Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
SUMMARY
Prepared for
NASA - George C. Marshall Space Flight
Center under Contract NAS&-20266
SfGNATOR LOC
SUMMARY D O C U M E N T
D5-13183
FINAL R E P O R T
P R E P A R E D UNDER C O N T R A C T N U M B E R N A S 8 - 2 0 2 6 6
SUBMITTED T O
G E O R G E C. M A R S H A L L S P A C E F L I G H T C E N T E R
N A T I O N A L AERONAUTICS AND S P A C E ADMINISTRATION
O C T O B E R 7, 1966
S U B M I T T E D BY
S Y S T E M S ANALYSIS C O N T R A C T O R
T H E BOEING C O M P A N Y
S P A C E DIVISION
L A U N C H SYSTEMS B R A N C H
H U N T S V I L L E , ALABAMA
D5-13183
FOREWORD
T h i s v o l u m e s u m m a r i z e s five t e c h n i c a l V e h i c l e D e s c r i p t i o n D o c u m e n t s
r e p o r t i n g a t e n - m o n t h s t u d y to p r e p a r e t e c h n i c a l and r e s o u r c e d a t a on
uprated payload Saturn V and i n t e r m e d i a t e payload Saturn v e h i c l e s .
T h i s study i s p a r t of a c o n t i n u i n g effort by t h e N a t i o n a l A e r o n a u t i c s and
Space A d m i n i s t r a t i o n (NASA) t o i n v e s t i g a t e the c a p a b i l i t y a n d f l e x i b i l i t y
of the S a t u r n V l a u n c h v e h i c l e and t o identify p r a c t i c a l m e t h o d s for
d i v e r s i f i e d u t i l i z a t i o n of i t s p a y l o a d c a p a b i l i t y . NASA C o n t r a c t NAS8 -20266
a u t h o r i z e s the w o r k r e p o r t e d h e r e i n and w a s s u p e r v i s e d and a d m i n i s t e r e d
b y t h e M a r s h a l l S p a c e F l i g h t C e n t e r ( M S F C ) . S-II d a t a w a s s u p p l i e d
by the S p a c e and I n f o r m a t i o n D i v i s i o n of N o r t h A m e r i c a n A v i a t i o n .
S-IVB d a t a w a s s u p p l i e d by the M i s s i l e a n d S p a c e S y s t e m s D i v i s i o n
of D o u g l a s A i r c r a f t C o m p a n y . L a u n c h s y s t e m d a t a w a s s u p p l i e d by t h e
D e n v e r D i v i s i o n of T h e M a r t i n C o m p a n y - Solid m o t o r d a t a w e r e s u p p l i e d
by U n i t e d T e c h n o l o g y C o r p o r a t i o n . T h e L a u n c h S y s t e m s B r a n c h ,
A e r o s p a c e G r o u p , S p a c e D i v i s i o n of T h e B o e i n g C o m p a n y w a s t h e
S y s t e m s A n a l y s i s c o n t r a c t o r for t h i s s t u d y .
P r o g r a m d o c u m e n t a t i o n i n c l u d e s a s u m m a r y v o l u m e (this d o c u m e n t ) ,
five v o l u m e s c o v e r i n g v e h i c l e d e s c r i p t i o n s , r e s e a r c h and t e c h n o l o g y
implications r e p o r t , and a cost document. Individual designations a r e
a s follows:
ii
D5-13183
ABSTRACT
KEY WORDS
iii
D5-13183
T A B L E OF CONTENTS
SECTION
FOREWARD
ABSTRACT
1.0 INTRODUCTION
2.0 SUMMARY
3. 0 GUIDE L I N E S AND ASSUMPTIONS
4.0 M L V - S A T - I N T - 2 0 / - 2 0 LAUNCH VEHICLES
5. 0 M L V - S A T - V - 3 B L A U N C H V E H I C L E S
6.0. M L V - S A T - V - 2 5 ( S ) L A U N C H V E H I C L E S
7.0 MLV-5AT-V-4(S)B
8..0 M L V - S A T - V - 2 3 ( L ) L A U N C H VEHICLE
9. 0 CONCLUSIONS AND R E C O M M E N D A T I O N S
iv
D5-13I83
FIGURES
F I G U R E NO. PAGE
1-1 P H A S E I L A U N C H V E H I C L E CANDIDATES 2
1-2 S E L E C T E D B A S E L I N E LAUNCH V E H I C L E S F O R P H A S E
II STUDY E F F O R T 4
2-1 VEHICLE COMPARISON 7
2-2 U P R A T E D V E H I C L E I N V E S T M E N T COST C O M P A R I S O N 8
2-3 T W O - S T A G E V E H I C L E COST E F F I C I E N C Y 8
2-4 T H R E E - S T A G E V E H I C L E COST E F F I C I E N C Y 9
4-1 INT V E H I C L E S 14
4-2 INT - 2 0 / - 2 1 V E H I C L E COMPARISON 17
4-3 F O U R E N G I N E S - I C - 2 0 STAGE 19
4-4 I N T - 2 0 ORBIT A L T I T U D E - A Z I M U T H P A Y L O A D
CAPABILITY 20
4-5 I N T - 2 1 ORBIT A L T I T U D E - A Z I M U T H P A Y L O A D
CAPABILITY 21
4-6 I N T - 2 0 P O L A R & SUN SYNCHRONOUS P A Y L O A D
(DIRECT A S C E N T ) 21
4-7 SYNCHRONOUS ORBIT PAYLOAD C A P A B I L I T Y 21
4-8 I N T - 2 0 / - 2 1 V E H I C L E D E V E L O P M E N T AND D E L I V E R Y
PLAN 22
4-9 INT V E H I C L E COST E F F I C I E N C Y COMPARISON 24
5-1 M L V - S A T - V - 3 B B A S E L I N E LAUNCH V E H I C L E 26
5-2 T R A D E STUDY U P P E R STAGE E N G I N E S 28
5-3 T R A D E STUDY P E R F O R M A N C E DATA 29
5-4 T R A D E STUDY V E H I C L E P A Y L O A D COMPARISON 29
5-5 S A T - V - 3 B & I N T - 1 7 COST E F F I C I E N C Y T R A D E 30
5-6 ORBIT A L T I T U D E - A Z I M U T H P A Y L O A D C A P A B I L I T Y 31
5-7 HIGH E N E R G Y P A Y L O A D C A P A B I L I T Y 32
5-8 T W O - S T A G E P O L A R & SUN SYNCHRONOUS ORBIT
PAYLOAD CAPABILITY 33
5-9 T H R E E - S T A G E P O L A R & SUN SYNCHRONOUS ORBIT
PAYLOAD CAPABILITY 33
5-10 ACOUSTIC E N V I R O N M E N T AND S T R U C T U R A L LOADS 34
5-11 SAT-V-4(S)B VEHICLE IMPACT 35
5-12 S A T - V - 3 B V E H I C L E D E V E L O P M E N T AND D E L I V E R Y
PLAN 38
6-1 MLV-SAT-V-25(S) BASELINE VEHICLE 40
6-2 P E R F O R M A N C E T R A D E DATA 41
6-3 COST E F F I C I E N C Y T R A D E DATA 42
6-4 ACOUSTIC E N V I R O N M E N T AND S T R U C T U R A L LOADS 46
6-5 SAT-V-25(S) VEHICLE IMPACT 47
v
D5-13183
FIGURES (Continued)
vi
D5-I3183
TABLES
4-1 I N T E R M E D I A T E V E H I C L E P E R F O R M A N C E SUMMARY 16
4-II SIGNIFICANT LOAD CRITERIA 20
4-III I N T - 2 0 COST SUMMARY 23
4-IV I N T - 2 1 COST SUMMARY 23
5-1 SIGNIFICANT LOAD CRITERIA 30
5-II S A T - V - 3 B COST SUMMARY 38
6-1 PAYLOAD CAPABILITY 44
6-II SIGNIFICANT LOAD CRITERIA 45
6-in S A T - V - 2 5 ( S ) COST SUMMARY 53
7-1 SOLID MOTOR CHARACTERISTICS 56
7-II PAYLOAD CAPABILITY 59
7-III SIGNIFICANT LOAD C R I T E R I A 61
7-IV S A T - V - 4 ( S ) B COST SUMMARY 70
8-1 T H R E E - S T A G E 72-HOUR LUNAR I N J E C T I O N P A Y L O A D
CAPABILITY 77
8-II SIGNIFICANT L O A D C R I T E R I A 77
8-UI S A T - V - 2 3 ( L ) COST SUMMARY 84
VI1
D5-13183
1.0 INTRODUCTION
1
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SIZE S30K
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D5-13183
C a t e g o r i e s 3 , 4, a n d 5 a r e a d v a n c e d S a t u r n V c o n f i g u r a t i o n s with
p a y l o a d c a p a b i l i t i e s beyond t h a t of t h e e x i s t i n g S a t u r n V-
T h e five c a t e g o r i e s of v e h i c l e s a r e :
C a t e g o r y 1 ( M L V - S A T - I N T -20) d u r i n g P h a s e I w a s a f a m i l y of
t w o - s t a g e l a u n c h v e h i c l e c a n d i d a t e s w i t h s t a n d a r d s i z e S - I C a n d S-IVB
s t a g e s u s i n g s t a n d a r d F - l e n g i n e s ( t h r e e , f o u r , and five) and a s t a n d a r d
J - 2 e n g i n e . A s i n g l e b a s e l i n e l a u n c h v e h i c l e ( F i g u r e 1-2) w a s s e l e c t e d
for t h e P h a s e II s t u d y e f f o r t .
C a t e g o r y 2 ( M L V - S A T - 1 N T - 2 1 ) d u r i n g P h a s e I w a s a f a m i l y of
t w o - s t a g e l a u n c h v e h i c l e c a n d i d a t e s w i t h s t a n d a r d s i z e S-IC a n d S-II
s t a g e s u s i n g s t a n d a r d F - l e n g i n e s ( t h r e e , f o u r , a n d five) a n d J - 2 e n g i n e s
(three, four, and five). A single b a s e l i n e l a u n c h v e h i c l e ( F i g u r e 1-2)
w a s s e l e c t e d for t h e P h a s e II study e f f o r t .
C a t e g o r y 3 (MLV - S A T - V - 3 B ) d u r i n g P h a s e I w a s a f a m i l y of t w o -
and t h r e e - s t a g e l a u n c h v e h i c l e c a n d i d a t e s with m o d i f i e d u p r a t e d S a t u r n V
s t a g e s u s i n g v a r i o u s t y p e s , n u m b e r s , and t h r u s t l e v e l s of a d v a n c e d
e n g i n e s in t h e u p p e r s t a g e s and u p r a t e d F - l e n g i n e s in t h e m o d i f i e d
S-IC s t a g e . A s i n g l e b a s e l i n e l a u n c h v e h i c l e ( F i g u r e 1-2) w a s s e l e c t e d
for the P h a s e II s t u d y e f f o r t .
C a t e g o r y 4 i n c l u d e d m o d i f i e d S a t u r n V l a u n c h v e h i c l e s with s t r a p - o n
s o l i d b o o s t - a s s i s t c o m p o n e n t s . T h r e e f a m i l i e s o£ v e h i c l e s w e r e s t u d i e d
a s follow:s:
a. MJ_,V-SAT-V-4(S)B d u r i n g P h a s e I w a s a f a m i l y of t w o - and t h r e e -
s t a g e l a u n c h v e h i c l e s w i t h m o d i f i e d S a t u r n V s t a g e s , s t a n d a r d F - l and
J - 2 e n g i n e s with s t r a p - O n 120-inch d i a m e t e r (five, s i x , a n d s e v e n
segment) solid m o t o r s . A single b a s e l i n e l a u n c h v e h i c l e ( F i g u r e 1-2)
w a s s e l e c t e d for t h e P h a s e II study effort.
b. M L V - S A T - V - 2 2 ( S ) d u r i n g P h a s e I w a s a f a m i l y of t w o - and t h r e e -
s t a g e l a u n c h v e h i c l e s with m o d i f i e d S a t u r n V s t a g e s u s i n g v a r i o u s t y p e s ,
n u m b e r s , and t h r u s t l e v e l s of a d v a n c e d e n g i n e s in the u p p e r s t a g e s ,
a m o d i f i e d S-IC s t a g e w i t h s t a n d a r d F - l e n g i n e s in the f i r s t s t a g e , and
s t r a p - o n 1 2 0 - i n c h d i a m e t e r (five, s i x , and s e v e n s e g m e n t ) s o l i d m o t o r s .
No l a u n c h v e h i c l e in t h i s f a m i l y w a s s t u d i e d beyond P h a s e I,
c. M L V - S A T - V - 2 5 ( S ) d u r i n g P h a s e I w a s a f a m i l y of t w o - and t h r e e -
s t a g e l a u n c h v e h i c l e s with m o d i f i e d S a t u r n V s t a g e s , s t a n d a r d F - l
a n d J - 2 e n g i n e s , a n d s t r a p - o n 1 5 6 - i n c h d i a m e t e r (two a n d t h r e e s e g m e n t )
s o l i d m o t o r s . A s i n g l e b a s e l i n e l a u n c h v e h i c l e ( F i g u r e 1-2) w a s s e l e c t e d
f o r t h e P h a s e II s t u d y e f f o r t .
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D5-13183
D5-13183
2.0 SUMMARY
INT-20 (2STGI
m-
INT-21 (2ST6I SATV-3B SATV-4ISIB SAT V-2SSI SAT V-Z3HI
F-l F-IJJ-2 2 STG 3 STG 2 STG 3 STG 2 STG 3STG 2 STG 1 STG
PAYLOAD 3 4 *~l M " 52 W *S
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7
D5-13183
I
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launch vehicles and / */
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Figure 2-4 s u m m a r i z e s •^ 1
cost efficiency for the /-«s
40 — - —-
t h r e e - s t a g e uprated I
3
D5-13183
m MTV.
p a y l o a d a c h i e v e d t o 579, 000 p o u n d s lfay
t o 100 n a u t i c a l m i l e E a r t h o r b i t
( S A T - V - 2 3 ( L ) ) . T h e liquid pod m rV ^
s t r a p - o n c o n c e p t , with u p r a t e d 1Ua -asiv -au
F - l s a n d a d v a n c e d e n g i n e s in the «o-
second stage ( S A T - V - 2 4 ( D ) ,
a c h i e v e d p a y l o a d s to 960, 000 p o u n d s «o
to 100 n a u t i c a l m i l e E a r t h o r b i t
when stage and total vehicle length a»
restrictions were relaxed.
no m m
PAYIOAC HP U S IRHRI.UIJMTIWNSFBITltA.JI
9
D5-13183
4
»
10
D5-13183
3. 0 GUIDE L I N E S AND A S S U M P T I O N S
T h e f o l l o w i n g guide l i n e s , g r o u n d r u l e s , and a s s u m p t i o n s w e r e u s e d
in the s t u d y .
3.1 GENERAL
C. A l l p r o p u l s i o n d a t a u s e d by the s t a g e c o n t r a c t o r s w e r e a p p r o v e d
by M S F C .
d. Both l a u n c h v e h i c l e a n d l a u n c h f a c i l i t y m o d i f i c a t i o n s w e r e
c o n s i d e r e d . E x c h a n g e of i n f o r m a t i o n b e t w e e n t h e l a u n c h f a c i l i t y and
l a u n c h v e h i c l e s t u d y c o n t r a c t o r s w a s c o o r d i n a t e d w i t h M S F C and KSC.
e. T r a j e c t o r y , p r o p e l l a n t d i s t r i b u t i o n , and s t a g e s i z e o p t i m i z a t i o n
p r o c e d u r e s u s e d w e r e c o m p a r a ' b l e to M S F C m e t h o d s .
f. T h e n o m i n a l m i s s i o n p r o f i l e s u s e d t o s i z e and e s t a b l i s h the
b a s e l i n e v e h i c l e d e s i g n , to e s t a b l i s h t r a j e c t o r i e s for h e a t i n g and c o n t r o l
a n a l y s i s i and a s a b a s i s for p e r f o r m a n c e c o m p a r i s o n w e r e :
1, T w o - s t a g e , d i r e c t a s c e n t to 100 n a u t i c a l m i l e c i r c u l a r o r b i t
altitude.
2. T h r e e - s t a g e , with p r e - o r b i t a l i g n i t i o n of the t h i r d s t a g e to
100 n a u t i c a l m i l e c i r c u l a r p a r k i n g o r b i t followed by a s e c o n d b u r n out of
o r b i t to 7 2 - h o u r l u n a r i n j e c t i o n . T h i s i s t h e p l a n n e d S a t u r n V m e t h o d .
11
D5-13183-3
S o m e v e h i c l e s u s e d t w o - s t a g e , d i r e c t a s c e n t to a 100 n a u t i c a l m i l e
c i r c u l a r p a r k i n g o r b i t followed by i g n i t i o n of a t h i r d s t a g e and b o o s t to a
72-hour lunar transfer trajectory.
g. L a u n c h a z i m u t h f r o m AMR w a s 70 d e g r e e s m e a s u r e d f r o m
n o r t h to south o v e r e a s t and flight p r o f i l e s w e r e o p t i m i z e d in the p i t c h p l a n e .
h. V e h i c l e h e i g h t , for b o t h t w o - a n d t h r e e - s t a g e v e h i c l e s , w a s
l i m i t e d t o 410 f e e t .
i. P a y l o a d d e n a i t y w a s h e l d a t five p o u n d s p e r c u b i c foot m a x i m u m
for two s t a g e o p e r a t i o n a n d 11 p o u n d s p e r c u b i c foot m a x i m u m for t h e
three-stage vehicle.
T h i r t y - t h r e e foot d i a m e t e r and 2 . 2 9 p r o p e l l a n t m i x t u r e r a t i o of t h e
e x i s t i n g S-IC s t a g e w e r e to be m a i n t a i n e d .
