- Horizontal Position ( 0 ) Distance = 33.02 cm / 13 in Relative Humidity RH - 10% Temperature = 22 C / 72 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 3.8 sec Exp. Run# Decay Rate (sec) 1 4 2 4 3 4 5 6 7 8 9 10 4 4 4 3 3 3 5 4

5 5 6

Ionizer Experiment for August 30, 2000 _osition = Horizontal Position ( 0 ) Distance = 55.88 cm / 22 in F_elative Humidity RH = 30% Temperature = 21 C / 70 F Voltage Setup (v) = 1000 - 300 Average Decay Rate = 10.0 sec Exp. Run# Decay Rate (sec) 1 8 2 12 3 12 4 7 5 12 6 10 7 11 8 11 9 8 10 9

Ionizer Experiment for August 29, 2000 Position = Horizontal Position ( 0 ) Distance - 55.88 cm / 22 in IRelative Humidity RH - 6% Temperature - 21 C / 70 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 16.3 sec Exp. Run# Decay Rate (sec) 1 15 2 16 3 15 4 5 6 7 8 9 10 19 21 13 14 16 17 17

3]

Ionizer Experiment for August 29, 2000 Position = Horizontal Position ( 0 ) Distance = 33.02 cm / 13 in _elative Humidity RH = 20% Temperature = 22 C / 72 F Voltage Setup (v) = 1000 - 300 Average Decay Rate = 5.2 sec Exp. Run# Decay Rate (sec) 1 6 2 6 3 4 5 6 7 8 9 10 4 5 5 5 5 5 6 5

Ionizer Experiment for August 29, 2000 Position ---Horizontal Position ( 0 ) Distance = 55.88 cm / 22 in Relative Humidity RH = 20% Temperature = 21 C / 70 F Voltage Setup (v) = 1000 - 400 Average Decay Rate - 16.3 sec Exp. Run# Decay Rate (sec) 1 16 2 18 3 4 5 6 7 8 9 10 17 16 14 17 16 19 15 15

Ionizer Experiment for August 29, 2000 Position = Horizontal Position ( 0 ) Distance - 55.88 cm / 22 in Relative Humidity RH = 6% Temperature = 21 C / 70 F Voltage Setup (v) = 1000 - 300 Average Decay Rate = 21.7 sec Exp. Run# Decay Rate (sec) 1 20 2 3 4 5 6 7 8 9 10 27 17 19 21 21 23 26 24 19

Ionizer Experiment for August 29, 2000 Position -- Horizontal Position ( 0 ) Distance = 55.88 cm ! 22 in Relative Humidity RH = 20% Temperature = 21 C 170 F Voltage Setup (v) = 1000 - 300 Average Decay Rate = 20.6 sec Exp. Run# 1 2 3 4 5 6 7 8 9 10 Decay Rate (sec) 21 21 18 23 18 21 20 20 22 22

32

Ionizer Experiment

for August 28, 2000

Position = Horizontal Position (0.) Distance = 55.88 cm / 22 in Relative Humidity RH = 10% Temperature = 22 C / 72 F Voltage Setup (v) = 1000 - 400 Average Decay Rate = 18.8 sec Exp. Run# Decay Rate (sec) 1 17 2 27 3 4 5 6 7 8 9 10 21 18 21 23 19 13 14 15

33

DATA From the experimental ionizer blower is the Humidity, The graph interaction meaning indicated 8. The "ANOVA" distance,

ANALYSIS

runs, it appeared that the distance from the charged plate to the ma,ior player of all three variables considered (i.e. Relative in this experiment. for depicting the experiment whose pattern = 23 = is called

and angle)

displayed at the bottom of the analysis section, is intended effect of the three variables simultaneously studied in the

is given by the statistical analysis of the experimental data. The results a factorial design, three factors tested at two levels, i.e. # of experiments statistical (ANalysis analysis process used to analyze this experimental data Of VAriances).

Low Distance = near (33.02 cm / 13 in) High Distance = far (55.88 cm / 22 in) Low RH = 10% High RH = 30% Low Angle = 0 (Horizontal Plate) High Angle = 90 (Direct Impingement) AVG = Average of 10 experimental values (no round off and with no decimal point)

In the following chart numbers 1 - 8 in the first column are the average values of 10 experimental A 1 2 3 4 5 6 7 8 0 1 0 1 0 1 0 1 B 0 0 1 t 0 0 1 1 C 0 0 0 0 1 1 1 1 AVG 3.8 18.8 3.6 7.6 2.2 6.1 2 7.1 Single Independent Variables A = Distance B=RH C = Angle

data.

34

In the following chart, AB, AC, BC, and ABC represent the combined interaction of 2 and 3 single independent variables. conditions. ABC -3.8 18.8 3.6 -7.6 2.2 -6.1 -2 7.1 12.2 3.05

** Number 4 here represents the number of differences or changes in the experimental A 1 2 3 4 5 6 7 8 Sum **Sum/4 -3.8 18.8 -3.6 7.6 -2.2 6.1 -2 7.1 28 7 B -3.8 -18.8 3.6 7.6 -2.2 -6.1 2 7.1 -10.6 -2.65 C -3.8 -18.8 -3.6 -7.6 2.2 6.1 2 7.1 -16.4 -4.1 AB 3.8 -18.8 -3.6 7.6 2.2 -6.1 -2 7.1 -9.8 -2.45 AC 3.8 -18.8 3.6 -7.6 -2.2 6.1 -2 7.1 -10 -2.5 BC 3.8 18.8 -3.6 -7.6 -2.2 -6.1 2 7.1 12.2 3.05

