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~\, LPC DWCUMENT NO. 629-6VOLUME II, BOOK 3

-- ---- ~_._.-

- _._------(NASA_CR-':123617)STUDYO-FSOLID-iiocKET N72-22777MOTORS FOR A SPACE SHUTTLE BOOSTER •. VOLURE2, BOOK 3: COST ESTI~ATING DATA .FlnalA H Vanderesch (Lockheed propulsl0n Co.)15 Mar. 1972 168 P CSCL 22H G3/28

DATA REQUIREMENT MA-02FINAL REPORTCR-/~3 b/?

TECHNICAL R"EPORT

COST ESTIMATING DATA

STUDY OF SOLID ROCKET MOTORSFOR A SPACE SHUTTLE BOOSTER

CONTRACT NO. NAS8-28429

JANUARY 13, 1972 TO MARCH 15, 1972

MARCH 15, 1972

PREPARED FORTHE NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

GEORGE C. MARSHALL SPACE FLIGHT CENTERMARSHALL SPACE FLIGHT CENTER. ALABAMA 35812

LOCKHEED PROPULSION COMPANY

P.O. BOX 111 REDLANDS. CALIFORNIA 92373-- ----- - - - -~-

,C/lr; 28 \

https://ntrs.nasa.gov/search.jsp?R=19720015127 2020-06-05T15:50:31+00:00Z

LPC Document No. 629-6Vol II, Book 3

Data Requirement MA-02

FINAL REPORT

TECHNICAL REPORTCOST ESTIMATING DATA

STUDY OF SOLID ROCKET MOTORSFOR A SPACE SHUTTLE BOOSTER

Contract No. NAS8- 28429

January 13, 1972 to March 15, 1972

A. H. Von Der EschLockheed Propulsion Company

Vice President, Technical and Marketing

MARCH 15, 1972

PREPARED FORTHE NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

GEORGE C. MARSHALL SPACE FLIGHT CENTERMARSHALL SPACE FLIGHT CENTER, ALABAMA 35812

ABSTRACT

Lockheed Propulsion Company has selected the l56-inch-diameter parallelburn Solid Rocket Motor (SRM) as the most cost-effective system that hasbeen demonstrated. This selection is based on the use of proven materials,minimum development costs, easily transportable size, and credibleengineering designs that are presently available. The criteria used abovefulfill the objectives as stated in the NASA Study Contract.

The basic study approach was to concentrate the costing aspects on thebaseline motor, and to draw from the baseline sufficient data to cost thealternate motor approaches.


P.O. BOX 111 REDLANDS. CALIFORNIA 92373

629-6VollI, Book 3

FOREWORD

This document is Book 3, Cost Estimating Data of Volume II TechnicalReport. It is a part of Lockheed Propulsion Company's final report for theStudy of Solid Rocket Motors for a Space Shuttle Booster. The final reportconsists of the following documents:

Volume I

Volume II

Book 1

Book 2

Book 3

Volume III

Volume IV

Executive Summary

Technical Report

Analysis and Design

Supporting Research and Technology

Cost Estimating Data

Program Acquis ition Planning

Mass Properties Report

- ii-


Section

629-6Vol II, Book 3

CONTENTS

1

2

INTRODUCTION

COST SUMMARY

2.1 156-7 PARALLEL

1-1

2-1

2-2

2.1.1 Option I - Basic with Thrust Terminationand TVC 2-2

2.1.2 Option II - Basic (W/0 Thrust Terminationand TVC 2-3

2. 1. 3 Option III - Bas ic with TV C 2 -4

2.1.4 Option IV - Bas ic with Thrus t Termination 2-5

2.2 156-6 SERIES - BASIC WITH THRUST TERMINATIONAND TVC 2-6

3 WORK BREAKDOWN STRUCTURE

3.1 DESCRIPTION OF CONTENT

3.1. 1 WBS Dictionary, DDT&E

3.1. 2 WBS Dictionary, Production

3.2 156-7 PARALLEL CONFIGURATION

3.2.1 Option I - Basic with Thrust Terminationand TVC

3.2.1.1 DDT&E

3.2.1.2 Production

3 -1

3-1

3-2

3-17

3-25

3-26

3-26

3-27

3.2.2 Option II - Basic (W/O Thrust Terminationand TVC) 3 -28

3.2.2.1 DDT&E

3.2.2.2 Production

3.2.3 Option III - Bas ic with TV C

3.2.3.1 DDT&E

3.2.3.2 Production

- iii-

3-28

3-29

3 -30

3 -30

3 -31


Section

629-6VallI, Book 3

CONTENTS (Continued)

3.2.4 Option IV - Basic with Thrust Termination 3 -32

3.2.4.1 DDT&E

3.2.4.2 Production

3 -32

3-33

3.3 156-6 SERIES, BASIC WITH THRUST TERMINATIONAND TVC 3-34

3.3.1 DDT&E

3.3.2 Production

3 -35

3 -36

3.4 120-7 PARALLEL CONFIGURATION WITH THRUSTTERMINATION AND TVC 3-37

4

3.4.1 DDT&E

3.4.2 Production

PROGRAM COST ESTIMATES, TABLE 1

4.1 DESCRIPTION OF TASK CONTENT



3 -38

3-39

4 -1

4 -1

4-4

4-5

4.2.1.1

4.2.1.2

Solid Rocket Motor (WBS 3.3.2)

Booster Vehicle (WBS 3.3)

4-5

4-6

4.2.2 Option II - Basic (W/0 Thrust Terminationand TVC) 4-7

4.2.2.1

4.2.2.2



4-7

4-8

4.2.3 Option III - Basic with TVC 4-9

4.2.3.1

4.2.3.2



-iv-

4-9

4-10

LOCKHEED PROPULSION COMPANYI

Section

629-6Vol II, Book 3


4.2.4 Option IV - Basic with Thrust Termination 4-11

4.2.4.1

4.2.4.2



4-11

4-12

4.3 156-6 SERIES, BASIC WITH THRUST TERMINATIONAND TVC 4-13

5

4.3.1 Solid Rocket Motor (WBS 3.3.2)

4.3.2 Booster Vehicle (WBS 3.3)

PROGRAM TIME PHASED FUNDING REQUIREMENTS,TABLE 2


5.2 156-7 SRM PARALLEL CONFIGURATION


4-13

4-14

5 -1

5-1

5 -3

5-4

5.2.1. 1

5.2.1.2



5-4

5-5

5.2.2 Option II - Basic (W/0 Thrust Terminationand TVC 5-6

5.2.2.1

5.2.2.2



5 -6

5-7

5.2.3 Option III - Basic with TVC 5-8

5.2.3.1

5.2.3.2



5-8

5-9

5.2.4 Option IV - Bas ic with Thrust Termination 5 -10

5.2.4.1

5.2.4.2



5-10

5-11

5.3 156 -6 SERIES, BASIC WITH THRUST TERMINATIONAND TVC 5-12

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Section

629-6Vol II, Book 3


6

5.3.1 Solid Rocket Motor (WBS 3.3.2)

5.3.2 Booster Vehicle (WBS 3.3)

RECURRING COST PER ALTERNATE LAUNCH RATE

6.1 DESCRIPTION OF COSTING APPROACH



5 -12

5 -13

6-1

6 -1

6 -3

6-3

6.2.1.1

6.2.1.2

6.2.1.3

Launch Rate Cost Summaries(Rates of 60, 40, 20 and 10)

Comparison Curves ,

Costing Rationale/Detail

6 -3

6 -7

6-8

6.2.2 Option II - Basic (W/0 Thrust Terminationand TV C) 6 - 18

6.2.2.1

6.2.2.2

6.2.2.3


Comparison Curves


6-18

6-22

6-23

6.2.3 Option III - Basic with TVC 6 -33

6.2.3.1

6.2.3.2

6.2.3.3


Comparison Curves


6 -33

6 -37

6-38

6.2.4 Option IV - Bas ic with Thrust Termination 6 -48

6.2.4. 1

6.2.4.2

6.2.4.3


Comparison Curves


-Vl-

6-48

6-52

6-53

LOCKHEED PROPULSION COMPANVI

II

Section

629-6VollI, Book 3


7 PROGRAM COST ESTIMATING RELATIONSHIPS(CERs) - TABLE 3 7-1

Appendix

7.1 PROGRAM COSTS = f (Booster Vehicle Gross Weight) 7-2

7.2 PRODUCTION/OPERATION COSTS = f (ProductionRate) 7-3

7.3 DDT&E COST = f (NUIllber of GTH and FTH) 7-4

A MISCELLANEOUS COST BACK-UP DATA

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A-I


PRECEDING PAGE BLANK NOT FILMED

SUMMARY

629-6Vol II, Book 3

Lockheed Propulsion Company's objective from the outset of the SpaceShuttle Program has been to provide complete and conservative design andcost parameters for an expendable Solid Rocket Motor (SRM) Booster Vehiclefor the Space Shuttle Program. With this approach, LPC has attempted toidentify the maximum technical and cost risks that could be encountered byNASA in employing a solid rocket motor as the Space Shuttle Booster Vehicle.Therefore, LPC believes that the baseline vehicle costs presented in thisreport are distinctly conservative and will be reduced upon further definitionand detailed estimating. Two items, which LPC has not included and whichwill affect a fixed-payload program cost, are escalation and profit, both ofwhich were directed in the Study Contract to be deleted from consideration.

As directed by NASA, LPC also attempted to determine "hard" versus "soft"costs, and an upper band was established above the baseline for a "worstcondition." As a result of Lockheed's solid rocket motor experience, thepropulsion system costs are "hard" and, therefore, an upper limit of 2 percent on the SRM cost has been defined. LPC believes that the Stage costsare "soft" and a 30-percent upper limit on the Stage cost was established.With the SRM and Stage combined, a total of 10-percent upward variationhas been identified in the Booster Vehicle (WBS 3.3) Program costs. Alower range has also been established, which identifies potential reductionsfor thrust vector control, thrust termination, and recovery.