3.3 SECOND S T A G E
a. P r o p e l l a n t m i x t u r e r a t i o of 5:1 a n d 33-foot d i a m e t e r w e r e t o
be m a i n t a i n e d .
b. M a x i m u m s t a g e l e n g t h for b a s e l i n e s e l e c t i o n w a s l i m i t e d to
1,160 i n c h e s .
3.4 THIRD S T A G E
a. P r o p e l l a n t m i x t u r e r a t i o of 5:1 and 2 6 0 - i n c h d i a m e t e r w e r e t o
be maintained.
b. M a x i m u m s t a g e l e n g t h e q u i v a l e n t to 3 5 0 , 0 0 0 p o u n d s p r o p e l l a n t
c a p a c i t y at a m i x t u r e r a t i o of 5:1 (about 16. 5 foot i n c r e a s e ) w a s to b e
maintained.
3.5 RESOURCES
a. W h e r e t w o - and t h r e e - s t a g e c o n f i g u r a t i o n s of the s a m e b a s i c
vehicle w e r e e x e r c i s e d , the t h r e e - s t a g e configuration was analyzed.
b. U p r a t e d S a t u r n V s t a g e s w e r e to be f a b r i c a t e d by t h e p r e s e n t
c o n t r a c t o r s a n d c o s t d a t a for t h e s t a g e s w e r e o b t a i n e d f r o m t h e c o n t r a c t o r s .
12
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3.6 SCHEDULE
3.7 PRICING
13
D5-13183
INT-20 INT-21
I. U.
323.3
281.4
F I G U R E 4-1 INT V E H I C L E S
14
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4.1.2 T r a d e Studies
— — _ — * . — • — - i — /
15
TABLE 4-1 INTERMEDIATE VEHICLE PERFORMANCE
4/4 4 . 87 3. 40
4/5 4. 87 3.30
5/3 6. 09 4. 56
5/5 6.09 4 . 42
750 - i
at
an-
8
INT20
S-1VS/S-M
150- MIEftSTME
air
ts
a< IOD-I
AVAIL
a: ? VBS
AFTER ATP
M- 1 SINGLE
BW
AUVEH
Ft/J-i 3/1 4/1 4/1 4/4 4/5 573 5/4 5/5 SINGLE
RID
MSRfcD S/YR 42.3 42.3 37.'8 37.8 35-8 35.5 15.5 33.5 NOPROO
U$R&D 1Z/YR17O.5170.5 INC U3M
168. 2 168. 2 166. 2 165, 9 165. 9 163. 9
$/l-B 80-6 496 431 402 395 337 il5 314
S-IC BURNTIME 146 212 154 148 143 161 155 150
(3-146) (2-146) (2 -146T2 -146J4-14!)(I-146)| t -146)(1-146)
F o r t h e r e m a i n i n g b a s e l i n e c a n d i d a t e s (shown on F i g u r e 4 - 2 ) , it w a s
n e c e s s a r y t o shut down one o r m o r e F - l e n g i n e s d u r i n g f i r s t s t a g e flight
to a v o i d t h e p r e s e n t 4. 68 g l o n g i t u d i n a l a c c e l e r a t i o n l i m i t . T h e t i m e of
shutdown a n d n u m b e r of e n g i n e s shut down a r e shown w i t h the f i r s t - s t a g e
b u r n t i m e on F i g u r e 4 - 2 .
17
D5-13183
P a y l o a d - c o s t - e f f i c i e n c i e s ( d o l l a r s p e r pound of p a y l o a d , s e e F i g u r e 4-2)
v a r y u n i f o r m l y , following t h e n a t u r a l t r e n d w h i c h i s : s m a l l e s t p a y l o a d -
l a r g e s t c o s t p e r pound for d e l i v e r y , and l a r g e s t p a y l o a d - l e a s t c o s t p e r
pound for d e l i v e r y .
T h e b a s e l i n e v e h i c l e s c h o s e n d u r i n g the P h a s e I a c t i v i t y w e r e defined
in d e t a i l , t h e i r c o m p l e t e c h a r a c t e r i s t i c s d e t e r m i n e d , and t h e i r r e s o u r c e
requirements established.
INT c o n f i g u r a t i o n s c h o s e n for f u r t h e r d e s i g n s t u d y a r e s h o w n on
F i g u r e 4 - 1 . T h e I N T - 2 0 h a s a s t a n d a r d S a t u r n V S-IC f i r s t s t a g e with
the c e n t e r F - l e n g i n e a n d a s s o c i a t e d s y s t e m s r e m o v e d . T h e s e c o n d
s t a g e i s a s t a n d a r d S-IVB w i t h i t s aft i n t e r f a c e a d a p t e d t o S-IC r e q u i r e -
m e n t s . T h e I N T - 2 1 u s e s s t a n d a r d S-IC and S-II s t a g e s . An S - I V B / S - I I
i n t e r s t a g e i s u s e d to a d a p t t o t h e i n s t r u m e n t unit a n d p a y l o a d .
T h e m a n n e r in w h i c h a f o u r - e n g i n e S-IC i s a c h i e v e d i s i l l u s t r a t e d
on F i g u r e 4 - 3 . T h e b a s e l i n e S-IC s t a g e p r o v i d e d b y NASA i n c o r p o r a t e s
an i n s u l a t e d L O X d u c t r a t h e r tKan a d u c t - i n - t u n n e l a r r a n g e m e n t . With
t h e duct r e m o v e d , it i s n e c e s s a r y t o s u p p o r t t h e c e n t e r duct s p o o l t o r e t a i n
c r o s s - f e e d c a p a b i l i t y . C o v e r p l a t e s and s e a l s c l o s e the LOX a n d fuel
b u l k h e a d s w h e r e l i n e s a r e r e m o v e d . H e a t s h i e l d p a n e l s and s u p p o r t s
f r o m o t h e r l o c a t i o n s r e p l a c e t h o s e u s e d w h e r e the e n g i n e i s m o u n t e d .
T h i s i n s t a l l a t i o n c a n be m a d e on a n y S-IC s t a g e w i t h i n s u l a t e d LOX
d u c t s . C o n v e r s e l y , a n S-IC I N T - 2 0 could r e a d i l y b e r e t u r n e d t o the
Saturn V configuration.
13
D5-13183
COVEK PLATE
COVE* PLATE
HIPLACES
CENTER ENGME
-20 »p SAT V
HEAT SKIEID
19
D5-13183
The reliability of the MOM GIMBAliD f-l'S GIMBALEB F-1'S GIMBAliD F-l'S
INT-20 is 0. 999 and the INT-21
is the same a s the baseline MAX. WFtfCTION Z.3BFG. £3 KG. 1SMG.
ANGLE INFLIGHT
AS-516 reliability of 0. 990.
P e r f o r m a n c e data w e r e HEATING
developed for the INT a for TYP AERODYNAMIC S-|C 1«°F lift 16I°F
numerous m i s s i o n s . The W 0 SOI MAX. IHU
20
D5-13183
-a LAUNCH AZIMUTH
W
T*„-|.25.
T«„-I.B
S-IVB BOOST TURNING
to
POLAR ORBITy
70 ttN
(ORBIT IHCLIWTKW-*!/ V»NM
so JO MM
100 200 300 *» $
ORBITALTIIUOEIHN. MILES 100 N* X SUN SYNCHRONOUS
ORBIT
FIGURE 4-5 I N T - 2 1 ORBIT m
ALTITUDE
AZIMUTH PAYLOAD
3D
CAPABILITY i3o i« iM m
LAUNCH AZIMUTH DFG
F I G U R E 4 - 6 I N T - 2 0 P O L A R Sr SUN
SYNCHRONOUS P A Y L O A D
(DIRECT ASCENT)
T/W 0 - f. 25
S-l I BOO ST TURNING
DIRECT ASCENT
ca
—> ZOO .80 NM
100 NM
< .80 NM
o
100 NM
POLAR
ORBIT
150
SUN SYN
ORBIT
irx
130 140 150 160
INITIAL LAUNCH AZIMUTH -DEC
FIGURE 4-7 SYNCHRONOUS ORBIT P A Y L O A D
CAPABILITY
21
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4.2.3 Resources
Study g r o u n d r u l e s r e q u i r i n g s i x i n t e r m e d i a t e a n d s i x S a t u r n V v e h i c l e s
p e r y e a r h a v e t h e s t r o n g e s t influence on r e s o u r c e s . T h e g r e a t e s t
i m p a c t on f a c i l i t i e s o c c u r s a t M I L A . H e r e , 100 m i l l i o n d o l l a r s a r e
r e q u i r e d for an additional mobile launcher, a mobile s e r v i c e s t r u c t u r e , and
f i r i n g r o o m e q u i p m e n t . O t h e r l a u n c h s y s t e m m o d i f i c a t i o n s and e q u i p m e n t
a r e about 23 m i l l i o n d o l l a r s .
1968 I9W 1970 1971 1772
2 I 3 i-U-U J_U 3 2 3 A 2 3 1 Z 3 4
PDP
CQMPUTt M?
DFSIGN& FACILITIES 7 I
AS?{MiU TFSTAIMSfC
DYNAMIC TEST (AS-500-DTV)
I I
H E WW CONST SEAOY ffLAUNOf SIYHRIMIXS WWBAMI
LC-39 7
16 SAT V, 6 INT PER YEAR)
I I
517 iW 5 ? W3
AS-515 A ON 0 0 0 *ONMYR
M H O
INTERMEDIATE DELIVERIES
-INT-516 HltlimillliMUlTiiimimnTi HMlO IRM -OTOtoi
-518 iiiiimiiiBniMiimilnliiillllllUTrnre
T a b l e s 4-III a n d 4 - I V s u m m a r i z e t h e c o s t s t h a t would be i n c u r r e d f o r
i m p l e m e n t i n g I N T - 2 0 a n d I N T - 2 1 , r e s p e c t i v e l y , p l u s t h e c o s t for 30 v e h i c l e s
including l a u n c h .
22
D5-13183
LAUNCH W H I C H * 1 1 • 1
FACILITIES
S-IC STAGE 112 a:
S - I W STAGE 4.4 4.4
LAUNCH WHICLE-KSC 12LT 3(42
FACILITIES TOTAL 134.4 3W-1 wo
SYSTEMS ENGINEERING AND 1NTFG«ATION 234,0 Z34.0
LAUNCH W H I C H
S-IC STAGE 14 508.3 2549 7*9.1
S-ll STAGE 13.* 444.4 174 8 634-1
S - I V I STAGE (INTERSTAGE]* 43.3 43.3
INSTRUMENT UNIT 128.2 L&2
IT. 5 1129.2 433.7 1540.4
LAUNCH WHJCLETOTAL
GROUND SUPPORT EQUIPMENT
4.1 27.0 341
S-IC STAGE
S - l l STAGE 2L1 2L1
FACILITIES
S-IC STAGE 13.2 13.2
.« .4
5-11 STAGE
LAUNCH WHICLE-KSC 1215 393.2 S14 7
137.3 393.2 5345
FACILITIES TOTAL
234.0 Z3A0
SYSTEMS ENGINEERING t INTEGRATION
1&9 U04.5 4317
LAUNCH SYSTEMS TOTAL
10 9 ZOL2 KB.I
•ADAPT S - l l TO IU
23
D5-13183
ion
AlASaiKVEHIOfS
v -» I
m
i «
-1 I
I»UF-I ; -Z1ISF-I
(UttK "" +&
-MUM —-^
M UF-l
20B (D40K
-SMOO 01UF-U7! «DK|
•titmo
100
zoo 300
PAYlQMI-K?LISraiNMOIttiT
[
Figure 4-9 s u m m a r i z e s the payload cost efficiency of the eight INT
vehicles (solid lines) not including R&tD flights. The dotted lines a r e
vehicles similar to INT-20 and INT -21 but using the ML.V-SAT-V-3B
stages (see Section 5.0 of t h i s document). T h e s e data demonstrate that
c:
INT vehicles could be derived from any of the uprated configurations
studied. The s t r a p - o n s y s t e m s , in addition to first and third or first
and second stage combinations, can also be assembled with z e r o , two,
c:
or four b o o s t - a s s i s t units.
r
L
L"
24
-J
D5-13183
25
D5-13183
STA 4604.5
r
396 DIA PAYLOAD- 4439
3 6 7 , 4 0 0 lbs.
4248
iJ
260 DIA PAYLOAD
160,600 lbs.
I.U. 3879 •
(3rd Stags) ' 3843
: 3721
MS-IVB A L 3 = 16.5 ft.
TMR = 5 = 1
W p 3 = 350 K lbs.
I x 4 0 0 K lbs. 110' 3277
Toroidal Eng.
3l6a5
II
(2 StogeM
C' \
7 \
3075 (Engine Gimbal)
2941 •
2810
2 o 7 7 •
410 f t
365
i i STA -115.5
"I
FIGURE 5-1 MLV-SAT-V-3B BASELINE LAUNCH VEHICLE
26
D5-13183
5 . 0 M L V - S A T - V - 3 E LAUNCH V E H I C L E S
T h e v e h i c l e , a s d e f i n e d i n t h e t r a d e study a c t i v i t y and s t u d i e d in
d e t a i l in t h e P h a s e II a c t i v i t y , i s a f e a s i b l e c o n f i g u r a t i o n and a Logical
c a n d i d a t e to p r o v i d e p a y l o a d s in e x c e s s of t h o s e c u r r e n t l y a v a i l a b l e
with the Saturn V vehicle.
5. 1 C O N F I G U R A T I O N S E L E C T I O N ( P H A S E I)
T r a d e s t u d i e s w e r e d i r e c t e d t o w a r d s d e r i v i n g s u f f i c i e n t d a t a to
a l l o w M S F C to d e t e r m i n e the b e s t c o m p r o m i s e M S - I I - 3 B s t a g e t h r u s t
l e v e l which s a t i s f i e d r e q u i r e m e n t s for b o t h the S A T - V - 3 B t h r e e - s t a g e
v e h i c l e and the M L V - S A T - I N T - 1 7 t w o - s t a g e v e h i c l e . T h e I N T - 1 7 u s e s
the S A T - V - 3 B u p p e r s t a g e s ( M S - I I / M S - I V B ) a s a g r o u n d l a u n c h v e h i c l e ,
a n d w a s s t u d i e d c o n c u r r e n t l y by N o r t h A m e r i c a n A v i a t i o n u n d e r s e p a r a t e
contract.
U p p e r s t a g e p r o p u l s i o n c o n s i d e r e d t w o a d v a n c e d engine c o n c e p t s ,
a t o r i o d a l a e r . o s p i k e e n g i n e a n d an a d v a n c e d b e l l e n g i n e ( s e e F i g u r e 5 - 2 ) .
5. 1. 2 Trade Studies
27
D5-13183
r
ADVANCED L
J - 2 (REF)
B E L L ENGINE
L
L
51.25"©
L
[
[
EXIT P L A N E
28
D5-13I83
thrust of around two million pounds using 400, 000 to 500, 000 pounds of
thrust per engine. Seven 300, 000 pound t h r u s t second stage engines
show a 2. 6 p e r c e n t i n c r e a s e over five 400, 000 pound thrust engines.
The lower t h r u s t engines
ffflfl OPTIMIZED WITH «0ffETVFHFCL£ UNOHLIMIT
rlH
exhibit better p e r f o r m a n c e r ~ f FIXED UPPER STAOS
because engine length was m i * aw 1 in
held constant. To d e c r e a s e m
engine thrust, the nozzle
on 7««K
rv\mm Wft "*
m //JaLi-o »L,-0
•i*
t h r o a t a r e a was d e c r e a s e d £3K>
J.H, I * SDK
ie:
thereby i n c r e a s i n g engine MR-41 7 ALj-lS' 4(HK
SHOOK
a r e a ratio and thus specific «7i«0K
impulse. Higher mixture I* JW-fcl
»S
ratio (6:1) in upper stages (WT-LTOrT)
<5XM •IB
showed a s m a l l payioad M HW-flPTl
improvement a s indicated. SO BO
3»
•m
These t r a d e study data,
KLL TOROIDAl BfU TOROIDAL
those p r e p a r e d on MLV-SAT-
INT-17 and t h e i r respective
t r a d e study r e s o u r c e analysis
were c o m p a r e d by NASA/MSFC FIGURE 5-4 TRADE STUDY VEHICLE
PAYLOAD COMPARISON
29
D5-13183
i n o r d e r to r e a c h a c o m p r o m i s e on engine quantity, t h r u s t , a n d t y p e . It
w a s found t h a t t h e I N T - 1 7 v e h i c l e would o p e r a t e m o s t efficiently a t
a p p r o x i m a t e l y 3 . 0 m i l l i o n p o u n d s of t h r u s t . On t h e o t h e r h a n d ,
S A T - V - 3 B n e e d s a s e c o n d s t a g e t h r u s t c l o s e r to 2 . 0 m i l l i o n p o u n d s for
m o s t efficient o p e r a t i o n . F a r t h e r , t h e S A T - V - 3 B t h i r d s t a g e r e q u i r e s
n o t m o r e t h a n 180, 000 p o u n d s of t h r u s t f o r m o s t efficient o p e r a t i o n .
N A S A / M S F C s e l e c t e d a c o m p r o m i s e s e c o n d s t a g e t h r u s t of 2 . 8 m i l l i o n
p o u n d s , s e v e n 400 t h o u s a n d pound e n g i n e s , for f u r t h e r s t u d y . T h e
c o m p r o m i s e d p e r f o r m a n c e by t h i s c h o i c e is i n d i c a t e d on F i g u r e 5 - 5 .
A l s o i n d i c a t e d i s the d e g r a d a t i o n to S A T - V - 3 B which would h a v e r e s u l t e d
had NASA c h o s e n a s t i l l h i g h e r t h r u s t Level {3. 0 m i l l i o n p o u n d s ) . M S F C
s e l e c t e d t h e t o r o i d a l a e r o s p i k e engine r a t h e r t h a n the b e l l nozzle e n g i n e
s i n c e t h e b e l l w a s e x a m i n e d i n d e t a i l in l a s t y e a r ' s s t u d i e s .