This chart represents the 4 paired scenarios where the distance changed from near to far. The first set (1,2), represents the combined effect of low RH and low angle. The second set (3,4), high RH and low angle. The third set (5,6), low RH and high angle. The last set (7,8), high RH and high angle. The graph below represents the average between shortest and farthest distance in each set. A 1 0 1 B 0 0 C 0 0 AVG 3.8 18.8 (3.8 + 18.8) / 2 = 11.3 11.3 - 5.6 = 5.7

31o[11o 36 I 5101o11 22 71o11 lt2

4 1 1 0 7.6 6 1 0 1 6.1 8 1 1 1 7.1

(3.6+7.6) (2.2 + 6.1 )

2=5.6 2 = 4.2 4.6-4.2=0.2

(2.0 + 7.1)

2 = 4.6

35

Interaction

Effects

of Distance,

RH, and Angle for Ionizer

Experiment

14 12
A

= I

II

O O O

10
I _

:
II

:
I

8 6 4 2 0 0

n,
M O O

:
. ,,.
r | I I ,,,vQ b

.'b...
I I l

:
5.6 A.4.6
I I I

C_

10 Relative I-e--

20 Humidity _

30 RH (%) High Angle ]

40

Low Angle

A further

analysis

of these

experimental

data would

involve

the

use

of a statistical

sottware package which, since a more complete

would fall beyond variable analysis

the scope of the purpose for this experiment would involve the following interaction

sequence: TABC ----Average of the experimental values + main effect of A + main effect orb + main effect ofC + interaction effect ofAB + interaction effect ofBC + interaction effect of AC + interaction data). effect of ABC + experimental error (how good this model fits the experimental

36

INCREASE

OF MOISTURE

CONTENT

IN WORK

AREA

The proposed alternative fact, to raise the humidity

to allow for pyro level above 30%.

operations to continue while RH_<30%, is in This task wouM require a modification of the modification at Pad B. The PLB, and Cabin purge circuits associated water piping, control of controlling the RH of

OPF ECS configuration, similar to the ECS humidification Pad B ECS has the ability to control the RH to the AFT, individually. valves, The system and consists sensors. of a humidifier, The system boiler, controllers,

has the capability

the purge air going to the Orbiter above 30% while maintaining the maximum specific moisture of no more than 37 grains of moisture per pound of dry air. Although this method DFRC scheme, would due work, it has two downsides: Portable would 1) this method Purge be costly Unit could as shown could below. is as follows (in not be implemented with such at a to the fact that the not be outfitted

and 2) the modification cost break

The approximate U.S. Dollars):

down

for the modification each

of one OPF ECS

Two Required Sensors Humidifier = $2,500.00 Humidifier Steam Piping Water Chamber Generator

= $300.00 = $1,500.00

(Boiler)

= $3,000.00

and Control Valves = $1,500.00 Softener = $2,600.00 = $5,000.00 Controllers = $250.00 each and Labor

Design Costs Two Foxboro Labor

= $4,000.00

Burden (Contractor Profit) = 1.8% of Parts Estimated Total = $24,000.00 If this modification approximately would be implemented

to all three OPF ECSs,

the total cost would

be

$72,000.00.

Dehumidifier

already

installed

at Pad 39-B

37

Boiler

Assembly

at Pad 39-B

Humidifier

Controller

for the ECS at Pad 39-B

38

RECOMMENDATIONS Some experimental issues Gompf, used and preliminary a NASA Professor adjunct

FOR findings

FUTURE about

ACTIONS ESDs and pyros were Area (BCC). we should Also body EEDs some discussed He pointed rather the small height, contact other

with Dr. Raymond Building we were vendor protective since Future the out that the ionizer just using to ask

consultant

in the Research College for pyro testing,

at the O&C

and Mathematics

at Brevard and

Community for future

in the experiment purposes, ionizers

was not designed for pyro operations. is moving, handling

operations,

it for testing manufacture such

if they details

and important

as how fast the technician a difference spark. when an inadvertent

fat, weight,

equipment,

etc. can make can trigger

at low RH levels,

these factors testing calls

for a simulation that the voltage

on an OPF-like drops down

Pyro operation to about 350

with volts.

RH<30% This

using be

ionizer

to verify

could

performed using wriststats, fire retardant coveralls, and personnel grounding. The key to provide electrostatic protection lies on timing because the faster the breakdown or switching better time of the protective will be. the experimental a bigger ionizer setup to a field experiment blower and try to obtain in the real some data. device after onset of applied electrostatic voltage, the the protection

Another possibility is to extend environment of the OPF with Perhaps in this OPF. However, for modifications

realistic setting, we may have different variables to consider within the if further testing does not satisfy the safety community, then budgeting to the OPF ECS must be considered. Also, to solve the low RH dehumidifier the proper may testing be considered. Of course, the portable and analysis before such a device could

problem at DFRC a portable dehumidifier must go through be used in the Orbiter.

39

REFERENCES Jonassen, "Orbiter Training

.

Niels,

"Electrostatics", Devices, April L. and University B., and

Chapman OS-400-LSC

& Hall, Student

1998. Handbook", USA _ Technical

2.

Pyrotechnic USK-155, Vincent Oxford Frank

28, 1998. Moore, Press, Arnold, Inc., ORD Robert 1994. Jack 1996. M 7-224 September Ordnance 4, 1951. Corps Manual" Ordnance H. Jr., editors, "Aerospace Ordnance C., editors, "Fundamentals of Space

Pisacane, Systems"

Pollard, Handbook", "Ordnance Corps,

Prentice-Hall, Safety Manual,

Department

of the Army,

40