Boldly Going Part 8
The External Tank’s bulk was a familiar one to any orbiter flight crew, who had all had their encounters with the giant orange monsters in ground training and on the ride up the elevator to the pad just days before. However, to find one here, its white anti-popcorning sealants nearly glowing in the orbital sunlight, was almost unnerving. For the first time, a flight crew made rendezvous with something larger than the Space Shuttle, and their challenge was not merely to stash it within the orbiter’s payload bay, but to belly up and dock to it. With
Enterprise’s keep alive panels deployed, access to the docking port on the
Leonardo Lab Module was blocked, as the port was mainly planned for future expansion. Instead, Engle and Nagel guided
Atlantis around the station to the ventral side of the external tank, opposite OV-101. There, a panel replaced in the intertank offered a docking hatch and the access to the inflatable passages located inside the ET’s intertank.
Atlantis’s flight crew made the docking look easy, and the orbiter settled into a hard dock. However, before reaching
Enterprise’s core modules, the STS-38R crew had to activate, inflate, and verify the so-called “hamster tubes” which Marshall had grafted around the thrust beam inside ET-007’s intertank. The intertank was massive, stretching the full 8.4m diameter of the tank. At the maximum point, the two tank domes allowed nearly the same 8.4m of axial length, but in the middle the two dome ends were separated by bare feet, allowing only enough room for the massive structural beam which carried the thrust from the two Solid Rocket Boosters during
Enterprise’s first and only ascent.
Late on Flight Day 2, Owen Garriott opened the hatch between the orbiter and the vestibule, with the station-side hatch still separating him from his second space station. In this awkward liminal space, Garriott and the rest of the flight crew worked to connect the fittings designed to allow
Atlantis to inflate and deploy the intertank tubes. The process was the largest flareup of Marshall’s past space station legacy to date. While the Marshall team had expected the first pressure introduced into the intertank passages to easily begin their deployment against the vacuum of space filling the rest of the intertank, the passages did not seem to inflate at first. The crew tried again, but after reaching several psi on the station-side of the hatch, they discontinued attempts for the day to allow ground controllers to work the problem. With Skylab looming large in program leadership minds, the crew resumed the next morning. It was decided that friction between the fabric folds might have exceeded ground expectations, and the crew were directed to simply slowly but steadily supply air into the module. The risk existed that a sudden “snap” to inflation would occur, which could damage the connections between the inflatable tubes and the rigid portions of the station. However, the friction seen as the pressure mounted--literally and metaphorically--reassured controllers that the risk was small. Finally, the tubes began to budge open. After consuming most of Flight Day 3 (putting the mission almost a full day behind schedule), the crew was finally able to open the hatch and gain access to the precious cubic meters of volume they had won in the passages between the tanks. Contrary to the common mental image of inflatable modules as similar to terrestrial bouncy castles, the walls of the module were quite bulky, three redundant bladders, a small MMOD layer in case the rigid outer skin of the intertank structure was holed, and internal insulation and fabric to cushion crew working their way around the circular hallway, a torus roughly two meters in diameter. Netting lined the inner and outer walls, serving both as hand-holds for locomotion and stowage for future gear.
The “hamster tubes” started at the “visitor entrance” to the station and wrapped more than 180 degrees around the intertank to the pressure hull leading to the Core Module Access Passage leading on to
Enterprise’s middeck. Two branches broke off as the passage wound under the thrust beam, one each accessing manholes into the LOX and LH2 tanks of ET-007, creating in total roughly 20 cubic meters of pressurized volume at what would, when the tanks were opened, eventually become the core of the station’s traffic patterns. For the moment, these branches were ignored beyond verifying the modified orbitally-accessible manholes remained sealed, as Engle, Garriott, and Nagel worked to make up for lost time. The rigid passage between the intertank and the
Enterprise core modules proved much easier to work with. Installed on the ground, clearing through the CMAP was simply a matter of checking and opening two pressure hatches, one on the intertank end and one at the other end recessed into the belly of the former OV-101. After checking air for breathability and watching carefully for any floating particles or debris, the STS-38R crew ended Flight Day 3 by finally gaining access to
Enterprise’s mid-deck. The crew celebrated by retrieving a waiting snack of ice cream from the station’s galley freezers before closing the hatches for safety and retiring to
Atlantis for a well-earned rest.
On Flight Day 4, the
Atlantis crew awoke to the sound of synthesized chimes and the ethereal soprano of Loulie Jean Norman, as a specially-recorded voiceover from William Shatner (never afraid of publicity) offered the crew a benediction for their “ongoing” mission and bid them to go now “where no one had gone before.” (A modification of the script which managed to frustrate many of the same fans the skit was meant to entertain.) Still, taking the words to heart, the crew pressed on into some of the most delicate work of the mission: activating
Space Station Enterprise and deploying the rest of its solar power system. When fully active,
Enterprise’s base load would rise from the 6 kW sustainable from the keep-alive panels to more than 16 kW (slightly more than
Atlantis’s own 14 kW due to the larger volume and modified systems). Once drawn on by the fully active systems, even the station’s nearly fully-charged batteries could sustain it for only a few days. To help bridge the gap,
Atlantis’ crew first rigged the connections between
Atlantis and
Enterprise. With
Atlantis’ payload bay carrying no experiments and only a Spacelab module full of cargo for future station crews which the crew had been too busy to begin to transfer,
Atlantis could spare a few critical kilowatts to stretch
Enterprise’s batteries while the crew went to work to deploy the station’s arrays.
To do so, STS-38R moved their main base of operations from
Atlantis to
Enterprise for the day, the middeck just different enough in layout to confuse the crew. Larger differences lurked on the cockpit level, which was converted to an “Orbital Operations Center”. The flight chair which Joe Engle had used so long ago was gone, providing more open space on the deck and places to hang checklists and procedure manuals. After getting main power online and getting their first view of the inside of the payload bay since calling tally ho on the station, the STS-38R crew broke up to divide and conquer. While Engle and Merbold went through the process of activating and accessing the
Leonardo Laboratory Module, Garriott and Nagel did the same for the station’s robotic manipulator, the CanadArm 2. Unlike the Shuttle version, the station’s arm was capable of detaching from its main base, as it had a grapple fixture at each end which included the ability to draw power from any grapple point which offered it. With this, the arm could be “walked” to multiple locations inside the payload bay and on the structure of the Enterprise Power Module, increasing the reach of the station’s crew. Future plans called for installing bases on the outside of ET-007, allowing the arm to “walk” to within reach of visiting orbiters to hand off future cargo and expansion modules. With Garriott and Sullivan suited and ready for an EVA in case anything went wrong, Nagel and Thuot commanded the Enterprise Power Module to fold up and out of the bay. The hamster tubes appeared to have absorbed any residual “Marshall Luck’ with space hardware, as the primary structural element of the EPM smoothly rotated up and out of the payload bay proper, allowing the “keep-alive” panels to extend over the starboard door sill like an oar. Flight Day 4 was completed by deploying the other solar array wing on the starboard side, adding another critical 12 kW of peak power to the station’s generating capabilities. Even averaged over an orbital night and day, that was enough to reduce the station’s parasitic draw on
Atlantis to just 2 kW. Though the STS-38R crew had begun the day almost 24 hours behind schedule, judicious parallel processing by the crew had reduced many of the “catch-up” tasks, as Merbold and the rest of the crew had worked in the LLM even as the operations to extend the solar arrays proceeded only meters behind them in the bay.
(Images by
@nixonshead )