-38 SATV
LOAD OHTERIA
... , • • • - —
MAX,fl (IBSFI 2 ) 735 ?»
i i « V
wa V , HEIGHT m i
CONTROL
410 363
IS-IC nw am 167°F
D e s i g n and a n a l y s e s w e r e c o n d u c t e d for t w o - a n d t h r e e - s t a g e
S A T - V - 3 B v e h i c l e s u s i n g the p r o p u l s i o n s y s t e m s c h o s e n by M S F C .
C o m p l e t e r e s o u r c e s w e r e p r e p a r e d for t h e t h r e e s t a g e v e h i c l e .
5. 2 . 1 Vehicle Description
The M L V - S A T - V - 3 B b a s e l i n e v e h i c l e i s s h o w n in F i g u r e 5 - 1 . The
M S - I C - 3 B s t a g e u s e s five 1. 8 m i l l i o n pound t h r u s t u p r a t e d F - l e n g i n e s .
F i r s t s t a g e l e n g t h i n c r e a s e i s 20 feet for a p r o p e l l a n t c a p a c i t y of 5. 6
m i l l i o n p o u n d s with a p r o p e l l a n t loading ( T / W o = 1.25) of 4. 99 m i l l i o n
p o u n d s and 4. 8 m i l l i o n p o u n d s f o r the two and t h r e e s t a g e v e h i c l e s ,
r e s p e c t i v e l y . T h e s e c o n d s t a g e h a s s e v e n 400, 000 pound t h r u s t t o r o i d a l
a e r o s p i k e e n g i n e s . It h a s a l e n g t h i n c r e a s e of 15. 5 feet f o r a p r o p e l l a n t
c a p a c i t y of 1.29 m i l l i o n p o u n d s . T h e s h o r t e r t o r o i d a l e n g i n e s a l l o w s a
6 2 - i n c h r e d u c t i o n in i n t e r s t a g e length t h e r e b y p e r m i t t i n g a c o m m e n s u r a t e
30
D5-13183
t a n k a g e i n c r e a s e . The t h i r d s t a g e (for t h r e e s t a g e a p p l i c a t i o n ) u s e s a
s i n g l e 400, 000 p o u n d t h r u s t t o r o i d a l a e r o s p i k e e n g i n e , a 1 6 . 5 foot l e n g t h
i n c r e a s e f o r a p r o p e l l a n t c a p a c i t y of 350, 000 p o u n d s of p r o p e l l a n t .
5.2.2 D e s i g n Study R e s u l t s
S i g n i f i c a n t l o a d c r i t e r i a , a n d o t h e r d a t a p e r t i n e n t to v e h i c l e d e s i g n ,
a r e s h o w n on T a b l e 5 - 1 , w i t h c o m p a r a t i v e S a t u r n V v a l u e s . Although
m a x i m u m d y n a m i c p r e s s u r e (q) a n d a c c e l e r a t i o n a r e s l i g h t l y l e s s for the
31
D5-13183
S A T - V - 3 B the i n c r e a s e i n v e h i c l e h e i g h t , t h e 33-foot d i a m e t e r t w o - s t a g e
payload, and i n c r e a s e d engines t h r u s t s have significantly i n c r e a s e d
s t r u c t u r a l l o a d s o v e r t h e e x i s t i n g S a t u r n V.
C o n t r o l m a x i m u m d e f l e c t i o n a n g l e i n flight h a s i n c r e a s e d f r o m 3 . 5
d e g r e e s (on S a t u r n V) to 4 . 3 d e g r e e s u s i n g the c u r r e n t a t t i t u d e , a t t i t u d e
r a t e c o n t r o l s y s t e m . T h i s i s w e l l within the c u r r e n t 5. 15 d e g r e e g i m -
b a l i n g c a p a b i l i t y of F - l e n g i n e s . A l t e r n a t e c o n t r o l m o d e s t u d i e s s h o w e d
t h a t a p p r o x i m a t e l y 12 p e r c e n t r e d u c t i o n i n m a x i m u m b e n d i n g r e s p o n s e
c o u l d b e e x p e c t e d if an a n g l e of a t t a c k f e e d b a c k loop w e r e a d d e d to t h e
attitude, attitude r a t e control mode.
Both a e r o d y n a m i c a n d b a s e h e a t i n g t e m p e r a t u r e s on the S A T - V - 3 B
v e h i c l e a r e c o m p a r a b l e to S a t u r n V.
The r e l i a b i l i t y of t h e
two and t h r e e stage c o n -
f i g u r a t i o n of S A T - V - 3 B
v e h i c l e i s 0. 975 a n d 0. 9 6 5 ,
respectively, as compared.
to 0. 990 a n d 0. 980 for t h e
baseline AS-516.
The a d d i t i o n a l
p r o p e l l a n t in a l l s t a g e s
i n c r e a s e s the 0. 4 p s i
on-pad explosive o v e r -
p r e s s u r e range 600/feet
c o m p a r e d to S a t u r n V but C3(TWICI SPECIFIC WRCY) - KmhKp
not enough to i m p a c t t h e
adjacent pad at MILA. F I G U R E 5-7 HIGH E N E R G Y P A Y L O A D
CAPABILITY
S a t u r n V flight and c r e w p r o v i s i o n s a r e s a t i s f a c t o r y f o r u s e with t h i s
v e h i c l e . No p r o b l e m s w e r e found w i t h s t r u c t u r a l d y n a m i c s , R F a t t e n u a t i o n
o r a n t e n n a look a n g l e .
S t r u c t u r a l l o a d s a n d a c o u s t i c e n v i r o n m e n t s a r e i l l u s t r a t e d on F i g u r e
5 - 1 0 , T h e a c o u s t i c l o a d s h a v e i n c r e a s e d s l i g h t l y in the f i r s t s t a g e but
a r e w i t h i n the e x i s t i n g s p e c i f i c a t i o n l i m i t . S o m e s e l e c t i v e r e q u a l i f i c a t i o n
of c o m p o n e n t s m a y be r e q u i r e d . T h e s e c o n d s t a g e a c o u s t i c l e v e l h a s
i n c r e a s e d sufficiently f r o m the s t a t i c f i r i n g of s e v e n 4, 000, 000 pound t h r u s t
t o r o i d a l e n g i n e s and i n f l i g h t c o n d i t i o n s to r e q u i r e a n e w s p e c l i m i t for t h i s
s t a g e . No p r o b l e m s e x i s t in t h e t h i r d s t a g e .
As shown in F i g u r e 5 - 1 0 , t h e c o m b i n e d l o a d i n g c o n d i t i o n h a s i n c r e a s e d
s i g n i f i c a n t l y c o m p a r e d to S a t u r n V, r e q u i r i n g a m a j o r s t r u c t u r a l beefup a s
32
D5-13183
130 !« 150 i« m
LAUNCH AZIMUTH - OtGS
LAUNCKAZIMI/m DECS
a s shown in F i g u r e 5 - 1 1 . P e r c e n t a g e i n c r e a s e s in d r y w e i g h t s of e a c h
S A T - V - 3 B s t a g e a r e a l s o t a b u l a t e d in F i g u r e 5 - 1 1 .
5. 3 RESOURCES
I n c r e a s e s in t h e length a n d t h r u s t of t h e S A T - V - 3 B - s t a g e s c o m p a r e d
to S a t u r n V i m p a c t production,- t e s t , t r a n s p o r t a t i o n and l a u n c h f a c i l i t i e s .
U p r a t e d F - 1 e n g i n e and new t o r o i d a l u p p e r s t a g e engine d e v e l o p m e n t s a r e
the m o s t c o s t l y i t e m s r e q u i r e d . E x i s t i n g f a c i l i t i e s w i l l be e m p l o y e d to
m a n u f a c t u r e a n d t e s t t h e M L V - S A T - V - 3 B . T h e s e f a c i l i t i e s a r e to be u s e d
on a n o n - i n t e r f e r e n c e b a s i s with n o r m a l S a t u r n V p r o d u c t i o n s c h e d u l e s ,
T h e p r e s e n t s t a g e a n d I. U. v e n d o r s w e r e a s s u m e d to be c o n t r a c t o r s for
the modified vehicle components.
A d y n a m i c t e s t v e h i c l e , s t r u c t u r a l t e s t c o m p o n e n t s , and two m a n -
r a t i n g R&D flights a r e r e q u i r e d . R e l o c a t i o n of w o r k p l a t f o r m s and i n c r e a s e
in h e i g h t is r e q u i r e d a t the M S F C D y n a m i c T e s t S t a n d to h a n d l e the new
c o n f i g u r a t i o n . T h e f i r s t s t a g e of the d y n a m i c t e s t v e h i c l e will be r e f u r -
b i s h e d a f t e r t e s t a n d u s e d a s a flight s t a g e . The s e c o n d s t a g e of the
d y n a m i c t e s t v e h i c l e will h a v e u n d e r g o n e s t r u c t u r a l s t a t i c t e s t p r i o r to
-D t e s t i n g .
33
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STATIC IN rStATfCFIRING
, INFLIGHT , LAUNCH FIRWCAICHP IB FLIGHT STATIC FIRING. LAUNCH
E
145 SATVSWC
3ATVSWC
J-
u: 155
MLV-SAT-V-3B
l«
-MAX4.K
GROUW r WBOUND
A p r o d u c t i o n r a t e of s i x v e h i c l e s p e r y e a r for a p e r i o d of five y e a r s
w a s u s e d to a s s e s s p r o d u c t i o n i m p a c t . A c o m p a n i o n i n t e r m e d i a t e p a y l o a d
v e h i c l e , a l s o p r o d u c e d a t s i x p e r y e a r for five y e a r s , w a s t h e S a t u r n IB,
m a k i n g u s e of t h e M S - I V B - 3 B .
MS-IC-3B
The t h r u s t i n c r e a s e f r o m 7 . 5 to 9- 0 m i l l i o n pounds n e c e s s i t a t e s
i n c r e a s e s in s k i n s t i f f e n e r a n d r i n g f r a m e g a g e t h r o u g h o u t the M S - I C
s t a g e . T h e s e c h a n g e s p l u s t h e i n c r e a s e in s t a g e length r e q u i r e r e q u a l -
ification of t h e e n t i r e s t r u c t u r e .
34
FORWARD SKIRT
77% > STRENGTH
AFT SKIRT
86% > STRENGTH
NEW
COMMON BLKD TOROIDAL ENGINE
INCREASED RADIUS FORWARD SKIRT
142% > STRENGTH
THRUST STRUCTURE LH2 TANK
NEW DESIGN 66' 44% > STRENGTH
7 NEW TO
LOX TANK
ADDITIONAL FRAMES
NEW FEED LINES
ONE ADDITIONAL
HELIUM BOTTLE
DRY WEIGHT INCREASE
MS-1C-3B- 14.2% INTERTANK
MS-ll-3B-35.6% 41% > STRENGTH
MS-IVB-3B-22.5%
THRUST S
FIGURE 5-L1 SAT-V-4(S)B VEHICLE IMPACT 35% > ST
D5-13183
T i m i n g Of the M S - I C - 3 B p r o d u c t i o n i s p a c e d by u p p e r s t a g e r e q u i r e -
m e n t s ; t h e r e f o r e . A u t h o r i t y to P r o c e e d i s not r e q u i r e d u n t i l 26 m o n t h s
a f t e r s t a r t of the u p p e r s t a g e p r o g r a m s . With t h i s t i m i n g , t h e f i r s t flight
a r t i c l e will be d e l i v e r e d t o MI3-.A 3 . 5 y e a r s a f t e r f i r s t s t a g e A T P .
MS-H-3B
The s t r u c t u r e a n d p r o p u l s i o n s y s t e m c h a n g e s t o t h i s s t a g e w i l l
n e c e s s i t a t e s t a t i c and d y n a m i c s t r u c t u r a l t e s t s a n d a " b a t t l e s h i p " t e s t
d e v e l o p m e n t p r o g r a m . T o m e e t t h e r e q u i r e d d e l i v e r y d a t e of t h e d y n a m i c
t e s t s t a g e , p r o d u c t i o n of t h e s t a n d a r d S-II would be a c c e l e r a t e d , s t a r t i n g
with S - I I - 1 8 . Two flight t e s t s t a g e s a r e i n c l u d e d in the d e v e l o p m e n t p h a s e .
S t a n d a r d t r a n s p o r t e q u i p m e n t i s g e n e r a l l y c o m p a t i b l e with t h e
&1S-II-3B, a l t h o u g h l e n g t h e n i n g of s t a g e t r a n s p o r t e r s would b e n e c e s s a r y ,
a s well a s m i n o r m o d i f i c a t i o n s s u c h a s r e l o c a t i o n of tie downs oh t h e
P o i n t B a r r o w , B o t h T y p e I and T y p e II t r a n s p o r t e r s c a n h a n d l e the a d d e d
weight, e x c e p t t h a t t i r e l o a d s m a y be e x c e s s i v e on t h e T y p e I I .
D e l i v e r y of t h e d y n a m i c t e s t s t a g e , n i n e m o n t h s p r i o r to the f i r s t
flight s t a g e , d e t e r m i n e s t h e point a t w h i c h p r o d u c t i o n of the s t a n d a r d S-II
would be p h a s e d out to a l l o w p h a s e - i n of n e w tooling for t h e M S - H - 3 B .
T h e s t r u c t u r e a n d p r o p u l s i o n s y s t e m r e v i s i o n s r e q u i r e m o d i f i c a t i o n of
s t a n d a r d tools o r d e s i g n of n e w t o o l s . T o o l i n g m a i n l y affected i s t h a t for
m a n u f a c t u r e of t h e LH-, t a n k , f o r w a r d a n d aft s k i r t s , i n t e r s t a g e , LOX
tank e x t e n s i o n and new t h r u s t s t r u c t u r e .
The S e a l B e a c h f a c i l i t y r e q u i r e s s o m e m o d i f i c a t i o n s , i n c l u d i n g m i n o r
building e x t e n s i o n s and r e v i s e d a s s e m b l y s e q u e n c e s . New f a c i l i t i e s
a r e n o t n e c e s s a r y , but s t a g e a s s e m b l y and buildup t o o l s will be m o d i f i e d .
Handling e q u i p m e n t a t a l t f a c i l i t i e s w i l l be m o d i f i e d for the i n c r e a s e d s t a g e
weight. M o d i f i c a t i o n a n d c h e c k o u t of the S t a t i c "Test T o w e r would b e
c o m p l e t e d in D e c e m b e r 1 9 7 1 , -the d y n a m i c t e s t s t a g e s h i p p e d to M S F C in
D e c e m b e r 1971, a n d t h e f i r s t o p e r a t i o n a l flight s t a g e c o m p l e t e d in
S e p t e m b e r 1973.
MS-lVBj-_3B
E n g i n e e r i n g d e s i g n o r r e d e s i g n effort i s n e e d e d m a i n l y in the s t r u c t u r e
a n d p r o p u l s i o n s y s t e m a r e a s b e c a u s e of t h e i n c r e a s e d t a n k v o l u m e ,
h i g h e r flight l o a d s a n d t h e i n s t a l l a t i o n of a new t y p e h i g h e r t h r u s t e n g i n e .
D e v e l o p m e n t a n d q u a l i f i c a t i o n e f f o r t i n v o l v e s a m o d e r a t e a m o u n t of w o r k
a s s o c i a t e d with the s a m e v e h i c l e c h a n g e s . A d y n a m i c t e s t s t a g e will be
f u r n i s h e d for t e s t a t N A S A / M S F C to v e r i f y p r e d i c t e d v i b r a t i o n m o d e s
and f r e q u e n c i e s .
36
D5-13183
Schedule
Cost
37
D5-I3183
LAUNCH VEHICLE
S-IC 3 t » g e 70.0 123.0 596.3 439.7 1214.0
S-II S t a g e 165.7 336, Z 551.1 686.9 1774.;
S-IVB Stage 97.8 62.9 362.4 114.4 642.4
I n s t r u m e n t Unit 130.7 130.7
GROUND S U P P O R T E Q U I P M E N T
S-IC Stage 10. Q £1.9 31.9
S-II S t a g e 2B.1 64.8 92.9
S-IVB S t a g e 33.7 48.5 82.2
FACILITIES
Toroidal Engine a 39,2 39.2
S-IC Stage 13.3 13. 3
S-II S t a g s 21.7 21.7
S-IVB Stage 7.2 5.4 12.6
L a u n c h Vehicle - K5C 81.7 721.8 BG3.5
Launch Vehicle - Other 4.a 4. e
FACILITIES TOTAL 128.7 39.2 727.2 895.1
39
D 5-13183
STA 4804.5
T
4439
396 DIA PAYLOAi
493,900 LBS
4248
2 6 0 " DIA PAYLOAD
I.U.
(3rd Stage)
i 188,800 LBS
3955 •
3919
J 3797
A L = IG.5 ft.
MS-IVB W P = 3 5 0 K lbs.
I x J-2 3330.5
MR = 5 - 1
LU--1-
(2ndT
i_L [ \f \
3244.5
3144
3017
(Engine Gimbal)
Stage)1 2885.5
410 f t
AL = 0 ft.
MS-II «p5=930 K lbs.
5 x J-2 2346
MR = 5 : I
2258 •
w •v
2162 (Engine Gimbal)
2062
2039
•
r /\ /\ /\ 1899
AL = 41.5 ft.
W P j = 6 . 6 4 M lbs.
SEPARATION
5 x 1522 K F-[
1360
MS-IC
A" 1098.5
998.5 (Fwd Attach)
116 ( A f t Attach)
Li
100 (Engine Gimbal)
i STA - 115.5
40
D5-13183
T h e S a t u r n V-25(S) v e h i c l e ( s e e F i g u r e 6-1) i s a S a t u r n V w i t h l e n g t h -
ened f i r s t a n d t h i r d s t a g e s , a d a p t e d for a t t a c h m e n t of four 1 5 6 - i n c h d i a m e t e r
solid p r o p e l l a n t m o t o r s .
