Full report

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NASA/TM--2001-211330 Internal Thermal Control System Hose Heat Transfer Fluid Thermal Expansion Evaluation Test Report P.O. Wieland Marshall Space Flight Center, Marshall Space Flight Center, Alabama H.D. Hawk Summer High School Apprenticeship Research Program Marshall Space Flight Center, Marshall Space Flight Center, Alabama October 2001

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The NASA STI Program Office...in Profile Since its founding, NASA has been dedicated to the advancement of aeronautics and space science. The NASA Scientific and Technical Information (STI) Program Office plays a key part in helping NASA maintain this important role. The NASA STI Program Office is operated by Langley Research Center, the lead center for NASA's scientific and technical information. The NASA STI Program Office provides access to the NASA STI Database, the largest collection of aeronautical and space science STI in the world. The Program Office is also NASA's institutional mechanism for disseminating the results of its research and development activities. These results are published by NASA in the NASA STI Report Series, which includes the following report types: TECHNICAL PUBLICATION. Reports of completed research or a major significant phase of research that present the results of NASA programs and include extensive data or theoretical analysis. Includes compilations of significant scientific and technical data and information deemed to be of continuing reference value. NASA's counterpart of peer-reviewed formal professional papers but has less stringent limitations on manuscript length and extent of graphic presentations. TECHNICAL MEMORANDUM. Scientific and technical findings that are preliminary or of specialized interest, e.g., quick release reports, working papers, and bibliographies that contain minimal annotation. Does not contain extensive analysis. CONTRACTOR REPORT. Scientific and technical findings by NASA-sponsored contractors and grantees. CONFERENCE PUBLICATION. Collected papers from scientific and technical conferences, symposia, seminars, or other meetings sponsored or cosponsored by NASA. SPECIAL PUBLICATION. Scientific, technical, or historical information from NASA programs, projects, and mission, often concerned with subjects having substantial public interest. TECHNICAL TRANSLATION. English-language translations of foreign scientific and technical material pertinent to NASA's mission. Specialized services that complement the STI Program Office's diverse offerings include creating custom thesauri, building customized databases, organizing and publishing research results.., even providing videos. For more information about the NASA STI Program Office, see the following: • Access the NASA STI Program Home Page at http ://www.sti.nasa.gov • E-mail your question via the Internet to help@ sti.nasa.gov • Fax your question to the NASA Access Help Desk at (301) 621-0134 • Telephone the NASA Access Help Desk at (301) 621-0390 Write to: NASA Access Help Desk NASA Center for AeroSpace Information 7121 Standard Drive Hanover, MD 21076-1320

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NASA/TM--2001-211330 Internal Thermal Control System Hose Heat Transfer Fluid Thermal Expansion Evaluation Test Report P.O. Wieland Marshall Space Flight Center, Marshall Space Flight Center, Alabama H.D. Hawk Summer High School Apprenticeship Research Program Marshall Space Flight Center, Marshall Space Flight Center, Alabama National Aeronautics and Space Administration Marshall Space Flight Center • MSFC, Alabama 35812 October 2001

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Acknowledgments Daniell Hawk participated in this project via the Summer High School Apprenticeship Research Program and assisted in collecting and evaluating test data, preparing plots, and assembling this Technical Memorandum. Bill Barnett, FD21, Marshall Space Flight Center, prepared the test article and test preparation sheet, and John Lowery and Amos Glenn, ASRI, operated the environmental chamber during the test. Jamie Miernik, Boeing, obtained the hose and end cap that were tested. Available from: NASA Center for AeroSpace Information 7121 Standard Drive Hanover, MD 21076 1320 (301) 621 0390 ii National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 (703) 487 4650

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TABLE OF CONTENTS ............................................................................................................................ 1 1. INTRODUCTION 2. TEST OBJECTIVE AND PURPOSE .............................................................................................. 1 3. APPLICABLE DOCUMENTS ........................................................................................................ 2 4. TESTING ......................................................................................................................................... 2 4.1 Test Method ............................................................................................................................... 2 ................................................................................................................................ 2 4.2 Test Article ............................................................................................................................... 3 4.3 Test Facility 5. PRETEST PREPARATION AND MEASUREMENTS ................................................................. 4 6. TEST RESULTS AND DISCUSSION ............................................................................................ 4 7. CONCLUSIONS .............................................................................................................................. 6 APPENDIX A--ITCS HOSE HEAT TRANSFER FLUID THERMAL EXPANSION EVALUATION TEST PLAN ................................................................................... 9 APPENDIX B--ITCS INTEGRATED HOSE ASSEMBLY COOLANT EXPANSION TEST PREPARATION SHEET ................................................................................ 17 °°° 111

