The Kennedy Space Center and Cape Canaveral Air Station (KSC/CCAS) location is the site of the largest helium consumption in the United States today at 80 million standard cubic feet (SCF) per year. The new Evolved Expendable Launch Vehicle (EELV) program will result in more than doubling that consumption. This paper documents the collaborative efforts of NASA Logistics Operations (LO) and EELV elements led and facilitated by Space Gateway Support (SGS), the Joint Base Operations and Support Contractor to best satisfy this new demand.
The background and historical development of helium supply and distribution at KSC and CCAS are reviewed. Also, the case is stated for an existing centralized compressor station near SLC 39 and a new underground pipeline to supply helium to the EELV launch complexes currently under construction on Complexes 37 and 41. The Concepts of Operation for the pipeline and a proposed Business Plan, which incorporates a unique partnership of commercial and NASA/AF interests provide cost effective and attractive services for the commercial launch program

Jorgensen, J. G.

English

Embry-Riddle Aeronautical University

The Space Congress® Proceedings 1999 (36th) Countdown to the Millennium Apr 28th, 2:00 PM Paper Session II-A - Helium Pipeline for Evolved Expendable Launch Vehicle (EELV) Program J. G. Jorgensen Transformation Space Gateway Support Follow this and additional works at: https://commons.erau.edu/space-congress-proceedings Scholarly Commons Citation Jorgensen, J. G., "Paper Session II-A - Helium Pipeline for Evolved Expendable Launch Vehicle (EELV) Program" (1999). The Space Congress® Proceedings. 7. https://commons.erau.edu/space-congress-proceedings/proceedings-1999-36th/april-28-1999/7 This Event is brought to you for free and open access by the Conferences at Scholarly Commons. It has been accepted for inclusion in The Space Congress® Proceedings by an authorized administrator of Scholarly Commons. For more information, please contact commons@erau.edu. 1Technical Paper for SessionCommerce: Space Access in a Global MarketHelium PipelineForEvolved Expendable Launch Vehicle (ELLV)ProgramJ. G. JorgensenTransformationSpace Gateway Support2IntroductionThe Kennedy Space Center and Cape Canaveral Air Station (KSC/CCAS) location is thesite of the largest helium consumption in the United States today at 80 million standard cubic feet(SCF) per year.  The new Evolved Expendable Launch Vehicle (EELV) program will result inmore than doubling that consumption.  This paper documents the collaborative efforts of NASALogistics Operations (LO) and EELV elements led and facilitated by Space Gateway Support(SGS), the Joint Base Operations and Support Contractor to best satisfy this new demand.The background and historical development of helium supply and distribution at KSC andCCAS are reviewed.  Also, the case is stated for an existing centralized compressor stationnear SLC 39 and a new underground pipeline to supply helium to the EELV launch complexescurrently under construction on Complexes 37 and 41.  The Concepts of Operation for thepipeline and a proposed Business Plan, which incorporates a unique partnership of commercialand NASA/AF interests provide cost effective and attractive services for the commercial launchprogram.BackgroundThe Converter Compressor Facility (CCF) is located midway between the Shuttle VehicleAssembly Building (VAB) and Launch Pad 39A on the north side of the crawlerway road.Essentially all helium used at KSC and CCAS is delivered in some form to the CCF where it ispressurized to 6000 psig and presently distributed to users as follows:· Above ground across country pipeline to the Shuttle Launch Pads 39A and 39B,VAB, and Orbiter Processing Facility (OPF) at nominally 6000 psig.· Compressed gas rail cars to the Titan SLC 40 and 41 at nominally 3800 psig.  · Compressed gas trailers  to the Delta and Atlas SLC 17 and 36, respectively, atnominally 6000 psig and 2400 psig.· Compressed gas trailers and K-bottles to vehicle and payload processing facilitiesand institutional shops and laboratories throughout KSC and CCAS.Until recently (since the late 1960s), gaseous helium was supplied by the Bureau of LandManagement in high-pressure railcars.  The railcars were positioned on a siding adjacent to theCCF and supplied helium to the compressor room presently consisting of 3 Hendersoncompressors at 350 SCFM each and 5 Joy compressors at 150 SCFM each for a combinedcapacity of 1800 SCFM at 6000 psig.In 1994, the Titan Acceleration Program caused a renewal of interest in construction ofan underground high-pressure helium pipeline originating at the CCF to accommodate the sharpincrease in helium consumption due to processing and launching of the hydrogen fueled Centaurupper stage.  