6. 1 C O N F I G U R A T I O N S E L E C T I O N (PHASE I)
By v a r y i n g t h e weight and t h r u s t of t h e 1 5 6 - i n c h s o l i d r o c k e t m o t o r s
and the w e i g h t of p r o p e l l a n t in t h e c o r e s t a g e s , a n u m b e r of r e l a t e d
SAT-V-25(S) v e h i c l e s w e r e e v o l v e d . P a y l o a d c a p a b i l i t y and v e h i c l e c o s t s
w e r e e s t a b l i s h e d for t h e s e v e h i c l e s in o r d e r to c h o o s e one a r r a n g e m e n t for
m o r e detailed analysis.
F i g u r e 6-2 i s t y p i c a l of the p a r a m e t r i c
p e r f o r m a n c e d a t a p r e p a r e d for t h e t r a d e
study. F i g u r e 6-2 i l l u s t r a t e s t h e n e t p a y -
l o a d for the v a r i o u s n u m b e r of s e g m e n t s in
t h e 1 5 6 - i n c h m o t o r s a s a function of liftoff
t h r u s t - t o - w e i g h t f o r the t h r e e - s t a g e v e h i c l e .
T h i s c h a r t s h o w s two c o n d i t i o n s , i. e. ,
(1) o p t i m i z e d f i r s t s t a g e p r o p e l l a n t w e i g h t F I G U R E 6-2 P E R F O R M A N C E
with s t a n d a r d s e c o n d s t a g e p r o p e l l a n t w e i g h t , T R A D E DATA
41
D5-13183
and (2) optimized propellant weights for the f i r s t and second stages. The
MS-IVB in all c a s e s was sized to maximize payload out of 100 nautical
m i l e E a r t h o r b i t to l u n a r i n j e c t i o n . N o t e t h a t t h e c u r v e s a r e t h e l o c i of
m a x i m u m p a y l o a d r e s u l t i n g , f r o m c o n s i d e r i n g different c o n s t a n t solid m o t o r
web a c t i o n t i m e s c o m b i n e d with v a r i o u s c o r e v e h i c l e l a u n c h w e i g h t s .
a. P a y l o a d i n c r e a s e s a p p r o x i m a t e l y eight p e r c e n t with e a c h a d d i t i o n a l
solid motor segment.
b. A p a y l o a d i n c r e a s e of m o r e than two p e r c e n t a c c r u e s by o p t i m i z i n g
second s t a g e l e n g t h . T y p i c a l o p t i m i z e d S-H s t a g e length i n c r e a s e s a r e
on the o r d e r of an a d d i t i o n a l t e n f e e t .
c. Significant p a y l o a d i n c r e a s e s a r e a t t r i b u t a b l e to t h e s h o r t e r b u r n t i m e
solid r o c k e t m o t o r s and the r e s u l t i n g h i g h e r v a l u e s for liftoff t h r u s t - t o -
weight r a t i o ,
In d e v e l o p i n g t h e s e d a t a , no s t r u c t u r a l p e n a l t i e s w e r e a s s e s s e d to t h e
c a n d i d a t e v e h i c l e s for t h e liftoff t h r u s t - t o - w e i g h t v a r i a t i o n . When s t r u c -
t u r a l w e i g h t p e n a l t i e s , a r e c o n s i d e r e d , a s they w e r e in o t h e r s i m i l a r s t u d i e s ,
it i s found t h a t beyond 1. 6 t o 1.8 t h r u s t - t o - w e i g h t , p a y l o a d i n c r e a s e s a r e
not a s l a r g e a s i n d i c a t e d on F i g u r e 6 - 2 .
F i g u r e 6 - 3 c o m p a r e s the p a y l o a d c o s t e f f i c i e n c y
OPTIMIZED S-l I of d i f f e r e n t s o l i d m o t o r w e i g h t s for the o p t i m i z e d
S - I I s t a g e and s t a n d a r d l e n g t h S-II s t a g e . T h e
c h a r t i n d i c a t e s t h a t S-II s t a g e o p t i m i z a t i o n i s not
w o r t h w h i l e but t h a t l a r g e r solid m o t o r w e i g h t s
c a n s i g n i f i c a n t l y i m p r o v e v e h i c l e c o s t efficiency,
F r o m t h e s e d a t a , and b e c a u s e m i n i m u m s o l i d
m o t o r b u r n t i m e w a s g r o u n d r u l e d a t 100. 6 s e c o n d s ,
i t w a s r e c o m m e n d e d to M S F C t h a t the v e h i c l e
Z.M i n d i c a t e d a s " b a s e l i n e " on F i g u r e s 6-2 and 6 - 3 be
c h o s e n for t h e n e x t p h a s e of study. M S F C a p p r o v e d
this selection.
ira wo no 200
PAYUM0-IB5*I03
F I G U R E 6 - 3 COST E F F I C I E N C Y
T R A D E DATA
42
D5-131S3
6. 2. 2 Design Study R e s u l t s
Use of this vehicle was also considered for applications where the
baseline core vehicle (liquid stages without solids) could be flown by itself
o r with only two s t r a p - o n solid m o t o r s . The payloads identified for these
a l t e r n a t e s a r e shown on Table 6-1.
43.
D5-13183
T 0 / W o = 1.25
231,466 38,475
W p l = 4,343,423 lb
T 0 / W 0 = 1.18
239,558 91, 568
W P 1 = 4,696,492 lb
T Q /W Q = 1.40
387,073 147,954
W p i = 6,000,000
T 0 / W Q = 1.734
493,900 188,800
W p i = 6,640,000 lb
44
D5-13183
T h e r e l i a b i l i t y of the t w o - and t h r e e - s t a g e c o n f i g u r a t i o n s of
S a t u r n V-25(S) a r e 0. 986 and 0. 964, r e s p e c t i v e l y , a s c o m p a r e d to
0. 990 and 0. 980 for t h e b a s e l i n e A S - 5 1 6 . T h e l o w e r v a l u e s for r e l i -
a b i l i t y c a n b e a t t r i b u t e d to t h e a d d i t i o n of t h e s t r a p - o n solid m o t o r s and
to l o n g e r f i r s t and t h i r d s t a g e b u r n t i m e s .
45
D5-13183
t h i s d i s t a n c e w i l l b e r e q u i r e d for j o i n t u s a g e o£ t h e s e p a d s when e i t h e r
pad c o n t a i n s a fueled c o r e v e h i c l e with t h e solid m o t o r s a t t a c h e d .
S t r u c t u r a l l o a d s a n d a c o u s t i c e n v i r o n m e n t a r e i l l u s t r a t e d in F i g u r e 6 - 4 .
The d e s i g n l o a d s a r e h i g h e r t h a n t h o s e for the s t a n d a r d S a t u r n V r e q u i r i n g
an i n c r e a s e in v e h i c l e s t r u c t u r a l w e i g h t . T h e p r e s e n t a c o u s t i c s p e c i f i c a t i o n
l i m i t s a r e e x c e e d e d a t s e v e r a l l o c a t i o n s on t h e f i r s t s t a g e . R e q u a l i f i c a t i o n
of a c o u s t i c a l l y s e n s i t i v e c o m p o n e n t s on t h i s s t a g e w i l l be r e q u i r e d .
M a j o r c o r e v e h i c l e c h a n g e s i n c l u d i n g the i m p a c t of s t r u c t u r a l load
i n c r e a s e s i s s u m m a r i z e d in F i g u r e 6 - 5 . D r y w e i g h t i n c r e a s e s a r e a l s o
tabulated.
46
MM MM taatf titf M mJ Unl L-J L-J L-J U-J
-FORWA
LOX TANK 89% >
ADDITIONAL FRAMES
502% > STRENGTH
INTERSTAGE -
86% > STRENGTH
THRUST STRUCTURE
33% > STRENGTH
6. 3 RESOURCES
T h e p r e s e n t s t a g e , e n g i n e , a n d I . U. m a n u f a c t u r e r s w e r e a s s u m e d to
be c o n t r a c t o r s for the m o d i f i e d v e h i c l e . A d y n a m i c t e s t v e h i c l e , s t r u c t u r a l
t e s t c o m p o n e n t s , and two R&D flights for m a n - r a t i n g a r e r e q u i r e d . A new
d y n a m i c t e s t stand will be r e q u i r e d for t e s t of t h i s v e h i c l e s i n c e i t s launch
w e i g h t e x c e e d s p r e s e n t S a t u r n V stand c a p a b i l i t y . T h e S-IC s t a g e of the
d y n a m i c t e s t v e h i c l e w i l l b e r e f u r b i s h e d a f t e r t e s t and u s e d a s a flight
a r t i c l e . T h e 1 5 6 - i n c h s o l i d r o c k e t m o t o r s with t h e i r t h r u s t v e c t o r c o n t r o l
s y s t e m m u s t be d e v e l o p e d and qualified for t h i s a p p l i c a t i o n
A p r o d u c t i o n r a t e of s i x v e h i c l e s p e r y e a r for a p e r i o d of five y e a r s
w a s u t i l i z e d to a s s e s s the p r o d u c t i o n i m p a c t .
MS-IC-25(S.)
T h e l o n g e r , h e a v i e r t a n k s of t h e M S - I C - 2 5 ( S ) c a n n o t be h y d r o s t a t i c
t e s t e d in the p r e s e n t M i c h o u d VAB p o s i t i o n . A new stand w i l l be n e e d e d
and c a n be l o c a t e d in a p r e s e n t l y u n u s e d p o s i t i o n in that building. T h e
final a s s e m b l y and tank a s s e m b l y s t a t i o n s a l s o m u s t be modified for i n c r e a s -
ed s t a g e length
T h e two p r e s e n t l y u n u s e d s t a g e t e s t p o s i t i o n s m u s t be m o d i f i e d to
a c c e p t t h e l o n g e r S-IC s t a g e s . C a b l e s will b e i n s t a l l e d to t h e p r e s e n t
t e s t c o n t r o l s t a t i o n s a n d c o m p u t e r s . S o m e new t e s t e q u i p m e n t (solid m o t o r
s i m u l a t o r s ) and m i n o r m o d i f i c a t i o n of e x i s t i n g e q u i p m e n t i s r e q u i r e d .
A m i n o r m o d i f i c a t i o n to the s t a g e t r a n s p o r t e r c a b l e s and s t e e r i n g
p o t e n t i o m e t e r w i l l a d a p t i t f o r t h e new s t a g e l e n g t h . H o w e v e r , the
48
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Both shuttle and sea going barges must have their decks strengthened
and supports and tie downs relocated for the longer heavier stage.
MS-II-2 5 (S)
MS-IVB-25(5)
The elongated tank of the MS-IVB required by this vehicle has a signifi-
cant impact on r e s o u r c e s . The standard S-IVB facilities for manufacturing,
assembly, test and checkout will need modification to accommodate this
l a r g e r , heavier stage. Additional machine tools and space a r e required for
the detail p a r t manufacturing. The m o s t significant a r e a i s the skin m i l l s
for machining the tanks. The 24 to 36 month delivery time for these machines
make early delivery of modified stages difficult. The a s s e m b l y and checkout
towers must be reworked to i n c r e a s e their v e r t i c a l capacity. Welding torches,
platforms, and stage interfaces must be relocated and adapted to the new
vehicle. A complicated scheduling problem exists to provide time to modify
49
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the f a c i l i t i e s with m i n i m u m i n t e r f e r e n c e w i t h d e l i v e r y of s t a n d a r d s t a g e s .
T h i s r e q u i r e s a c c e l e r a t i n g t h e p r o d u c t i o n r a t e of the s t a n d a r d s t a g e s and
s t o r i n g t h e m for d e l i v e r y On t h e i r n o r m a l shipping d a t e . T h i s could o v e r -
l o a d s o m e of t h e c h e c k o u t t o w e r s a n d r e q u i r e e i t h e r e x t e n s i v e o v e r t i m e o r
a d d i t i o n a l f a c i l i t i e s and GSE. T h e s t a t i c f i r i n g a t S a c r a m e n t o r e q u i r e s
modifying t h e t e s t s t a n d . A s t r e a m l i n i n g of the t e s t p r o c e d u r e i s r e c o m m e n d -
ed a s a m e a n s of s i g n i f i c a n t l y r e d u c i n g t h e c o s t of t h e s e m o d i f i c a t i o n s . The
s t r e a m l i n i n g w o u l d p e r m i t m a k i n g t h e p o s t - f i r i n g c h e c k o u t in t h e t e s t stand
and e l i m i n a t e modifying t h e v e r t i c a l c h e c k o u t l a b o r a t o r y cells.-
T h e t r a n s p o r t i n g e q u i p m e n t will r e q u i r e s o m e r e d e s i g n a n d a l l s h i p -
m e n t s w i l l be by w a t e r s i n c e t h e p r e s e n t S u p e r Guppy a i r c r a f t c a n n o t c a r r y
the e l o n g a t e d s t a g e .
L a u n c h F a c i l i t y and .Launch O p e r a t i o n s I m p a c t
T h e i m p a c t of t h i s v e h i c l e on t h e l a u n c h f a c i l i t y and O p e r a t i o n s w a s
studied by T h e M a r t i n C o m p a n y u n d e r s e p a r a t e c o n t r a c t to K e n n e d y S p a c e
C e n t e r . T h i s study a c t i v i t y d e s c r i b e d the m i n i m u m i m p a c t l a u n c h s e q u e n c e s
for t h i s v e h i c l e a s shown below.
T h e m o d i f i e d c o r e v e h i c l e w i l l be a s s e m b l e d a c c o r d i n g to s t a n d a r d
p r o c e d u r e s in t h e VAB on a m o d i f i e d m o b i l e l a u n c h e r (ML) a n d w i l l
s u b s e q u e n t l y b e t r a n s p o r t e d to t h e p a d for a t t a c h m e n t of the solid r-ocket
m o t o r s . C o n c u r r e n t w i t h t h e c o r e v e h i c l e a s s e m b l y and c h e c k o u t , t h e
solid r o c k e t m o t o r s (SRM) s e g m e n t s and c l o s u r e a s s e m b l i e s w i l l u n d e r g o
r e c e i v i n g i n s p e c t i o n , c o m p o n e n t i n s t a l l a t i o n and i n d i v i d u a l c h e c k o u t in a
new m o b i l e e r e c t i o n and p r o c e s s i n g s t r u c t u r e (MEPS) at a r e m o t e s i t e .
After the liquid c o r e v e h i c l e on the m o b i l e l a u n c h e r h a s been s e c u r e d to
the l a u n c h p a d , t h e M E P S w i t h i n s p e c t e d s e g m e n t s and p r e - a s s e m b l y
c l o s u r e s for a l l four of t h e solid r o c k e t m o t o r s w i l l m o v e to t h e l a u n c h
pad and w i l l be m a t e d w i t h t h e m o b i l e l a u n c h e r and g r o u n d s t r u c t u r e f o r
t r a n s f e r o p e r a t i o n s of the s o l i d r o c k e t m o t o r s e g m e n t s ( s e e F i g u r e 6 - 6 ) .
Two c r a n e s m o u n t e d on t h e M E P S w i l l be u s e d to lift and a t t a c h the. aft
solid r o c k e t m o t o r c l o s u r e (with the p r e - a s s e m b l e d aft a t t a c h m e n t s k i r t )
to the liquid c o r e . A s s e m b l y of two S R M s w i l l b e a c c o m p l i s h e d c o n c u r r e n t l y .
T h e t h r e e c e n t e r s e g m e n t s and the f o r w a r d c l o s u r e w i l l then be s t a c k e d on
top of e a c h of t h e aft c l o s u r e s . T h i s p r o c e d u r e w i l l be d u p l i c a t e d for
a s s e m b l y and m a t i n g of t h e r e m a i n i n g two solid r o c k e t m o t o r s . After
a s s e m b l y i s m a d e and a l i g n m e n t of all four S R M s i s c o m p l e t e d , t h e M E P S
w i l l then be t r a n s p o r t e d b a c k to i t s p a r k i n g p o s i t i o n . F r o m t h i s point on,
the l a u n c h o p e r a t i o n s p r o c e e d in a m a n n e r s i m i l a r to t h o s e for t h e S a t u r n V
v e h i c l e wit,h t h e e x c e p t i o n of t h e a d d e d o p e r a t i o n s for i n t e g r a t e d s o l i d r o c k e t
m o t o r c h e c k o u t and f o r s o l i d r o c k e t m o t o r a r m i n g .
50
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i / - sim ABOUT t
-«*-s I I
ELEWIQH
F I G U R E 6-6 M O B I L E E R E C T I O N AND
PROCESSING STRUCTURE
I n t r o d u c t i o n of t h e 1 5 6 - i n c h solid r o c k e t m o t o r s i n c r e a s e s p a d
o c c u p a n c y t i m e f r o m 58 to 70 d a y s . H o w e v e r , e m e r g e n c y t a k e - d o w n
c a n b e a c c o m p l i s h e d in 39 h o u r s , w e l l w i t h i n t h e 7 2 - h o u r h u r r i c a n e
warning time.