The Booster Vehicle selected as the baseline configuration is a parallelburn (two-motor) 156-inch-diameter SRM vehicle sized for the large(65,000-poWld) Orbiter payload. The baseline program assumed for studypurposes includes a 5-year (1973 - 1978)deve1opment/quali£ication program,a 13 -year (1976 - 1988) production program, and an ll-year (1978 - 1988),440 vehicle launch program.

The development program includes 25 SRMs; 5 development motor tests,4 PFR T motor tests, 2 inert booster vehicles (2 SRMs per vehicle) and 6launches (1 unmanned and 5 manned flights with 2 SRMs per vehicle). All25 motors in the development program will be fabricated in LPC's existing,lar ge -motor Potrero manufacturing facility. The development programschedule was established at 5 years to minimize annual funding and couldbe shortened by as much as 1 year without impacting the launch schedule.

The production program of 440 launches includes manufacture of 883 SRMs(880 for launches and 3 for production facility start-up demonstration) and440 sets of Stage hardware. Due to the nature of the solid rocket motor,quality is ensured by the facility process controls in manufacturing. Thusa three -motor test program is planned to demonstrate that the productionfacilities will reproducibly de liver the SRMs qualified during deve lopment.As directed in the Study Contract, all launches were considered to be fromKennedy Space Center (KSC).

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LOCKHEED PROPULBION COMPANY

629-6Vol II, Book 3

Lockheed Propulsion Company, as prime contractor for the Booster Vehicle,would utilize all of the industry production capability before additional facilityexpansion. LPC would subcontract to at least two other SRM manufacturersfor a portion of the production motors. Additionally, all components wouldbe considered for dual procurement to ensure a redundant capability forBooster Vehicle delivery. This LPC plan provides Booster Vehicle procurement at a very low risk to NASA in the event of a labor, facility, or materialproblem at any time during the program. This approach also results in arelatively low facility expansion cost ($ 25. 7 million) for the production program and avoids the building of a brand new facility, which would costapproximately $ 70 million.

The three production facility start-up demonstration tests are consideredadequate by LPC to qualify the three production facilities (LPC and two others)for the baseline costing effort. It was considered that NASA might desireadditional testing to qualify the new subcontractors ("second sources ") and,therefore, nine motor tests were included in establishing the upper limit 2percent variation in SRM costing. However, LPC recommends only threetests and has used this in the baseline costing.

Previous ly, it has been stated that the baseline des ign is conservative. Asevidence of this, all metal structures have a minimum safety factor of 1.4.This has naturally imposed an additional cost on materials, but LPC believesthat this should be maintained, thus guaranteeing the high reliability requiredfor a man -rated system. As a bo.nus feature, analysis indicates that themotor chamber with this safety factor (wall thickness 0.460 inch) will withstand water impact loads at 100 feet per second and at entrance angles up to45 degrees. Although recovery/reuse is not considered in the baselinecosting, Lockheed's SRM design should therefore not require additionalstrengthening (higher material costs) should recovery/reuse prove cost-effe ctive for the Booster Vehicle.

As further evidence of a conservative design, the safety factor for all ablative insulation materials was established at 2. O. Once again, it is felt thatthis should be maintained for man -rated reliability. In the areas of thrusttermination (TT) and thrust vector control (TVC), no firm requirement wasestablished by either the Phase B contractors or by the customer. LPCassumed that the Booster Vehicle would require both TT and TVC, plus astrenuous TVC duty cycle, which sized the system conservatively.

The baseline costs are backed by firm vendor quotes on procured components and conservative labor estimates. Lockheed's labor estimates wereprepared from a task definition or "ground-up" standpoint, based on previous LPC large -motor experience, other LPC rocket motor programs,and also on related industry experience on solid prope llant rocket motors.Nine full-s cale, 156 -inch-diameter demonstration motors have been testfired to date, five by Lockheed Propulsion Company. These tests are summarized in the following table.

-x-

LOCKHEED PROPULSION COMPANY I

629-6Vol II, Book .3

SUMMARY OF 156 -INCH LARGE SOLID ROCKET MOTOR TESTS

Test DataMotor Des cription Maximum Average

No. Date Des ignation Fabrication Thrust (lb) Thrust (lb)

L 1964 May 156-3 LPC 0.95M 0.88M

2. Sep 156-4 LPC l.09M l.OOM

3. 1965 Feb 156-2C-1 TCC 3.25M 2.97M

4. Dec 156 -1 TCC l.47M L29M

5. Dec 156 -5 LPC 3. 11M 2.84M

6. 1966 Jan 156 -6 LPC l.03M 0.94M=7. Apr L-73 LPC 0.66M 0.60M

8. May 156-7 TCC 0.39M 0.32M

9. May 156-9 TCC 0.98M 0.88M

All of these motors, with thrust levels up to three million pounds, performedwithin 2 percent of their calculated parameters, and only one incident (involvingthe los s of an exit cone in a moveable nozzle test by another contractor) wasexperienced. This is a significant feat in that each of the nine motors wasa "one -of-a-kind" configuration and involved reuse of LPC -designed casehardware as many as four times. Lockheed is proud of this 100-percentsuccessful completion of its five 156 -inch motor tests, which were accomplished under -budget on firm fixed price contracts (s ee USAF Testimonialsin Appendix A of the Cost Book).

As previously stated, the experience gained in these programs was appliedby all LPC branches in estimating the labor for the Booster Vehicle. In thearea of motor processing, the hands -on-hardware "first-unit" labor hoursfor the baseline were estimated, and then a 90-percent labor improvementor learning curve was applied. Comparison with both LPC experience andother SRM industry experience indicates that this is conservative; in themajority of previous programs, improvement curves in the middle to loweighties have been experienced. For example, on the basis of two largeweapon systems, Minuteman and Poseidon, an improvement curve in the 80to 85 -percent range should be achievable in the Booster Vehicle. For thisadditional reason, LPC, employing a 90-percent curve, has estimated thebaseline configuration production costs in a conservative manner.

As another consideration in development of the costs, LPC began this studyon 13 January 1972 assuming that the Booster System (WBS 3.0) was to becosted. On 2 February, LPC was notified that the SRM contractors were toprice at the Booster Vehicle level (WBS 3.3). While this was intended byNASA to alleviate the SRM contractors I efforts in the short study time available, it did turn out to add another variable, which is reflected as additionalconservatism in the LPC costs. Included in LPC's costs are some itemsthat could be interpreted as belonging under Booster Management (WBS 3.1),System Engineering (WBS 3.2), or Booster System Support (WBS 3.5), whichmay not be included in the cost estimates of the other study contractors.

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629-6Vol II, Book 3

The Booster Vehicle program costs (WBS 3.3) presented by LPC on 14 and23 February 1972 were based on the previously defined configuration andcosting assumptions. The LPC baseline Booster Vehicle cost estimatepresented on these dates is summarized below.

DevelopmentProduction

Total ProgramCost/Launch

RecurringCost/Launch

TotalSRM Stage Booster Vehicle

$ 141.6M $ 48.2M $ 189.8M2,545.7M 929.0M 3,474.7M

$2,687.3M $977.2M $3,664.5M

$ 6.0M $ 2.2M $ 8.2M

$ 5.8M $ 2.0M $ 7.8M

The total program cost per launch is developed by dividing the total programcost (3,664.5 million) by the total number of manned launches (445). Althoughcost per launch does not normally include amortization of DDT&E or nonrecurring production items, LPC chose to attempt to display the total program liability that NASA could encounter in employing a solid rocket motorBooster Vehicle. The standard way of displaying cost per launch is by usingthe recurring unit cost, which, for LPC' s baselin~, is $ 7. 8M. Once again,these program costs were developed early in the Study Program with theobjective of identifying the maximum technical and cost risk that could beencountered by NASA.

On 12 February, after the cut -off date for the 14 and 23 February presentations' Lockheed began a second iteration of the program baseline configuration and cost. Labor and material were analyzed in more depth, moredefinition was prepared to separate recurring from nonrecurring costs, andthe Operations portions of the SRM and Stage were separated into more identifiable activities. This resulted iri a redistribution of the baseline costs asshown in the following two tables:

SRM Stage Operations Total

Development $ 13 1. OM $ 31.0M $ 27.8M $ 189.8MProduction 2,4'"940-'%+ 626.5M 544.3M 3,474.7M

£, 8tJ~.;~'a.t$2,434.9M $657.5M $572.1M $3,664.5M

Note that in both tables the previous ly shown total program costs haveremained unchanged but are redistributed by LPC for better understanding.

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LOCKHEED PROPULSION COMPANyl

629-6Vol II, Book 3

Recurring TotalTotal Costs Cost/Launch Cost/Launch

Recurring SRMproduction $ 2,242.8M $5.lM $5.1M

Recurring Stageproduction 626.5M 104M 104M

Recurringoperations 544.3M 1.2M 1.2M

Nonrecurringproduction 61.lM 0 O.lM

Development 189.8M 0 Oo4M

Total $3,664.5M $7.7M(a) $8.2M

The next step in the second iteration of the baseline configuration and costwas to review areas where cost might be overly conservative and could thusbe reduced. Since the hardware is a major portion of the SRM cost, additional definition and breakdown of vendor component and material costs wererequested from the subcontract suppliers. In vehicle configuration, betterdesign definition was developed and rebids were prepared in some areas.As an example, in January, prior to completion of the TVC system sizing,quotes had to be obtained on the actuator. LPC requested bids on the actuatorused on the Sl-C Vehicle, knowing that it would be more than adequate for thejob. The actuator requirement was found to be far less and was rebid at asignificantly lower cost. Safety factors of all hardware were maintainedand the material costs still reflect safety factors of 1. 4 on structures and2.0 on ablative insulations.

