This paper discusses the ground and flight operations aspects to the Pad Abort 1 launch. The paper details the processes used to plan all operations. The paper then discussions the difficulties of integration and testing, while detailing some of the lessons learned throughout the entire launch campaign. Flight operational aspects of the launc~ are covered in order to provide the listener with the full suite of operational issues encountered in preparation for the first flight test of the Orion Launch Abort System

Hackenberg, Davis L.

Hicks, Wayne

NASA Technical Reports Server

1 
Ground and Flight Operations 
Davis Hackenberg 
Davis.L.Hackenberg@nasa.gov 
Wayne Hicks 
Wayne.Hicks@Zeltech.com 
Orion Pad Abort 1 Flight Test 
The Operations Team with the  
PA-1 Test Vehicle 
https://ntrs.nasa.gov/search.jsp?R=20110010950 2019-08-30T15:18:10+00:00Z
2 
Presentation Overview 
•  Operational Planning 
•  Facilities Preparation 
•  Integration and Testing 
•  Flight Ops 
•  Other Challenges and Successes 
OPERATIONAL PLANNING 
3 
Approach to Operational Planning  
4 
Project’s Concepts, Assumptions, & Constraints Concept of Operations 
Integration Activities and Tasks Ground Operations Plan Hardware Integration Flow 
Facility Requirements Facility Requirement Documents 
GSE Plan 
GSE IRDs, ICDs, Specs Ground Support Equipment  Requirements 
Transportation Plans 
Roles and Responsibilities 
Safety Requirements Documents 
Systems Safety Hazard Report 
Site Safety Plans 
Emergency Preparedness Plans 
Transportation Requirements 
Safety Hazards & Mitigations 
For each major sequence, identify the activities and tasks to perform. 
Use the task descriptions to identify requirements. 
Develop top-level operational concepts and integration sequences. 
Knowing the work to be performed and how equipment will be 
operated, identify the safety hazards and the mitigations. 
Procedures 
Develop procedures to perform the integration tasks and 
to operate equipment.  Include safety mitigations. 
Master Procedures List 
Integration & Test Procedures 
Ground Operations Team 
Flight Operations Team 
Staffing Plan 
Training Requirements (Plan) 
Training Records 
Identify personnel and skills mixes needed to 
perform tasks and operate equipment. 
PROCESS PRODUCTS 
Project’s overarching concepts, assumptions, & 
constraints drove the operational planning 
Operations Group Responsibilities 
•  Plan for six flight tests: 
•  Two (2) Pad Abort tests 
•  Four (4) Ascent Abort tests 
•  Prepare the Test Vehicles 
•  Build the Launch Facilities 
•  Provide Mission Architecture to 
control test vehicle and to 
capture vehicle performance and 
aerodynamic data  
•  Perform the flight tests 
Mandates 
•  Meet ambitious launch schedule 
•  Protect for late installation of 
long lead time and life-limited 
items 
•  Use aggressive test and 
verification approach  
5 
Considerations drove the Ground Operations planning 
•  Integrate the Test Vehicle in 2 phases to reduce time 
spent at launch site 
•  For PA-1: 
•  Perform non-hazardous Crew Module integration at 
NASA Dryden Flight Research Center 
•  Assemble Launch Abort System at Launch Site 
•  Perform final hazardous processing at Launch Site 
Considerations drove the Mission Operations Architecture 
•  Perform flight tests on an equipped test range 
•  Test range large enough to contain flight trajectories 
•  Use Mobile Launch Concept 
Considerations drove the Launch Faciltiies 
•  Support both Pad Abort and Ascent Abort tests 
•  Provide integration areas for Launch Abort System, 
Crew Module, and Abort Test Booster. 
•  Launch Complex sited for hazardous ordnance 
processing and explosives operations 
Concept of Operations Document established top 
level vehicle, ground, and flight operations concepts 
6 
Contents 
1.   Organizational Roles and Responsibilities 
2.   Goals and Objectives 
3.  Abort Flight Test Scenarios 
4.  Test Vehicle Concepts 
5.  Ground Operations and Integration Flows 
6.  Flight Operations 
7.  Flight Operations for Ares Launch Opportunity 
8.  Training 
Purpose 
•  Identifies organizational roles and responsibilities 
•  Describes the Test Vehicle, its components and the 
component functions, and the component providers. 