M o d i f i c a t i o n s a t the l a u n c h p a d i n c l u d e r e i n f o r c e m e n t of t h e m o b i l e
l a u n c h e r s u p p o r t p i e r s and pad s t r u c t u r e a n d t h e p r o v i s i o n of h e a t s h i e l d s
for pad m o u n t e d e q u i p m e n t a n d ' s t r u c t u r e , new f l a m e d e f l e c t o r s and i m -
p r o v e d f l a m e d e f l e c t o r a n c h o r a g e , f l a m e p r o t e c t i o n for f l a m e t r e n c h
w a l l s , a u x i l i a r y e x h a u s t d e f l e c t o r s h i e l d s and i n c r e a s e d high p r e s s u r e
g a s a n d p r o p e l l a n t s t o r a g e c a p a b i l i t i e s . A d d i t i o n a l q u a n t i t y and flow
r a t e s of i n d u s t r i a l w a t e r w i l l be r e q u i r e d with i n c r e a s e d p u m p i n g c a p a c i t y
and u p g r a d i n g of t h e h y d r o m a t i c s y s t e m s . T h e w a t e r m a i n s s e r v i n g the
pad a r e a a r e a d e q u a t e without m o d i f i c a t i o n . E x i s t i n g e l e c t r i c a l power
and c o m m u n i c a t i o n s a r e s a t i s f a c t o r y .
T h e "mobile s e r v i c e s t r u c t u r e (MSS) w i l l r e q u i r e a h e i g h t e x t e n s i o n to a
51
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T h e c r a w l e r t r a n s p o r t e r w h i c h w i l l be u s e d to t r a n s p o r t t h e m o b i l e
l a u n c h e r and M E P S w i l l r e q u i r e u p r a t i n g by a p p r o x i m a t e l y 11 p e r c e n t
to h a n d l e the i n c r e a s e d l o a d s c a u s e d by t h e h e a v i e r MSS. T h e s e m o d i f i -
c a t i o n s w i l l i n c l u d e s t r u c t u r a l beefup and a n e w , m o r e p o w e r f u l s t e e r i n g
system.
Schedules
Costs
A v e h i c l e c o s t s u m m a r y i s shown in T a b l e 6-III-
52
J
D5-13183
J
] 1W | iw I 1W | ma
1 I 1 | 1 I < I I J I [ 3^41 1 j _?j 3 I t I 1 J 11 3 I « 1 1 M l I i
* P
)T ^ w 4
!!••••• IT *'
1971 1T7Z
Ijijlll
WHMHIFME
nw>i
I
DESIGN a FACILITIES SPttCOM-
-- niwn
DYNAMIC TEST OMCUttS COW
l .T
mrrnr
1
•IGMMH
L C - » MOO
STAGE DCVELOPMEHT
MMC'BIS)
I II
1 MS-ll-aS)
MS-IVB-ast
iimcr
tn
nwtiuit j
1
IBMI-D
JW'DIA SOLID S
t UNITS
a
IW
L •MkUUemMcoMun cime*«TH
t MFHSHMCOBUTI Wccotim
]
OCJK*. «K»mi
i sur-unflDititttMe * n-goc< »IL* SOtlSTttMCS
* mac s-ic STITIC r u n o IHMTRJOfl
tnocnvuiE
I LAUNCH VEHICLE
fiooit A s s i s t
5-lC Stage
5-11 S t a g e
77-1
58.7
96.7
640.1
513.8
440.5
273.8
IBS. 5
537.2
991.0
761.0
S-IVB S t a g e
1 I n s t r u m e n t Unit
LAUNCH V E H I C L E T O T A L
72.0
Z07.8 96.7
359. 1
136.1
1649. 3
37.7
940. 5
469.0
136.1
2894, 3
GROUND S U P P O R T E Q U I P M E N T
1 Boovt A s s i s t
S-IC S t a g e
S-II S t a g e
S-IVB S t a g e
17.0
11.5
5.5
26.4
57.6
5. 5
43.4
69.1
33.7 48. 5 S2.2
GSE T O T A L 62. Z 5. 5 132. 5 200.2
! FACILITIES
S-IC Stage 19.6 19-6
S-II S t a g e .7 .7
I S-IVB S t a g e
L a u n c h V e h i c l e - KSC
Launch Vehicle - Other
5.4
192.5
10.0
5.7
727.2
U.l
919-7
10.0
FACILITIES TOTAL ZZi.l 732.9 9*1.1
S Y S T E M S E N O I N E E R I N O fc I N T E G R A T I O N z.y 475.8 478.5
! LAUNCH SYSTEMS T O T A L 500.9 102.2 2990.5 940.5
60 3 39 31.0 4534.1
1
1
R i D F L I G H T S (2) 324.2
I
53
I
D5 -13183
STA 4804,5
4473.5
I.U. 3595
( 3 r d Stage] 3559
3437
3165
3082.5 •
2 9 8 2 (Engine Qimbal)
2891 •
2855 •
2723
MS-M flL = 0
Wp = 9 3 0 K lbs.
2184
5 x J-2 N 2096 •
MR = 5 = 1 2 0 0 0 (Engine Gitnba!)
1900 •
1877
1737
fiU = 28 ft.
MS-IC Wp = S M lbs. • SEPARATION
5 1 1522 K F-l
1196
T
Four 7 Segment (20
Solid Rochet Motors
1052
8 7 4 (Fwd A t t a c h )
732
WD '- 2 . 2 8 M lbs.
i i i STA - [15.5
54
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7.0 MLV-SAT-V-4(S)B
7. 1 C O N F I G U R A T I O N S E L E C T I O N ( P H A S E I)
7. 1. 1 Candidate Configurations
55
T A B L E 7-1 SOLID MOTOR CHARACTERISTICS
UA -1205 UA -120
15-Segment) (6-Segm
w e i g h t s fixed, a n d p r o p e l l a n t w e i g h t s f o r a l l s t a g e s o p t i m i z e d . F o r t h e
o p t i m i z e d v e h i c l e s , t h e S-IYB s t a g e would h a v e to be l e n g t h e n e d a p r o x i -
m a t e l y 14 f e e t w h i l e t h e S-II s t a g e r e m a i n s at i t s s t a n d a r d l e n g t h and t h e
S-IC s t a g e i s i n c r e a s e d in l e n g t h by a b o u t 28 feet. A s i m i l a r study of
t w o - s t a g e v e h i c l e s s h o w s the o p t i m u m c o r e v e h i c l e to b e b a s i c a l l y a
s t a n d a r d S-II s t a g e and a 2 8 - f o o t l o n g e r M S - I C s t a g e .
The F i g u r e 7-2 d a t a d e m o n s t r a t e s t h a t :
a. P a y l o a d i n c r e a s e s a p p r o x i m a t e l y 4 . 5 p e r c e n t with e a c h a d d i t i o n a l
solid motor s e g m e n t (increased solid propellant weight).
b. P a y l o a d gains of a p p r o x i m a t e l y 3 p e r c e n t a c c r u e by o p t i m i z i n g
p r o p e l l a n t w e i g h t s in a l l s t a g e s .
S i n c e study g r o u n d r u l e s s p e c i f i e d that
NO0F5FGMENTS
u p p e r s t a g e m o d i f i c a t i o n s be m i n i m i z e d ,
a fixed length u p p e r s t a g e v e h i c l e was
FIGURE 7-3 T R A D E STUDY
c h o s e n for the n e x t p h a s e of s t u d y . T h e
COST DATA
s e l e c t e d v e h i c l e i s i n d i c a t e d on F i g u r e s
7-2 and 7 - 3 a s " B a s e l i n e . "
7.2 DESIGN S T U D Y V E H I C L E ( P H A S E H)
The s i n g l e S A T - V - 4 ( S ) B s e l e c t e d d u r i n g the P h a s e I a c t i v i t y w a s
defined in d e t a i l , i t s c a p a b i l i t i e s and c h a r a c t e r i s t i c s w e r e d e t e r m i n e d
and i t s r e s o u r c e r e q u i r e m e n t s e s t a b l i s h e d .
57
D5-13183
T h e b a s e l i n e S A T - V - 4 ( S ) B v e h i c l e i s s h o w n i n F i g u r e 7 - 1 . It i n -
c o r p o r a t e s s t a n d a r d l e n g t h u p p e r s t a g e s and a 28-foot l o n g e r f i r s t - s t a g e
a u g m e n t e d by four s e v e n - s e g m e n t 120-inch r o c k e t m o t o r s . The solid
m o t o r s , a s d e s i g n a t e d by M S F C , c o n f o r m t o p r e l i m i n a r y d e s i g n s d e v e l o p e d
by U n i t e d T e c h n o l o g y C e n t e r for T i t a n H I - C a p p l i c a t i o n s . E a c h m o t o r
h a s an i n i t i a l s e a l e v e l t h r u s t of 1. 4 m i l l i o n p o u n d s a n d a p r o p e l l a n t
weight of 579, 000 p o u n d s . E a c h m o t o r h a s a l i q u i d i n j e c t i o n (NpO'j)
t h r u s t v e c t o r c o n t r o l s y s t e m to a u g m e n t the c o n t r o l c a p a b i l i t i e s of the
g i m b a l e d F - i e n g i n e s d u r i n g flight t h r o u g h the m a x q r e g i m e . The liquid
c o r e s t a g e s of S A T - V - 4 ( S ) B a r e e q u i p p e d with s t a n d a r d F - 1 and J - 2
e n g i n e s . T h e f i r s t s t a g e of the v e h i c l e i s r o t a t e d 45 d e g r e e s f r o m i t s
p o s i t i o n in the s t a n d a r d S a t u r n V c o n f i g u r a t i o n to m i n i m i z e t h e i m p a c t
on l a u n c h f a c i l i t i e s and o p e r a t i o n s . T h e s e c o n d s t a g e is s t a n d a r d
S-II l e n g t h with a p r o p e l l a n t c a p a c i t y of 930, 000 p o u n d s . The t h i r d
s t a g e (for t h r e e - s t a g e a p p l i c a t i o n s ) is s t a n d a r d S - I V B l e n g t h with 230, 000
p o u n d s p r o p e l l a n t c a p a c i t y . S i n c e study funds a n d t i m i n g w e r e l i m i t e d ,
the d e s i r a b l e i n c r e a s e d l e n g t h S - I V B w a s not s t u d i e d a n d the S-II s t a g e
for M L V - S A T - V - 2 5 ( S ) w a s u s e d d i r e c t l y on S A T - V - 4 ( S ) B .
1
7.2.2 D e s i g n Study R e s u l t s m LAWH AirMiJ™
1
'
iS-
-?^"^.
*v
The S A T - V - 4 { S ) B t w o - s t a g e BIHtCTASCENT
p a y l o a d c a p a b i l i t y to 100 n a u - i%?*:
180°
t i c a l m i l e s o r b i t i s 379 t h o u -
^
s a n d pounds and i t s 72 h o u r
lunar injection t h r e e - s t a g e
5
"fa
300
1
S*^ fs
^
a v **3$
N V_
c a p a b i l i t y is 139 t h o u s a n d V -s
,
pounds.
4 m
U s e of t h i s v e h i c l e w a s CUU
a l s o c o n s i d e r e d for a p p l i c a t i o n
w h e r e t h e c o r e v e h i c l e {liquid 1 V
A d d i t i o n a l s t u d i e s i d e n t i f i e d i n f o r m a t i o n u s e f u l for m i s s i o n p l a n n i n g .
P a y l o a d s a v a i l a b l e for v a r i o u s o r b i t a l a l t i t u d e s b e t w e e n 30 and 300
n a u t i c a l m i l e s a n d l a u n c h a z i m u t h s b e t w e e n 45 d e g r e e s a n d 180 d e g r e e s
a r e s h o w n in F i g u r e 7 - 4 . P o l a r a n d n e a r p o l a r qrb.it p a y l o a d s a r e shown
53
D5-13183
T 0 / W 0 =1.25
243,512 89,444
W„, = 7,387,368 lb
T /W Q = 1.18
° 251,683 92,445
W D 1 = 4,740,350 lb
T 0 / W 0 = 1.25
320,725 117,805
Wts, - 5,358,842 lb
T o / W 0 = 1.18
330,920 121,549
W D 1 = 5,855,789 lb
T 0 / W 0 = 1.25
379,300 139,300
W™ * 6,000,000 lb
59
D5-13183
?STAavrHICLESIN™lHAl«.S5IONPL-3mi i n F i g u r e 7 _ 5 _ T h r e e . s t a g e mission
Significant load c r i t e r i a a n d o t h e r d a t a
p e r t i n e n t to v e h i c l e d e s i g n a r e shown
on T a b l e 7-III with c o m p a r a t i v e S a t u r n
V v a l u e s . Although m a x dynamic p r e s s u r e
(q) and a c c e l e r a t i o n a r e r e d u c e d , c o m p a r e d
to SAT V, t h e 410-foot v e h i c l e h e i g h t
c o u p l e d with the 33-foot d i a m e t e r t w o -
stage payload shape has a l a r g e impact
on s t r u c t u r a l d e s i g n r e q u i r e m e n t s .
iw l« 150 T h e f i r s t s t a g e c o n t r o l r e q u i r e m e n t s of
UUNCHAZIMfTH- DFG the SAT-V-4{S)B n e c e s s i t a t e additional
F I G U R E 7 - 5 P O L A R & SUN c o n t r o l beyond t h e p r e s e n t fins and g i m b a l
SYNCHRONOUS ORBIT c a p a b i l i t y of the F - l ' s u s i n g the c u r r e n t
PAYLOAD CAPABILITY attitude, attitude rate control system.
A l t e r n a t e c o n t r o l mode s t u d i e s s h o w e d
t h a t a p p r o x i m a t e l y a 5 p e r c e n t r e d u c t i o n in m a x i m u m b e n d i n g r e s p o n s e
could be e x p e c t e d if an a n g l e of a t t a c k f e e d b a c k c o n t r o l m o d e w e r e e m -
p l o y e d . T h e u s e of t h e l i q u i d i n j e c t i o n t h r u s t v e c t o r c o n t r o l on t h e s o l i d
m o t o r is r e q u i r e d for
-HIGHFMESGV 21 HOUR SYNCHRONOUS ORBIT
30 s e c o n d s n e a r m a x i -
m u m q t i m e of flight,
a s shown i n T a b l e 7-111.
S i n c e the s o l i d m o t o r
TVC r e q u i r e m e n t s a r e
l e s s t h a n the T i t a n I I I - C ,
the liquid i n j e c t a n t t a n k s
w i l l be o f f - l o a d e d to c a r r y
only t h e r e q u i r e d fluid.
The u s e of e n l a r g e d fins
in lieu of s o l i d m o t o r
T V C was a l s o c o n s i d e r e d .
This analysis indicated
t h a t the fin s i z e for the
30
2
C , (TWICE SPECIFIC ENERGY) M K M J 5 K ) baseline SAT-V-4(S)B
v e h i c l e would have to be
F I G U R E 7-6 THREE-STAGE
double t h a t r e q u i r e d for
HIGH E N E R G Y MISSION
AS-5L6 {150 s q u a r e f e e t
CAPABILITY
60
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S t u d i e s w e r e c o n d u c t e d to d e t e r m i n e ROTATED « "
61
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l» FACTOR OF SAFETY • U
MONTH OF YEAR
F I G U R E 7-7 T W O - S T A G E W I N D / P A Y L O A D SENSITIVITY
FACTORV0F SAFETY-L*
STRUCTURAL MODIFICATIONS NOMINA! PAYLQAD LENGTH - W FT.
MODIFICATION STEPS
L NO MODIFICATION
t MODIFY I.U
100 \ MODIFY S-l I FWO.
SKIRT I TANK SHELL
* N D O i r r S - l l AFT SKIRT
. IS-IWS-ll IKIERSTACE
n M M COMPLETES
PER COT FULL STRUCTURAL
LAUNCH MODS.)
AVAILABILITY
»
JAN FEB MAR APR MAY JUN JUL AUG OCT NOV DtC
MONTH OF YEAR
62
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F l i g h t a n d c r e w s a f e t y a r e s a t i s f a c t o r y for t h i s v e h i c l e . C o m m u n i -
c a t i o n s for s o m e s t a t i o n s m a y p o s s i b l y be " b l a c k e d o u t " due to t h e e x h a u s t
plume i n t e r f e r e n c e . Other s t a t i o n s , however, will have c l e a r c o m m u n i -
cations during these periods a n d can provide continuous communications.
A s s u m i n g an Apollo p a y l o a d and l a u n c h e s c a p e s y s t e m , t h e a b o r t
l e a d t i m e f o r t h i s v e h i c l e Was d e v e l o p e d for c o m p a r i s o n with that of t h e
S a t u r n V. U s i n g a s o l i d m o t o r T N T e q u i v a l e n c y of 100 p e r c e n t , a n a b o r t
l e a d t i m e of 2 . 76 s e c o n d s is r e q u i r e d for t h i s v e h i c l e v e r s u s 2. 19 s e c o n d s
for t h e S a t u r n V. A b o r t l e a d t i m e i s t h a t t i m e p r i o r to e x p l o s i o n of t h e
v e h i c l e t h a t t h e l a u n c h e s c a p e s y s t e m f i r i n g p u l s e m u s t be i n i t i a t e d .
O t h e r s t u d i e s s h o w e d t h a t no p r o b l e m s for a b o r t a r e a n t i c i p a t e d b e c a u s e
of s e p a r a t i o n d y n a m i c s .
A e r o d y n a m i c h e a t i n g for t h e M X J V - S A T - V - 4 ( S ) E i s s i g n i f i c a n t l y
l o w e r t h a n the S a t u r n V. T h e a e r o d y n a m i c h e a t i n g i n d i c a t o r (AHI) at
6 5 3 , 000 f o o t - p o u n d s p e r s q u a r e foot f o r t h e S A T - V - 4 ( 5 ) B i s 18 p e r c e n t
l o w e r t h a n t h e n o m i n a l SAT V A H I v a l u e of 7 9 2 , 000 f o o t - p o u n d s p e r
s q u a r e foot a n d 30 p e r c e n t b e l o w t h e m a x i m u m AHI v a l u e for the S a t u r n
V of 924, 000 f o o t - p o u n d s p e r s q u a r e foot. T h e s h o c k wave f r o m the
s o l i d m o t o r n o s e c a p m a y i m p i n g e on the f i r s t s t a g e n e a r t h e i n t e r t a n k
and local insulation may be r e q u i r e d .