The Aerospace Corporation studied helium supply for Titan Centaur launch processingand concluded that the interests of the launch vehicle programs would be best served bysharing the cost of establishing a utility infrastructure capable of providing continuous heliumsupply to the facilities of major users.  Further, the most complete solution to the problems of providing helium supply would be toconstruct a gaseous helium pipeline from Converter Compressor Facility 39 to SLC-40 and SLC-41.  The single drawback is the initial cost.  The advantages would begin immediately.3Recharging the helium storage batteries at SLC-40 and SLC-41, would be continuous as requiredby demand, and virtually free of any conflicts with pad operations or weather constraints.Maintenance on the compressor fleet and the number of helium transfer operations woulddecrease dramatically.The Air Force subsequently funded a design by Brown & Root for a pipeline from the CCFto the new Centaur Processing Facility (CPF), considerably south of the Titan launch complexes.The design was nearly completed but the funding for construction was denied in part due to theconcerns developing regarding the CPF.Scheduling and funding constraints precluded the pipeline construction at that time, aswell as facility modifications to expand the high pressure battery capacity on the launchcomplexes.  The Base Operations Contractor provided a temporary solution by installing a heliumrailcar offload station and buried high pressure tubing to feed the launch pad systems.  The fullBLM railcars at 3800 psig were transported to the Titan ITL when required and depressurized toapproximately 2400 psig, the operating pressure of the pad systems.  The partially filled railcarswere then transported back to the CCF for emptying through the compressor station.A dramatic transformation has occurred in the United States since the passage of the1960 Helium Act.  Gradually the helium market shifted from Government to commercialconsumers.  Production shifted from Government to commercial suppliers.  Distribution shiftedfrom predominately high-pressure government railcars to networks of commercial transfillstations supplied by large liquid helium semi trailers.  In 1996 these factors ultimately led to theenactment of the Helium Privatization Act which mandated the shutdown of the Bureau of LandManagement (BLM) Helium operations effective April 1, 1998.  The impacts to KSC/CCAS werethat helium must be procured commercially and, most significantly, helium would no longer beavailable in high-pressure railcars.A NASA Headquarters led tiger team analyzed the impact of privatization on the Agencyand found that all NASA centers could be supplied by the existing commercial capability fromtransfill stations.  The KSC was an exception, however, due to the massive flow requirement forlaunch support activities.  Ultimately, the decision was reached to modify the KSC ConverterCompression Facility on Complex 39 to accommodate supply in liquid form.  Those modificationsto CCF 39 have been completed, helium is now purchased commercially by NASA and theshutdown of the Bureau of Land Management Helium Operations was completed on April 1,1998.The CCF 39 helium plant is believed to be the largest of its type in the country.  Thepreexisting compressor station with total capacity of 1800 SCFM at 6000 psig can be fed fromeither preexisting high pressure gas railcars or over-the-road compressed gas trailers systems.The recent modification installed a liquid helium conversion system that converts liquid to gas andcompresses the gas to the induction pressure of the preexisting compressor station.  The liquidhelium supply and conversion subsystem is the primary mode of plant operation.  Each liquidhelium trailer carries approximately 1 million SCF of gas equivalent.  The railcar or trailer feedsystems are available for contingency in the event of outage of the liquid subsystem.EELV ImpactThe dual sourcing in 1997 for the Evolved Expandable Launch Vehicle program hasresulted in the current plans for construction and/or modification and adaptation of vehicleprocessing and launch facilities which are in varying stages of maturity.  The Boeing Delta IVvehicle will launch from Complex 37 and the Lockheed Martin Atlas II AR vehicle will launch fromComplex 41.  