NATIONAL AERONAUTICS AND SPACE ADMINISTRATION
CONSTRUCTION OF FACILITIES
FISCAL YEAR 1996 ESTIMATES
SUMMARY
HUMAN SPACE FLIGHT
Amount
------
(Dollars)
Space Station:
Construction of Neutral Buoyancy Laboratory, Johnson Space Center..... 14,800,000
Other Human Space Flight:
Replace Chemical Analysis Facility, Kennedy Space Center.............. 7,500,000
Replace Space Shuttle Main Engine Processing Facility,
Kennedy Space Center................................................ 4,900,000
Modernize Firex System, Pads A and B, Kennedy Space Center............ 5,000,000
Total Human Space Flight 32,200,000
==========
CONSTRUCTION OF FACILITIES
FISCAL YEAR 1996 ESTIMATES
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PROJECT TITLE: Construction of Neutral Buoyancy Laboratory
INSTALLATION: Lyndon B. Johnson Space Center
FY 1996 Estimate: $14,800,000
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LOCATION OF PROJECT: Houston, Harris County, Texas
COGNIZANT HEADQUARTERS OFFICE: Office of Space Flight
FY 1995 AND PRIOR YEARS FUNDING: The following prior years funding is related to this project:
Planning
and Design Construction Total
Specific Construction Funding............. $4,515,634 $20,200,000 $24,715,634
Capitalized Investment.................... --- --- ---
Total............................... $4,515,634 $20,200,000 $24,715,634
SUMMARY PURPOSE AND SCOPE:
This project provides the second and final increment of funding for acquisition of the Neutral
Buoyancy Laboratory (NBL) to meet the requirements for extravehicular activity (EVA) simulations
for astronaut training, EVA procedures development, and validation for the Space Station assembly
and operations. NASAs FY 1995 budget for the Space Station included $20.2 million for the first
increment of funds for construction of the NBL. NASA has recently negotiated a firm fixed-price
lease/purchase agreement in the amount of $35 million with McDonnell Douglas Corporation for the
Clear Lake Development Facility (CLDF) and the construction of the NBL. The $20.2 million
appropriated in FY 1995 will be used to implement the lease/purchase agreement and the
modification of the CLDF for the NBL. This $14.8 million will be used to complete the
acquisition. The Congressional Committees have been formally advised of this acquisition plan.
PROJECT JUSTIFICATION:
This project is required for EVA simulations for astronaut training and procedures development
for the Space Station. A major critical requirement is the validation of EVA timelines to
ensure that the EVA activities can be successfully carried out. Experience from several satellite
retrieval/servicing EVA tasks, such as Solar Maximum, Westar/Palapa, Syncom, Intelsat-VI, and the
recent Hubble Space Telescope, has clearly shown that the more realistic, complete simulations
made possible by the larger pool size of the NBL will significantly increase assurance of
successful and safe EVA mission operations.
Techniques developed and refined in neutral buoyancy facilities allow astronauts in space suits
to perform space-related EVA operations on the ground in a way that correlates closely to actual
on orbit task performance. Existing facilities were sized for existing program hardware. Larger
facilities are required for the larger Space Station flight hardware assemblies. The NBL will
accommodate the large space hardware portions and provide realistic EVA development and operations
planning activities during the Space Station buildup and follow-on operations. There are no
acceptable neutral buoyancy facilities available for providing adequate Space Station EVA
evaluations and astronaut training. The NBL also will be the primary EVA facility for Space
Shuttle and other program requirements.
IMPACT OF DELAY:
The NBL is required to support Space Station assembly engineering and training and will be
invaluable for the assembly missions which involve significant EVA complexities. Delay in
providing the NBL will seriously impact Space Station assembly and operations.
PROJECT DESCRIPTION:
The lease/purchase agreement includes the following CLDF facilities and all necessary
modifications to the Assembly and Test Building (ATB) to provide an NBL within the ATB.
All of the following facilities are metal panel structures that include heating, ventilation,
air conditioning, associated utility services, parking, and access roadways:
* The Assembly and Test Building, approximately 101,800 gross square feet,
will house the NBL with tank dimensions of approximately
202 by 102 by 40 feet.
* The Light Manufacturing Facility, approximately 98,200 gross square feet,
will accommodate construction, modification, and storage for training
mockups used in the NBL.
* The Avionics Development Facility, approximately 51,600 gross square feet,
will provide contiguous laboratory space for avionics and associated software
development, integration and testing space for approximately 250 people
associated with these operations.
A separate metal building of approximately 3,000 square feet which houses the breathing
gas system will also be provided. Activation items include furniture, telephone system
installation, and facility start-up supplies. The laboratory will be a steel framed
structure with insulated metal panels comprising approximately 72,000 square feet. The
tank will be 202 by 102 by 40 feet deep.
