1= OCT 83 ROCKWELL INTERNATIONAL CORP C1C-0-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 1 OF 9 COCA FIRING UNIT OPERATING INSTRUCTIONS O 5 ****************************************************************************** ~ *** SAFETY CRITICAL *** A3 THRUST CHAMBER ENTR Y /o /9-83 WRITTEN/REVISED BY : /.\,(/. APPROVED BY : /p-?-/ -83 SYSTEM SAFETY: Q,, T. Q. A,REV I V G... ;o ; / 9; 83.... SAFETY & ENVIRONMENTAL HEALTH :... : ****************************************************************************** ~ PURPOSE : THIS PROCEDURE ESTABLISHES THE CONDITIONS WHICH SHALL BE NET FOR PERSONNEL ENTRY INTO THE 35 :1 AND THE 77 :1 THRUST CHAMBERS INSTALLED 114 A3, IN ACCORDANCE WITH FLP NO. 710. THIS PROCEDURE SHALL NOT BE INITIATED UNTIL E.I.C. DETERMINES CRYOGENIC PROPELLANT SYSTEMS ABOVE LIQUID TEMPERATURES (NOMINAL 2 TO 3 HR WARMUP). 7.0 RESPONSIBILITIE S 1.1 THE SUPERVISOR SHALL BE RESPONSIBLE FOR : 1.1.1 ENSURING THAT EQUIPMENT IS AVAILABLE AND WORKING PROPERLY. THIS EQUIPMENT SHALL INCLUDE, AS A MINIMUM, PORTABLE OXYGEN ANALYZER, PORTABLE HYDROGEN DETECTOR, AIR LINE BREATHING EQUIPMENT AND EXPLOSION PROOF EXTENSION LIGHT. THE STAND LEADMAN SHALL BE RESPONSIBLE FOR : INSTRUCTING ALL PERSONNEL INVOLVED IN ACTUAL CHAMBER ENTRY OR IN SUPPORT OF THAT ENTRY AND IN THE USE OF ALL EQUIPMENT PROVIDED. HE SHALL ESPECIALLY STRESS THE HAZARD OF OXYGEN DEFICIENCY, HYDROGEN CONTENT AND THE NEED FOR IMMEDIATE EXIT FROM THE CHAMBER WHEN ABNORMAL CONDITIONS ARE SUSPECTED. (SUCH AS VALVE ACTUATIONS, PURGE FLOW, OXYGEN DEFICIENCY, INCREASE IN HYDROGEN CONTENT, ETC. ) 1.3 THE STANDBY SHALL BE RESPONSIBLE FOR : 1.3.1 ENSURING THAT A THRUST CHAMBER ENTRY PERMIT IS PROPERLY FILLED OUT AND SIGNED BY EACH PERSON ENTERING THE THRUST CHAMBER. 1.3.2 MAINTAINING COMMUNICATION WITH THE STAND TALKER ( IF PRESENT) SO THAT HE MAY ADIVSE THE PERSON IN THE CHAMBER OF ANY FACIILITY VALVES TO BE ACTUATED OR OF ANY VENTS OR OTHER ACTIONS WHICH MIGHT STARTLE. I N ADDITION, HE SHALL REQUEST THE STAND TALKER TO ADVISE THE CONSOLE OPERATOR ( IF PRESENT ) THAT A MAN IS IN THE CHAMBER TWICE EVERY HOUR. 1.3.3 NOTE : NORMALLY NO FACILITY VALVES WILL BE ACTUATED WHILE PERSONNE L ARE IN THE CHAMBER. IF FACILITY VALVE ACTUATION ARE DEEMED NECESSARY, APPROVAL MUST BE OBTAINED FROM THE AREA MANAGER. I BNA00373280 HDMSeOOI 86584
