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STATIC TEST

FACILITYR-C-msm lDT

MSF

SATURN

[General lnf or mation)

APRIL 15, 1963

l NTRODUCT l ON

This booklet presents

at the Marshall Space Flight Center of direct interest to Chrysler personnel

information on those test

and ground support

facilities

responsible for

the captive test

program of

the Saturn S-1

and S-1B

stages.

LIST OF CONTENTS

MAP REDSTONE ARSENAL AND HUNTSVILLE,

AERIAL VIEW OF MSFC TEST AREA YEAST" PERSPECTIVE DRAWING OF MSFC TEST AREA "EAST" DESCRIPTION OF SATURN I STATIC TEST TOWER

ARTIST CONCEPTION OF THE STATIC TEST TOWER AFTER MODIFICATION ARTIST CUTAWAY OF THE TOWER AND TEST POSITION LESS NEW ANNEX

FLOOR PLAN TEST TOWER ANNEX FLOOR PLAN TEST TOWER ANNEX

FLOOR PLAN TEST TOWER ANNEX (SECOND FLOOR) STATIC TEST TOWER CAPABILITY DURING NORMAL STATIC TEST STATIC TEST TOWER SUPPORT FACILITIES (TABULAR FORM) PLAN VIEW OF FACILITIES SUPPORTING THE STATIC TEST TOWER PHOTO LIQUID OXYGEN, GASEOUS NITROGEN STORAGE FACILITIES SCHEMATIC LOX STORAGE AND TRANSFER SYSTEMS SCHEMATIC NITROGEN SYSTEM SCHEMATIC INDUSTRIAL WATER AND FIREX SYSTEMS PHOTO UNDERGROUND FUEL STORAG?3 FACILITY SCHEMATIC FUEL STORAGE AND TRANSFER SYSTEMS DESCRIPTION OF THE BLOCKHOUSE ARTIST CONCEPTION OF THE BLOCKHOUSE AFTER MODIFICATION PHOTO BLOCKHOUSE FLOOR FLAX BLOCKHOUSE (BASEMENT) FLOOR PLAN BLOCKHOUSE (FIRST FLOOR) FLOOR PLAN BLOCKHOUSE (CONTROL ROOM) PHOTO AND DESCRIPTION OF THE PNSTRZTMENTATION EQUIPMENT PHOTO CHECKOUT, CONTROL, AND MINITORING CONSOLES PHOTO STAGF, INTJIRFACE TEST SET CONSOLES DESCRIPTION OF READY STORAGE AREAS PHOTO NITROGEN TRANSFER, STORAGE, AND CONVERSION FACILITY PHOTO LIQUID NITROGEN STORAGE VESSELS PHOTO FUEL STORAGE AXD TwSFER FACILITY DESCRIPTION OF THE DYNAMIC TEST STAND PHOTO DYNAMIC STAND DESCRIPTION OF THE POWER PLANT TEST STAND PHOTO POWER PLANT TEST STAND PHOTO POWER PLANT TEST STAND WITH BLOCKHOUSE IN FOREGROUND DESCRIPTION OF THE WATER RESERVOIR AND BOOSTER PUMP STATION PHOTO BOOSTER PUMP STATION AND RESERVOIR

ALABAMA

(FIRST

FLOOR)

(INTERMEDIATE

MEZZANINE)

POWER PLANT

BOOSTER PUMP

POWER PLANT

TEsr

sTAND

M S F C

TEST

(EAST)

RESERVOIR

COMPLEX

ADITANCED DYnAMIC

TEST

STAND

SATURN I

DYNAMIC

TEST STAND

NITROGEN STORAGE

CONVERSI

FACILITY

TRANSFER, &

STATIC TEST

STORAGE

UNDERGROml

STORAGE

.

STATIC TEST TOWER

The Static Test Tower

static fire complete Sat~:rr:-i and

approximately 140 seconds and 1,504,000 pounds thrust. The basic structure is

a reinforced concrete tower

concrete annex to the rear. Housed within the structure are engineering offices,

is a two-position

facility designed and constructed to

stages for

full

1B Boozter

duration tests of

reinforced

140 feet

in height with a three-level

instrumentation and control

terminal

facility power system,

for the deflector and firex systems.

two elevators,

rooms,

equipment used

access stairs,

and an

in vehicle preparation, industrial water system

The structures for restraining the vehicles during captive firings are fastened to the tower and to special spread footings bearing on H-piles.