•  Described the top-level integrations flows and the 
integration locations. 
•  Describes the mission architecture and the roles for 
conducting the flight operations.  
•  Conveys top-level guidance from which to start developing 
requirements and specifications 
NASA Project Orion 
Flight Test Office 
Abort Flight Test 
Concept of 
Operations 
FTO-AFT-OPS-001 
January 19, 2007 
Revision A 
Ground Operations Plan provided the detailed 
integration flows, activities, and task descriptions 
7 
Contents (Abbreviated Listing) 
1.   Roles and Responsibilities 
3.  Approach to Development 
4.  Ground Planning Documentation 
5.  Facilities 
6.  Ground Support Equipment 
7.  Initial Integration at Dryden Flight Research Center 
8.  Final Integration at WSMR 
9.  Pad Operations at WSMR 
10.  Recovery and Disposition Activities after Flight Test 
Purpose 
•  Provides the detailed hardware integration flows. 
•  Assembly and integration tasks described in detail. 
•  Identifies personnel, facility, and equipment resources 
required to perform each task. 
•  Includes over 250 storyboards 
•  Task descriptions provide the starting point for developing 
procedures. 
NASA Project Orion 
Flight Test Office 
Abort Flight Test 
PA-1 
Ground 
Operations 
Plan 
FTO-AFT-OPS-001 
January 19, 2007 
Revision A 
Over 250 Storyboards like this one used pictures to 
convey the integration sequences 
8 
3 
1 Each operation linked to Integration Flow 
Activity Sequence includes detailed task 
descriptions 
Flight Hardware clearly shown 
•  Crew Module (in this example) 
Ground Support Equipment: 
•  Crew Module Transporter 
•  Crew Module Lift Fixture 
Facility Resources can be identified: 
•  Aircraft Integration Facility 
Facility Equipment and placements: 
•  Mobile Crane 
•  Load Cell 
Procedures 
•  Convert Integration Stand to Transporter 
•  Transport Crew Module 
•  Critical Lift Pre-Task Planning 
•  CM Weight Determination Procedure 
•  “Critical Lift” involves hazardous ops 
2 
4 
4 
6 
1 
2 
3 
4 
5 
6 
6 
5 
7 7 
Personnel 
•  Task Team Leader 
•  Safety Lead 
•  QA Lead 
•  Lift Manager 
•  Tug Operator 
•  Mobilizer Operators 
•  Crane Operator 
•  Mechanics 
8 
3 
8 
8 
Storyboards were good predictors of actual 
operations 
9 
Storyboard Actual 
Storyboard for the Crew Module Iyy Inertia Test 
10 
Storyboard Actual 
Swim Lanes were another tool used to plan 
resources, verifications, and prerequisites 
11 
FACILITIES PREPARATION 
12 
Facilities Description 
•  Facility Requirements Document (FRD) used to document launch 
complex requirements and to initiate design effort 
•  Construction of LC-32E facilities commenced on October 1, 2007 
–  Final Integration and Test Facility (FITF) 
–  Launch Pad 
–  Launch Services Pad 
–  Operations Support Trailer (OST) 
•  Construction of FITF complete in April 2008 
•  Construction of Launch Pad complete in August 2008 
13 
PA-1 Vehicle on Launch Pad and FITF 
14 
Launch Pad and Gantry Final Integration and Test Facility (FITF) Integration Bays inside FITF 
Operations Support Trailer 
LC-32 East  
Aerial View of Orion Launch Complex 32 East 
Launch Pad and Gantry 
Launch Pad Services Area 
Final Integration and Test Facility 
Operations Support Trailer 
Field Storage Area 
INTEGRATION AND TESTING 
15 
Test Vehicle assembly, integration, and testing 
occurred in two phases 
16 
CM 
Delivery 
Phase I: 
Crew Module integrated initially at 
Dryden Flight Research Center 
Phase II: 
Final Integration occurred at the 
White Sands Missile Range 
Structures 
& Mechs 
Harness 
& Pallets 
Functional 
Tests 
Fwd Bay 
Fitchecks Mass Properties 
RF Range 
Tests 
Ship to 
WSMR 
Recovery Flight 
Test 
Pad 
Tests 
Stacking Integrated 
Electrical 
Tests 
CM 
Delivery 
Functional 
Tests 
CM/SR 
Mate 
Fwd Bay 
Integration 
LAS 
