Chris Tutt AMS-02 Phase II Safety Review 1

Composite Overwrapped Pressure Vessels

Chris Tutt

AMS-02 Project Manager

Chris Tutt AMS-02 Phase II Safety Review 2

Review of Hazard

Hazard to be controlled is structural failure of Composite Overwrapped Pressure Vessels (COPVs). Structural failure from overpressurization. Structural failure from damage to overwrap.

AMS-02 has three COPVs Xenon Tank and Carbon Dioxide Tanks for

the TRD Gas Supply. Warm Helium Tank for the Cryomagnet.

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Review of Tank Design All tanks designed and manufactured by Arde’. Each is a duplicate of an existing tank with

previous space flight history. Xe tank previously used in Plasma Contactor Unit

currently on ISS. CO2 tank previously used on X-33. Warm Helium Tank previous used on Pegasus ELV.

Tank manufacturing done per AIAA-S-081 requirements.

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TRD Gas Supply

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TRD Heaters and Thermostats Heaters and thermostats

were added to the outside surface of the TRD tanks. Procedure reviewed by MIT

and Arde’. Work done by MIT technician

with Arde’ QA present. Tank reinspected and proof

pressure test redone after installation.

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Warm Helium Tank

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COPV Structural Analysis and Testing

Tanks have all been verified against AIAA-S-081 design requirements. Required burst factor of 1.5 x MDP

• Xenon tank: 3.1 x MDP

• CO2 tank: 2.0 x MDP

• Helium tank: 2.5 x MDP

Required proof test to 1.5 x MOP• Xenon tank: 1.8 x MOP

• CO2 tank: 3.3 x MOP

• Helium tank: 2.5 x MOP

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Proof Test Requirements KNPR 8715.3 para 13.18.1c and d require an inspection

and proof pressure test prior to first pressurization at KSC.

All COPVs will arrive at KSC filled. No top-offs of these vessels are currently planned.

COPVs will have already demonstrated structural integrity for KSC environment. All vessels will have already held pressure for months. Thermal environment from thermal/vac testing will envelope

anything seen at KSC. All vessels will have seen vibration environment from multiple

plane and truck transports. Tanks will not be emptied and refilled.

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Special Ground Handling Requirements KNPR 8715.3 paras 13.8.1e, f, and g have

special handling requirements if tanks are pressurized above 1/3 design burst pressure.

None of the AMS-02 tanks will pass this limit: Xenon Tank: Burst pressure 9300 psid, MOP 2500

psid (26.9%) CO2 Tank: Burst pressure 6400 psid, MOP 1440 psid

(22.5%) Warm Helium Tank: Burst pressure 8845 psid, MOP

2900 psid (32.8%)

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Warm Helium Tank Damage ProtectionWarm Helium Tank was inspected at Arde’

prior to shipment and found to be free of defects.

Upon delivery to SM, tank has been stored in its shipping crate physically separate from main work area.

Tank will be installed on Vacuum Case concurrently with its rigid MMOD shield, which will protect the tank from incidental contact.

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Warm Helium Tank Debris Shield

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TRD Tanks Damage Protection TRD tanks inspected by Arde’ after

manufacturing and found to be free of defects. Fiberglass covers installed to protect tank

surface during ground handling and installation. Removed on three occasions. Allow installation of the tank heaters. Allow installation of the tank thermostats. Allow installation of the tank MLI.

Covers will remain on until flight MMOD shields installed, which will protect tanks from incidental contact.

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TRD Gas Supply Debris Shield

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Proposed Safety Controls AMS-02 COPVs are low risk for sudden failure.

Tanks have been fully certified to all design and analysis requirements in KNPR 8715.3 and AIAA-S-081.

Tanks will be filled prior to arrival and will have held pressure for months.

Tanks will be protected by MMOD shields during all KSC operations.

Tanks will never be loaded above 1/3 of burst pressure.

No additional controls apart from standard pressure vessel regulations should be required.