For the purpose of this discussion, it is assumed  that the Delta IV vehicle withLiquid Hydrogen/Liquid Oxygen booster and second stage will require helium supply in flows and4durations.  This would be similar to that required for Shuttle and the Atlas II AR vehicle withLH2/LO2 propulsion system.  The second stage will only require helium supply similar to the TitanCentaur.  This would drive significant capital investment in the launch complex infrastructure forhelium supply, storage and distribution and in the incremental cost of operation and maintenanceof permanently installed systems for both programs.For Complex 37,  the concept of operation would be to supply helium from over-the-roadcompressed gas trailers to an on-complex compressor station which would feed a highpressure storage battery and distribution system.  For Complex 41, the concept of operationwould be to supply helium using the railcars filled from CCF 39 as is currently done to an on-complex compressor station and expanded high-pressure gas storage battery feeding adistribution system.  Estimation of the expected capital investment for the helium infrastructure onthe two complexes is not available.  To enable a comparison, some assumptions may be made.The current purchase price for 300 cuft water volume, 6000 psig operating pressure vessels ison the order of $250,000 each.  If these launch complexes have stand-alone compressor andstorage systems instead of the pipeline supply, a large number of vessels would be required,probably on the order of $10 million in purchase price alone.  If the pipeline enabled the reductionof vessels by 50%, $5 million would be avoided plus the investment in compressors andremaining infrastructure.  These new requirements for helium raise, once again, the issue of a pipeline originating atthe CCF 39.  In this instance, there is a compelling argument both operationally and economicallyfor the pipeline.  The pivotal factor is that the economic aspects of previous studies attempted tocompute the payback  of the capital investment for installation of the pipeline solely by estimatingthe savings of incremental cost of operation and maintenance and payback periods varying from10 to 20 years.  If the avoidance of capital investment or reduction of capital investment onComplex 37 and 41 is considered, the installation cost for the pipeline is significantly more thancovered by the avoided investment alone.The following pipeline installation cost data is extracted from the 1993 AerospaceStudies.  A 10% add on for contingency and new requirements, pressure control and metering atthe user interface and annual 2.75% escalation are applied in the data below to derive aconservative estimate for planning purposes.Location Distance, Feet 1993 Base Cost 1999 - 2000 ProjectionSLC-39 to SLC-41 25,000 $1.9 M $2.5 MSLC-41 to CX-37 20,000 $1.5 M $2.0 M5Operating ConceptProject Location  The 3-inch (nominal) 6000 psig pipeline will start downstream of the existing compressorsystem.  The line will progress south under the crawlerway (directional bore) and then east tothe Cape road south of Complex 39A.  The line will essentially follow the existing 6000 psig GN2line to Complex 41.  The GHe line will continue south along the Cape road then follow the old A1Aroad terminating in a meter station at the perimeter fence of Complex 37.Product LogisticsThe NASA Logistics Operations Directorate has the responsibility for establishing heliumsupply contracts, as well as  ordering, accounting and other logistics activities.  Their role is alsoto see that user requirements are forecast and that appropriate support plans are formulated andcoordinated.   As a result of the BLM ceasing helium operations as previously discussed, KSCinstituted a NASA-wide consolidated helium acquisition procurement strategy.  The resultingcontract utilizes four commercial vendors who supply 22 different NASA and NASA contractorlocations throughout the United States.  By using this consolidated contract approach, optimumcompetitive pricing was obtained as well as a reliable supply of helium.O&M and InterfacesSGS will be responsible for operating and maintaining the CCF and the pipeline distributionsystem up to the terminal meter stations.  Pipeline Management  The focal point in the overall management of the pipeline network would be at the CCF.The CCF has direct system status information.  This includes real time system flows, pressuresand other data to assure user interface requirements are being met.  Personnel at the CCFmaintain communication with users, SGS Fluids Management and NASA/LO.  