Delivery 
Structural 
Mates 
DFI 
Sensors 
Functional 
Tests 
Crew Module was outfitted with sensors, avionics, 
and mechanisms at NASA Dryden 
17 
CM Arrival via C-17 Painted w/Test Pattern 
Mass Properties Tests Crew Module being integrated in Shuttle Hangar at 
NASA Dryden Flight Research Center 
Avionics Pallets and 
Harnesses Installed 
Installing Sensors and Cameras 
CM Functional and RF  Tests 
Launch Abort System was assembled and checked 
at the launch site 
18 
Motor Roll Transfer 
onto integration trailer 
Adapter Cone 
placement 
LAS being prepared in the Final Integration and Test Facility 
Structural Mates 
LAS Ready for Roll-Out 
LAS Functional Tests 
Integrated electrical tests verified 
Crew Module and Launch Abort System interfaces 
19 
Crew Module Forward 
Bay Integration 
Setting up cameras to 
monitor Phasing Test 
Attitude Control 
Motor Functional 
Test 
Crew Module / Launch Abort System  Soft Mate Testing 
Pad Operations included stacking the Test Vehicle 
and performing final tests and launch preparations 
20 
Crew Module being stacked onto 
Launch Pad 
Test Vehicle stacked onto Launch Pad 
Launch Abort System 
being stacked onto 
Crew Module 
Thermal Cover 
installed 
Measuring Stack Straightness 
with Laser Scans 
FLIGHT OPERATIONS 
PLANNING AND EXECUTION 
21 
22 
Flight Ops Challenges 
•  Mobile Control Room Architecture 
•  Launch Team Training 
•  Range Assets 
Mobile Operations - WSMR Mission Architecture 
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2009 
Launch Team Training 
2/3–Avionics Post Install 
Functional Testing 
6/29–AIL Test 
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2010 
9/24 – WSMR CST 
5/6 – Launch! 
2/3–Avionics Post Install 
Functional Testing 
7/11-DFRC RF 
Open Loop / CST 
3/13–Deluge Event 
10/21 - RIRR 
1/18 – Sync E+ 
3/1 – Softmate 
Testing 
3/24 – CM Post 
Stack Functional 
3/30 – “Green 
Card” Training 
4/20 – Mission 
Rehearsal 
5/5 - Range 
Lockdown 
3/29 – Playback 
4/5 – FTA Post 
Stack Functional 
•  In addition to Training on timeline in the 1.5 months prior to launch 
•  3 Table Top Reviews (TTR) with the entire team 
•  2 Emergency/Contingency Procedure simulation trainings 
•  2 PAO rehearsals 
•  3 Test Specific TTR’s and Emergency procedure planning 
•  Mishap Response Planning 
•  Recovery Ops dry-run 
•  Incorporation of training around launch timeframe is difficult and required full commitment from the 
entire project 
WSMR Tracking Assets Used for PA-1 
25 
Radar Camera’s 
A FEW KEY CHALLENGES 
AND SUCCESSES 
26 
The Project overcame many challenges 
27 
Flight Test 
Organization 
Ops and Vehicle 
Planning 
Unforeseen 
Events 
Re-plan and 
Coordinate 
Schedule 
Pressures 
Begin Execution 
Final Execution 
28 
Coordination and Resources 
•  Coordination and planning of resources was difficult due to a constantly changing 
schedule 
•  Keeping all parties involved at all times during integration phases allowed for 
extra support during surges – A representative for people at the test location 
proved extremely useful 
•  Running 2 shifts the final month prior to launch included engineering and 
technician support from all project locations.   
•  Daily Ops tag-up helped improved situational awareness in all time zones 
•  Utilization of the entire teams knowledge and skills was essential in meeting the 
aggressive launch date that was planned 2 months prior 
29 
Pathfinder and Risk Reduction Operations 
•  Conducted for all operations that involved pyrotechnics, including integration and 
lifts. (In plan)  
•  Fit checks (opportunity based) 
•  Conducted (as time allowed) for Day-of-Flight Operations and other key issues 
such as integration with WSMR (opportunity based) 
Challenges: 
•  Required significant planning and dedication by the entire team. 