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LIST OF FIGURES ° IHA test article ....................................................................................................................... 3 2. Test article pressure ............................................................................................................... 4 3. Test article pressure profiles .................................................................................................. 5 4. Estimated temperature to reach the maximum pressure ........................................................ 7 iv

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LIST OF ACRONYMS HTF heat transfer fluid IHA integrated hose assembly ISS International Space Station ITCS Internal Thermal Control System MSFC Marshall Space Flight Center PACRATS Payloads and Components Real-Time Automated Test System PTFE polytetrafluoroethylene QD quick disconnect RFCA rack flow control assembly TPS test preparation sheet

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TECHNICALMEMORANDUM INTERNAL THERMAL CONTROL SYSTEM HOSE HEAT TRANSFER FLUID THERMAL EXPANSION EVALUATION TEST REPORT 1. INTRODUCTION The Internal Thermal Control System (ITCS) of the International Space Station (ISS) is designed to transfer heat to maintain optimum temperatures for the crew and equipment inside the modules. Excess heat is removed and cool locations are warmed as needed. During assembly of the ISS, jumper hoses are used by the astronauts on board to connect the ITCS loops in adjacent modules. A jumper hose with quick disconnects (QDs) and end caps attached is referred to as an integrated hose assembly (IHA). It would be preferable to launch the IHAs prefilled with heat transfer fluid (HTF), but there is a concern that in the event of high temperature during storage or transportation, the IHAs may leak or become damaged due to excessive pressure. To address this concern, a test was requested by the ISS Program Thermal Control Lead, Joe Chambliss, to evaluate the ability of an IHA to be launched "wet" and safely accommodate the increased pressure of the HTF if the temperature increased to the worst-case condition of 60 °C (140 °F). This testing was performed at Marshall Space Flight Center (MSFC) in June 2000 on a flightlike hose with a flight end cap to evaluate the maximum pressure that would occur under the worst-case temperature condition. Four cases were run with test conditions subjecting the test article up to 71 °C (160 °F), and results show that the pressure at this temperature reached -_228 kPa (33 psia), well below the design maximum of 689 kPa (100 psia). The test conditions and results are described in this Technical Memorandum. 2. TEST OBJECTIVE AND PURPOSE The objective of this test is to simulate the conditions that may be experienced by an isolated IHA, filled with HTF and capped on both ends. The purpose is to determine whether the IHA can accommodate the increased pressure due to HTF expansion when heated from room temperature to 60 °C (140 °F) without exceeding the design maximum pressure of 689 kPa (100 psia), leaking, or being damaged. In addition, measurement of the bend radius of the hose and of the mass of HTF in the filled hose are needed for designing the transportation containers.

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1. APPLICABLE The following documents axe applicable to this test: DOCUMENTS • "ITCS Rack Flow Control Assembly Fill Procedure," SK683-53379, 21 April 1999 • "ITCS Hose HTF Thermal Expansion Evaluation Test Plan," May 2000 (revised June 21, 2000) (app. A) • "Test Preparation Sheet," FD21TST-TPS-ITCS-00-001 4. TESTING (app. B). The test was performed from June 27-30, 2000. The test method, article, and facility axe described in sections 4.1 through 4.3. 4.1 Test Method A flightlike IHA was tested by simulating the worst-case condition plus 11 °C (20 °F); i.e., 71 °C (160 °F). The pressure was monitored and the hose was regularly checked for any signs of leakage or other damage. Four cases were run with increasing temperature profiles: two cases at 60 °C (140 °F), one case at 66 °C (150 °F), and one case at 71 °C (160 °F). The rate of temperature change, increasing and decreasing, for each case was <17 °C/hr (30 °F/hr). The test plan is in appendix A and the test preparation sheet (TPS) is in appendix B. 4.2 Test Article The test article consisted of an IHA, plus an aluminum adapter block fabricated to attach a pressure transducer and a three-way valve for connecting a vacuum source and a pressurized tank conraining HTE The serial number of the IHA is 683-56836-385. This had been a flight IHA but was rejected due to a change in materials. A flight-qualified end cap covered the QD at the other end of the hose. The hose is made of convoluted teflon (polytetrafluoroethylene (PTFE)) with a nominal diameter of 12.7 mm (0.5 in) and a length of 762 mm (30 in), including fittings. The assembled test article is shown schematically in figure 1. 2