The r e l i a b i l i t y of t h e t w o - and t h r e e - s t a g e M L V - S A T ~ V - 4 ( S ) B v e h i c l e
i s 0. 984 a n d 0 . 9 6 7 , r e s p e c t i v e l y , a s c o m p a r e d to . 990 a n d . 980 for t h e
baseline AS-516. The l o w e r r e l i a b i l i t y c a n be a t t r i b u t e d to the m o d i -
fications to t h e s t a g e s and the a d d i t i o n of the s t r a p - o n s o l i d m o t o r s .
S e p a r a t i o n of t h e s o l i d m o t o r s f r o m the c o r e v e h i c l e c a n be a c c o m -
p l i s h e d s a t i s f a c t o r i l y u s i n g e x p l o s i v e s e p a r a t i o n d e v i c e s a n d the p r e s e n t
T i t a n HIC s e p a r a t i o n r o c k e t m o t o r s .
63
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. MI v ueumi if (tun
175
US
. 1»
l*V-SAT-B-«SIB
« US
. MAX**
r-
D
J|f-REBOUH0
MWXi^ff
4.3 RESOURCES
64
IU
2B5% > STRENGTH
FORWARD SKIRT
217% > STRENGTH
PROPELLANT TANKS
78%>STRENGTH
INTERSTAGE'
66% > STRENGTH
T h e S - I C s t a g e of t h e d y n a m i c t e s t v e h i c l e w i l l b e r e f u r b i s h e d a f t e r
t e s t and u s e d a s a flight a r t i c l e .
M a j o r t o o l i n g a n d a s s e m b l y r e q u i r e m e n t s a t M i c h o u d i n c l u d e an
a d d i t i o n a l tank a s s e m b l y s t a t i o n , an a d d i t i o n a l t a n k c l e a n i n g p o s i t i o n ,
and some additional and modified tooling. Additional warehousing,
q u a l i t y a s s u r a n c e , and r e c e i v i n g i n s p e c t i o n a r e a s w i l l be r e q u i r e d .
T h e s e a d d i t i o n s p r o v i d e t h e c a p a b i l i t y of i n t r o d u c i n g t h e n e w c o n f i g u -
ration with m i n i m u m downtime.
M o d i f i c a t i o n of the S - I C t e s t f i r i n g s t a n d s a t M T F and M S F C a r e
r e q u i r e d only due to i n c r e a s e d s t a g e l e n g t h a n d p r o p e l l a n t c a p a c i t y .
Solid m o t o r s w i l l not b e f i r e d in c o n j u n c t i o n w i t h t h e s t a g e s t a t i c t e s t .
The s t a g e t r a n s p o r t e r a n d the b a r g e s m u s t b e m o d i f i e d t o a c c o m m o d a t e
the i n c r e a s e d stage length. Additional solid motor handling and t r a n s -
portation equipment will b e r e q u i r e d .
MS-II-4(S)B
T h e r e v i s e d s t r u c t u r a l d e s i g n w i l l r e q u i r e m o d i f i c a t i o n of t h e f a b -
r i c a t i o n a n d a s s e m b l y t o o l s for the f o r w a r d a n d aft s k i r t s , LH? t a n k
66
D5-13183
w a l l s , i n t e r s t a g e and a e r o - f a i r i n g s . T h e S e a l B e a c h f a c i l i t i e s r e q u i r e
a m i n i m u m of m o d i f i c a t i o n ; the m a j o r w o r k r e q u i r e d i s m o d i f i c a t i o n to
t h e s t r u c t u r a l t e s t t o w e r for the i n c r e a s e d t e s t l o a d s . S o m e h a n d l i n g
e q u i p m e n t a t T u l s a and S e a l B e a c h w i l l r e q u i r e m o d i f i c a t i o n a s a r e s u l t
of t h e i n c r e a s e d s t a g e w e i g h t .
T h e c u r r e n t S-II p r o g r a m t r a n s p o r t e q u i p m e n t a n d v e h i c l e s a r e
c o m p a t i b l e with t h e MS-II-4{S)B s t a g e d e s i g n ; no m o d i f i c a t i o n s would
be r e q u i r e d to h a n d l e t h e a d d i t i o n a l s t a g e w e i g h t .
Due to s t u d y funding l i m i t a t i o n s , a s e p a r a t e M S - I I - 4 ( S ) B r e s o u r c e s
study w a s not m a d e . T h e M S - I I - 2 5 ( S ) s t a g e r e s o u r c e d a t a w a s u s e d
without m o d i f i c a t i o n f o r S A T - V - 4 ( S ) B .
MS-IVB-4{S)B
The m o d i f i e d c o r e v e h i c l e w i l l be a s s e m b l e d a c c o r d i n g to s t a n d a r d
p r o c e d u r e s in t h e VAB on t h e M o b i l e L a u n c h e r a n d w i l l s u b s e q u e n t l y be
t r a n s p o r t e d to t h e p a d w h e r e t h e solid r o c k e t m o t o r s will be a t t a c h e d .
T h e Solid m o t o r s e g m e n t s w i l l be a s s e m b l e d in a M o b i l e A s s e m b l y and
Handling S t r u c t u r e (MAHS), at a s i t e t o be p r o v i d e d , a n d t r a n s p o r t e d by
t h i s MAHS to the l a u n c h p a d f o r s u b s e q u e n t a s s e m b l y of the s o l i d s to the
67
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ELEVATION
68
D5-13183
s p a c e f o r t h e s o l i d r o c k e t m o t o r n o z z l e s . I n s u l a t i o n in s e l e c t e d a r e a s
w i l l h e r e q u i r e d tQ p r o t e c t t h e M L d u r i n g l a u n c h .
T h e t o t a l c o s t f o r t h e m o d i f i c a t i o n a n d a d d i t i o n s d e s c r i b e d i s 177. 3
m i l l i o n d o l l a r s . Of s i g n i f i c a n c e i s t h e f a c t t h a t a m a j o r p o r t i o n of t h i s
c o s t i s due to the r e q u i r e m e n t s for a new a s w e l l a s a m o d i f i e d m o b i l e
l a u n c h e r (ML) a n d a new a s w e l l a s a modified m o b i l e s e r v i c e s t r u c t u r e
(MSS). T h e s e n e w i t e m s a r e f o r c e d b e c a u s e of the g r o u n d r u l e which
l i m i t s t h e t i m e b e t w e e n t h e l a s t s t a n d a r d SAT V l a u n c h and the f i r s t
M L V - S A T - V - 4 ( S ) B l a u n c h to f i r e m o n t h s . If t h i s t i m e could b e e x t e n d e d
to p r e c l u d e t h e s e n e w i t e m s , t h e a b o v e c o s t could be r e d u c e d by a p p r o x i -
m a t e l y 80 m i l l i o n d o l l a r s .
Schedule
t tHI mt
IW Ii two W71 1*7?
1 ,it3,l l,i t4 1.1,1,4 I 2j_J * I 1 3 « B A
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KV-SATV-*SJB imik mini milium
F I G U R E 7-12 S A T - V - 4 ( S ) B V E H I C L E D E V E L O P M E N T AND D E L I V E R Y P L A N
69
DS-13183
Costs
A comparison of the r e l a -
tive values of cost effective-
ness for the MLV-SAT-V-4
(S)B; -22(S) and -25(S), shows
that the most cost effective
method for further improvement
of performance is through the
use of l a r g e r solid m o t o r s
r a t h e r than through the use of
uprated upper stage engines.
This comparison is shown in
F i g u r e 7-13.
71
STA 4 804.5
44395
4248.5
3697
3661
3539
3002.5
2986; 5 •
2893 (Engine Gimbol)
2795 •
£759 •
2627
2088
2000 •
1904 {Engine Gimbol)
1804 •
1781
1699 (Fwd Attach) p
164!
1448 p
1356 p
• SEPARATION
1005
821 p
729 p
699 p
695
607 p
365
317 p
225 p
116 (Aft Attach)
100 (Engine Gimbgl)
STA -115.5
72
D5-13,183
T h e S a t u r n V-23(L) v e h i c l e ( s e e F i g u r e 8-1) i s a m o d i f i e d S a t u r n V
w i t h l e n g t h e n e d f i r s t and t h i r d s t a g e s , and a d a p t e d for a t t a c h m e n t of four
2 6 0 - i n c h d i a m e t e r liquid p r o p e l l a n t p o d s . T h e modified S a t u r n V c o r e
and liquid p r o p e l l a n t p o d s u s e s s t a n d a r d F - l and J - 2 e n g i n e s .
T h e S A T - V ~ 2 3 ( L ) v e h i c l e a s d e f i n e d i n t h e t r a d e s t u d y a c t i v i t y and
s t u d i e d in d e t a i l in P h a s e II a c t i v i t y i s a f e a s i b l e c o n f i g u r a t i o n and a
l o g i c a l c a n d i d a t e t o p r o v i d e p a y l o a d s . i n e x c e s s of t h o s e c u r r e n t l y a v a i l a b l e
with t h e S a t u r n V v e h i c l e .
T h e S a t u r n V - 2 4 ( L ) v e h i c l e ( s e e F i g u r e 1-1) i s s i m i l a r to S A T - V - 2 3 ( L )
e x c e p t that f i r s t s t a g e a n d liquid p r o p e l l a n t p o d s u s e d u p r a t e d 1. 8 m i l l i o n
pound t h r u s t F - l e n g i n e s and t h e u p p e r s t a g e s u s e d v a r i o u s n u m b e r s and
t h r u s t l e v e l s of u p r a t e d e n g i n e s a s defined f o r t h e S A T - V - 3 B v e h i c l e .
T h e S A T - V - 2 4 { L ) v e h i c l e w a s only s t u d i e d d u r i n g t h e P h a s e I study
a c t i v i t y . A v e h i c l e c o n f i g u r a t i o n c o u l d n o t b e defined t h a t fell within t h e
410 foot study g r o u n d r u l e h e i g h t l i m i t a t i o n a s defined in S e c t i o n 3. 0.
8. 1 C O N F I G U R A T I O N S E L E C T I O N ( P H A S E I)
B y v a r y i n g t h e p r o p e l l a n t w e i g h t b e t w e e n t h e c o r e s t a g e s and p o d s , a
n u m b e r of r e l a t e d S A T - V - 2 3 ( L ) and S A T - V - 2 4 ( L ) v e h i c l e s r e s u l t e d . Pay-
load c a p a b i l i t y a n d v e h i c l e c o s t s w e r e e s t a b l i s h e d for t h e s e two f a m i l i e s
Of v e h i c l e s in o r d e r to c h o o s e a s i n g l e b a s e l i n e v e h i c l e for m o r e d e t a i l e d
analysis.
8. 1. 1 Candidate Configurations
P o d p r o p e l l a n t c a p a c i t y w a s d e t e r m i n e d by t r a d i n g p r o p e l l a n t b e t w e e n
73
D5-13183
8. 1.2 T r a d e Studies
F i g u r e 8-2 r e p r e s e n t s t h e p r o p e l l a n t t r a d e b e t w e e n t h e M S - I C - 2 3 ( L )
c o r e s t a g e and t h e liquid p r o p e l l a n t p o d s for the SAT-V-23(L.) v e h i c l e .
T h e l o w e r s e t of c u r v e s i s f o r t h e t h r e e s t a g e 72-ho.ur l u n a r i n j e c t i o n
m i s s i o n a n d t h e u p p e r s e t of c u r v e s f o r t h e t w o - s t a g e 100 n a u t i c a l m i l e e a r t h
o r b i t m i s s i o n . A s shown, t h e v a r i a t i o n of p e r f o r m a n c e a s a function of
p o d - t o - M S - I C b u r n t i m e a n d p r o p e l l a n t l o a d i n g i s not e x t r e m e l y s e n s i t i v e
fcr e i t h e r two o r t h r e e s t a g e v e h i c l e s . T h e b a s e l i n e SAT-V-23(1_) w a s
s e l e c t e d , t h e r e f o r e , , to s a t i s f y the 410 foot v e h i c l e h e i g h t l i m i t .
T
W p l 4W p z 0PnMIZfD •HO" I0PTI
41?
SO Wp? - BOOK FIXED
1
3 Wpj-WKFItfO «r
3
i 3»
30 60 70
8URNTIW/5-IC BURN TIM -PERCENT
F i g u r e 8 - 3 s h o w s net p a y l o a d v e r s u s t h e n u m b e r of e n g i n e s ( d a s h e d
l i n g s ) and t h r u s t p e r engine ( s o l i d l i n e s ) on t h e M S - I I - 2 4 ( L ) s t a g e for
v e h i c l e s w i t h p r o p e l l a n t o p t i m i z e d s t a g e s and v e h i c l e s w i t h s e c o n d s t a g e
l i m i t e d t o 15. 5 feet l e n g t h i n c r e a s e and t h i r d s t a g e l i m i t e d to 16- 5 feet length
i n c r e a s e . A s shown on F i g u r e 8 - 3 , with fixed u p p e r s t a g e s a n d a M S - I I - 2 4 ( L )
74
D5-13183
t h r u s t of 1.6 m i l l i o n p o u n d s (lower f a m i l y of c u r v e s ) , t h e m i n i m u m v e h i c l e
h e i g h t for t h e S A T - V - 2 4 ( L ) w a s 507 f e e t a t a p a y l o a d of 3 4 8 , 000 p o u n d s .
O p t i m i z i n g t h e p r o p e l l a n t l o a d i n g in t h e u p p e r s t a g e s a t a M S - I I - 2 4 ( L )
t h r u s t l e v e l of 1. 6 m i l l i o n p o u n d s w o u l d r e s u l t in a p a y l o a d of 369, 000
p o u n d s to 7 2 - h o u r l u n a r i n j e c t i o n and 860, 000 p o u n d s to 100 n a u t i c a l
m i l e o r b i t w i t h a v e h i c l e h e i g h t of 536 feet. A l s o , a t M S - I I - 2 4 ( L ) t h r u s t
l e v e l of b e t w e e n 2. 8 a n d 3. 0 m i l l i o n p o u n d s a p a y l o a d of 410, 000 p o u n d s
t o LOR and 9&0 t 000 p o u n d s to 100 n a u t i c a l m i l e o r b i t c a n b e o b t a i n e d
w i t h a v e h i c l e h e i g h t of 600 feet. S i n c e no v e h i c l e fell w i t h i n t h e 410 foot
height l i m i t , S A T - V - 2 4 ( L ) w a s not c o n s i d e r e d f u r t h e r .
(tart
i»n
T r a d e s t u d i e s of liquid p r o p e l l a n t p o d d i a m e t e r s i z e r a n g i n g b e t w e e n
156 to 396 i n c h e s show that v e h i c l e a n d p r o g r a m c o s t a r e r e l a t i v e l y i n -
s e n s i t i v e to pod d i a m e t e r s b e t w e e n ZOO to 300 i n c h e s . A 2 6 0 - i n c h d i a m e t e r
pod w a s s e l e c t e d for b e s t o v e r a l l v e h i c l e g e o m e t r y .
75
D5-13183
The 131-foot long pods (as shown in F i g u r e 8-4) attach to the MS-IC-
Z3(L) stage at the outboard engine locations, use S-IC technology, s t r u c t u r a l
concepts, and s y s t e m s . Each pod has two standard F - l engines which
gimbal to supplement the control capabilities of the core vehicle Each pod
i s an independent stage which can be checked out and test fired as a unit.
Use of this vehicle was also considered for application where the
baseline core vehicle (without the liquid pods) could fly alone or with
two strap-on liquid pods. The payloads identified for these alternates
a r e shown on Table 8 - 1 .
76
T A B L E 8-1 T H R E E - S T A G E 72-HOUR LUNAR
INJECTION PAYLOAD CAPABILITY
No. of P o d s p£, - 1 0 J L b s .
0 80
155
220
Significant l o a d c r i t e r i a a n d o t h e r d a t a p e r t i n e n t to v e h i c l e d e s i g n
a r e shown on T a b l e 8-H w i t h c o m p a r a t i v e S a t u r n V v a l u e s .
T h e c o n t r o l r e q u i r e m e n t of t h e S A T - V - -mi MTV
T h e a e r o d y n a m i c h e a t i n g of t h e M S -
MAX. QEFUTTIQN 41 KG J.5M6.
IC-23(L) forward skirt has i n c r e a s e d from ANGU1NFLIGH1
1 6 7 ° F {Saturn V) to 2 1 5 ° F due to t h e shock
p a t t e r n s from t h e pod nose cones. This i n - WATINC
c r e a s e d t e m p e r a t u r e i s not a p r o b l e m . TYP. AERODYNAMIC
IS-iCRM). SXT.I
MAX TEMP Z15°f 1«°F
B a s e h e a t i n g of t h e M S - I C - 2 3 ( L ) i n -
BASE IMAXTW.J Waft
c r e a s e s f r o m 1 9 0 0 ° F (Saturn V) to 2 2 0 0 ° F .
The heat shield can withstand the increased
base temperature.
C o m m u n i c a t i o n s for s o m e s t a t i o n s w i l l *BAStLIWS16WITHT.yw
•0 o
-LZ5
77
D5-U1B3
D i g i t a l s i m u l a t i o n of s e p a r a t i o n d y n a m i c s for t h e e x p e n d e d p o d s
d e m o n s t r a t e s that a positive c o r e / p o d separation c l e a r a n c e i s obtained
a n d t h a t a x i a l c l e a r a n c e o c c u r s a t 1. 83 s e c o n d s a f t e r s e p a r a t i o n .
T h e a d d i t i o n a l p r o p e l l a n t in the f i r s t a n d t h i r d s t a g e s a n d t h e four
liquid p r o p e l l a n t p o d s i n c r e a s e s t h e 0. 4 p s i on-p.ad o v e r - p r e s s u r e
d i s t a n c e t o a v a l u e 28 p e r c e n t g r e a t e r than t h e d i s t a n c e b e t w e e n P a d A
and P a d B on L a u n c h C o m p l e x 39. W a i v e r s for t h i s d i s t a n c e m i l b e
r e q u i r e d for j o i n t u s a g e of t h e s e p a d s when e i t h e r pad c o n t a i n s a fueled
c o r e w i t h fueled p o d s . T h e a c o u s t i c l e v e l w i l l r e q u i r e p r o t e c t i o n of
p e r s o n n e l during launch o p e r a t i o n s .
