INTRODUCTION Apollo and Apollo Applications is a study initiated early in October at the direction of the Hon. Olin E. Teague, chairman, Subcommittee on NASA Oversight with the objective of reviewing performance, schedule, resources status and interactions of these two major NASA programs. A total of 12 conferences were planned and held including the major NASA Manned Space Flight centers and key Apollo and Apollo Applications contractors as shown below: October 5, 1967: Office of Manned Space Flight, Introductory Conference. October 9, 1967: Manned Spacecraft Center. October 10, 1967: Chrysler/Michoud. October 11, 1967: Boeing/Michoud. October 12, 1967: Marshall Space Flight Center. October 13, 1967: McDonnell Douglas/St. Louis, Mo. October 27, 1967: Martin/Denver, Colo. October 31, 1967: Lockheed/Sunnyvale, Calif. November 1, 1967: North American Rockwell/Downey, Calif November 2, 1967: McDonnell-Douglas/Huntington Beach, Calif. November 13, 1967: Kennedy Space Center. November 17, 1967: Grumman/Bethpage, N.Y. November 28-30, 1967: Office of Manned Space Flight Exit Conference. The results of these conferences are reviewed from the point of view of problems and accomplishments, along with identification of those problems which the management of the organizations visited consider pacing or controlling their accomplishment of the program. Following a program analysis, abstracts provided by the participants are included to provide additional detail. A complete record of all conference material is on file at the committee offices. (XIII) PROGRAM ANALYSIS APOLLO I. SPACECRAFT A. Technical Problems and Accomplishments Manned Spacecraft Center.-Apollo spacecraft, the Command and Service Modules and the Lunar Module, under contract to North American Rockwell and Grumman respectively, are experiencing similar problems. This portion of the program is the responsibility of the Manned Spacecraft Center and status reported by MSC during the October 9 conference indicated major common problems of weight growth; invention, selection, and incorporation of suitable materials to achieve fireproofing within the spacecraft; quality control and fireproofing of the cabin wiring. A major problem unique to the Command Module, that of concern for its ability to withstand earth impact if an earth landing were necessary. The Lunar Module program has had a continuing problem of instability of the Ascent Stage engine during tests which are deliberately designed to induce instability if the potential exists. Tests on new injector designs at Bell Aerospace and an alternate injector design at Rocketdyne Division of North American Rockwell have yielded encouraging results but final qualification remains to be accomplished. North American Rockwell. During the North American Rockwell conference, the difficulties of weight growth, flammability proofing, and wiring installation were pointed out. An additional problem of leakage of the service propulsion system ball valve was also reported to be of concern. Although the above were reported as problems, North American Rockwell indicated that significant progress has and is being made in their solution. A number of promising new materials have been introduced, e.g., Ladicote, used to cover circuit breakers; nitroso rubber which will not burn in a 16 p.s.i. oxygen atmosphere, used as a cover for the Ladicote to prevent surface burning and for electric terminals; and beta cloth glassbags for relay covers. Plastic cover panels will be copper clad; wiring has been refined; the quantity of Velcro used as a retentive surface has been reduced from 5,000 to 200 square inches, 80 percent of the silicone rubber has been eliminated and both materials have been isolated to the extent possible to avoid fire propagation. Both materials have been placed under strict control with respect to additions and changes. North American Rockwell (NAR) stressed that a new, more rigorous level of inspection and quality control has been instituted and is working effectively. NAR is also deliberately subjecting material to tests which are more severe than specification in their flammability evaluation. Grumman.-The major problems reviewed by Grumman regarding the Lunar Module (LM) were largely fire related, such as materials changes to eliminate flammability and increase in spacecraft weight caused by these changes. The flammability hazard, however, less severe than the Command and Service Module because of the lower oxygen cabin pressure (approx. 