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QD Connector With Cap QD1 1/2-in-DiameterHose Approximately36 in Long Vacuum Source Pressure Transducer P1 MS Fitting Valve Vl Adapter Block AB1 HTFSupply Figure 1. IHA test article. 4.3 Test Facility The environmental chamber used for this test is an Ecosphere thermal/humidity chamber by Despatch (model 16664) located in Building 4619 at MSFC. This chamber, designated as TH3, is capable of maintaining the temperature anywhere in the range of-70 to 180 -°C (-94 to 356 °F). The chamber allows an unobstructed, usable internal volume that is cube shaped, measuring 1,219 mm (48 in) deep, 1,118 mm (44 in) high, and 1,168 mm (46 in) wide. The chamber has a front opening door with a 610-mm (24-in) square view window located in the center of the door. A Watlow multiloop process controller manages the operation of the chamber and enables the user to maintain the temperature at a constant value or to continuously vary the temperature according to a predefined program. The Watlow controller allows the operator to manually enter up to 256 temperature steps, with segment times up to 100 h. Temperatures within the allowable range can be maintained to +2 °C (3.6 °F), dry bulb or wet bulb, of the nominal value. Temperature and pressure data were recorded Automated Test System (PACRATS) every 20 s. by the Payloads and Components Real-Time The IHA was filled with HTF in Building 4755, using the same equipment as was used to fill the ITCS simulator facility.

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1. PRETEST PREPARATION AND MEASUREMENTS The empty test article was weighed and the mass was 1403.6 g (3.07 lb). The bend radius of the empty hose was measured as =76 mm (3 in). The test article was filled with HTF per procedure SK683- 53379, which involves evacuating the IHA to <50 milliTorr before filling with HTF to 207 kPa (30 psia). The filling procedure was designed to ensure that no air bubbles were present in the IHA. (The presence of air bubbles would likely result in higher pressures due to the greater thermal expansion of air compared to water.) After filling with HTF, the bend radius was again measured and found to be =76 mm (3 in), and the mass was measured as 1532.5 g (3.35 lb). The mass of HTF in the hose was therefore 128.9 g (0.28 lb), or 4.3 g (0.01 lb) for each inch of hose length. At 101 kPa (14.7 psia) and 25 °C (77 °F), the volume of HTF in the hose is 0.129 L (0.034 gal), or 0.0043 L (0.0011 gal) for each inch of hose length. 6. TEST RESULTS AND DISCUSSION During pretest preparation on Friday, June 23, 2000, the test article was pressurized to 207 kPa (30 psia) during filling with HTE Over the weekend, the pressure dropped to <117 kPa (17 psia) with no indication that any leakage had occurred. On Monday, June 26, 2000, the test article was repressurized to 207 kPa (30 psia) in Building 4755, then transported to Building 4619 and connected to the data recording equipment. By the time data recording was initiated, the pressure had dropped to 186 kPa (27 psia). By Tuesday morning, the pressure had dropped to 162 kPa (23.5 psia), again, with no indication of leakage (fig. 2). These pressures were all recorded at ambient temperatures. The pressure was holding at 162 kPa (23.5 psia), indicating that the pressure drop was not due to leakage, and it was decided to proceed with test case 1 on Tuesday. (The drops in pressure shortly before the beginning of case 1 axe likely due to temperature drops as air conditioning equipment in the building was activated.) 34 ] Case 1 Case 2 Case3 Case4 32_ 140 °F 140 °F 150 °F 160 °F / 3o/ Ambient A 28 Temperature . 24 22 20 18 ................... 16 Data Point (time) t[ Figure 2. Test article pressure. 4