The motor processing tasks and the improvement/learning curve werereviewed in considerable depth. A steeper curve (86 percent) was selectedas realistic but still sufficiently conservative in comparison to other majorsolid rocket motor programs and LPC's 156 -inch motor experience.Assembly and support labor were also analyzed and some areas of redundancy between WBS paragraphs were identified and deleted. The analysisof labor and material on the SRM has resulted in a lower unit cost positionfor the SRM baseline. These analyses have been time -consuming and,although some areas of the Stage attachment hardware and Operations havebeen reviewed and reduced, additional effort is being expended by Lockheedtoward further definition, analysis, and reduction.

To support a final report date of 15 March, a cut-off was made on 8 Marchin the second costing iteration. The reduced program costs are shown inthe following table as "Baseline, Revis ion 1" and are compared by item tothe original baseline costs shown previously.

(a) As a minor note, the redistribution identified additional nonrecurringproduction costs, resulting in a lower recurring cost per launch.

-xiii-

LOCKHEED PROPULIIION COMPANY

Recurring SRM ProductionRecurring Stage ProductionRecurring OperationsNonrecurring ProductionDevelopment

Total Cost/Launch

Recurring Cost/Launch

BaselineCost

$ 2,242. 8M626.5M544.3M6l.1M

189.8M

$ 3,664.5M

$ 8.2M

$ 7.7M

Reduction

$266.8M155.7M

98.0Mo

3.7M

$524.2M

$ l.lM

$ l.lM

629-6Vo1lI, Book 3

BaselineRevision 1

$ 1,976. OM470.8M446.3M

6l.1M186.1M

$3,140.3M

$ 7.1M

$ 6.6M

Each of the reductions shown in this table is discussed in the Addendum tothe cost book of the final report. The cost per launch, both recurring andtotal, has been reduced by over a million dollars. Further analysis willyield even more reductions in the areas of Stage and Operations. It isbelieved by Lockheed that the SRM, however, will not yield further majorreductions without a change in either performance or hardware safety factors, which is not recommended by LPC.

Therefore, the Baseline Revision 1 costs ($3, 140.3B) are submitted asLockheed's formal position on the SRM Booster Vehicle (WBS 3.3).

The conclusions of the LPC study are:

(1)

(2)

(3 )

(4 )

(5 )

(6 )

The LPC 156 -inch -diameter baseline design meets all thetechnical requirements for the Booster Vehicle.

The baseline design appears to have the structural capabilityto withstand recovery-load impacts should recovery/reuseprove cost-effective for the Booster Vehicle.

The SRM Booster Vehicle, because of its demonstratedtechnology, can be developed to meet all NASA schedulerequirements.

The Baseline Revision 1 costs are realistic and achievableand are subject to further reduction.

The cost for development ($186.1M) of an expendable SRMBooster Vehicle are less than 4.0 percent of the total SpaceShuttle Deve lopment budget ($ 5. 5B).

The Baseline Revision 1 SRM Booster Vehicle cost perlaunch (recurring $6.6M, total $7.1M) is less expensivethan that of a liquid booster.

In summary, Lockheed believes that an SRM propulsion system can performthe mission, can be easily developed in the time available, and will proveto be a cost-effective booster vehicle for the Space Shuttle Program.

-XIV-


629-6Vol II, Book 3

Section 1

INTRODUCTION

This document is Volume II, Book 3; Cost Estimating Data, of the LockheedPropulsion Company's (LPC) final report for the Study of Solid RocketMotors for a Space Shuttle Booster. The study was conducted for theNational Aeronautics and Space Administration (NASA) under contract number NAS 8-28429. The report is submitted in response to Data RequirementMA-02.

1.1 BASELINE COSTS

Lockheed Propulsion Company has established the baseline cost estimatingdata included herein, based on the following data requirements:

• SRM Program Cost Estimates have been prepared and reportedin the Table 1 format for the Baseline Vehicle, and the BaselineVehicle - Revis ion 1.

• SRM Program Time-Phased Funding requirements, based onItem 1 above, have been prepared and reported in the Table 2format.

• SRM Program Parameteric Cost Estimating Relationships (CERs)have been prepared and reported in the Table 3 format as requestedin Exhibit A, Scope of Work.

Lockheed Propulsion Company, utilizing, further groundrules as establishedby Exhibit A, Scope of Work, has prepared the most realistic cost estimatepossible within the time constraints. Actual costs of previous 156-inch SRMdevelopment programs have been utilized to the fullest extent and are prominently displayed to add credibility to the estimates contained herein.

More detailed groundrules were established later in the study period forcosting the three major sections of the Table 1 formats. These costs aredivided into three major categories as follows:

• DDT~E will consist of all costs incurred for the design, fabrication,ground test, and flight test of Orbiters 1 and 2, and Boosters 1 and2. DDT&E will include the total cos t of the dynamic tes t and thevertical flight designated as test or development flight. These costsinclude all tooling, and the STE, ground support equipment, spares,

1-1

LOCKHEEO PROPULSION COMPANY

629-6Vol II, Book 3

and other efforts required leading up to, and supporting, the testflight. DDT&E also will include the cost of the first five mannedorbital flights, including support for receiving assembly and checkout, spares, operations support, etc.

• Production is defined as the costs associated with producing additional flight motors and modification and!or updating of the flighttest hardware required for operation through acceptance of thehardware by the Government, including all costs associated with(1) fabrication, (2) ground tes t and factory checkout of flight hardware, (3) initial operational spares required for malfunctioning,and (4) maintenance of tooling and special test equipment.

• Operations is defined as the cost as sociated with the followingactivities:

Flight support is defined as (1) replacement spares to supportoperational airborne hardware, (2) sustaining engineering tosupport the production of spares and hardware modification,and (3) maintenance of GSE and spares for GSE.

Launch Operations includes the cos ts for receiving the flighthardware, assembly of the vehicle, checkout, prelaunch testand checkout, servicing, launching, and refurbishing of thelaunch site facilities.

Mission Operations includes the cost of supporting missioncontrol, mission planning, flight crew training, and simulationaids required for crew training (excluding the cost of thoseidentified elsewhere).

• Costs are stated in 1970 dollars with no LPC fee to be included,however, vendor costs include fee.

• Transportation will be included, as appropriate, in DDT &E andProduction.

• Facilities will be included, as appropriate, in DDT &E and Production for both LPC and LPC's vendors depending on the launch siteand rate.

• Booster Recovery Program will be costed separately.

Lockheed's baseline costs include only those program events and activitiesdeemed essential to meet the final report objectives as stipulated in ContractNAS 8-28429. To this end LPC has added for clarification a Work BreakdownStructure (WBS) dictionary to provide the reader with a definition of the content of each WBS block. This placement of cos ts becomes increas ingly important because of the magnitude of the total Shuttle Program.

1- 2

LOCKHEED PROPULSION COMPANI

629-6Vol II, Book 3

Due to time limitations imposed for gathering information for presentationin the February NASA/MSFC and NASA/Headquarters meetings, it was notalways possible to gain sufficient insight to the level desired for the finalreport.

Further detailed cost analysis work has been conducted at LPC in the interimperiod, and it is therefore possible to identify reductions that are within the"cost bands" as displayed at the briefings referenced above. The "cost band"charts are displayed in Appendix A, Miscellaneous Backup Data, and in theExecutive Summary (Volume I).

1.2 ADDENDUM 1 - (BASELINE - REVISION 1)

In the latter part of the study, it became apparent that the baseline costcould be reduced and still be within the original cost bands as presented inthe February 14th and 23rd presentations. Lockheed Propulsion Companyaccomplished this and the lower baseline costs are reflected as Baseline Revision 1.

Because time was not available to change all the WBS forms, LPC electedin this report to show both the original baseline and Baseline -Revision 1report. It must be clearly understood that Baseline - Revision 1 representsthe best cost estimate, and LPC's cost position. The SRM is considered"hard" whereas the stage and operations cost could be reduced further.

1.3 CONCLUSION

In conclusion, it is contended that Lockheed's costs, summarized in thechart below, and based on years of 156-inch experience, are realisticfigures and cover all NASA study objectives.

1-3


629-6Vol II, Book 3

Total Booster Vehicle Program Costs

Baseline Cost - Revision 1

(Cost in Millions)

Revision 1Baseline Cost Reductions Baseline Costs

Recurring SRM ProductionRecurring Stage ProductionRecurring OperationsNonrecurring ProductionDDT&E

Total

Total Cost/Launch

Recurring Cost/Launch

$2,242.8626.5544.3

61.1189.8

$3,664.5

$ 8.2

$ 7.7

$ 266.8155.798.0

3.8

$ 524.2

$1,976.0470.8446.3

61.1186.1

$3,140.3

$ 7.1

$6.6

Lockheed Propulsion Company has completed the study of the Solid RocketMotor (SRM) as boosters for the Space Shuttle. The study results show thatthe 156-inch SRMs can accomplish the intended purpose of the booster at asignificantly lower cost than that estimated for liquid propellant engines.The Baseline - Revision 1 presented above is LPC's best estimate and firmcos t position.

The costs shown in this report reflect the results of the use of existing largesolid motor tech~ology. The costs further reflect the industry experienceobtained in the successful firings of nine lS6-inch motors and numerous 120inch motors. The credibility of the use of l56-inch motors is the record ofcomplete success for these units in testing at performance levels equivalentto the requirements of the Shuttle Booster. Lockheed Propulsion Companyhas built and successfully tested, within budget, more than half of the 156inch motors produced by the solid rocket industry. This is the basis ofcredibility for this es timate.

