The EGS Program provides complete vehicle integration and launch services for the SLS launch vehicle and spacecraft/payload. A system of facilities, equipment and personnel trained in launch vehicle and integration and launch operations is in place.
Payloads are manufactured/assembled at the payload provider’s manufacturing facility and arrive at KSC in customer-provided shipping containers or by aircraft. Any support required for off- loading at KSC can be negotiated during development of the LSSRD. Upon arrival at KSC, the spacecraft and associated GSE will be delivered to an assigned PPF or HPF for standalone processing. EGS provides transportation, handling and security for the spacecraft and customer-
supplied GSE from arrival through delivery to appropriate processing facility and then delivery to the VAB. The payload will be quiescent during transport between KSC facilities. The standalone processing performed by the payload customer includes all activities from receiving and inspection through final testing and checkout of spacecraft prior to PLA and payload mating and encapsulation. The actual operations that each payload will undergo during this customer processing phase varies according to mission. Any GSE that the payload will require during this processing phase will be provided by the payload customer. Standalone processing will be conducted prior to turnover of the spacecraft/payload to EGS.
Following the completion of payload processing activities either at the manufacturer or at a KSC integration facility, the payload will be turned over to EGS for encapsulation, beginning the offline processing phase. Any hazardous processing, such as hypergol fueling or ordnance installation, will be completed offline in the PHSF. Any fueling GSE will be provided by the payload customer. Integration of the payload to SLS hardware is performed in this phase. Activities performed by EGS during this phase include mating of spacecraft/payload to PLA and interface testing, potential removal of customer GSE, system performance testing and encapsulation. Lastly, after encapsulation, EGS will transport the mated ISPE to the VAB.
Upon arrival at the VAB, the ISPE (typically transported on a KAMAG) will enter the VAB via the transfer aisle. The EGS Program leads the operations for stacking and integrating the ISPE onto the SLS vehicle. The ISPE is lifted by overhead crane from the transporter, which is secured in the transfer aisle, and placed on the SLS vehicle, which is staged on the ML in HB 3. The ISPE is attached and secured to the SLS ICPS or EUS prior to any umbilicals being connected or any integrated tests being performed. At this time, customer personnel, supported by EGS, will set up the Payload User Room and the required GSE will be position in the Payload User Room. The payload EGSE must be compatible with the Payload Accommodation Subsystem (PAS). Following the stacking of the payload, testing of the integrated SLS with the payload and ML will be performed. This will, at minimum, consist of an interface verification test. Upon completion of the integrated test and checkout, rollout operations will be executed, followed by pad operations. Rollout preparations include final closeouts of the payload and PLF/USA and any preparations for monitoring the payload and GSE during the SLS and ML rollout to the pad.
Pad operations take place when the ML is connected to the launch pad. Once those interfaces are mated, checkouts of the vehicle to ground systems are conducted to ensure all interfaces are functional. This usually consists of a health check of the payload to ensure interfaces were not affected during rollout. This leads up to launch operations. The SLS vehicle, ML, pad, Payload User Room and LCC are now activated. Power-up of ground systems and flight vehicle ensues, followed by loading of cryogenic fuels and monitoring of launch commit criteria (LCC). Final launch countdown is initiated. During liftoff, the ML umbilicals are retracted. Payload element data systems must be compatible with the EGS Launch Control System (LCS) for ground processing and launch countdown monitoring. Figure 7-14 shows a representative operational flow for the SLS
For all of the various payload elements, the same basic processing phases will be followed for payload encapsulation at the PPF. Figure 7-17 shows this process for a CPL encapsulated by a canister USA in an offline processing facility, but the process would be similar for PPL encapsulated by a sectored fairing.
Prior to payload arrival, the USA Canister or PLF sectors are delivered to the PPF where they are inspected and prepared for payload encapsulation. The USA or PLF is debagged, cleaned and inspected, then placed on GSE for assembly and rotation operations. Encapsulation operations begin with the placement of the transportation pallet assembly in the encapsulation area and the installation of the PLA. The payload is then configured for encapsulation and mated to the PLA. Payload-specific integrated checkouts may be performed upon the completion of this procedure per the manufacturer’s requirements. The USA or PLF sectors are positioned and configured for encapsulation in the PPF HB. The USA or PLF is then mated to the PLA and the encapsulated payload is prepared for transportation from the PPF to the VAB. The payload transporter is equipped with an ECS capable of providing a conditioned air purge to the payload in transit. This allows for positive pressure, humidity and temperature control for encapsulated payloads up to 65,000 lbm (29,483 kg). Once in the VAB, the temporary ECS is disconnected and an integrated lift is used to move the encapsulated payload from the transportation pallet to the top of the integrated vehicle stack, where it is mated with the EUS.