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As expected,thedataclearlyshowthatthepressureincreasesasthe temperaturerises,for all cases.However,asshownin figure3, for case1,thepressureprofile is significantlydifferentfromthe followingcases. Forcase1,thecurvehasamuchshallowerslopeandis almostlinear.Thepressureincrease is significantlylessthanfor thefollowing cases,includingcase2 thatfollowedthesametemperature profile.Thisis thoughtto berelatedto expansionof thehosedueto theabove-ambientpressure,which wouldresultin decreasingpressure,mitigatingthe pressureincreasedueto increasingtemperature. However,asthetemperaturenears60°C (140°F), theslopechangesto matchthe slopeof case2 above 57.2°C (135°F).Thisindicatesthatexpansionof thehosehadessentiallyceased,sothefinal partof the curveparallelsthelatercases,where,it is assumed,additionalexpansionof thehoseis minimal.At 60°C (140°F)the pressurereachedjust over200kPa(29psia).Whenthetemperaturewasreduced to ambient,thepressuredecreasedto 134kPa(19.5psia). 35 3O Case1 Case2 A •_ 25 Case4 20 O. 15 10 I I I I I 60 80 100 120 140 160 180 Temperature(°F) Figure 3. Test article pressureprofiles. Cases 2, 3, and 4 show closely parallel pressure profiles, successively peaking at somewhat higher pressures due to the higher successive temperatures. With each successive case, there is also a slight decrease in pressure (3.4 to 9 kPa (0.5 to 1.3 psia)) at a given temperature. This decrease is partly or totally related to effusion of the HTF through the PTFE hose material. The reported effusion rates, provided by Ahmad Sleiman of Boeing, are 1.74 × 10 3 g/min/in 2 at 18.3 °C (65 °F) and 7.68 × 10 3 g/min/in 2 at 48.9 °C (120 °F). (Precise measurement of the mass before and after the test would provide some insight into the mass of HTF lost during the test related to effusion, but the mass measurements taken for this test were not sufficiently precise for this purpose.) At the target temperature of each case, a short, vertical portion indicates a pressure increase at those temperatures. This is due to thermal equalization of the test article, which has an aluminum block on one end and a metal QD with a cap on the other. The thermal lag of the masses of these items contributes to this pressure increase.

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1. CONCLUSIONS Thetestarticlewasinitially pressurizedto 207kPa(30psia)with HTF,perthe Boeingprocedure for filling therackflow controlassembly(RFCA).Asdemonstratedduringthis test,thepressurewill decreaseto nearambientwithin a fewdays,dueprimarilyto expansionof theflexiblehose.Forthis test, thetestarticlewasrepressurized,whichwill makethetestresultsconservative;i.e.,withoutthe repressurization,whichis not calledfor in theprocedure,themaximumpressureswouldhavebeen lower.Thefollowingconclusionscanbedrawnfromthetestresults: 1. Theinitial dropin pressureatambienttemperaturesbeforecase1is relatedto expansion of the flexiblehose. Thisconclusionis supportedby thepressuredroplevelingoutpriorto case1,indicating thatexpansionhadceased,aswell asthebehavioraftercase1,whenthe pressurecurves areessentiallyparallelandthelow pressurepointsaxeveryclose,indicatingthatexpansion of thehosehadessentiallystopped. 2. Theshapeof thecase1pressureprofileis dueto expansionofthehoseaswell asexpansion of the HTFwhileheatingis occurring. Simultaneousinfluenceof thetwo opposingeffectscausedtheresultingshapefor case1. Expansionof thehoseleadsto decreasedpressurewhileincreasedtemperatureleadsto increasedpressureof theHTE It is thoughtthatthehighertemperaturesallowedadditional hoseexpansionaftertheexpansionhadstabilizedatambienttemperature.Withoutadditional hoseexpansion,themaximumpressurewouldhavebeen-_241kPa(35psia)for case1. 3. Theslightdropin pressuresatthesametemperatureswith succeedingcasesis dueto effusion of the HTFthroughthe PTFEhose. Whilecontinuedexpansionof thehosemightalsocausesucharesult,the evenspacingand smoothcurvesof theprofilesaxemoreconsistentwith gradualfluid loss,whichcouldoccur by effusion.Theincreasein effusionrateasthetemperatureincreasesis reflectedin the slightly broadeningspacingbetweenthecurvesasthetemperatureincreases. 4. Undertheexpectedworst-casethermalconditions,thepressurein a filled IHA will remain well belowthemaximumdesignpressure(689kPa(100psia)). Extrapolatingfromthetestdatato estimatethemaximumallowabletemperature,figure4 showsthat689kPa(100psia)wouldnot bereacheduntil-_115°C (240°F).