PROJECT COST ESTIMATE: Total estimated cost of the project is $35.0M. Previous funding
OF $20.2M was provided in FY 1995.
LIST OF RELATED GRAPHICS: Figure 1 - Lease/purchase site
FUTURE ESTIMATED FUNDING REQUIRED TO COMPLETE THIS PROJECT: None
CONSTRUCTION OF FACILITIES
FISCAL YEAR 1996 ESTIMATES
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PROJECT TITLE: Replace Chemical Analysis Facility
INSTALLATION: John F. Kennedy Space Center
FY 1996 ESTIMATE: $7,500,000
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LOCATION OF PROJECT: John F. Kennedy Space Center, Brevard County, Florida
COGNIZANT HEADQUARTERS OFFICE: Office of Space Flight
FY 1995 AND PRIOR YEARS FUNDING: The following prior years funding is related to this project:
Planning
and Design Construction Total
Specific Construction Funding............. $1,187,982 $7,500,000 $8,687,982
Capitalized Investment.................... --- --- ---
Total............................... $1,187,982 $7,500,000 $8,687,982
SUMMARY PURPOSE AND SCOPE:
The purpose of this project is to upgrade the existing Space Shuttle Chemical Analysis Facility
by replacing approximately 2,800 square meters and relocating the tanker maintenance garage.
PROJECT JUSTIFICATION:
The Chemical Analysis Facility is overcrowded, does not comply with OSHA fire safety standards,
has aging utility systems, and has friable asbestos in the roof deck and mechanical areas.
Modifications to replace the utility systems, install fire sprinklers, install
non-chlorofluorocarbon (CFC) cleaning equipment upgrades, and remove the asbestos have been
canceled due to the requirement to keep this mission critical operation on-line. The facility
is currently operated 7 days per week to support the chemical analysis of Space Shuttle and
Air Force flight components, and on-site institutional environmental sample analysis for KSC
and Cape Canaveral Air Force Stations. In addition, the existing facility is located within
the Shuttle launch impact zone requiring evacuation and subsequent work stoppage on launch
days.
IMPACT OF DELAY:
Continued use of the existing facility would result in fire safety noncompliance, overcrowding,
noncompliance with non-CFC cleaning equipment upgrades, and increased breakdowns of out-dated
utility systems.
PROJECT DESCRIPTION:
This project provides for replacing approximately 2,800 square meters for chemical analysis labs,
office area, field cleaning annex, hypergol decontamination building, warehouse, POL chemical
storage building, and a hazardous waste storage building. A fire protection and detection system
will be installed. Services provided will include communication, electricity, water, sewer,
compressed air, and hazardous waste storage. Vapor containment equipment to supplement the
existing CFC equipment will also be incorporated into this facility. Also included is the relocation
of all activities associated with the maintenance of the tankers and trailers for cryogenics, gases,
and other fluids used to support launch operations. The original site will also be restored to
grade.
PROJECT COST ESTIMATE: Unit of Unit
Measure Quantity Cost Cost
Construction................................ --- --- --- $7,500,000
---------
Civil............................... LS --- --- 440,000
Structural.......................... LS --- --- 4,380,000
Mechanical.......................... LS --- --- 1,500,000
Electrical.......................... LS --- --- 1,180,000
Total............................................................... $7,500,000
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LIST OF RELATED GRAPHICS: Figure 1 - Location Plan Figure 2 - Perspective
OTHER EQUIPMENT SUMMARY: $4,600,000 of analytical equipment will be provided from other program
resources.
FUTURE ESTIMATED CONSTRUCTION FUNDING REQUIRED TO COMPLETE THIS PROJECT: None
CONSTRUCTION OF FACILITIES
FISCAL YEAR 1996 ESTIMATES
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PROJECT TITLE: Replace Space Shuttle Main Engine Processing Facility
INSTALLATION: John F. Kennedy Space Center
FY 1996 ESTIMATE: $4,900,000
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LOCATION OF PROJECT: John F. Kennedy Space Center, Brevard County, Florida
COGNIZANT HEADQUARTERS OFFICE: Office of Space Flight
FY 1995 AND PRIOR YEARS FUNDING: The following prior years funding is related to this project:
Planning
and Design Construction Total
Specific Construction Funding............. $493,836 --- $ 493,836
Capitalized Investment.................... --- $12,665,718 12,665,718
Total............................... $493,836 $12,665,718 $13,159,554
======== =========== ==========
SUMMARY PURPOSE AND SCOPE:
The purpose of this project is to upgrade the existing Space Shuttle Main Engine (SSME) shop by
replacing approximately 2,800 square meters.