1-4

LOCKHEED PROPULSION COMPANVI

Section 2

COST SUMMARY

2-1

629-6Vol II, Book 3


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629-6Vol II, Book 3

Section 3

WORK BREAKDOWN STRUCTURE (WBS)

The Work Breakdown Structure (WBS) as presented in the NASA Work Statement has been used throughout the Study Program. Lockheed PropulsionCompany has expanded this Work Breakdown Structure for clarity and toprovide credible, identifiable costs for each level of the Work BreakdownStructure.


Task descriptions, as well as the costs, are segregated into two categories:(1) Design, Development, Test and Evaluation (DDT&E),and (2) Production.Each WBS description is cross -references to the WBS by WBS numbers,and are applicable to all LPG Program Options.

3 -1


629-6Vol II Book 3

3. 1. 1 W BS Dictionary, DDT &E

WBS NO.3. 3 BOOSTER VEHICLE

Contained herein is the total cost required to develop a Solid Rocket Motorbooster assembly presented in Figure 3-1, that meets the requirements ofthe Space Shuttle. Included are all costs for booster system development,one unmanned KSC launch, five manned launches, and related launchsupport.

Facilities for the development program and tooling for the development andproduction program are included in this total development cost. These costsare detailed in appropriate subtasks.

All tasks considered are within the safety and performance requirements fora man-rated system.

Figu re 3-1 156-1 NCH VEH ICLE BASELI NEPARALLEL BURN

2EACH 156-IN. SRMs

WEIGHTS LB x 10-6

ORBITER LIFT-OFF WEIGHT 1.800

BOOSTER LIFT-OFF WEIGHT 2.835

GROSS LIFT-OFF WEIGHT 4.635

3-2

LOCKHElEO PROPULeION COMPANY I

629-6Vol II Book 3

WBS NO.3. 3.1 STRUCTURE

This task includes the design and development of the mechanical componentsneces sary to attach the SRMs to the launch vehicle, and methods of SRMseparation after burnout as summarized in Figure 3 - 2. No costs are directlychargeable to this task level, but rather to the applicable subtasks.

Figure 3-2 STRUCTURE (WBS 3. 3.11

LAUNCHPADINTERFACE

MARMONCLAMPRETENTION

/~, .....'<;f- .. -

c(/~ v-~/ FLARED AFT SKIRT----l--~-IL_.J• /"1.......-:

-c.- L '<D(:1 DOUBLE CONIC NON-SEPARATING1 r.- NOSE FAIRING

FORWARDED SECTION WT 22,249 LBAFT SECTION WT 10,841TOTAL / SRM 33.090

ORBITER FWD ATTACH 0BRACKET - SLIDINQ. RELEASE - T~~~TERor ATTACHSADDLE~~JFOOT PADS jn~ I

., \ FWD ATTACH. \ \. SADDLE - THRUST

(UMBI '. _ " TAKE OUT AFTCONN ." ATTACH SADDLE

. A.~ BOOSTER PROVIDES

~ / ~~:~OTORMovE'.><ATTACH POINT GROWTH,

AT MOTOR c. SEPARATION'L CLEARANCE

RETAINING t~~~::::::::iii' (2 EXPLOSIVE 1;;-- - --;L': :: II" _ j-BOLTSI - -

(DFWD TRACK & BRACKET ON ORBITER @AFT TRACK & BRACKET ON ORBITER

W BS NO.3. 3. 1. 1 ATTACHMENTS

Assigned to this task are all labor and materials for the design, development,and manufacture of structural components required to mate the SRMs to theorbiter vehicle tank. Engineering effort will include assessment of thereaction loads into the tank during flight, hardware design, component manufacture, structural tests, material and manufacturing specification preparation, and delivery of sufficient units to support two ground test vehicleassemblies and six flight launches.

3-3


629-6Vol II Book 3

Components on the HO tank, which remain with the tank after separation,are not included.

WBS NO. 3.3.1. 2 CLUSTERING AND INTERSTAGE

No effort is required under this task for the parallel configuration.

W BS NO.3. 3. 1. 3 FAIRINGS

This category includes all labor and materials associated with developmentof the forward and aft fairings on the SRMs. The forward fairing will beconical, tapering from the SRM case diameter to a rounded point at theforward end. It shall be designed to house the stage separation mechanism(and possibly recovery equipment) within a clean aerodynamic configuration.The mechanism internal to the forward fairing will not be costed in this task.

The aft fairing shall be designed to support the launch vehicle while on thepad, and to protect the nozzle from aerodynamic flight loads created by theairstream.

Costs shall include engineering design, component manufacture, and verification for two inert booster assemblies and six flight launches.

WBS NO. 3.3.1.4 AERODYNAMIC SURFACES

No effort is required under this task for the parallel burn configuration.

WBS NO.3. 3.1. 5 SEPARATION

This task includes all labor and materials related to the separation of theSRM from the orbiter vehicle. Separation shall be by initiation of explosivebolts to release the SRMs from the HO tank, and the activation of separationrockets to direct the SRM away from the orbiter. Instrumentation,· sensors,and electrical circuits and controls required for separation are included inWBS tasks 3.3.3 and 3.3.2.3.3.

Technical effort shall consist of the separation system design, componentevaluation, separation rocket development and test, and manufacture ofsufficient components for two inert as semblies and six flight launches. Benchtesting of all explosive and propulsive units will be conducted to ensurecompliance to all system safety and reliability requirements.

3-4

LOCKHEED PROPULSION COMPANJ

629-6Vol II Book 3

WBS NO.3. 3.2 SOLID ROCKET MOTOR

This task contains the accumulation of the costs required to develop theSolid Rocket Motor portion of the Booster Vehicle as shown in Figure 3 -3.Included are all efforts related to SRM design, manufacturing, material andcomponent procurement, production and development tooling, developmentfacilities, and flight support.

Figure 3-3 SOLI D ROCKET MOTOR (WBS 3. 3.2)

WEI GHT SUMMARY

GROSS WEIGHT -1.38 x 10~ LBPROPELLANT - 1.23 x 10

6LB

TOTALINERTS- 0.15xl0 LBMASS RATIO - 0.89

PERFORMANCE SUMMARY

INITIAL THRUST - 2.94 x 106 LBBURNTIME- 138 SECMEOP - 1000 PS I

O~5fTDIATYPICAL FOR 6 SEGMENTSPARAllE~ B-URNl

---j

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§

WBS NO.3. 3.2. 1 PROGRAM MANAGEMENT

This WBS number is to accumulate task assignments for all personneldirectly responsible for program control. Costs will be collected underthe appropriate subtasks.

3 -5


629-6Vol II Book 3

WBS NO.3. 3. 2.1. I PROGRAM DIRECTION

This task will include labor related to Program Management planning andcontrol. The Program Office shall perform tasks related to overall programdirection, i. e., ensuring schedule commitments are met, compliance withcontract financial and technical requirements, and advance planning. Program direction shall be by is suance of a program plan to define the contractual scope of work, and the continued program control of the manufacturing,engineering and product assurance technical effort. The Program Officewill provide the necessary contract controls to evaluate performance ofprogram tasks against the established goals.

WBS NO.3. 3.2.1. 2 DATA

The labor as signed to this task shall be that required for AdministrativeServices and Computer Operation personnel to prepare and maintain datarecords of all SRM booster designs, design changes, production performance,and customer reports. This task also includes the labor required to preparetooling reports, safety reports, manpower utilization reports, etc.

WBS NO.3. 3.2.2 SYSTEMS ENGINEERING

This task is for the accumulation of costs associated with development effortof the SRM system, including system definition and interfaces, ground supportequipment, and reliability. Costs will be assigned to the applicable subtask.

W BS NO.3. 3. 2. 2. I SYSTEM DEFINITION AND INTERFACE

This task includes the effo·rt to study the effect of the SRM operation on theSpace Shuttle. Technical studies shall include such items as methods ofabort control, thrust termination effects on orbiter flight and safety, requirements for destruct systems, and methods and requirements for tailoring andadjusting the SRM thrust and impulse. It also includes all aerodynamic andflight trajectory analysis.

Hardware development or testing are not included within this tas k.

WBS NO.3. 3. 2. 2. 2 GROUND SUPPOR T EQUIPMENT DEFINITION

Assigned to this task are the efforts associated with interfacing the engineering design to the ground support equipment. Included are studies of weight,c. g. s, safety, environmental constraints, and methods of handling. Directeffort related to equipment design and fabrication are contained in WBS No.3.3.2.5.1.

Particular emphasis will be applied to the requirements of the boostersystem at KSC.

3 -6

LOCKHEEO PROPULSION COMPANJ

629-6Vol II Book 3

WBS NO.3. 3.2.2.3 RELIABILITY, PRODUCIBILITY, MAINTAINABILITY

This task includes the technical effort related to the study of SRM components,materials, and manufacture to assess the reliability, producibility, andmaintainability of the SRM. Evaluation of methods for measuring and assuringSRM quality and the transfer of these data to meaningful control procedureswill be required.

Reliability Engineering will develop and conduct a program of reliability andstatistical analysis directed toward the assessment of design and verificationof manufacturing processes. Tasks will include evaluation of designs, reviewof failure modes and effects, and corresponding numerical assessments ofreliability. This task is accomplished through evolution of control criteriaand statistical assessment of critical attributes or processes. Typical ofthese would be propellant burn rate and physical properties for which controllimits are established and trends are tracked and reported to the affectedorganization and management. This effort directly supports preparation ofperiodic reporting of Quality Trends as directed by the Quality Programrequirements.

WBS NO.3. 3. 2. 3 SOLID ROCKET MOTORS

Accumulated within this task are all aspects of design, manufacture, andmaterials associated with the SRM. Costs are not associated with this taskas it is an accumulation of subtasks 3.3.2.3.1 thru 3. 3.2.3.6.