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120- 100- A 80- _D 60- O. 40- 20- O- I 0 100 I 200 240 300 Temperature (°F) Figure 4. Estimated temperature to reach the maximum pressure. 5. Based on the given thermal conditions and the IHA characteristics, the IHAs can safely be filled with HTF prior to launch. Even if the hoses axe repressurized to 207 kPa (30 psia) after expansion has ceased, the estimated maximum pressure at 40 °C (140 °F) is 276 kPa (40 psia), assuming the same pressure curve but starting at 207 kPa (30 psia). 6. The bend radius of the IHA when filled with HTF is very close to the bend radius of an empty IHA. This measurement was made by loosely, but firmly, coiling the IHA, then allowing it to relax in an unconstrained manner, with the masses of the QD with cap and adapter block with valve attached at the ends. If necessary, it could be coiled tighter than a 76-mm (3-in) radius, but that would induce a higher level of stresses. 7

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APPENDIX AmlTCS HOSE HEAT TRANSFER FLUID THERMAL EXPANSION EVALUATION TEST PLAN 9

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ITCS HTF Thermal Evaluation Hose Expansion Test Plan Paul Wieland NASA/MSFC/FD21 256-544-7215 May 2000 (Revised June 21, 2000) 10

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Contents 1.0 Introduction ........................................................................................................................................ 3 2.0 Test Objective ..................................................................................................................................... 3 3.0 Test Approach ..................................................................................................................................... 3 4.0 Applicable Documents ........................................................................................................................ 3 5.0 Test Method ........................................................................................................................................ 3 6.0 Test Requirements .............................................................................................................................. 4 6.1 Materials/Equipment Required ..................................................................................................... 4 6.2 Facility Requirements ................................................................................................................... 4 6.3 Personnel Requirements ................................................................................................................ 5 7.0 Test Procedure .................................................................................................................................... 5 7.1 Pretest Preparation ........................................................................................................................ 6 7.2 Test Steps ...................................................................................................................................... 6 7.3 Post Test ........................................................................................................................................ 6 8.0 Evaluation Criteria and Risks ............................................................................................................. 6 9.0 Cost and Schedule .............................................................................................................................. 7 10.0 Documentation .................................................................................................................................... 7 Figures Figure 6.1-1. IHA Test Assembly .............................................................................................................. 4 Figure 6.2-1. IHA Coolant Expansion Test Setup ..................................................................................... 5 11

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1.0 Introduction Internal Thermal Control System (ITCS) jumper hoses will be used by the astronauts on-board the International Space Station (ISS) to connect the ITCS loops in adjacent modules. A jumper hose with quick disconnects (QD) and end caps attached is referred to as an Integrated Hose Assembly (IHA). It would be preferable to launch the IHAs already filled with heat transfer fluid (HTF), but there is a concern that in the event of high temperature during storage or transportation the IHAs may leak or become damaged due to excessive pressure. To address this concern, a test was requested by the ISS Program Thermal Control Lead (Joe Chambliss) to evaluate the ability of an IHA to be launched "wet" and safely accommodate the increased pressure of the HTF if the temperature increased to the worstcase condition of 140°1. This test plan describes the equipment and facility requirements for performing this test, general test procedures, and the evaluation criteria. 2.0 Test Objective The objective of this test is to simulate the conditions which may be experienced by an isolated IHA, capped on both ends, and to determine whether the IHA can accommodate the increased pressure due to HTF expansion when heated from room temperature pressure of 100 psia, leaking, or being damaged. 3.0 Test Approach to 140°1, without exceeding the design maximum A flight-like IHA (serial number 683-56836-385) will be tested by simulating the worst-case condition plus 20°1, i.e., 160°1. The pressure will be monitored leakage or other damage. and the hose will also be checked for any signs of Note: The hose was originally flight hardware but is now obsolete due to a change in materials, however, the cap for the hose is flight hardware and appropriate 4.0 Applicable Documents procedures must be followed. Internal Thermal Control System Rack Flow Control Assembly Fill Procedure, SK683-53379, 21 April 1999 5.0 Test Method The test IHA will be filled with coolant per procedure SK683-53379, which involves evacuating the IHA to <50 milliTorr before filling with HT1. The worst-case conditions will be duplicated by heating a coolant-filled, sealed IHA in an environmental chamber, located in Building 4619 at the Marshall Space Flight Center (MSFC). Four cases will be run: two with a target temperature of 140°1, one with a target of 150°1, and one with a target of 160°E 12