•  Scheduling around other required activities was difficult 
•  Timing of operations not ideal relative to other project activities such as 
acceptance testing 
•  Developing SOP’s 
Successes 
•  Personnel safety maximized for all operations 
•  Procedures released on time and conducted with minimal red-lines. 
•  Risk Reduction – changes and issues were identified early  
•  Confidence in operations allowed them to easily be performed on night shift 
•  Finished operations ahead of schedule!!! 
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2009 
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2008 
Pathfinder Ops - Pyrotechnics Integration Timeline 
7/11-FBC Arrives at DFRC 
from LaRC 
10/3–Mass 
Properties Testing 
12/3–Avionics Post Ship 
Functional Testing 
2/3–Avionics Post Install 
Functional Testing 
6/4- Avionics Sync D 
6/29–AIL Test 
7/11-RF Open Loop / 
CST 
8/16–FB Thrusters 
and Sep Bolts 
1/21–AV1,2,3 Pallet 
Installs 
9/15–Avionics 
Harnness Install 
12/1–Install 
Reworked Avionics 
Harnesses 
3/30 – Pyro Summit 
7/22–Pyro Summit 
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2010 
1/7 – CM Pyro 
Installs Complete 
9/24 - 
CST 
11/30 – CM Pyro 
Integration 
4/28 – Final BWIR 
4/14 – Final Pyro 
Connections 
5/6 – Launch! 
4/4 - LAS Stack 
3/22 – CM Stack 
Recovery 
31 
1.  Receive Post-Landing Assessment from MOF (Scorecard) 
2.  Deploy to LZ staging Point 
3.  UXB sweep for UXO 
4.  Assess hazards preventing safe approach 
5.  Approach and Safe 
6.  Repeat 4&5 according to Hazard Analysis 
7.  Transport to LC32 or other destination 
NOTE: Photo document entire process 
32 
Questions? 
BACK-UP 
33 
Off Nominal Procedures Overview 
Power On Prelaunch 
Abort Enable 
•  PECs charged 
•  LAS Rdy Mode  
 (ACM 140 vdc – ON) 
•  SIGIs – NAV Mode 
LAS BIT 
“Pause / Hold” 
•  MSS 
•  Hold Fire Control – select Hold 
•  S/A Safe Cmd – select Rotate to 
Safe Position 
•  Hold and assess situation 
•  Vehicle still powered but in Launch 
Safe Mode 
•  Team decision 
•  Recycle SIGI, reset T-0, try again 
•  Abort Scrub, cancel for the day 
•  Hold and evaluate 
•  Monitor system 
health and status 
•  Consider – 
•  RF – Off 
•  ACM 140vdc on for 
pintle checks 
•  7 min to fully discharge 
power hybrid 
Abort Execute 
T-2 mins 
Launch 
Countdown Milestones 
“Kill” 
ACM Vulnerable 
6 min window 
ACM Vulnerable 
Kill 
Kill 
Kill 
•  Hold and evaluate 
•  Monitor system health 
and status 
•  Consider – 
•  OFI / DFI RF – Off 
•  FDRs – Stop Recording 
•  Transfer To External 
Power 
Emergency Call Emergency Call 
•  Parameter - Load 
•  SIGIs - On 
•  Avionics - POST 
•  DFI - On 
•  LAS RDAUs - On 
•  OFI RF - On 
•  DFI RF - On 
•  SIGIs – Start Alignment 
•  Transfer to Internal then 
back to External Power 
•  ACM - On 
•  LAS S/As - Arm/Safe 
Checkout 
•  Reset Counter 
•  Reset Time 
•  FDRs – Start Recording 
•  Transfer to Internal Power 
•  PEC Power - On 
•  LAS S/As - Arm 
WSMR Assets 
WSMR Cox RCC 
Mobile Operations Facility (MOF) 
Mission 
Mission 
System Data Comm 
Vehicle Integration Van (VIV) 
PA-1 Communications Plan 
Version 4-10-10 
WSMR Cmd 
Cell Phones 
UHF Trunk Radios 
Belt Packs 
MOF 
Mission Support 
EOD-2 
B1830 


Orion Pad Abort 1 Flight Test - Ground and Flight Operations

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