6 p.s.i.) of the LM. Ascent Stage Propulsion engine instability reviewed at MSC, was considered by Grumman to be a possible source of program slippage if reevaluation of electronic assemblies at higher vibration levels demonstrate any problem. Grumman reported progress in a number of areas, ground testing of the fire test vehicle (M-6) was underway; delivery of flight spacecraft (LM-1), fire test vehicle (M-6) and LM test article (LTA-8) had been completed; helium leaks in LM-1 joints developed during checkout at Kennedy Space Center and were rectified; and a weight savings program instituted which Grumman felt would enable them to stay within the weight limits. B. Management Problems and Accomplishments The Manned Spacecraft Center's problems in the management area were stated to be primarily the effect of the Administrative Operations fiscal year 1968 budget reductions, particularly on overtime and travel. North American Rockwell's key management difficulties were stated to be the complexity of incorporating the many required fire related changes while maintaining delivery schedules and the associated problem of the continuing need for overtime. The need for maintaining a capability for solution of problems while employment is declining and difficulty in attracting competent, young engineering graduates were said to be of concern. Grumman also indicated that the maintenance of a skilled and experienced engineering staff for possible later flight related problem solving and support is a growing problem of management. North American Rockwell and Grumman expressed confidence that marked improvement in problem solving had been achieved and in regaining program momentum. Both spacecraft contractors have established individual program management teams for the first four spacecraft. Both North American and Grumman indicated that they have made progress in improving cost control, and change control. C. Spacecraft Pacing or Controlling Items as discussed during the conferences were as follows: MSC: 1. Completion of ground tests. 2. Software (computer) programs for the spacecraft. North American Rockwell: Successful completion of Qualification Tests. Grumman: 1. The task of multivehicle testing while maintaining LM-2, LM-3 delivery schedule. 2. Radar, abort guidance, environmental control system, and Ascent Stage Propulsion. II. LAUNCH VEHICLES A. Technical Problems and Accomplishments Marshall Space Flight Center (MSFC).—Saturn Launch Vehicles IB and V were considered to be in a technically excellent position. MSFC cited degradation during long term storage as a concern for the Saturn IB. The Saturn V still had unknowns until its flight worthiness had been fully tested. The successful launch of Apollo 4 (Saturn 501) on November 9, 1967, has added confidence in this area. Chrysler/Michoud. The October 10 conference at the Chrysler facility at Michoud identified a possible degradation in storage of SIB stages as a potential problem. During the past year, the major technical problem encountered and solved by Chrysler included the presence of moisture in the liquid oxygen seal cavities of the H-1 engine. Corrective action has eliminated this problem and the general technical position of the program is favorable. Boeing/Michoud.-No technical problems were identified that would effect successful launch. Accomplishments at Boeing include solution of a problem involving engine servoactuators, maintaining an on-or-ahead-of-schedule and under cost program status. Boeing and NASA have instituted a single point failure analysis program sufficiently early to provide increased reliability in the launch vehicle. North American Rockwell.-Producer of the S-II (second stage) for the Saturn V reviewed two technical problems which have been largely resolved. Cracks have been found in a stress relieved area on the S-II-7 stage. North American Rockwell stated they will consider these cracks as problem areas until their laboratory test programs are complete even though all testing, thus far, has demonstrated no problems. North American Rockwell has solved a tank insulation problem earlier in the year. During checkout of the SA-501 for the Apollo 4 launch, a problem involving the lox tank baffles developed and was corrected. A progressive improvement in manufacturing has also been accomplished in the areas of structures, welding quality, wiring and engineering change control as experience has been gained in manufacture. McDonnell-Douglas.-The key accomplishments discussed by McDonnell-Douglas were the conduct of the program on schedule, within cost, at a low level of overtime (3 to 4 percent). They stated that nine S-IVB stages are in storage. B. Management Problems and Accomplishments Marshall Space Flight Center Administrative Operations budget reductions and their effect on travel and overtime payment was stated to be a major management problem. As with industry the problem of retaining competent personnel and hiring young engineering graduates were identified as major future problems as the total level of work declines. Launch Vehicle Contractors.-Each of the contractors confirmed a concern for retaining a competent engineering organization to solve problems as the program proceeds through the flight program. The 89-149 0-68- -2 |