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6.0 Test Requirements Controlled conditions axe needed as well as the means to monitor the pressure in the IHA. The IHA, and equipment that directly connects to the IHA fittings, must be cleaned to cleanliness level 300. Appropriate safety precautions must also be taken. The materials and equipment that are required and the facility support requirements axe described below. The hose will be filled with HTF according to procedure SK683-53379. 6.1 Materials/Equipment Required A suitable flight-like IHA (undamaged), fittings and connectors, a pressure transducer compatible with operation at 160°1, and HTF axe required. The IHA to be provided by Boeing has a QD connector on one end and a threaded MS fitting on the other. A connector block is required for attaching the pressure transducer, and vacuum and fill valve to the IHA. This configuration is shown in Figure 6.1-1. The pressure transducer must have current calibration for the test. QD Connector With Cap QD1 1/2-in-DiameterHose Approximately36 in Long Vacuum Source Pressure Transducer P1 MS Fitting Valve Adapter Vl Block AB1 HTFSupply Figure 6.1-1. IHA Test Assembly 6.2 Facility Requirements Facility support requirements include: 1. A suitable test preparation area to prepare the IHA test article for testing, 2. The means to evacuate the IHA test article and fill it with HT1, 3. An environmental chamber capable of cycling between ambient conditions and the test target temperatures and capable of maintaining the target temperatures for the required durations (sufficient to ensure thermal equilibrium with the IHA test article), 4. A means to record the data (pressure, temperature, time), and 5. Suitable precautions in the event of leakage of the IHA test article or other safety-related concerns. The IHA test article will be installed in the environmental chamber as indicated in figure 6.2-1. The pressure transducer will have data lines which connect to recording equipment outside the chamber. 13

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QD Connector WithCap 1/-in-DiameterHose _ Approximately36 in Long EnvironmentalChamber Pressure / TransducerI I P] I I I I m MSFitting_ Valve Adapter (OttPosition) Block AB1 Figure 6.2-1. IHA Coolant Expansion Test Setup 6.3 Personnel Requirements In addition to test personnel from FD21 and ED26, quality assurance personnel from QS 10 will need to approve the test due to the use of a flight hardware end cap. 7.0 Test Procedure The test procedure should include the following steps. 7.1 Pretest Preparation 1. Connect the required fittings to the IHA, including article with HTE valve and hoses required for filling the IHA test 2. Attach a pressure gauge and ensure proper tightness of all fittings. 3. Fill the test article with HTF by procedure SK683-53379. (Evacuate the test article to <50 millitorr prior to ensure complete fill with HTF). 4. Place the test article in the environmental chamber and connect to the monitoring equipment. 5. Place paper (or other means to readily detect leakage) under the test article. 7.2 Test Steps 6. Record the initial pressure (~ 15 psig) and temperature. Increase the temperature in the chamber at a maximum rate of 30°F/hour. Record the temperature and pressure every 10 minutes (or more frequently). 7. If the pressure reaches 100 psia during temperature the temperature. 14 ramp-up, STOP the test immediately and reduce