BNA00373281 HDMSeOOI 86585 17 OCT 83 ROCKWELL INTERNATIONAL CORP C1C-0-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 2 OF 9 1.3.4 THE STANDBY, WHILE REMAINING OUTSIDE THE CHAMBER, SHALL CONTINUOUSLY MONITOR THE WELL-BEING OF THE PERSON IN THE CHAMBER AND THE OXYGEN AND HYDROGEN CONTENT IN THE CHAMBER.. IF THE OX Y N CONTENT FOR EXTENDED ENTRY IS LESS THAN 7Ax_ GREATER OR FOR ALL ENTRY IF THE HYDROGEN CONTENT REACHES 0.8% OF L.E.L. THE STANDBY WILL NOTIFY PERSONNEL TO EVACUATE THE THRUST CHAMBER & NOTIFY ENGINEERING & LEADMAN OF THE PROBLEM. 1.3.5 THE STANDBY SHALL RETAIN THE ENTRY PERMIT DURING THE COURSE OF THE WORK AND SHALL BE RESPONSIBLE FOR HAVING THE RED TAGS REMOVED AND MAKING NOTIFICATIONS TO THE STAND TALKER AND CONTROL CENTER AT COMPLETION OF THE WORK. 1.4 COMPLIANCE WITH THIS PROCEDURE IS REQUIRED OF ALL PERSONNEL ENTERING THRUST CHAMBERS. THE MASK, WHEN REQUIRED, SHALL BE CLEANED PER PARA. 2.5 AND ENTRY PERMIT SIGNED. 1.5 THE CONSOLE OPERATOR SHALL BE RESPONSIBLE FOR THE FOLLOWING 1.5.1 VALVE POSITION VERIFICATION S 1.5.2 RED TAGGING THE CONSOLES TO PREVENT UNAUTHORIZED VALVE ACTUATIONS, PREVENT CONSOLE PATCH BOARD REMOVAL AND PREVENT CONSOLE POWER FROM BEING TURNED OFF. 2.0 EQUIPMEN T 2.1 ALL BREATHING EQUIPMENT UTILIZED IN THRUST CHAMBER ENTRY SHALL BE APPROVED BY HEALTH AND SAFETY. 2.2 SHORT TERM ENTRY 2.2.1 ENTRIES FOR SIMPLE VISUAL INSPECTIONS OR REPAIR. A FACE MASK HOSE AND PUMP AND/OR BREATHING AIR IS TO BE UTILIZED. REF. ROCKETDYNE FIELD LABORATORIES PROCEDURE NO. 710 "THRUST CHAMBER ENTRY". NOTE : WHEN THE FACE MASK AIR PUMP IS USED, THE AIR PUMP MUST BE 15 FEET FROM THE NOZZLE & OUTSIDE OF ANY PROTECTIVE CLOSUR E 2.2.2 ALL PERSONNEL ENTERING THE THRUST CHAMBER & WEARING A FACE MASK &/OR BREATHING AIR WILL HAVE SATISFACTORILY COMPLETED THE "TRAINING & CERTIFICATION REQUIREMENTS FOR AIR PUMP/AIR LINE RESPIRATOR" & HAVE A FORM 609-A-5 REV 5-80 CARD. 2.2.3 A SHORT TERM THRUST CHAMBER ENTRY MAY BE MADE WITH THE THROAT PLUG INSTALLED AND PRESSURIZED TO NO GREATER THAN 25.0 PSIG. THE STANDBY WILL MONITOR THE PRESSURE AT ALL TIME WHILE THE THRUST CHAMBER ENTRY IS BEING PERFORMED.
