Establishing Hazardous Gas Launch Commit Criteria for the Space Shuttle External Tank Intertank Compartment

Until recently, the simultaneous detection and evaluation of multiple Space Transportation System (STS) element compartments for propellant leakage was not possible during the External Tank (ET) pre-pressurization (pre-press) phase of propellant loading; late in the loading sequence (T-3 min to T-0). There exist launch commit criteria (LCCS) designed to protect against leaks resulting in flammable mixtures in the intertank during the functional life of the ET; start of propellant loading through ET-Orbiter separation. However thus far, leak protection had relied on the premise that if a propellant supply system leak were to exist, it would be a leak of fixed area present at the start of propellant loading (dumb leak mode) and such a leak could be detected earlier in the loading sequence than the pre-press phase. No measures had ever been implemented which would protect against leaks potentially developing late in the loading sequence (smart leak mode), The STS community had baselined this situation as an accepted risk their decision supported by exhaustive hardware acceptance criteria and a history of many successful launches. With the recent development of improvements to the hazardous gas detection system (HGDS), an opportunity arose to monitor the intertank compartment for hazardous gas concentrations beyond the T-3 minute mark. In this timeframe the propellant supply system is pressurized for flight and protection was sought against potential leaks generated by this pressurization process. The challenge at hand was to develop LCCs in this timeframe that were not too conservative to unnecessarily prohibit a launch, yet not too liberal to endanger crew safety and mission success. Since essentially no measurement history existed in this timeframe, the LCCs would have to rely on analysis alone. At NASA's direction, Lockheed Martin Michoud Space Systems (LMMSS) developed requirements that would protect against a smart leak during pre-press. A smart leak protection strategy is noteworthy from an STS main propulsion system (NWS) community perspective. This paper presents the resultant requirements as well as the technical and program issues involved with establishing hazardous gas LCCs for the ET intertank compartment.