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1. If thepressure< 100psiawhenthetargettemperatureis reached(140°1,140°1,150°1,and160°F) holdthetemperaturelongenoughto ensurethoroughheatingandto checkthroughthechamber windowfor signsof leakage.Noteanyleakagein thetestlog. 9. Reducethetemperatureata maximumrateof 30°F/houruntil neax-ambienttemperatureis reached. 10.Openthe chamberandcheckthetestarticlefor indicationsof leakageor damage. 11.Returnto step7 for thenexttargettemperature. 12.Uponcompletionof thelasttargettemperaturecycle,removethetestarticlefromthechamberand inspectfor indicationsof leakageor damage. 7.3 Post Test Following completion of the test cycles, the test article is to be disassembled and the cap and hose cleaned to specification level 300 for return to Boeing. A report on the results of the testing will be prepared. 8.0 Evaluation Criteria and Risks The purpose of the testing is to determine whether the IHA can accommodate the worst-case scenario of 140°1. To ensure this, the testing will reach a high temperature of 160°1. To demonstrate that the hose can successfully do this, the pressure must remain below the 100 psia limit while at this temperature, no leakage should occur, and the hose should remain undamaged. Potential risks to performing this test relate to acquisition of materials and availability of facilities and personnel. Presently, the need for funding has not been identified, though it may be necessary to purchase items such as fittings for attaching the pressure gauge. 9.0 Cost and Schedule It is expected that the test will utilize existing equipment and materials, and therefore require minimal cost and time. No requirements for purchasing items have presently been identified. The IHA and cap will be loaned by Boeing. A preliminary schedule is given below. The duration required for acquiring the IHA and cleaning parts is unknown. The test itself is expected to take only a few days. 15

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Activity Preparetestplanandprocedure, paperworkfor environmentalchamber, QA, etc. Acquirehoseandparts Assembletestarticle(includingcleaning, asneeded) Performtest Post-testactivity(includingcleaningand returnof hoseandcapto Boeing) Testreport 10.0 Documentation Week 1 2 3 4 5 6 xxxxxxxxxxxxxxxxx xxxxx xxxxxxxxx xxxxx xxxxxx xxxxx Documentation of this project includes this test project plan, a test procedure, a test plan (TPS) prepared by the test group, test log and raw test results from the test conductor, and a report on the results of the test. 16

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APPENDIX BmlTCS INTEGRATED HOSE ASSEMBLY COOLANT EXPANSION TEST PREPARATION SHEET 17

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REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operation and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503 1. AGENCY USE ONLY (Leave Blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED October 2001 Technical Memorandum 4. TITLE AND SUBTITLE 5. FUNDING NUMBERS Internal Thermal Control System Hose Heat Transfer Fluid Thermal Expansion Evaluation Test Report 6. AUTHORS P.O. Wieland and H.D. Hawk* 7. PERFORMING ORGANIZATION NAMES(S) AND ADDRESS(ES) George C. Marshall Space Flight Center Marshall Space Flight Center, AL 35812 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) National Aeronautics and Space Administration Washington, DC 20546_0001 11. SUPPLEMENTARY NOTES Prepared by Flight Projects Directorate 8. PERFORMING ORGANIZATION REPORT NUMBER M-1031 10. SPONSORING/MONITORING AGENCY REPORT NUMBER NASA/TM--2001-211330 *Summer High School Apprenticeship Research Program, Marshall Space Flight Center, AL 12a. DISTRIB UTION/AVAILABILITY STATEMENT Unclassified-Unlimited Subject Category 18 Nonstandard Distribution 13. ABSTRACT (Maximum 200 words) 12b. DISTRIBUTION CODE During assembly of the International Space Station, the Internal Thermal Control Systems in adjacent modules are connected by jumper hoses referred to as integrated hose assemblies (IHAs). A test of an IHA has been performed at the Marshall Space Flight Center to determine whether the pressure in an IHA filled with heat transfer fluid would exceed the maximum design pressure when subjected to elevated temperatures (up to 60 °C (140 °F)) that may be experienced during storage or transportation. The results of the test show that the pressure in the IHA remains below 227 kPa (33 psia) (well below the 689 kPa (100 psia) maximum design pressure) even at a temperature of 71 °C (160 °F), with no indication of leakage or damage to the hose. Therefore, based on the results of this test, the IHA can safely be filled with coolant prior to launch. The test and results are documented in this Technical Memorandum. 14. SUBJECT TERMS ITCS, jumper hose, thermal control system 17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION OF REPORT OF THIS PAGE Unclassified Unclassified NSN 7540-01-280-5500 15. NUMBER OF PAGES 28 16. PRICE CODE 19, SECURITY CLASSIFICATION 20, LIMITATION OF ABSTRACT OF ABSTRACT Unclassified Unlimited Standard Form 298 (Rev. 2-89) Prescribedby ANSISld 239 18 298 102