BNA00373282 HDMSeOOI 86586 17 OCT 83 ROCKWELL INTERNATIONAL CORP CIC-0-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 3 OF 9 ********,****,*******************,*,****************************************** PERSONNEL MUST EVACUATE INTERIOR OF THRUST CHAMBER IF THE THROAT PLUG PRESSURE EXCEEDS 25.0 PSIG. 2.3 (EXTENDED ENTR Y 2.3.1 FOR ONS REQUIRING EXTENSIVE TIME IN CHAMBER OR FOR OPERATIONS THAT ARE HINDERED BY THE USE OF FACE MASK AND BREATHING AIR, THE FOLLOWING PROCEDURE IS TO BE UTILIZED. NOTE : WHEN THE FACE MASK AIR PUMP IS USED, THE AIR PUMP MUST BE 15 FEET FROM THE NOZZLE & OUTSIDE OF ANY PROTECTIVE CLOSUR E 2.3.2 PROVIDE AIR BLOWER WITH FLEXIBLE HOSE ( 2" TO 6" ) SECURED TO LADDER OR CHAMBER WALL WITH HOSE EXIT VERTICALLY UP IN UPPER REGION OF CHAMBER ( BELOW THROAT). PROVIDE OXYGEN AND HYDROGEN ANALYZERS WITH REMOTE SENSORS WHICH ARE TO BE ATTACHED TO ENTRANT 'S LAPEL, UPPER REGION OF THRUST CHAMBER WALL, OR UPPER PORTION OF LADDER. NOTE : SET THE AIR BLOWER SO IT IS 15 FEET FROM THE NOZZLE EXIT & OUTSIDE OF ANY PROTECTIVE CLOSURE. ***************************************************************************** * ENTRY INTO A THRUST CHAMBER IS A HAZARDOUS OPERATION. AIR SUPPLIED BREATHING EQUIPMENT MUST BE WORN BY PERSONNE L WHEN INSTALLING AIR BLOWER WITH FLEXIBLE HOSE AND WHEN MAKING INITIAL ENTRY TO CHECK THE ENVIRONMENT AFTER AIR IS SUPPLIED. ****************************************************************************** ******************************************************************************. THE ENVIRONMENT WITHIN THE THRUST CHAMBER MUST BE NONFLAMMABLE AND NON-EXPLOSIVE. ******************************************************************************. THE MAN WHO WILL ENTER THE THRUST CHAMBER TO MAKE HYDROGEN AND OXYGEN DETECTOR CHECKS WILL WEAR BREATHING EQUIPMENT, EITHER A FULL FACE MASK, OR A NOSE-MOUTH MASK, WITH BREATHING AIR SUPPLIED TO THE MASK FROM A SUITABLE SOURCE.
17 OCT 83 ROCKWELL INTERNATIONAL CORP C1C - O-T82 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 4 OF 9 ************,***************** ** ************* ******* ************************* * THE CONCENTRATION OF FLAMMABLE GAS MUST NOT EXCEED 20 PERCENT OF THE LOWER EXPLOSIVE LIMIT OF THE GAS. THE LOWER EXPLOSIVE LIMIT OF HYDROGEN IS 4 PERCENT, 20 PERCENT OF THIS IS 0.8 PERCENT. **************************,***************************************************. ***************************************************************************** * No THE OXYGEN LEVEL MUST BE BETWEEN 19. 5 PERCENT AND 24.5 PERCENT FOR EXTENDED ENTRY. NOTE : THE OXYGEN METER MUST BE SET WITH THE METER OUTSIDE OF THE NOZZLE & PROTECTIVE CLOSURE PRIOR TO ITS USE. ***************************************************************************** * WHEN IT IS DETERMINED THAT THE HYDROGEN CONTENT IS BELOW THE LOWER EXPLOSIVE LIMIT, AND THE-OXYGEN CONTENT IS BETWEEN 19.5 PERCENT AND 24.5 PERCENT, THE BREATHING MASK MAY BE REMOVED FOR THE THRUS T CHAMBER ENTRY. ************************,**************************************************** * ****************************************************************************** PERSONNEL MUST EVACUATE INTERIOR OF THRUST CHAMBER IF OXYGEN CONTENT EXCEEDS 24.5 PERCENT AND/OR HYDROGEN CONTENT EXCEEDS 0.8 PERCENT (20 PERCENT LEL ) ***************************************************************************** * 2.4 BEFORE USE, PARTICULAR CARE SHOULD BE TAKEN TO CHECK THE OPERATION OF EQUIPMENT. 