C o m b i n e d s t r u c t u r a l l o a d s and a c o u s t i c e n v i r o n m e n t s a r e i l l u s t r a t e d
in F i g u r e 8 - 5 . T h e d e s i g n l o a d s h a v e i n c r e a s e d s u b s t a n t i a l l y and r e s u l t
in v e h i c l e d r y w e i g h t s w h i c h a r e a p p r o x i m a t e l y 25 p e r c e n t h i g h e r than
t h o s e f o r t h e A S - 5 1 6 . T h e a c o u s t i c a l e n v i r o n m e n t i s h i g h e r than S a t u r n V
s p e c i f i c a t i o n s f o r s o m e v e h i c l e a r e a s on t h e f i r s t s t a g e . A c o u s t i c r e -
q u a l i f i c a t i o n of a p p r o x i m a t e l y 70 p e r c e n t of t h e a c o u s t i c a l l y s e n s i t i v e
c o m p o n e n t s on t h i s s t a g e w i l l b e r e q u i r e d .
r LAUNCH
JHFLICttT^ UUHCH INFLIGHT
A J,r.fl A T I C F""NC mam
THIS TUMSIEH UMM1HM EliSIl ON P « SKI
MVM»WIUftKSU». NEWSPECLIMIT r—
5ATVSPEC
73
D5-13I83
T h e i m p a c t of s t r u c t u r a l load i n c r e a s e on t h e c o r e v e h i c l e i s shown
in F i g u r e 8 - 6 .
8. 3 R e s o u r c e g_
E x i s t i n g a n d new f a c i l i t i e s w i l l be e m p l o y e d to m a n u f a c t u r e and t e s t
t h e M L V - S A T - V - 2 3 ( L ) . T h e s e f a c i l i t i e s a r e to be u s e d on a n o n - i n t e r f e r e n c e
b a s i s w i t h the S a t u r n V p r o d u c t i o n s c h e d u l e s . T h e p r e s e n t s t a g e and I U
m a n u f a c t u r e r s w e r e a s s u m e d to be c o n t r a c t o r s for the MLV-SAT-V-23(L)
components.
T h i r t y M L V - S A T - V - 2 3 ( L ) o p e r a t i o n a l v e h i c l e s at a r a t e of s i x p e r
y e a r for five y e a r s f o r m t h e b a s i s for t h e p r o d u c t i o n c o s t
A new d y n a m i c t e s t s t a n d i s r e q u i r e d b e c a u s e t h e S A T - V - 2 3 ( L )
l a u n c h w e i g h t e x c e e d s S a t u r n V d y n a m i c t e s t s t a n d foundation c a p a b i l i t y
by 30 p e r c e n t .
MS-IC-23(L)
T h e i m p a c t of the f i r s t s t a g e c h a n g e s on m a n u f a c t u r i n g and t e s t
f a c i l i t i e s i s c r e a t e d p r i m a r i l y by the i n c r e a s e d s t a g e length and m a t e r i a l
thickness T h e r e v i s i o n to t o o l i n g for M S - I C - 2 3 ( L ) i s the s a m e a s m a d e
for the M S - I C - 3 B s i n c e the s t a g e l e n g t h s a r e i d e n t i c a l a n d m a t e r i a l
t h i c k n e s s is s i m i l a r .
Liquid P r o p e l l a n t P o d s - M S - I C - 2 3 ( L )
P o d r e q u i r e m e n t s a r e s i m i l a r to t h o s e of a n y new s t a g e . New
s t r u c t u r e w i l l b e q u a l i f i e d a n d i t s u l t i m a t e load c a r r y i n g c a p a b i l i t y d e -
t e r m i n e d . A full pod s t r u c t u r e i s c o n s t r u c t e d for t h i s p u r p o s e . O p e r a t i n g
components (propulsion, mechanical, electrical/electronic) presently
u s e d on S-IC a n d in an u n c h a n g e d o r l e s s s e v e r e e m d r o n m e n t on the pod
do not r e q u i r e f u r t h e r t e s t i n g . T h e bulk pf pod c o r n p o n e n t s fall in t h i s c a t e g o r
P o d p o s t - m a n u f a c t u r i n g t e s t i n g c a n b e a c c o m p l i s h e d in the e x i s t i n g
S - I C t e s t c e l l s a t Michoud.
A s t a t i c f i r i n g t e s t s t a g e ( b a t t l e s h i p w e i g h t ) i s p r o v i d e d to qualify
t h e two engine c l u s t e r .
79
2 1 3 * > STRENGTH
FORWARD SKIRT
177% > STRENGTH
PROPELLANT TANKS
76% UPPER
U % LOWER > STRENGTH
FORWARD SKIRT
C O M M O N BLKD 210% > STRENGTH
INCREASED RADIUS
AFT SKIRT LH2 TANK 626% > STRENGTH
116% > STRENGTH,
INTERSTAGE'
87% > STRENGTH
INTERSTAGE
83% > STRENGTH
INTERTANK
80% •) STRENGTH
I 1 r—i r -i
D5-13183
T h e m a n u f a c t u r i n g plan for t h e S A T - V - 2 3 { L ) l i q u i d p o d s i s s i m i l a r
to t h e S-IC e x c e p t for w e l d i n g s k i n s l o n g i t u d i n a l l y r a t h e r than c y l i n d r i c a l l y
and r e d u c i n g b u l k h e a d g o r e s f r o m s i x t e e n to s i x .
A new m a n u f a c t u r i n g f a c i l i t y w i t h a p p r o x i m a t e l y two m i l l i o n s q u a r e
feet of a r e a i s n e e d e d t o p r o d u c e 24 p o d s p e r y e a r . T h e f a c i l i t y c o u l d b e
located at Michoud,
A s c a l e d - d o w n S-IC d u a l p o s i t i o n t e s t s t a n d a n d s t o r a g e f a c i l i t i e s
m u s t be p r o v i d e d at M T F for pod a c c e p t a n c e f i r i n g .
MS-n-Z3(L)
T h e M S - I I - 2 3 ( L ) s t a g e R D T & E p r o g r a m w a s i n f l u e n c e d by two f a c t o r s -
s t a g e d e s i g n m o d i f i c a t i o n s and s c h e d u l e d e l i v e r y d a t e s for t e s t h a r d w a r e .
T h e s t a g e d e s i g n i n c l u d e s a s t r e n g t h e n e d s t r u c t u r e ; t h e r e f o r e , a new
s t r u c t u r a l s t a t i c t e s t w i l l be r e q u i r e d . D e l i v e r y of t h e d y n a m i c t e s t s t a g e
n i n e m o n t h s b e f o r e t h e flight t e s t of the new s t a g e r e q u i r e s a c c e l e r a t i o n of
p r o d u c t i o n to t w e l v e s t a g e s p e r y e a r for the s t a n d a r d S-II s t a g e p r o g r a m .
S t o r a g e h a s b e e n a s s u m e d a v a i l a b l e for t h e s e s t a g e s a t no a d d i t i o n a l c o s t .
Two flight t e s t s t a g e s a r e a l s o i n c l u d e d in t h e d e v e l o p m e n t p r o g r a m -
T h e m a n u f a c t u r i n g r e q u i r e m e n t s a r e a l s o defined by s c h e d u l e d e l i v e r y
d a t e s and s t a g e s t r u c t u r a l d e s i g n . S c h e d u l i n g of t h e M S - I I - 2 3 ( L ) s t a t i c /
d y n a m i c (S/D) t e s t s t a g e n e c e s s i t a t e s a c c e l e r a t i o n of the s t a n d a r d S-II
p r o d u c t i o n to a c c u m u l a t e sufficient s t a g e s to m a i n t a i n d e l i v e r y to KSC
a t t w o - m o n t h i n t e r v a l s . M a n u f a c t u r e of the f i r s t flight t e s t s t a g e i s
s t a r t e d four m o n t h s a f t e r t h e S / D s t a g e . T h e r e v i s e d s t r u c t u r a l d e s i g n
r e q u i r e s m o d i f i c a t i o n of t o o l s for f a b r i c a t i o n and a s s e m b l y of t h e f o r w a r d
and aft s k i r t s , Lrlg t a n k w a l l s , i n t e r s t a g e , aft LOX b u l k h e a d a n d a e r o d y -
namic fairings.
T h e Seal B e a c h f a c i l i t y r e q u i r e s o n l y m i n o r c h a n g e s , p r i n c i p a l l y
m o d i f i c a t i o n to t h e s t r u c t u r a l t e s t t o w e r to t a k e t h e i n c r e a s e d t e s t l o a d s .
S o m e h a n d l i n g e q u i p m e n t a t T u l s a and S e a l B e a c h w i l l r e q u i r e m o d i f i c a t i o n .
T h e S t a t i c T e s t T o w e r m o d i f i c a t i o n m u s t be c o m p l e t e d by S e p t e m b e r 1 9 7 1 .
for t e s t of t h e M S - I I - 2 3 ( L ) . A f t e r s t a t i c t e s t , t h e s t a g e i s m o d i f i e d for t h e
d y n a m i c t e s t a n d s h i p p e d to M S F C in A u g u s t 1972. B i - m o n t h l y d e l i v e r y of
t h e 30 flight s t a g e s o c c u r s a f t e r c o m p l e t i o n of t h e s e c o n d flight t e s t s t a g e
M S - I I - 3 6 {October 1973).
31
D5-13183
MS-IVB-23(L)
T h e g r e a t e r l e n g t h a n d w e i g h t n e c e s s i t a t e m a j o r m o d i f i c a t i o n to the
S t a g e T r a n s p o r t e r and c e r t a i n i t e m s of h a n d l i n g e q u i p m e n t , a n d m i n o r
c h a n g e s to o t h e r i t e m s . M i n o r m o d i f i c a t i o n s of p r o p u l s i o n and e l e c t r i c a l
GSE a r e a l s o r e q u i r e d .
C o m p l e x a r r a n g e m e n t s a r e r e q u i r e d to p r o v i d e t i m e for m o d i f i c a t i o n
of t o o l i n g and f a c i l i t i e s w i t h o u t affecting d e l i v e r y of s t a n d a r d s t a g e s -
T h e t i m e for m o d i f i c a t i o n a n d e x p a n s i o n of t h e t o o l i n g and f a b r i c a t i o n
f a c i l i t i e s i s p r o v i d e d by a t e m p o r a r y a c c e l e r a t i o n of t h e a s s e m b l y of t h e
standard stage and then s t o r a g e p r i o r to delivery.
T h e r e a r e no m a j o r p r o b l e m s in t h e o t h e r r e s o u r c e a r e a s . T h e d e s i g n
i s w i t b i n p r e s e n t f a b r i c a t i o n t e c h n o l o g y . No new o r u n i q u e t e s t i n g p r o c e d u r e
i s r e q u i r e d . M o d i f i c a t i o n s w i l l be r e q u i r e d to t r a n s p o r t a t i o n a n d h a n d l i n g
e q u i p m e n t , T h e i n c r e a s e d s t a g e s i z e p r e c l u d e s u s e of the Super Guppy and
necessitates ocean shipment.
L a u n c h F a c i l i t y and O p e r a t i o n a l I m p a c t
T h e m o d i f i e d c o r e v e h i c l e w i l l be a s s e m b l e d a c c o r d i n g to s t a n d a r d
p r o c e d u r e s in t h e VAB o n t h e M o b i l e L a u n c h e r . The pods a s s e m b l e d at
M i c h o u d w i l l be s h i p p e d to M I L A w h e r e t h e y w i l l b e a t t a c h e d to t h e c o r e
v e h i c l e in t h e VAB. A f t e r t e s t a n d c h e c k o u t , t h e v e h i c l e w i l l be m o v e d
to t h e l a u n c h p a d .
N o r m a l o p e r a t i o n s for t h e v e h i c l e w i l l b e r e s u m e d and a d d i t i o n a l
o p e r a t i o n s a s r e q u i r e d for t h e p o d final c h e c k o u t and a r m i n g w i l l be
accomplished.
Schedules
T h e v e h i c l e t i m i n g i s b a s e d on new m a n u f a c t u r i n g and t e s t f a c i l i t i e s
for t h e p o d s , g r o u n d t e s t p o d m a n u f a c t u r e and t e s t b e f o r e t h e f i r s t flight
a r t i c l e r e a c h e s MILA in t h e s e c o n d q u a r t e r of 1 9 7 3 .
82
D5-13183
Costs
T h e v e h i c l e c o s t s u m m a r y i s shown on T a b l e 8-II1.
1OT
DESIGN * FACILITIES
DYNAMIC TEST
LC3SM0D
STACE DEVaoPMENT
MS-IC-2UC0RE
MS-IC-a POO
Ms-u-a
MS-tVS-HL
VEHICLE DB.IVESIE5
mv-SATV-a.
4 * » ft t n w i
l MFntlMMMjiicawuii
\ arnmamniwiiii
* •Ti-isuvcanwtm
*ssa«iiiiTicn
CMTICM.MIM
UVM
mil
"»*UltJf>CT«K
SUIUINtCdKST MOUW
ira mp tuimrtniKu
i n s r jfrturamm nicm
F I G U R E 8-7 SAT-V-23{L) V E H I C L E D E V E L O P M E N T AND D E L I V E R Y P L A N
LAUNCH VEHICLE
B o p s t ASSiat - Pod 132. T 1023. 8 398.4 1554.9
5-lC Stage 67.6 595.7 249.0 912.3
S-II S t a g e 52. 7 .517.6 161.3 757.6
S-IVB S t a g e 72. 1 5 59.3 36.4 467.8
Instrument Unit 131.5 131.5
LAUNCH V E H I d L E T O T A L 331.1 2627.9 865.1 3824. L
GROUND S U P P O R T E Q U I P M E N T
Boost A s s i s t - Pod
33.4 43.2 76.6
5-IC Stags
16. 2 27.0 43,2
S-II Staga 11. 5 57.6 69.1
S-IVB S t a g e S3. 7 48. 5 82.2
GSE T O T A L 94. 8 176.3 371.1
FACILITIES
Boost Assist - Pod 229.9 229.9
S-IC Stags 54. 3 56. 5
5-II Stage .7 .7
S-IVB Stage 6.0 5.4 11.4
I n s t r u m e n t Unit
L a u n c h V e h i c l e - KSC 213.2 764.6 977.8
Launch Vehicle - Other 10.0 10.0
FACILITIES TOTAL 770.0 1276.3
SYSTEMS ENGINEERING 1 INTEGRATION 2.7 475.8 507.5
9- 0 CONCLUSIONS AND R E C O M M E N D A T I O N S
Specific b a s e l i n e v e h i c l e s studied w i t h i n f a c i l i t y l i m i t a t i o n g r o u n d
r u l e s w e r e l i m i t e d to a m a x i m u m p a y l o a d of 579, 000 p o u n d s to a 100
nautical mile E a r t h orbit.
T h e r e f o r e , it i s r e c o m m e n d e d that in t h e s e l e c t i o n of t h e i n t e r m e d i a t e
p a y l o a d Vehicles t h a t both c o s t e f f e c t i v e n e s s and f l e x i b i l i t y be c o n s i d e r e d -
In the u t i l i z a t i o n of e x i s t i n g S a t u r n V s t a g e s for i n t e r m e d i a t e p a y l o a d
application, a l l p o s s i b l e a r r a n g e m e n t s should be i m p l e m e n t e d s i m u l -
t a n e o u s l y to o b t a i n t h i s f l e x i b i l i t y . It i s f u r t h e r c o n c l u d e d t h a t a l l
Uprated S a t u r n V v e h i c l e s a l s o have i n t e r m e d i a t e d e r i v a t i v e s . In o t h e r
w o r d s , w h e n a n u p r a t e d v e h i c l e i s c h o s e n for d e v e l o p m e n t , c o n s i d e r a t i o n
s h o u l d b e g i v e n to d e v e l o p i n g s i m u l t a n e o u s l y i t s i n t e r m e d i a t e p a y l o a d
capabilities.
T h e u p r a t e d v e h i c l e s defined i n t h e t r a d e s t u d y and s t u d i e d in d e t a i l
in P h a s e II a r e f e a s i b l e c o n f i g u r a t i o n s and l o g i c a l c a n d i d a t e s for p a y l o a d s
in e x c e s s of the c u r r e n t S a t u r n V c a p a b i l i t y . No m a j o r p r o b l e m a r e a s
w e r e i d e n t i f i e d for e i t h e r d e v e l o p m e n t or p r o d u c t i o n . No s i g n i f i c a n t
a d v e r s e flight e n v i r o n m e n t a l c h a r a c t e r i s t i c s w e r e i d e n t i f i e d .
M a j o r v e h i c l e m o d i f i c a t i o n s to adapt t h e S a t u r n V v e h i c l e to t h e s e
new u p r a t e d c o n f i g u r a t i o n s w e r e defined a s f o l l o w s .
a. S t r u c t u r a l m o d i f i c a t i o n of a l l s t a g e s to e n a b l e the v e h i c l e to
w i t h s t a n d the h i g h e r l o a d s i m p o s e d due to the l a r g e r p a y l o a d c a p a b i l i t y
a n d i n c r e a s e d p a y l o a d e n v e l o p e ( i n c r e a s e d p a y l o a d d i a m e t e r and 410 foot
vehicle height).