This task encompasses 25 SRMs for use as follows:

Development

PFRT

Inert

Flight

5

4

4

12

Effort is required for technical support for all subtasks. Some of this effortis described in this category, but costs will be allocated proportionally tothe applicable subtasks. Typical of this is the SRM manufacturing operationsplanning and control, including preparation of manufacturing schedules, process control plans, tooling schedules, and process equipment schedules.

WBS NO. 3.3.2.3.1 STRUCTURES

This task includes all effort associated with the engineering requirements fordevelopment of the SRM materials and components. The costs associatedwith this task are cumulative from the following major component subtasks:

3-7


629-6Vol II Book 3

3.3.2.3.1.1 SRM Motor Case

3.3.2.3.1.2 Nozzle

3.3.2.3.1.3 Igniter Assembly

3.3.2.3.1.4 Thrust Termination

3.3. 2.3. 1. 5 Propellant

The technical development required for the SRM will be based on previousLPC and industry large motor technology, and the engineering effortrequired to transfer this knowledge to a man-rated, reliable space shuttlebooster.

Where level-of-effort for planning and control is required, it may be described in the category, but costs will be apportioned to the applicable subtasks.

For each subtask, the costs shall include, but not be limited to, the following:

• All procurement costs

• Component inspection

• Product assurance reporting

• Process procedure preparation

• Process improvement evaluation

• Drawing and specification preparation and is suance

• Document control

• Component traceability

WBS NO.3. 3. 2.3.1.1 SRM MOTOR CASE

The SRM motor case consists of seven identical center segments and twohemispherical end domes. Under this task, the engineering effort includesthe structural design of the case, material selection studies, fabricationmethods, and selection and verification of inspection and acceptance techniques. Also included in this task are design and proof testing of the segmentjoining method, stress analysis for launch and flight environments, and anevaluation of methods for corrosion prevention. Engineering technicalsupport will be supplied to the various lower-level subcontractors to establish controls and specifications on materials and procedures. A minimumof two hydroburst tests will be conducted for case design verification.

3 -8

ILOCKHEED PROPULSION COMPANY

629-6Vol II Book 3

Case insulation design and manufacture is included in this task. It shallconsist of material thermal analysis, erosion analysis, and performancepredictions of the static test motors. Engineering support shall be given tothe insulation material supplier and case insulation vendor to developmaterial and process documentation for quality control purposes.

To assess the practicality of reuse/refurbishment, the cases from fourstatic test-fired motors will be reprocessed into cases for the inert boosterassemblies.

WBS NO.3. 3.2.3.1. 2 NOZZLE

This task includes all engineering effort associated with design, manufacture,and verification of the nozzle and Lockseal for the SRM. Included are suchbasic tasks as structural attachment to the case, ablative performance predictions, and thermal stress analysis of the plastic components. As sociateddevelopment effort will include materials selection and testing, manufacturingmethods selection and verification, vendor manufacturing verification, andspecification documentation.

No assignable nozzle component tests will be conducted, but thoroughanalysis of performance will be conducted on nozzles fired on the static testmotors.

Lockseal testing shall, at a minimum, consist of the following:

• Subscale material and process studies

• Subscale bench tests

• Fullscale bench tests

Throughout the Development effort, particular emphasis will be placed onstandardizing material and process parameters so that the Productionnozzles will be of uniform quality.

Process methods will be developed to remove and replace the plastic portionof fired nozzles. A minimum of four nozzles will be so processed.

WBS NO.3. 3.2.3.1. 3 IGNITER

This task includes all effort associated with design, testing, and manufactureof the igniter assembly. Design effort will include items such as casestructural capability, internal and external insulation thermal protection,propellant grain design, and ignition electrical requirements. Vendorsupport is required for all the igniter subcomponents such as the case,insulation, and closures. A test program will be conducted to proveignition reliability and igniter performance reproducibility.

A minimum of six open-air igniter firings will be conducted.

3-9


629-6Vol II Book 3

Effort associated with the electrical and control requirements external to theigniter are to be accumulated in W BS 3.3.3 and 3.3.5.

WBS NO.3. 3.2.3.1.4 THRUST TERMINATION

Collected within this task are the efforts required to design, manufacture,and verify the SRM thrust termination {TIT} system. The TIT system willemploy shaped charges that will cut openings in the SRM forward dome.Engineering effort will include shaped charge design, exhaust stack andinsulation design, and ballistics analysis. A series of tests will be conductedto sequentially verify the system as shown below:

• Charge cutting ability on flat plate

• TIT action on pressurized forward domes

• TIT performance on SRMs

The TIT system will be tested at AFRPL for evaluation. One SRM willhave the TIT activated during motor tailoff with a reduced chamber pressure,and one SRM will have the TIT activated while under full pressure. Thesemotor tests are costed in W BS No.3. 3.2.3.5.

WBS NO.3. 3.2.3.1. 5 PROPELLANT

This task includes all effort related to the manufacture, testing, processingand loading of the propellant into the SRM segments. Propellant development is not required, but adjustments to the proposed LPC-580A propellantformulation may be necessary to optimize burn rate and liner bond conditions.Engineering support will be required to update andlor prepare material andprocess specifications, establish acceptance limits, and verify inspectionmethods.

Included in this category are the efforts associated with raw material lotacceptance, propellant mixing, motor line and cast operations, and surfaceinhibiting.

Procedures, sampling plans, inspection plans, and process control planswill be developed and updated as required.

W BS NO.3. 3. 2.3. 2 TVC

This task includes all effort associated with the design, development, andqualification of the SRM TVC system. It includes all effort not assignableto the fixed nozzle design such as the Lockseal actuators, plumbing, andassociated hardware. Wherever possible, off-the-shelf components will be

3-10


629-6Vol II Book 3

used. The technical effort will comprise all required component designs,integration design with the case and nozzle, and system verification. Inaddition to full system testing on the SRM static test motors, componenttests will, at a minimum, include the following:

Servo Actuator: System performance

Servo Valves: One burst test

Actuator Bodies: One burst test

Hydraulic Power Supply: One burst test

TVC System: Pres surized bench-tests to cycle lifefailure and/or pres sure failure

Companion support will be required at the component vendors to developadequate process and material specifications for production quality.

This category also includes a portion of the costs developed under WBS No.3.3.3.1. Such costs are developed as a system cost, and apportioned to thiscategory as being more applicable to the SRM than to the stage costs.

WBS NO.3. 3.2.3.3 SRM POWER AND ELECTRICAL

This category includes all labor and materials associated with the development of the SRM electrical components and consists of instrumentationincluding motor performance sensors and signal conditioners. Tests will beconducted to assure component reliability and safety. Mockup manufacturingtesting will be conducted prior to inclusion in the SRMs.

The power system for SRM and stage operation are costed in WBS No.3. 3.5.

WBS NO. 3.3.2.3.4 SRM INSTALLATION AND ASSEMBLY

This category includes all costs associated with assembly and componentinstallation of the SRM. It includes the development of all procedures, preparation of instruction manuals, and definition of tooling and handlingrequirements.

For the Development program it includes the assembly of all motors forGround Test (WBS No.3. 3.2.3.6) and the inert and live motors at KSC. Costsassociated with stage assembly and stage equipment (avionics, power, etc)are costed in WBS No.3. 3. 6 and 3.3.7.

Specifically included are those items developed and manufactured in WBS No.3.3.2.3.1. It also includes the miscellaneous as sembly materials such asO-rings, adhesives and lubricants required in the SRM assembly.

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629-6Vol II Book 3

WBS NO.3. 3.2.3.5 GROUND TEST

This task includes all full-scale SRM test activity except that assemblyactivity defined under WBS No.3. 3. 2.3.4. The basic tas k includes coordination of test equipment procurement and installation, preparation of testprocedures and authorizing documentation, conduct of specialized computerprogramming peculiar to the test firing operations, and similar preparationsfor conducting test operations. Test firing operations include filling ofhydraulic and gas pres sure tanks, application of instrumentation, hookupand check of control, firing and data, conduct of prefire briefings and visitorcontrol, photography of firing activities and acquisition of firing data. Postfire activities include reduction of data, photography and processing of stilland motion picture film, removal and disposition of the expended test articleand refurbishment of test and data acquisition equipment and related electronics and wiring. Post-test activity does not include any refurbishment(e. g., hydrotest, etc) of the expended test articles.

Reporting activity includes preparation of data for engineering assessment,provision of detail test operational records and provision of still and motionpicture photography.

This task is limited to five development and four PFRT static motor firings,however, procedures and manuals for KSC flight test data acquisition willbe prepared.

W BS NO.3. 3.2.3.6 TOOLING

This category includes all labor and material costs to design, fabricate,inspect and verify tooling required for manufacture and assembly of the SRM,excluding AGE assembly requirements (WBS No.3. 3.2.5.1). Requirementsfor development and production are included but costed separately. All tooldesigns shall be documented and schedules and records of maintenance,repairs, and rework shall be maintained. Tool definition shall include allitems required for SRM manufacture, shipping containers (reusable orexpendable) required for component protection, assembly handling devices,inspection jigs and in-process protective devices. Tooling used for manufacture of a component at a vendor's facility also are included.

W BS NO.3. 3.2. 4 FACILITIES

This task includes all costs associated with the purchase of land and equipment and the design, construction, and expansion of facilities required forthe manufacture and assembly of the SRMs during the Development program.Effort shall include the following:

• Equipment selection and procurement

• Site selection and land improvement

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629-6Vol II Book 3

• Facility and building layout concept including flow analysis andequipment integration

• Facility layout and approval

• Building design

• Construction of buildings and modification of existing buildings

• Equipment installation and checkout

• Maintenance of buildings, grounds and equipment

Facility checkout (such as mixer trials) shall be collected in WBS No.3.3.2.3.