2.5 PRIOR TO USE, BY EACH PERSONNEL, THE MASK ASSEMBLY SHALL BE WASHED WITH SOAP & WATER, WIPED DRY & THEN DISINFECTED BY SPONGING WITH BACTINE OR 70 PERCENT SOLUTION OF ETHYL ALCOHOL. 3.0 PREREQUISITE CONDITIONS FOR ENTRY : ENTRY INTO A THRUST CHAMBER SHALL BE PERMITTED ONLY AFTER IT HAS BEEN ESTABLISHED THAT THE FOLLOWING CONDITIONS ARE MET : 3. 1 3.2.... VERIFY STACK IS EXTINGUISHED OR EXTINGUISH LOW PRESSURE STACK PER CT-0-23S IF IGNITED..... VERIFY THE FOLLOWING VALVES ARE IN THE SPECIFIED POSITION : IF VALVE POSITIONS CHANGE FROM SPECIFIED POSITIONS CONSOLE OPERATOR SHALL NOTIFY STANDBY TO EVACUATE CHAMBER AND NOTIFY ENGINEERING. I I II I I I BNA00373283 HDMSeOOI 86587
BNA00373284 HDMSeOOI 86588 17 OCT 83 ROCKWELL INTERNATIONAL CORP C1C - 0-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 5 OF 9 ROCKETDYNE DIVISION 1032A 0T40A 3.2.7.... LOX SUCTION DUCT TRICKLES PURGE HAND VALVE ( LC-47 ) CLOSED 3.2.2.... VERIFY ENG GN2 HAND S/0 LC-43 CLOSED. 3.2.3.... VERIFY ENGINE GHE HAND S / 0 LC-42 CLOSED. 3.2.4.... VERIFY HPOTP INTERMEDIATE SEAL PURGE HAND S / O VALVE LC-41 CLOSED 3.2.5.... VERIFY LH2 TANK SLOW VENT HT-10 - OPE N 3.2.6.... VERIFY LOX TANK SLOW VENT LT-20 - OPEN 3.2.7.... A3 UPPER LOX PREVALVE ( LT-2) CLOSED. 3.2.8.... A3 UPPER FUEL PREVALVE ( HT-4) CLOSED. 3.2.9.... A3 LOWER LOX PREVALVE ( LC-2) CLOSED. 3.2.10.... A3 LOWER FUEL PREVALVE ( FC-2) CLOSED. 3.2.11.... VERIFY THE ASTRODATA IS IN SIGNAL, THEN VERIFY THE ENGINE FUEL BLEED SYS IS VENTED ( DBI 259-100 COUNTS MAX) NOTIFY ENGINEERING FOR DISPOSITION IF ABOVE THE MAX COUNT. 3.2.12.... IF (FC-3 ) IS NOT RED TAGGED, THE ENGINE FUEL BLEED SYS MAY BE VENTED BY CYCLING FC-3 OPEN THEN CLOSE. DNA IF FC - 3 IS RED TAGGED. 3.2.13.... VERIFY THE ENGINE LOX BLEED SYS IS VENTED TO LESS THAN 5 PSIG ON IND 123A3. NOTIFY ENGINEERING FOR DISPOSITION IF PRESS IS ABOVE 5 PSIG. 3.2.14.... IF ( LC-3) IS NOT RED TAGGED, THE ENGINE LOX BLEED SYS MAY BE VENTED BY CYCLING LC-3 OPEN THEN CLOSE. DNA IF LC-3 IS RED TAGGED. 3.2.15.... ENG LOX CHILL BYPASS ( LC-3 B / P) CLOSE D 3.2.16.... NOTIFY CADS OPERATOR OF THRUST CHAMBER ENTRY AND NO ENGINE VALVE OPERATIONS TO BE PERFORMED. 3.3.... VERIFY LOX AND FUEL SUCTION DUCTS ARE VENTED TO ZERO DIG IND 123A6 AND 125A4. IF NOT, CYCLE BLEEDS AS FOLLOW S NOTE : DNA STEPS 3.3.1 THROUGH 3.3.4 IF DUCTS ARE VENTED. 3.3.1.... LPOTP IN BLEED ( LC-7) OPEN, THEN CLOSE D 3.3.2.... LH2 R.L. CHILL BLEED ( FC-6) OPE N 3.3.3.... ENG FUEL CHILL ( FC-4) OPEN, THEN CLOSED 3.3.4.... LH2 R.L. CHILL BLEED ( FC-6) CLOSE D 3.4 INSTALL " MAN IN CHAMBER " RED TAG SIGNS ON A3 CONSOLE, COCA 1 COMMON CONSOLE AND CADS CONSOLE.