Lateral thrust by buttresses. long by 30-foot

to a drainage and waste disposal system. Both positions are served by a track- mounted 45-ton gantry crane and a 100-ton roll ing overhead crane supported by

a truss system above the tower,

loads which occur during the engine gimbaling test are absorbed

Each position has a water-cooled

flame deflector and a 170-foot

wide concrete blast trench.

Each blast trench

is connected

bringing the total

tower

height

to 186 feet.

Each flame deflector has a coolant water flowrate of approximately 46,500

gpm.

Tower fire protection is provided by a Firex system with a maximum flwrate of 31,000 gprn. The tower is linked to the blockhouse by an underground reinforced concrete instrumentation cable tunnel, which also serves as an emergency escape

passage for

personnel.

Supporting

facil i ties

include:

(a)

A LOX storage and transfer facility consisting of two 14,000 gallon and two 28,000 gallon double-walled vacuum insulated storage tanks, four 250-gpm 400-foot head pumps used for transfer and intertanking, and two 250-gpm

200-foot

head pumps at the connections for unloading rail cars or motor

transports.

(b)

A 5000 psi GN2 storage and transfer faci 1 i ty consisting of a battery of

h his facility

thirty-five

bottles of

35 cubic feet water volume each.

has common useage servicing other

test facilities

at

the MSFC.)

(c)

A fuel

storage and

transfer

faci 1 i ty

to support and supplement

the fuel

(RP-1)

suppl ied

to

the test

tower

from the ready storage area.

This faci 1i ty

consists of

transfer pumps.

two 20,000-gallon

underground storage vessels and two 250-gpm

(d)

(e)

5000

psi He1 ium connections and transfer

to mob i 1e storage and transfer

un i ts.

piping at the test

tower

for hookup

A

water

storage and transfer

f ac i 1 i ty

cons is t i ng of

two one-mi 1 1 ion gal lon

storage tanks and seven

10,000

gprn diesel-driven

pumps.

ARTIST

WITH

CUTAWAY OF

THE

STATIC TEST TOWER AND

IN BACKGROUND.

THE

ORIGINAL BLOCK HOUSE

EAST TEST POSITION

1

\

/

ELEVATOR

BREAK

AREA

G

SHOP AREA

I M/G

I

ROOM

104'- 0"

STATIC

TOWER

Jr2o!oUwm, r

ANNEX

L~~~~.SHAFT

STATIC

TOWER

ROX

ANNEX

SCALE

l"-12'#

E-

\O

OFFICE

AREA

STATIC TOWER

ANNEX

SCALE <= 12"

STATIC TEST TOWER CAPABILITY DURING NORMAL STATIC TEST

OF SATURN S-1 BLOCK I I

STAGES

REQUIRED TIME TO LOAD BOOSTER PROPELLANT TANKS

LOX

:

1

hour

10 minutes

(after

pre-cool)

Fuel .: (RP- I) :

1

hour

PROPELLANT FLOWRATES

(LOAD1NG)

LOX

Fuel:

:

800 gpm

585 gpm

LOX BOlLOFF RATE

2,500

gal/hr

at 70% Humidity,

~o'F,

29.92

PROPELLANT QUANTITIES (FULL LOAD)

LOX :

63,000

gal

Fuel:

41,000 gal

FLAME DEFLECTOR WATER FLOW DURATION

in.

Hg Barometric Pressure

Full flow (upper and lower deflector) 13 minutes Upper def 1ector: 7 hours

FLAME DEFLECTOR WATER FLOWRATES

Full

flow:

46,500

gpm

Upper deflector:

5,000

gpm

GN7 TOWER PRESSURE

3,000

psi

after

reduction from 5,000

psi

on 2nd

level

of Tower annex

v

SYSTEM

MODE

CAPAC l TY

 

Fi 1 1

 

(2)

28,000

gal

L i qu i d Oxygen

Fill

(2) 14,000gal

Drain

 

Fi 11

 

(2)

17,000

ga 1

Drain

 

Fuel

(RP-1)

Fi 11

or

(2)

10,000

ga 1

 

Drain

 

Fill

or

(2)

10,000gal

Dra in

 

Gaseous

Ni trogen

F i

1

1

(35)

35

cu

f t

 

@ 5,000

psi

15 cu

ft

He1 ium

 

Fi 11

Trai ler

 

@ 5,000

psi

Industrial

 

(2)

1,000,000

Water

 

ga 1

 

--

Electrical

 