WBS NO. 3.3.2.5 SUPPORT EQUIPMENT AN·D SPARES

This category is for cost accumulation only and no costs are directlyassignable. It includes costs collected under WBS No.3. 3.2.5.1 and3.3.2.5.2.

WBS NO. 3.3.2.5.1 AGE DESIGN AND FABRICATION

This category includes all labor and materials required to design, fabricateand acceptance-test the equipment required to handle and assemble the SRMand its components. It includes that equipment for use at the factory andfor the inert and live SRM boosters at KSC. Allowances shall be made fordesign updating, modifications, and maintenance throughout development.Manuals on design, maint~nance and refurbishment shall be prepared.Considered here are the requirements for the DDT&E effort only.

WBS NO. 3.3.2.5.2 SPARES

This task includes all material and labor to procure and produce spares forthe Development program. Included shall be allowances for expected repairand rework of those major items that are discrepant but not rejectable.

Although the need for spares is unanticipated, one set shall be planned tosupport the development ground test and launch program.

Design, quality, and data requirements for spares will be identical to thebasic program requirements.

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629-6Vol II Book 3

WBS NO. 3.3.2.6· FLIGHT-TEST SUPPORT

This task includes all labor associated with the flight-test performance of theSRMs. It includes the development of procedures to be used in predictingand evaluating the SRM flight performance, preparation of preflight motorassessments, analysis of flight data, updating of performance requirementsand liaison with the customer and other contractors relating to SRM requirements and performance. This task covers only the first six launches at KSC.

W BS NO.3. 3.2. 7 OPERATIONS SUPPORT

This task is an accumulation of costs associated with the transportation ofthe SRMs to KSC and the coordination of SRM operations at KSC.

WBSNO. 3.3.2.7.1 OPERATIONS SUPPORT

This category in cludes the labor of technical personnel to establish anddevelop a plan for control of the SRM booster logistics, maintenance, andprocessing at KSC in direct support of the first six launches. It will includethe effort for technical personnel to handle design changes, assembly procedure reviews, receiving inspection, and storage conditions, and to maintain logistics records. This task includes effort on all components developedand delivered under WBS No.3. 3.2 and SRM Assembly WBS No.3. 3.2.3.4.It does not include support of vehicle assembly, WBS No.3. 3. 6.

W BS NO.3. 3.2. 7. 2 T RANSPOR T ATION

This task is for as signment of cost directly related to the transportation ofSRM segments and associated components to KSC for two inert assembliesand six live launches. Labor costs are not assignable to this WBS, butrather to the specific subtask under WBS No.3. 3.2.3.

W BS NO.3. 3. 3 AVIONICS

This task includes the electronics and data collection associated with theflight control and flight performance of the SRM booster. No costs areassignable directly to this task number.

W BS NO.3. 3. 3. I FLIGHT CONTROL ELECTRONICS

All labor and material for design, development, test, and manufacture ofthe flight control electronics shall be charged to this tas k. Included are thecommand and control systems for the TVC. All components will be breadboard checked out and then tested for safety and reliability in the finalconfiguration. Manufacture and performance specifications will be prepared

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. ILOCKHEED PROPULSION COMPANY

629-6Vol II Book 3

for all components and the total system. Sufficient assemblies shall besupplied for two inert assemblies and six flight launches.

WBS NO.3. 3. 3.2 GUIDANCE AND NAVIGATION

This task is not applicable to a parallel launch configuration.

WBS NO. 3.3.3.3 DATA MANAGEMENT

The costs for this task include the labor and materials for the stage systemsinstrumentation/diagnostics and stage electronic logic and sequencingfunctions and circuit electrical initiation command systems. Technicaleffort is required to design, procure, and checkout the individual components(subsystem) and the total system with the electronics listed under WBS No.3.3.3.1. Sufficient systems will be prepared to support two inert boosterassemblies and six flight launches.

WBS NO.3. 3. 4 CONTROL SYSTEMS

No costs are associated with this task for parallel configuration.

WBS NO. 3.3.5 POWER

This is a summation task and no charges are to be assigned directly.Because subtask 3.3.5.2 is not applicable, it is the same as 3.3.5.1 in content and costs.

WBS NO.3. 3. 5.1 ELECTRICAL

This task includes all labor and materials required to develop the electricalpower system for the SRM. Redundant power supplies will be used: forwardend high voltage power for initiation, thrust termination, and separation; aftend low voltage power for thrust vector control actuation. This task includesall batteries, power distribution boxes and cabling, high voltage firing unitsand output cables and inverters, required performance characteristics,capability to meet logistic and flight environments, EMI and RF hazards,etc. Sufficient parts shall be manufactured for two inert assemblies andsix launch flights. The system shall also be tested on four static testmotors.

WBS NO.3. 3. 5.2 HYDRAULICS

No input is required for the parallel configuration.

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629-6Vol II Book 3

WBS NO. 3.3.6 INSTALLATION, ASSEMBLY, AND CHECKOUT

This category of cost includes the labor required for the development ofequipment/ s ystems/procedures for the following:

• Acceptance testing of stage packages

• Assembly and checkout of all stage systems

• Assembly and checkout associated with mating stage systems tobuilt-up SRM

• Assembly and checkout associated with mating full SRM stage tothe orbiter

• Launch support of total vehicle for the SRM stage system

It also includes the operation costs to implement the above requirementsand procedures for two inert and six live assemblies.

It does not include assembly and checkout of the SRMs which are collectedin WBS No.3. 3.2.3.4.

WBS NO.3. 3. 7 MAJOR GROUND TESTS

This category emcompasses two major tasks; first, the effort required tosupport the booster/ stage systems checkout and operation in the SRM groundtests (WBS No.3. 3.2.3.5), and second, launch support at KSC for all DDT&Einert structural vehicle tests and flight tests.

In the first task, although only single SRMs will be ground-tested, portionsof the structures, such as fairings and separation (WBS No.3. 3.1), the TVCcontrols (WBS No. 3.3.3.1) and the power system (WBS No.3. 3. 5) will beevaluated and performance will be measured.

For lack of a more suitable WBS assignment, all KSC launch support is tobe included. This includes logistics control, component troubleshooting,documentation of components, engineering design documentation coordination,and general sustaining technical launch support personnel. On the DDT &Eprogram, technical support will be required throughout all phases of testingand evaluating the two inert assemblies and the associated AGE.

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LOCKHEEO PROPULSION COMPANY·

629-6Vol II Book 3

3. 1. 2 W BS Dictionary, Production

WBS NO.3. 3 BOOSTER VEHICLE

All costs required to manufacture, deliver, assemble, and launch 440 SolidRocket Motor Booster assemblies (880 SRMs) are totaled within this task.

Tooling for these SRMs was included in the Development Program.

Continuing technical support is planned during the Production program, butno major technical changes are planned.

WBS NO.3. 3.1 STRUCTURE

This category includes all costs related to the fabrication of the mechanicalattachments of the SRMs to the orbiter vehicle. Costs are not assignableto the WBS number, but rather to the applicable subtasks.

WBS NO.3. 3.1. 1 ATTACHMENTS

This task includes all material and labor costs to support the requiredlaunches. Included are all structural components of the attachment structureexcept those parts remaining with the HO tank after separation. Technicalsupport is required to maintain design configuration and provide productionengineering and quality control at the subcontractors.

WBS NO.3. 3.1. 2 CLUSTERING AND INTERST AGE

No effort is required in this task for parallel configuration.

W BS NO.3. 3. 1. 3 FAIRINGS

This cost includes all labor and material associated with the SRM forwardand aft fairings. It includes continuing engineering design support, specification changes, and technical and product assurance liaison with manufacturing vendors.

WBS NO.3. 3. 1.4 AERODYNAMIC SURFACES

No effort is required under this WBS for the parallel burn configuration.

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629-6Vol II Book 3

WBS NO. 3.3.1.5 SEPARATION

Within this category are all costs for delivery of the required mechanical,ordnance, and propulsion components required to provide separation of theSRMs after burnout from the orbiter's HO tank. Included in the WBS are theexplosive bolts, release pins and separation rockets, and the required continuing engineering support.

Quality assurance acceptance tasks will be conducted to inspect, on asampling basis, all explosive and propulsive devices.

WBS NO.3. 3.2 SOLID ROCKET MOTOR

Accumulated in this task will be all SRM costs required to support 440launches from KSC. In addition, three Pre-Production Qualification (pPQ)motors will be manufactured and static-test-fired to provide verification ofany minor design changes created during the Development program, and toverify the acceptability of the production facility. These motors will betest-fired at Potrero.

No costs will be charged directly to this number.

WBS NO. 3.3.2.1 PROGRAM MANAGEMENT

This is a cost accumulation task level for all costs required to manage andcontrol the SRM Booster Production Program. Costs will be assigned to theapplicable subtasks.

WBS NO.3. 3.2.1. 1 PROGRAM MANAGEMENT

This task will include all labor required to manage the SRM booster program.Program Management shall provide continual program technical direction,financial planning, customer coordination, subcontractor control, andliaison with other Space Shuttle contractors as required.

WBS NO.3. 3.2.1. 2 DATA

The labor assigned to this task shall be that required for AdministrativeServices and Computer Operation personnel, to prepare and maintain datarecords of all SRM booster designs, design changes, production performanceand customer reports. This task also includes the labor required to preparedocumentation such as tooling reports, safety reports, manpower utilizationreports, etc.

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629-6Vol II Book 3

WBS NO.3. 3.2.2 SYSTEMS ENGINEERING

This task includes all effort required to maintain the SRM Booster Systemdefinition. Costs will be assigned directly to the applicable subtask andaccumulated to this number.