BNA00373285 HDMSeOOI 86589 17 OCT 83 ROCKWELL INTERNATIONAL CORP C1C - 0-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 6 OF 9 ROCKETDYNE DIVISION 7032A 0140 A 3.5.... VALVE SAFETY KEY SWITCH TO THE " CHAMBER SAFE FOR ENTRY " POSITION 3.6.... ATTACH SIGN TO THE SAFETY KEY SWITCH STATING "CAUTION - MAN I N CHAMBER - DO NOT OPERATE". 3.7.... SNIFF CHECK CHAMBER FOR HYDROGEN. ENTRY IS NOT PERMITTED IF THE HYDROGEN CONCENTRATION EXCEEDS 0. 8 PERCENT ( 20 PERCENT OF L.E.L. 3.8.... FOR EXTENDED ENTRY, VERIFY THE FOLLOWING PNEUMATIC CONSOLE STATIONS ARE SECURE AND THE STATION BLEED HAND VALVES ARE OPEN. IF SHORT TERM ENTRY, DNA SECTION 3.8 THORUGH 3.8. 6 3.8.1.... "H" STATION BLEED ( PC-65H) 3.8.2.... "R " STATION BLEED ( PC-65R) 3.8.3.... "S" STATION BLEED ( PC-65S) 3.8.4.... "T" STATION BLEED ( PC-65T) 3.8.5.... "U" STATION BLEED ( PC65-U) 3.8.6.... "X" STATION BLEED ( PC-65X ) 3.9.... HANG " MAN IN CHAMBER " SIGN ON THE PNEUMATIC CONSOLE. 3.10.... IF STATION " H" OR "R " IS REQUIRED TO BE UP TO MAINTAIN HARDWARE PURGES, THE ENTRY BECOMES SHORT TER M FOR SHORT TERM ENTRY, VERIFY THE FOLLOWING PNEUMATIC CONSOLE STATIONS ARE SECURED AND THE STATION BLEED HAND VALVES ARE OPEN. IF EXTENDED ENTRY, DNA SECTION 3.T0 THROUGH 3.10. 4 3.10.1.... "S" STATION BLEED ( PC-65S) 3.10.2.... "T" STATION BLEED ( PC-65T) 3.10.3.... "U " STATION BLEED ( PC-65U) 3.10.4.... " X" STATION BLEED ( PC-65X ) 3.11.... HANG " MAN IN CHAMBER " SIGN ON THE PNEUMATIC CONSOLE. 3.12.... OBTAIN OK FROM E.I.C. FOR CHAMBER ENTRY IF ENTRY TO BE PERFORMED WITHIN 2 HOURS OF TEST SECURING TIME. 4.0 SECURING FROM THRUST CHAMBER ENTR Y NOTE : DNA SECTION 4.0 THROUGH 4.8 ON THIS PROCEDURE IS THE THRUST CHAMBER ENTRY IS NOT COMPLETE AND A NEW ENTRY PROCEDURE ( C1C-0-182 ) IS FILLED OUT. 4.1.... LH2 R / L CHILL BLEED ( FC-6) CLOSED 4.2.... LPOTP IN BLEED ( LC-7) CLOSED
I I I I I I LII BNA00373286 HDMSeOOI 86590 1.7 OCT 8 3 4. 3 4. 4 4. 5 4. 6 4.7 4. 8 4.9 ROCKWELL INTERNATIONAL CORP CTC-O-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 7 OF 9.... REMOVE "MAN IN CHAMBER" RED TAGS FROM CADS, A3 COCA 1 COMMON CONSOLES..... REMOVE SIGN FROM "VALVE SAFETY KEY SWITCH" AND SW KEY TO "CHAMBER UNSAFE FOR ENTRY" POSITION..... REMOVE THE "MAN IN CHAMBER" SIGN FROM THE PNEUMATIC CONSOLE CLOSE REG STATION H BLEED VALVE (PC-65H) AND RUN UP REG STATION H TO THE GREEN ZONE..... LOX SYS TRICKLE PURGE HAND VALVE (LC-47) OPE N.... CLEAN BREATHING EQUIPMENT PER PARA. 2.5 AND STORE..... STORE OXYGEN METER & HYDROGEN DETECTOR