500 KVA

 

STATIC TEST TOWER SUPPORT FACILITIES

PUMP RATE

(2)

250 gpm

(2)

250gpm

Gravity + 10

PS 1

(2)

250 gpm

Gravi ty

(2)

250 gpm

(2)

100 gpm

(7)

10,000gpm

LINE

F ILTRA-

 

SIZE

TlON

 

FROM

TO

REMARKS

 

6

in

20

mu

LOX

Storage

Tower

 

4

in

20

mu

LOX

Storage

Tower

10

in

Tower

LOX Pit

LOX

Pit

located

 

S.W.

of

Tower

6

in

20

mu

Fuel

Storage

Tower

 

24

in

Tower

Fuel

 

Storage

4

in

20

to

Ready

Tower

(~upplementary

 

70

mu

Storage

 

4

in

20

to

Ready

Tower

Support)

 
 

70

mu

Storage

 
 

High

2in

80mu

Pressure

Tower

Reduced to 3,000

 

Storage

psi on the Tower

Battery

and filtered

10 mu

to

3/4

in

Trai ler At- tachmen t

Tower

Reduced to 3,000 psi at the

or

1

in

80

mu

near GN2

trailer. Filtered

 

storage

on

the tower

 
 

to

10 mu

30

in

1/4inch

Water

 

Tower

 
 

Storage &

Def 1ector5

 

Booster

Pump

&

Fi rex

3

#

210

Tower

Sub

Tower

Li ne Vol tage

 
 

Stat ion

4160 V

"

lndustr~alWater

Liquid Ox gen --------- ------------

Fuel (RP-I') ------------

Gaseous Nitrogen (GN2)---------

FACILITIES

SUPPORTING

STTE &W

GN2 f

STORAGE

The Blockhouse

is

the control

positions -- Static Test Tower

and data acquisition center

for

East,

Static Test Tower West,

five test

Power

Plant

Test

Stand,

Cold Calibration Test

Stand North,

and

the Cold Calibration

Test

Stand South.

An underground cable tunnel

connects

the facility

with the Static Test Tower.

facilities

mentioned.

Underground cable ducts connect

it

to

the other

Original construction is of reinforced concrete for protection of personnel. A concrete block addition has been made on the northeast side to house

instrument maintenance equipment.

A second zddition now under construction

will add 20,600 square feet of blast-resistant construction ot the main

building on the West

proposed J-2

Test Facility.

side and 400

feet of

cable and escape tunnel

to

the

test

stand,

and a tunnel

to the proposed advanced Dynamic

ARTIST CONCEPmON OF MODIFIED BIQGKHOUSE WI21.I MODIFIED STATIC T.EST TOG.JER IN BAQEGROUL\JD

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READY STORAGE AREAS

The Ready Storage Area consists of a liquid nitrogen storage and transfer facility and a liquid fuel storage and transfer facility.

The nitrogen facility consists of five 12,000-gallon, one 14,000-gallon and two 7,000-gallon vacuum insulated double-walled cylindrical

storage

of the nitrogen ready storage area include two steam heated 25,000-scf/ hr vaporizers at 3,000 psi outlet pressure, two 25,000-scf/hr transfer pumps, two 250-gpm unloading pumps, two 250-gpm transfer pumps, and three fan-blown ambient air temperature 4,800-scf/rnin vaporizers at 5,000 psi outlet pressure. These three vaporizers provide the gaseous nitrogen used at the Static Test Tower and the Power Plant Test Stand.

tanks for storing 1iquid ni trogen at -325'~.

The other components

The second group of storage tanks for

250-gpm 250-foot

equipment consists of

four

Transfer

10,000-gallon

equipment

underground

hydrocarbon fuels.

head transfer

includes

two

and two

pumps with filters and meters,

125-gpm

intertank transfer

to the Static Test Tower,

pumps.

Transfer

lines connect

the facility

Power Plant Test Stand,

and other facilities.

NITRES? TRAhTSF!iB, STORAOE,UD

Gij?TV;.;RSICFl

FACIUTP - CafVGNE?UTTS TEST FACILTTY I!$ BALli3RCUfJn

DYNAM IC TEST STAND

Mechanical tests on multistage vehicles are performed on the Dynamic Test

Stand.

the determination of

and under simulated free flight. The Dynamic Test Stand provides additional capacity for the training of personnel in the details of stage handling

and launch preparation.