This assuresproper coordination in the supply of helium, contingency procedures, and operation of theconverter and compressor equipment to maintain pipeline flows and pressures.  This teamingarrangement also allows for the resolution of conflicts and supply priorities.  During any launchcountdown the CCF personnel provide around the clock surveillance of the helium systems andmonitor the progress of the countdown.Business PlanThe Business Plan for the pipeline is in two parts:  the construction of the pipeline, andthe ongoing operation of the helium system, including purchase of helium andoperation/maintenance of the CCF and pipeline to supply EELV.Pipeline ConstructionAt the time this paper was prepared, a number of options were being explored toimplement  the construction phase of the project.  The recommended option was to construct thepipeline as a commercial enterprise with SGS as project manager including coordination foroverall project implementation. SGS will be the liaison with NASA and AF to determine/defineGovernment requirements and assure compliance.  SGS will prepare the environmentalassessment, obtain and coordinate necessary permits and easements, coordinate designreviews as necessary and perform construction monitoring.  SGS will implement the constructionusing a design/build contract.  The 1994 Brown and Root design drawings and TechnicalSpecifications will be provided to the selected contractor for their use as appropriate.   The6project will be funded by the EELV principals, Boeing and Lockheed Martin, according to anagreed-upon equitable allocation.The pipeline will be co-owned by Boeing and Lockheed Martin according to an ownershipagreement.  ItÕs intended that the period of co-ownership be no longer than necessary for theprincipals to depreciate their investment.  As soon as possible, the pipeline will revert to thegovernment for the governmentÕs use so long as the requirements of the EELV principals onComplex 41 and 37 are satisfied.Ongoing Operation of the Helium System  Helium for all programs will continue to be procured by the NASA Logistic OperationsDirectorate for supply to the CCF.  The Joint Base Operations and Support Contract under whichSGS currently operates and maintains the CCF and existing pipelines will be modified to includethe addition of the EELV helium flow requirements, maintenance of the new underground pipelineand meter stations and management/administration associated with a carrier account includingprice determinations and billing.  The price of the delivered 6000 psi GHe to the end user will beestablished by adding the contract purchase price of the LHe to the shared costs of operationand maintenance of the CCF for conversion and compression of the helium.  The volume will bedetermined by a calibrated meter station at each user location.  The conversion and compressioncosts include electrical power, labor, equipment, facility maintenance, and other costs(conversion losses, etc.) necessary to supply the quality and quantity of GHe to the systemusers.  These conversion and compression costs will be charged to the end users based ontheir consumption recorded at the meter stations.  A formula will be developed to roll up all costsinto a delivered unit price based on delivered volumes and billed monthly under a reimbursableagreement.  The year 2000 unit price is currently projected to be $80 per MSCF.The cost of helium supply system improvements benefiting all users would be shared byall users and reflected in the delivered unit price.  Improvements, or expanded capability requiredby and beneficial to a particular user, would be paid for by that user in a separate fundingarrangement.  Such potential future costs are not included in the above.SummaryAlthough the final determinations and agreements necessary for implementation have notbeen completed at the writing of this paper, all indications are positive that the pipeline project willbe implemented as described.  If so, it will be a success due to the collaboration of the Boeingand Lockheed Martin EELV elements, SGS, and NASA/AF to use the KSC and CCASinfrastructure in a way that is most beneficial toward the ultimate objectives of cost competitiveand reliable access to space.

Paper Session II-A - Helium Pipeline for Evolved Expendable Launch Vehicle (EELV) Program

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Paper Session II-A - Helium Pipeline for Evolved Expendable Launch Vehicle (EELV) Program

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