I BNA00373287 HDMSeOOI 86591 17 OCT 83 ROCKWELL INTERNATIONAL CORP C1C-0-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 8 OF 9 THRUST CHAMBER ENTRY PERMIT ITEMS 1-12 MUST BE INITIALED BEFORE ENTRY ITEMS 13 THRU 15 MUST BE INITIALED AFTER ENTR Y NOTE : DNA ITEMS 13 THRU 15 ON THIS PROCEDURE IF THE THRUST CHAMBER ENTRY IS NOT COMPLETE AND A NEW ENTRY PROCEDURE (C1C-0-T82) IS FILLED OU T DATE... TEST POSITION.. TIME. MARK APPLICABLE : SHORT TERM ENTRY EXTENDED ENTRY Sr^,y!' (#-r Al-Cf S7,4,1ti CNrcu. opt INITIALS OF ox INITIALS OF STANDBY PERSON ENTERING T/ C 1. BOTH STANDBY AND PERSON ENTERING T/C HAVE READ PROCEDURE C1C-0-182 AND ARE AWARE OF THE POTENTIAL HAZARD WHICH NECESSITATES, COMPLIANCE WIT H THIS PROCEDURE. 2. STAND TALKER (IF PRESENT) HAS BEEN NOTIFIED OF INTENT TO ENTER CHAMBE R 3. VERIFY THE A3 VALVE SAFETY KEY SWITCH IS IN THE " CHAMBER SAFE FOR ENTRY" POSITION AND THE KEY SWITCH HAS BEEN TAGGED. ( SEE PARA 3.5 AND 3.6 OF PROCEDURE CIC-0-182 ) 4. PROPELLANT MAIN VALVES AND PRE- VALVES ARE CLOSED AND DUCTING BETWEEN IS NOT PRESSURIZED. (SEE PARA 3.2.5 THRU 3.3.4). 5. SECURE PURGES PER PARA 3.2.1 THRU 3.2. 4 6. REQUEST OF CONTROL CENTER TO HANG RED TAG ON A3, COMMON CONSOLES AND CADS CONSOLES STATING "MAN IN CHAMBER DO NOT OPERATE CONSOLE " 7. DETERMINATION OF OXYGEN AND HYDROGEN CONCENTRATION HAS BEEN MADE. 8. BREATHING EQUIPMENT HAS BEEN CHECKED, CLEANED PER PARA 2.5 AND WILL BE WORN WHEN REQ'D
17 OCT 83 ROCKWELL INTERNATIONAL CORP C1C-0-182 R3 NORTH AMERICAN AEROSPACE GROUP PAGE 9 OF 9 9. A SUITABLE PADDED LADDER OR STABL E WORK PLATFORM WILL BE UTILIZED (IF REQUIRED). 10. PERSON ENTERING USING A FACE MASK &/ OR BREATHING AIR WIL L HAVE HAD A MEDICAL EXAM & I S CERTIFIED FOR AIR LINE RESPIRATOR. 11. IF A ENTRY WITH THE THROAT PLUG INSTALL AND PRESSURIZED IS MADE, VERIFY REQUIREMENTS OF PARA 2.2.3 ARE MET. 12. PREPARATION FOR ENTRY IS COMPLETE - OK TO ENTER. (LEADMAN OR SUPERVISOR INITIALS ) 13. AFTER COMPLETION OF WORK IN THRUST CHAMBER - ALL GEAR HAS BEEN PROPERLY STORED, CONTROL CENTER AND STAND TALKER NOTIFIED AND RED TAGS REMOVED. 14. ACTIVATE PURGE SYSTEM SECURED PER PARA. 3.2.1 IF REQUIRED FOR STAND OPERATIONS. (TRICKLE PURGE AND AT PNEU CONSOLE ) 15. SWITCH THE CHAMBER SAFETY SW TO "CHAMBER UNSAFE FOR ENTRY" BNA00373288 HDMSeOOI 86592