WBS NO.3. 3. 2. 2.1 SYSTEM DEFINITION AND INTERFACE

This category includes all labor associated with the continuing performanceeffects of the SRM Booster operation on the Space Shuttle. Included hereinare such items as technical liaison (not Program Management) with thePrime Contractor or other shuttle subcontractors regarding the flight affectsof the SRM Boosters.

WBS NO.3. 3.2.2.2 GROUND SUPPORT EQUIPMENT DEFINITION

This task includes all technical effort, including Prime Contractor liaison,to ensure adequate interface of the SRM requirements to the ground supportequipment. It will include technical preparation of all required handlingprocedures and manuals.

Direct effort related to the design and fabrication of the equipment is assignedto WBS No.3. 3.2.5.1.

WBS NO.3. 3.2.2.3 RELIABILITY, PRODUCIBILITY, MAINTAINABILITY

This task is for assignment of all labor required to control the reliabilityof the SRM booster throughout the launch program. It will include thecollection and analysis of materials and manufacturing production qualityrecords, and the SRM flight performance data. In addition, controls andrecommendations will be established and updated to ensure system reliabilityand performance.

The control criteria established from design limits and experience in theDevelopment program will set the baseline for controls to be used in theProduction phase. These controls, including both dimensional attributeson hardware and critical processes that affect product performance will bestatistically analyzed to show any quality trends.

WBS NO.3. 3.2.3 SOLID ROCKET MOTORS

This task includes all aspects of design, manufacture and materialassociated with the SRM. No costs are associated with this task as it is anaccumulation of WBS tasks 3.3.2.3.1 thru 3.3.2.3.6.

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629-6Vol II Book 3

This task encompasses 883 SRMs for use as follows:

Flight

PPQ (See WBS No. 3.3.2)

Total

880

3

883

Requirements for spares are assigned to WBS No.3. 3.2.5.2.

Certain effort is required for technical support for all subtasks. These maybe described in this category, but costs will be allocated proportionally tothe applicable subtasks. Typical of this is the SRM manufacturing, operationsplanning and control, including preparation of manufacturing schedules, process control plans, tooling schedules, and process equipment schedules.

WBSNO. 3.3.2.3.1 STRUCTURES

This task includes all costs associated with the procurement and manufactureof the SRM. It includes the requirements for the following:

3.3.2.3.1 SRM Motor Case

3.3.2.3.2 Nozzle and Lockseal

3.3.2.3.3 Igniter Assembly

3.3.2.3.4 Thrust Termination

3.3.2.3.5 Propellant and Motor Loading

The requirements for each of these were described separately in subsection3.1.1 for the DDT &E plan under the WBS numbers indicated. For the production plan, the requirements are similar and are not separately described,however the costs will be as signable to the specific subtasks. Specificeffort to be costed include the following:

• Vendor production costs including facilities

• Engineering design update and drawing maintenance

• Specification maintenance

• SRM segment production

• Product assurance testing of component acceptability

CD Product assurance process inspection

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629-6Vol II Book 3

• Engineering vendor control

• MRB system implementation

• Component rework

• Establishment of dual sources of critical items

• Checkout of production facilities

WBS NO.3. 3. 2. 3. 3 TVC

This task includes all labor and materials related to delivery of TVC systemssufficient to support the production program. This includes continuing technical design support, manufacturing control, and quality assurance benchtesting. It also includes a portion of TVC control costs described in theDDT&E plan.

WBS NO.3. 3.2.3.3 SRM POWER AND ELECTRICAL

This category includes all costs for procurement and product assuranceacceptance and testing of the SRM instrumentation/diagnostics includingmotor performance sensors and signal conditioners.

WBS NO. 3.3.2.3.4 SRM INSTALLATION AND ASSEMBLY

This category includes all costs associated with assembly and componentinstallation of the SRMs. Specifically included are those items developedand manufactured in WBS Nos. 3.3.2.3.1, . 2~ and. 3. It also includes themiscellaneous assembly materials such as O-rings, adhesives and lubri-

.cants required in the SRM assembly.

Costs associated with stage assembly are under WBS No.3. 3. 6.

Also to be included are the costs of assembly of three PPQ motors for testat LPC.

WBS NO. 3.3.2.3.5 GROUND TEST

This task includes the costs as sociated with the static -test-firing of threePPQ SRMs. No stage tests are required.

WBS NO. 3.3.2.3.6 TOOLING

All tooling costs for production were included in DDT &E. This task, therefore, includes only those costs required for sustaining tool inspection,maintenance and rework.

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629-6Vol II Book 3

WBS NO. 3.3.2.4 FACILITIES

This task includes all costs required to buy land and equipment and to design,construct and expand buildings for the manufacture and assembly of SRMs.

Effort shall include the following:

• Equipment selection and procurement

• Site selection and land improvement

• Facility and building layout concept including flow analysis andequipment integration

• Facility layout and approval

• Building design

• Construction of new buildings and modification of existing buildings

• Equipment installation and checkout

• Maintenance of buildings, grounds and equipment

Facility checkout (such as mixer trials) shall be costed against WBS No.3.3.2.3.

WBS NO.3. 3.2.5 SUPPORT EQUIPMENT AND SPARES

This category is for cost accumulation of WBS tasks 3.3.2.5. I and 3.3.2.5.2.

WBS NO. 3.3.2.5.1 AGE DESIGN AND FABRICATION

This category includes all costs associated with the design, procurement,and maintenance of AGE to handle the SRMs. This is for requirements overand above that required for DDT&E.

WBS NO. 3.3.2.5.2 SPARES FABRICATION

This task includes all labor and materials directly assignable to the production of SRM and GSE spares to support the launch program. Storage atKSC of SRM components will provide several months inventory of parts.

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LOCKHEEO PROPULSION COMPANyl

629-6Vol II Book 3

WBS NO.3. 3.2.6 FLIGHT TEST SUPPORT

This task includes all labor as sociated with the flight-test performance ofthe SRMs, including preflight motor assessment, analysis of SRM flight data,updating of performance requirements and liaison with the customer andother contractors relating to SRM requirements and performance.

WBS NO. 3.3.2.7 OPERATIONS SUPPORT

This task is a summation of the subtasks associated with the SRM logisticsat KSC.

WBS NO. 3.3.2.7.1 OPERATIONS SUPPORT

This task includes the labor for logistics control of the SRMs and associatedhardware; Sustaining engineering and manufacturing personnel will beresponsible for SRM storage, assembly, and maintenance. They will alsomaintain SRM and component documentation records, coordinate requireddesign, process, and procedure changes, and control liaison between LPCand the customer in any SRM problem area.

WBS NO. 3.3.2.7.2 TRANSPORTATION

This task is for assignment of cost directly related to the transportation ofSRM segments to KSC. Labor costs are not assignable to this, but ratherto the specific subtask under WBS No.3. 3.2.3.

W BS NO.3. 3. 3 AVIONICS

This task includes the electronics and data collection associated with theflight control and flight performance of the SRM booster. No costs areassignable directly to this task number.

WBS NO. 3.3.3.1 FLIGHT CONTROL ELECTRONICS

All labor and material for sustaining design and manufacture of the flightcontrol electronics shall be charged to this task. Included are the commandand control systems for the TVC.. Manufacture and performance specifications and vendor control will be maintained for all components and thetotal system. Sufficient assemblies shall be supplied for the 440 launches.Quality control plan implementation will be required.

WBS NO. 3.3.3.2 GUIDANCE AND NAVIGATION

This tas k is not applicable to a parallel launch configuration.

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629-6Vol II Book 3

W BS NO.3. 3. 3. 3 DATA MANAGEMENT

This task includes all the materials and labor for the stage systeminstrumentation/diagnostics and stage electronic logic. It also includessequencing functions and event electrical initiation command systems for440 launches.

WBS NO.3. 3. 4 CONTROL SYSTEMS

No costs are associated with this task for parallel configuration.

WBS NO. 3.3.5 POWER

This task includes the electrical and hydraulic power systems for thebooster. Because WBS No.3. 3.5.2, Hydraulic Power, is not applicable tothis design, the only cost is for electrical power, WBS No.3. 3. 5.1.

WBS NO.3. 3. 5. I ELECTRICAL

This task includes all material and labor costs for delivery of the boosterelectrical power system. Sustaining technical effort is required for designcontrol, vendor control, and product assurance acceptance and tests.

WBS NO.3. 3. 5.2 HYDRAULICS

No input is required for the parallel configuration.

WBS NO. 3.3.6 INSTALLATION, ASSEMBLY, AND CHECKOUT

This category of cost includes all effort related to the assembly of the 440launch vehicles. It includes such tasks as stage system checkout, SRM/stage assembly, and SRM booster/vehicle assembly.

WBS NO.3. 3. 7 MAJOR GROUND TESTS

Because of the lack of a defined WBS, this task includes all effort associatedwith support of the launch operation not assignable to another specific WBS.Included are such tasks as stage logistics, engineering design documentationmaintenance, and SRM/Orbiter flight assessment and data review.

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LOCKHEED PROPULSION COMPANY.

629-6Volil, Book 3

3.2 156-7 SRM, PARALLEL CONFIGURATION

In accordance with the Statement of Work, and subsequent direction receivedfrom NASA, DDT&E and Production for the Parallel configuration has beencosted in the four Options listed below•. A WBS chart is included for eachoption for DDT&E and Production. Motor quantities are listed on each WBSchart.