PROJECT JUSTIFICATION:
SSME operations at KSC are currently conducted in the Vehicle Assembly Building (VAB) low bay in
an area not originally designed for those activities. The capacity of the current three vertical
workstand shop is inadequate to support the volume of SSME processing. An area designed
specifically for SSME processing is required to provide adequate space, optimize work and
material flow, upgrade personnel safety, preclude engine damages and improve flight hardware
quality assurance.
IMPACT OF DELAY:
Any delay will continue the present risk to personnel safety and engine damage while processing
SSMEs. Extremely limited space reduces engine throughput and conflicts with the VAB Abatement
Plan goals. It will also continue the current costly overtime processing caused by working
around Solid Rocket Motor stacking and movement schedules which require evacuation of the VAB to
meet mandatory safety requirements.
PROJECT DESCRIPTION:
This project constructs a 2,800 square meter building addition to the east end of the existing
Orbiter Processing Building-3 (OPF-3) Annex. It will be constructed of similar materials - steel
framed and metal panel systems walls - as the OPF-3 and its low bay annex. The space will
consist of three main areas: A high bay with a 15-ton overhead crane, a vertical processing area
with workstands, and a 10-ton overhead crane, and ancillary storage and support space. Support
requirements such as the existing security systems, storage, shops, and locker room at OPF-3 will
be shared resulting in program savings.
PROJECT COST ESTIMATE: Unit of Unit
Measure Quantity Cost Cost
Construction................................ --- --- --- $4,900,000
---------
Structure........................... LS --- --- 3,000,000
Mechanical.......................... LS --- --- 900,000
Electrical.......................... LS --- --- 400,000
Cranes.............................. LS --- --- 600,000
Total............................................................... $4,900,000
==========
LIST OF RELATED GRAPHICS: Figure 1 - Location Plan Figure 2 - Perspective
OTHER EQUIPMENT SUMMARY: $2,500,000 of equipment will be provided from other program resources.
FUTURE ESTIMATED CONSTRUCTION FUNDING REQUIRED TO COMPLETE THIS PROJECT: None
CONSTRUCTION OF FACILITIES
FISCAL YEAR 1996 ESTIMATES
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PROJECT TITLE: Modernize Firex System, Pads A and B
INSTALLATION: John F. Kennedy Space Center
FY 1996 ESTIMATE: $5,000,000
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LOCATION OF PROJECT: John F. Kennedy Space Center, Brevard County, Florida
COGNIZANT HEADQUARTERS OFFICE: Office of Space Flight
FY 1995 AND PRIOR YEARS FUNDING: The following prior years funding is related to this project:
Planning
and Design Construction Total
Specific Construction Funding............. $875,429 $ 4,800,000 $ 5,675,429
Capitalized Investment.................... --- 216,362,462 216,362,462
Total............................... $875,429 $221,162,462 $222,037,891
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SUMMARY PURPOSE AND SCOPE:
This project upgrades the Firex system by replacing pumps, motors, pipes and all associated
control system hardware.
PROJECT JUSTIFICATION:
The existing pumps, motors, and underground piping have deteriorated over the past 25 years. A
majority of system replacement components are no longer manufactured. With the present system
configuration, nominal flow rates are marginal. Pad Compressed Air System needs to be moved to
the LC-39 Water Pumping Station to avoid SRB exhaust cloud. These modifications will assure
system performance over the life of the Shuttle program.
IMPACT OF DELAY:
Increasing system and component failures could render the Pad A and B Firex Protection System
inadequate during an emergency. Personnel safety will be compromised and damage to the Pads
could occur.
PROJECT DESCRIPTION:
This project upgrades existing Firex pumps, motors, and diesels required for system pressure
specifications. Also, a new 500 mm underground pipe will be installed between the Pump Station
and Pads A and B. The Pad Compressed Air System will be moved to the Water Pumping Station.
PROJECT COST ESTIMATE: Unit of Unit
Measure Quantity Cost Cost
Construction................................ --- --- --- $5,000,000
---------
Pumps............................... LS --- --- 2,100,000
Pipe Installation................... LS --- --- 2,700,000
Components & Installation........... LS --- --- 175,000
Demolition.......................... LS --- --- 25,000
Total............................................................... $5,000,000
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LIST OF RELATED GRAPHICS: Figure 1 - Location Plan Figure 2 - Site Plan (LC-39 Pad A)
Figure 3 - Site Plan (LC-39 Pad B)
FUTURE ESTIMATED CONSTRUCTION FUNDING REQUIRED TO COMPLETE THIS PROJECT: None