This facility

allows for

natural

the checkout of

mechanical

both on

mating features, launch arms

bending characteristics

Ground support equipment such as hydraulic systems,

pneumatic systems, electrical connections, and launcher supports can be

checked out under simulated launch conditions.

The test stand consists of

204-foot steel tower. The foundation accommodates the same launch supports

that are used at Cape Canaveral

fully

an elevator,working flight conditions,

tions,

and support for a 75-ton

The derrick and a secondary jib

various vehicle stages

mast

a heavily

reinforced concrete foundation and a

support

the entire vehicle

in the

structure has access stairs and

vehicle supports for free

umbilical

arms and connec-

boom.

and will

tower

fueled condition.

The steel

platforms,

lateral

wind protection,

support for

supports,

stiff-leg

derrick with an 80-foot

install

hoist are used to

and assemble the

in the facility.

The entire structure with crane

installed is about 260 feet

above the ground level.

Facility

instrumentation

is provided by

the control

center

located to the

east of

the Dynamic Tower.

In the present Saturn testing program,

103,320

gallons of

deionized water

is

used to simulate propellant weights

onboard

the first

stage,

The

propellant weights

2-inch diameter

in the S-IV

stage are simulated by

16,750

pounds of

polyethylene balls

in the hydrogen tanks

and 695,000

gallons

of water

to simulate the weight of

liquid oxygen.

The vehicles

are suspended

by cables

to achieve the free flight

effect.

The vehicle is raised about one inch off its supports previous to shaking. The weights of the vehicles in the present series of tests during the shaking procedure is approximately one million, one hundred and twenty thousand pounds. Deflections of the longitudinal axis in the booster

section are in

the area of

13 to

2

inches.

SATU,W

BOOSTER mTH S Lf! IN STAND.

3Y?IM:IC

TST FACILITY

---

--

JUPIm NOSE GCW5 & AFT UNIT BEING LImm ZTIi S P DUTi5bi:Y

POWER PLANT TEST STAND

Single engines are static fired at

facility

booster.

the Power Plant Test

engine used

188,000

Stand.

This

is capable of

The H-1

firing the H-1

in the Saturn S-1

pounds with a

engine has a thrust of

160 second

can be measured and tests

(maximum) duration. A1 1

engine characteristics

the Saturn engine and

made for both inboard and outboard configurations of

suction

S-1 static test program and for hardware development testing in connection

improvement program.

with the S-1

line systems.

The facility will

be available for

support of

the

stage product

The water cooled deflector has a flow of 5,000 to 6,000 gpm. The stainless steel propellant tankage assembly has capacity for 9,000 gallons of LOX

and 6,000

and nitrogen supply from the Ready Storage Area. The facility has within

gal lons of RP-1.

The Power Plant Test Stand receives

its fuel

its complex a LOX storage and transfer

system of

21,000

gallons.

Instrumentation and control the blockhouse.

are provided by underground connections

to

H-1 POlnlER PLANT TBT STAND (EAST OTEd)

WATER RESERVO l R

lndustrial

water

for

test

area use is stored

in two

interconnected covered

steel

(90 feet

in diameter

and 22 feet

high)

tanks

of

one million gallons

capacity supported by reinforced concrete foundations. The difference in

elevation of

static

the pomp house

Arsenal lndustrial Water System and an automatic valve system maintain the

the reservoirs bases

22 feet

at

is 210 psi.

and booster

pumps.

fill

pumps allows

a minimum

head of

the booster

A

10-inch

The maximum line pressure at

to

the Redstone

line connected

reservoir

full

West

reservoi r

and ready for

to

the booster

use.

Two 30-inch

pump stat ion.

steel

lines connect

the

Nominal

is

rate

storage capacity

70,000

is

two million gallons.

The maximum depletion

is 4,000

gpm.

gpm and

the maximum replenishing rate

BOOSTER PUMP STAT lON

The Booster Pump Station houses the pumps for the industrial water supply system. Pumping facilities include one 1500-gpm electrically-driven pump, three 3250-gpm electrically-driven pumps, and seven 10,000-gpm, d i esel -dr i ven pumps.

The water

distribution

system consists of

through

the area and a 30-inch

steel

pipe

a

16-inch cast

iron pipe

loop

to

the Power Plant

loop

Test Stand and to the Static Test Tower. Flowmeters are provided in both lines. Pressure regulators limit pressure in the 16-inch line to 150 psig at the pump station. Maximum delivery pressure to the 30-inch line is 200 to 210 psig.