35
D5-13183
b. S t r u c t u r a l m o d i f i c a t i o n of s o m e s t a g e s for i n c r e a s e d t a n k l e n g t h s
and i n c r e a s e d e n g i n e t h r u s t .
c. S e l e c t i v e r e q u a l i f i c a t i o n of t h e a c o u s t i c a l l y s e n s i t i v e c o m p o n e n t s
to qualify t h e s e c o m p o n e n t s for t h e i n c r e a s e d a c o u s t i c a l e n v i r o n m e n t -
G e n e r a l c o m p a r a t i v e c o n c l u s i o n s a r r i v e d at f r o m t h e NAS8-20266
studies a r e a s follows.
T h e S A T - V - 3 B l a u n c h v e h i c l e h a s t h e b e s t p a y l o a d to l a u n c h w e i g h t
of a l l t h e u p r a t e d v e h i c l e s s t u d i e d . T h e S A T - V - 3 B h a s the m i n i m u m
l a u n c h i m p a c t of a l l t h e u p r a t e d l a u n c h v e h i c l e s s t u d i e d . On t h e o t h e r
h a n d , t h i s v e h i c l e r e q u i r e s the m o s t r e s e a r c h and d e v e l o p m e n t c o s t
p e r pound of p a y l o a d , and r e q u i r e s the m o s t l e a d t i m e of a l l u p r a t e d
launch vehicles studied-
36
D5-13183
87
D5-13183-6
Prepared for
NASA - George C. Marshall Space Flight
Center under Contract NAS8-20266
October 7, 1966
INDEXING DATA
DATE OPR T PGM SUBJECT
z-s-cv-4 ':;i..y
•1GNAT0R LOC
Sac - ,
FINAL REPORT
P R E P A R E D UNDER CONTRACT N U M B E R N A S 8 - 2 0 2 6 6
SUBMITTED TO
G E O R G E C. M A R S H A L L S P A C E F L I G H T C E N T E R
N A T I O N A L A E R O N A U T I C S AND S P A C E ADMINISTRATION
O C T O B E R 7, 1966
S U B M I T T E D BY
S Y S T E M S ANALYSIS C O N T R A C T O R
T H E BOEING COMPANY
S P A C E DIVISION
LAUNCH SYSTEMS BRANCH
H U N T S V I L L E , ALABAMA
D5-13183-6
ABSTRACT
T h i s d o c u m e n t r e p o r t s t h e r e s e a r c h and t e c h n o l o g y i m p l i c a t i o n s
involving the S a t u r n vehicles studied u n d e r NASA/MSFC Contract
N A S 8 - 2 0 2 6 6 , " S t u d i e s of I m p r o v e d S a t u r n V V e h i c l e s a n d I n t e r m e d i a t e
P a y l o a d S a t u r n V e h i c l e s fF-115)," f r o m D e c e m b e r 6, 1965, to
O c t o b e r 7, 1966- P h a s e I of t h e study w a s a p a r a m e t r i c p e r f o r m -
a n c e a n d r e s o u r c e s a n a l y s i s to s e l e c t o n e b a s e l i n e c o n f i g u r a t i o n for
e a c h of t h e s i x v e h i c l e s . P h a s e II of the s t u d y i n c l u d e d a fluid and
flight m e c h a n i c s s t u d y , d e s i g n i m p a c t on s y s t e m s , a n d a r e s o u r c e s
a n a l y s i s for e a c h b a s e l i n e v e h i c l e . The intermediate payload vehicle
d e r i v a t i v e s of S a t u r n V a r e a l o g i c a l m e a n s of p r o v i d i n g o r b i t a l p a y -
l o a d c a p a b i l i t y b e t w e e n that of t h e S a t u r n IB and t h e t w o - s t a g e
S a t u r n V. T h e u p r a t e d v e h i c l e s a r e f e a s i b l e c o n f i g u r a t i o n s and
l o g i c a l c a n d i d a t e s for pay-loads in e x c e s s of t h e c u r r e n t S a t u r n V
capability. No m a j o r p r o b l e m a r e a s w e r e i d e n t i f i e d f o r e i t h e r
development or production.
KEY WORDS
Contract NAS8-20266
D5-13183-6
Intermediate Saturn Vehicles
Saturn V
Research Implications
Technology Implications
Problem Areas
Uprated Saturn Vehicles
l
r
D5-13183-6
££^
FOREWORD
T h i s v o l u m e c o n t a i n s t h e r e s e a r c h and t e c h n o l o g y i m p l i c a t i o n s
r e s u l t i n g f r o m a t e n - m o n t h s t u d y to p r e p a r e t e c h n i c a l a n d r e s o u r c e
d a t a on u p r a t e d p a y l o a d S a t u r n V and i n t e r m e d i a t e p a y l o a d S a t u r n
vehicles. T h i s s t u d y w a s p a r t of a c o n t i n u i n g effort by the N a t i o n a l
A e r o n a u t i c s and S p a c e A d m i n i s t r a t i o n (NASA) to i n v e s t i g a t e t h e c a p a -
b i l i t y and f l e x i b i l i t y of t h e S a t u r n V l a u n c h v e h i c l e a n d to identify
p r a c t i c a l m e t h o d s for d i v e r s i f i e d u t i l i z a t i o n of i t s p a y l o a d c a p a b i l i t y .
NASA C o n t r a c t NAS8-20266 a u t h o r i z e s t h e w o r k r e p o r t e d h e r e i n and
w a s s u p e r v i s e d a n d a d m i n i s t e r e d by t h e M a r s h a l l S p a c e F l i g h t C e n t e r
(MSFC). S-II d a t a w e r e s u p p l i e d by t h e S p a c e & I n f o r m a t i o n D i v i s i o n
of N o r t h A m e r i c a n A v i a t i o n . S - I V B d a t a w e r e s u p p l i e d by t h e M i s s i l e
& S p a c e S y s t e m s D i v i s i o n of D o u g l a s A i r c r a f t C o m p a n y . Launch s y s -
t e m d a t a w e r e s u p p l i e d by t h e D e n v e r D i v i s i o n of T h e M a r t i n C o m p a n y .
Solid m o t o r d a t a w e r e s u p p l i e d by United T e c h n o l o g y C o r p o r a t i o n .
T h e L a u n c h S y s t e m s B r a n c h , A e r o s p a c e G r o u p , S p a c e D i v i s i o n of
T h e B o e i n g C o m p a n y , w a s t h e S y s t e m s A n a l y s i s c o n t r a c t o r for t h i s
study.
P r o g r a m d o c u m e n t a t i o n i n c l u d e s a s u m m a r y v o l u m e , five v o l u m e s
c o v e r i n g v e h i c l e d e s c r i p t i o n s , r e s e a r c h and t e c h n o l o g y i m p l i c a t i o n s
r e p o r t (this d o c u m e n t ) , and a c o s t d o c u m e n t . Individual designations
a r e a s follows:
il
D5-13183-6
TABLE O F CONTENTS
PAGE
A B S T R A C T AND KEY WORDS i
FOREWORD ii
TABLE OF CONTENTS iii
ILLUSTRATIONS iv
1- 0 INTRODUCTION 1
2.0 STUDY R E S U L T S 6
4. 0 E L E C T R O N I C S AND C O N T R O L T E C H N O L O G I C A L 10
IMPLICATIONS
4. 1 L A U N C H TOWER C L E A R A N C E 10
4 , 2 E F F E C T O F C O N T R O L MODES ON V E H I C L E 10
LOADS
4. 3 R A N G E / V E H I C L E COMMUNICATION 11
INTERFERENCE
4 . 3, I R F I n t e r f e r e n c e F r o m A d d e d S t r a p - O n 11
Structure
4. 3. 2 R F I n t e r f e r e n c e F r o m Modified E x h a u s t 12
Plume
4 . 3 . 3 Modified A n t e n n a S y s t e m 12
5. 0 M A T E R I A L S AND S T R U C T U R E S T E C H N O L O G I C A L 14
IMPLICATIONS
5.1 S T A B I L I T Y C R I T I C A L S T I F F E N E D C Y L I N D R I C A L 24
S H E L L DESIGN
5. 2 P A Y L O A D E N V E L O P E WIND S E N S I T I V I T Y 14
5. 3 F L I G H T LOADS P R O B A B I L I T Y 15
5. 4 GROUND WIND LOADS 16
ill
D5-I3183-6
ILLUSTRATIONS
P H A S E I LAUNCH V E H I C L E CANDIDATES
S E L E C T E D B A S E L I N E LAUNCH V E H I C L E S
FOR P H A S E n STUDY E F F O R T
T Y P I C A L AERODYNAMIC DATA
T Y P I C A L GROUND WIND S P E E D E N V E L O P E
IV
1. 0 INTRODUCTION
The vehicles s t u d i e d w e r e c o m b i n a t i o n s of e x i s t i n g o r m o d i f i e d
Saturn V stages; some vehicles also included b o o s t - a s s i s t components.
A p r i m a r y study r e q u i r e m e n t w a s to m a k e m a x i m u m u s e of e x i s t i n g
Saturn technology and s u p p o r t e q u i p m e n t .
In g e n e r a l , t h e NAS8-20266 study p r o g r a m o b j e c t i v e s w e r e t o :
b. P r e p a r e sufficient t e c h n i c a l d a t a to define v e h i c l e e n -
v i r o n m e n t s , d e s i g n , c a p a b i l i t i e s , and c h a r a c t e r i s t i c s ;
c. Define s u p p o r t s y s t e m requirements;
e. E s t i m a t e c o s t r e q u i r e d for i m p l e m e n t a t i o n of the s y s t e m
p l u s p r o d u c t i o n of t h i r t y flight a r t i c l e s in five y e a r s .
F o r e a c h of t h e s i x b a s e l i n e v e h i c l e s s e l e c t e d ( s e e F i g u r e 1-2),
P h a s e II d i r e c t e d t h e effort to defining g r o u n d and flight e n v i r o n -
m e n t s , defining s y s t e m d e s i g n and r e s o u r c e i m p a c t for e a c h s t a g e
and the total vehicle, and determining vehicle mission capabilities
and c h a r a c t e r i s t i c s .
1
GROUND RULES
MAX VEHICLE A A A
S I Z E - 4 1 0 FT
MAX M S - H
SIZE 1160 IN M5-IVB MS-IVB MS
MAX M S - I V B MS-IVB
SIZE 3SOK
PROPELLANT ^
AT MR 5 :i MS-II MS-H MS-II MS
MAX PAYLOAC
5 LB/FT-3 S-ll
(2 STG) tf
I I LB/FT3 MS-IC MS-IC MS-IC MS
(3 STG) 9-1C + SRM
STD:STANDARD
+ SRM +
flL=CHANGE IN
STAGE LENGTH •m w
LAUNCH INT-21 S A T - V - 3 B S A T - V - 4 ( S ) B SAT-V-22(S) S A T - V -
VEHICUE I NT-20
CATEGORY
ADVANCED ADVANCED
STD J - 2 S STD J - 2 3 STO J - 2 S STD J
SECOND ENGINES ENGINES
A X 120 I N 4 X 120 IN 4 X 15
STRAP-ON DIA SOLID DIA SOLID DIA S
COMPONENTS MOTORS MOTOR S MOTO
ntlKWIIffMIOttro
Kin —
r*0-ta p*-w.«PLii
-Pi-lH.lUIUONMOUm
S-IM-M
Jl-IJ. UJ-l. MRftl
i-ica S-ll
H-Hir-l
-SIC
tL'ft 5lF-]
* p l - IHHIRS
r D -I.NMLIS
-INT-20- INT - 2 1 .
IW
mn • «ftfT
/ft
Sk-mjUM UMM -Ct-W,WlW Pt-«.WILBSWflNAA P i - U » , m i l s 10ft Pt-SM.JO
!*»„•L2P
-Mi-IVI-«fl>.
t l - d liJ'l, HRJ-L *L'l*J'IU-i,W.fcl
- Mj-tMr$> I • JM-H-JSKI
iL-0. J i J - * , l « i - l IL-D.. Si J-l MIS.]
&
-*i-IC*tSli •ws-ic-wsi
1L-W, J.F-1
W CIA KM
* f p -l.»7
•SAT
*, • a IM
V-4(S)B-
us
J -SAT-V-25(S)- J
FIGURE l-^ SELECTED BASELINE LAUNCH VEHICLES FOR PHASE II S
D5-13183-6 ^WBOKgy,
4
D5-13183-6 &CFMW4
3^
c. MI/V~-SAT-V-25{S) during P h a s e I was a family of two- and
t h r e e - s t a g e launch vehicles with modified Saturn V s t a g e s , standard
F - l and J - 2 engines, and strap-on 156-inch d i a m e t e r (two, t h r e e ,
and four segmented) solid m o t o r s . A single b a s e l i n e launch vehicle
(Figure 1-2) was selected for the P h a s e II study effort.
5
D5-13183-6 •«OM5»V4gVv
6
D5-13183-6
3,1.1 P r o b l e m Definition
C O R E ONLY
S T R A P - O N MOTOR S
STRAP-ON MOTORS, RAP-ON MOTORS,
F I N S & SHROUDS u
& SHROUDS
N STRAP-ON MOTORS
O U
(0
C O R E ONLY
M
O
H GAP/DS.0. =0
0 C O R E WITH
STRAP-ON
MOTORS
0
i
P.
<
en
MACH NO.
8
D5-13183-6
\ h
a
i-j
H MOBILE
LAUNCHER
HARDSTAND
s. L. WIND SPEED
FIGURE 3-2 TYPICAL GROUND WIND SPEED ENVELOPE
3 2 2 Solution Approach
9
4 . 0 ELECTRONICS AND CONTROL, TECHNOLOGICAL. IMPLICATIONS
4. 1.1 P r o b l e m Definition
4. 1. 2 Solution Approach
4.2.1 P r o b l e m Definition
10
D5-13183-6
^
4. 2. Z Solution Approach
4. 3.1.1 P r o b l e m Definition
11
D5-13183-6
It m a y be n e c e s s a r y t o r e l o c a t e t h e a n t e n n a s by m o v i n g t h e m o u t w a r d
f o r w a r d , o r t o a d i f f e r e n t a n g u l a r p o s i t i o n to i m p r o v e t h e r a d i a t i o n
p a t t e r n a n d / o r l o o k a n g l e . It m a y a l s o be n e c e s s a r y to c h a n g e t h e d e s i g n
of the a n t e n n a s y s t e m s t o i m p r o v e the r a d i a t i o n p a t t e r n .
4. 3 . 2 R F I n t e r f e r e n c e F r o m Modified E x h a u s t F l u m e
4. 3 . 2 . 1 P r o b l e m Definition
The u p r a t e d v e h i c l e s h a v e e n l a r g e d e x h a u s t p l u m e s due to i n c r e a s e d
m a s s flow. The s o l i d s t f a p - o n m o t o r s a l s o add d i f f e r e n t e x h a u s t p r o -
d u c t s , i n c l u d i n g m e t a l p a r t i c l e s , w h i c h i n c r e a s e the d e g r a d a t i o n of t h e
RF system.
4. 3 . 2. 2 Solution Approach
The i m p r o v e m e n t s t u d y i n d i c a t e d a r e q u i r e m e n t to p l a c e a r e d u n d a n t
s e t of M 3 - I C a n t e n n a s on t h e s t r a p - o n b o o s t e r s which w o u l d be u s e d
p r i o r to s t a g i n g of t h e s t r a p - o n b o o s t e r s . The s t r a p - o n b o o s t e r s h a v e R F
s y s t e m s i n d e p e n d e n t of t h e S a t u r n V, but r e q u i r e c o m b i n a t i o n of the
f o u r b o o s t e r R F c i r c u i t s on t h e M S - I C a n d r e d i s t r i b u t i o n t o a n t e n n a s on t h e
s t r a p - o n s . The l o n g e r c i r c u i t p a t h s a n d a d d e d s w i t c h i n g f r o m the t r a n s -
m i t t e r s t o the a n t e n n a s m a y p r o d u c e i n c r e a s e d R F d e g r a d a t i o n a s w e l l
as presenting h a r d w a r e p r o b l e m s for the proposed s y s t e m .
4. 3. 3 . 2 Solution A p p r o a c h
The m o d i f i e d a n t e n n a s y s t e m s p r o p o s e d (in S e c t i o n s 6. 1. 4 of d o c u m e n t s
D5-13183-3, - 4 , a n d -5) f o r u s e w i t h the s t r a p - o n b o o s t e r s s h o u l d be
e v a l u a t e d a n a l y t i c a l l y , a n d t h e n t e s t e d with a s y s t e m s b r e a d b o a r d u s i n g
S-IC components.
12
D5-13183-6 ^MKggi
13
D5-13183-6
5.1.1 P r o b l e m Definition
5, 2.1 P r o b l e m Definition
14
D5-13183-6
5.3.1 P r o b l e m Definition
5. 3. 2 Solution Approach
Up to this t i m e such solutions have not been practicable due to the limited
wind information available, extensive computer times r e q u i r e d to obtain solu-
tions for adequate statistical samples of m e a s u r e d profiles, limited accuracy
of the profiles t h e m s e l v e s , and absence of c o r r e l a t i o n s between mean wind and
random turbulence r e s p o n s e s . As a result, no methods have been tailored to
this purpose which encompass the complete solution.
15
D5-13183-6 ^gEgX/Vg-V.
5. 4.1 P r o b l e m Definition
16
D5-13183-6
17
P5-13183-6
6. 1 PROBLEM DEFINITION
6. 2 SOLUTION APPROACH
;
The feasibility of a simplified liquid pod design which will be c o s t -
competitive with solid m o t o r s should be determined. The design should be
optimized from a cost and reliability standpoint, with l e s s e r emphasis on
performance.
Evaluation of pod components and s y s t e m s to define performance
J c h a r a c t e r i s t i c s and cost would lend not only to understanding the specific
r e a s o n s for cost differences, but also to identify m e a n s of optimizing cost
effectiveness. The potential of incorporating the following into the pod d e -
sign should r e c e i v e attention:
a. Simplified engine - eliminate turbopump (pressure-fed) - minimum
valves and controls.