Option I (subsection 3.2.1) Basic motor with Thrust Vector Control(TVC) and Thrust Termination (TT)

Option II (subsection 3.2.2) Basic motor without TVC and TT

Option ill (subsection 3.2.3) Basic motor with TVC only

Option IV (subsection 3.2.4) Basic motor with TT only

Figure 3-4 OPTION ISRM PARALLEL BASELI NE

WEIGHT SUMMARY

GROSS WEIGHT -1.38 x 106 LBPROPELLANT - 1.23 x 106 LBTOTAL INERTS - 0.15x 106 LBMASS RATIO - 0.89

5 POINT STARAFT SEGMENT ONLY

PERFORMANCE SUMMARY

INITIAL THRUST - 2.94 x 106 LBBURN TIME - 138 SECMEOP - 1000 PS I

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3.3 156 -6 SRM, SERIES CONFIGURATION

aThe 156 -6 SRM i~ costed in one configuration only. The basic motor costedincludes TVC and "TT. " Motor, quantities are listed on each WBS chart.

Figure 3-5 SRM SERIES CONFIGURATION 056-6)~--------------_-..:...._-

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14---------94FT----------

PERFORMANCE SUMMARY

INITI AL THRUST - 2.31 x 106 LBBURN TIME - 138 SECMEOP - 1000 PS I

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629-6Vol II, Book 3

3.4 120-7 SRM, PARALLEL CONFIGURATION

The 120-7 SRM consists of the basic motor and includes Liquid Injection,TVC, and Thrust Termination. Motor quantities are listed on each WBSchart.

It should be noted that if the 120-7 SRM used a Cold Gas Lockseal TVCsystem, the Production unit cost would be reduced by approximately$100,000 each.

3 -37


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Section 4

PROGRAM COST ESTIMATES, TABLE 1

Cost estimates for the 156-7 SRM (Parallel Configuration), Options I, II,III, and IV, and the 156 -6 SRM (Series Configuration) are presented inTable 1 format. Table l(a) (WBS 3.3.2) is for the SRM only, and Table l(b)(WBS 3.3) is for the total Booster Vehicle. The costs listed in each categoryare taken from the appropriate WBS block{s) and spread into the variouscategories. The following description of task content is provided to assistthe reader in understanding the cost content of each category.

4.1 DESCRIPTION OF TASK CONTENT - TABLE 1

4.1.1 Table l(a), SRM Only (WBS 3.3.2)

Design, Development, Test and Evaluation (DDT&E). DDT&E consists ofall costs incurred for the design, fabrication, ground test, and flight tests.DDT&E also includes the cost of two dynamic tests and the vertical-flight,designated as test or development flight. These costs include all tooling/STE required for DDT&E and Production. DDT&E also includes the costof the first five manned orbital flights.

Engineering Design and Development (EDD). EDD includes Engineeringdesign and development, component testing, subscale testing, and inertmotors.

Structures (WBS 3.3.2.3.1)

Case:

Nozzle:

Igniter:

Includes des ign and development, component testing,subs cale testing, and refurbishment of four cases forinert motors and inspection

Includes design and development, component testing,subs cale testing, and inspection. Options I and IIIinclude a Lockseal nozzle, Options II and IV includea fixed nozzle

Includes design and development, component testing.subs cale testing, and inspection

4 -1


ThrustTermination:

Propellant:

629-6Vol II, Book 3

Includes design and development, component testing,subs cale testing, and inspe ction. Options II and IIIexclude Thrust Termination

includes proces,s development, subscale mixing andcasting for live and inert propellant, and inspection.

TVC (WBS 3.3.2.'3.2)

Includes design and development, component testing, bench tests, andfull-scale testing. This category is for the actuation system only.Options II and IV exclude Thrust Vector Control.

Power, Electrical (WBS 3.3.2.3.3)

Includes design and development and component testing. Includespower and electrical system for TVC, TT, and Initiators.

Installation, Assembly and Checkout (WBS 3.3.2.3.4)

No effort in EDD. Applies to full-scale motors in Ground TestHardware (GTH) and Flight Test Hardware (FTH).

Ground Test (WBS 3.3.2.3.5)

Includes batch-check motor firings, subs cale firings, and full-s caleigniter firings.

Tooling (WBS 3.3.2.3.6). Includes all tooling and test equipment requiredfor the DDT&E and Production Program.

Ground Test Hardware (GTH). Includes the costs for procurement, fabrication, and static test firing of five development and four PFRT full-s calemotors. These costs are contained in the following WBS blocks:

(1) Structures, WBS 3.3.2.3.1

(2) TVC, WBS 3.3.2.3.2, Options I and III

(3) Power, Electrical, WBS 3.3.2.3.3

(4) Installation, Assembly and Checkout, WBS 3.3.2.3.4

(5) Ground Test, WBS 3.3.2.3.5

Flight Test Hardware (FTH). Includes the costs of procurement and fabrication of Flight Test Motors (FTMs). This includes one unmanned launchand five manned launches. Transportation and launch support are includedin the Operations category. The WBS blocks for GTH also include costs forFTHs.

4-2

LDCKHEE'O PROPULSION CDMPANJ'

629-6Vol II, Book 3

Other. Includes the cost of all Program Management (WBS 3.3.2. l),Systems Engineering (WBS 3.3.2.2), and Facilities (WBS 3.3.2.4) for theDDT&E program.

Production. Includes all costs for procurement, fabrication, facilities,and tooling maintenance for the Production Program.

Program Management (WBS 3.3.2. 1). Includes cost for program direction, coordination, and data requirements for the Production Program.

Systems Engineering (W BS 3.3.2.2). Includes cost for Systems Engineering and Quality Engineering for the Production Program.

SRM (WBS 3.3.2.3 ). Includes costs for procurement, fabrication,tooling maintenance, and assembly of the FTM segments at the launchsite. These costs are contained in the following WBS blocks:

(1) Structures, WBS 3.3.2.3. I

(2) TVC, W BS 3.3.2.3.2, Options I and III

(3) Power, Electrical, WBS 3.3.2.3.3

(4) Installation, Assembly and Checkout, WBS 3.3.2.3.4

(5) Ground Test, WBS 3.3.2.3.5

(6) Tooling Maintenance, WBS 3.3.2.3.6

Facilities (WBS 3.3.2.4). Includes the cost for Production facilities.

Operations. Includes all transportation, Operations Support, Spares, andAGE for the DDT&E and Production Programs. These costs are containedin the following WBS blocks:

(l) Support Equipment and Spares, WBS 3.3.2.5

(2) Flight Test Support, WBS 3.3.2.6

(3) Operations Support, WBS 3.3.2.7

4.1.2 Table l(b), Booster Vehicle (WBS 3.3)

Design, Development, Test and Evaluation (DDT&E). Table l(b), as presented herein, contains the costs for the SRM (WBS 3.3.2) and the BoosterVehicle (WBS 3.3). The tasks associated with each category are the sameas des cribed in Table 1(a).

Production. The costs for Production include the SRM and stage. Thecontent of each category is the same as presented in Table l(a).

4-3


629-6Vol II, Book 3

Operations. The costs for Operations are for the SRM and stage. Thecontent of each category is the same as presented in Table l(a).


The costs for this section are presented in format 1(a) and 1(b) for thefollowing options:

4.2.1 Option I (with TVC and Thrust Termination)

4.2.2 Option II (without TVC and Thrust Termination)

4.2.3 Option III (with TVC)

4.2.4 Option IV (with Thrust Termination)

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629-6Volli, Book 3

Section 5

PROGRAM TIME -PHASED FUNDING REQUIREMENTS, TABLE 2

Funding requirements for the 156-7 SRM (Parallel) and 156-6 SRM (Series)are presented in Table 2 format for the SRM (Table 2(a), WBS 3.3.2), andthe total Booster Vehicle (Table 2(b), WBS 3.3). The costs for the variouselements are taken from the appropriate W BS blocks on Table 1, and arespread consistent with the directions contained in NASA letter PM-EP-MGR,dated 31 January 1972.


Table 2(a), SRM Only (WBS 3.3.2)

Design, Development, and Test (DDT&E). DDT&E consists of all costsincurred for the design, fabrication, ground test, and flight tests. DDT&Eincludes the total cost of the two dynamic test vehicles and the vertical flightdes ignated as test or development flight. These costs include all tooling,and the STE, ground support equipment, spares and other efforts required,leading up to and supporting the test flight. DDT&E also includes the cost ofthe first five manned orbital flights, including support for receiving,assembly and checkout, spares, operations support, etc.

Cost Elements - Nonrecurring

Development

STE/ST

Dummy Engines

Flight Engines

OS FS & Spares

Includes EDD (less inert motors), GTH, and Other(less Facilities) from Table 1

Includes Tooling from Table 1

Includes the inert motors from Table 1, EDD

Includes FTH and part of Program Managementfrom Table 1

Includes the following WBS blocks from DDT&E:Support Equipment and Spares, WBS 3.3.2.5Flight Test Support, WBS 3.3.2.6Operations Support, WBS 3.3.2.7

Recurring (Production). Production is defined as the costs associatedwith producing additional flight engines and modification and/or updating ofthe flight test hardware required for operation through acceptance of the

5-1


629-6Vol II, Book 3

hardware by the Government, including all costs associated with: (1) fabrication, modification, updating, assembly and checkout of flight hardware,(2) ground test and factory checkout of flight hardware, (3) initial operationalspares required for manufacturing, and (4) maintenance of tooling and specialtest equipment.

Cost Elements - Investment

Deliver New Engines Includes total Production (lessFacilities) from Table 1

Ground Support Equipment Includes WBS block for Ground SupportEquipment, 3.3.2.5.1

Operations. Operations is defined as the cost associated with thefollowing activities:

a. Flight support is defined as (1) replacement spares to supportoperational airborne hardware, (2) sustaining engineering tosupport the production of spares and hardware modifications,and (3) maintenance of GSE and spares for GSE.

b. Launch Operations: The costs for receiving the flight hardware,assembly of the vehicle, checkout, prelaunch test and checkout,servicing, launching, and refurbishing of the launch site facilities.

Flight Support Includes cost from WBS block 3.3.2.6,Flight Test Support

Operations Includes cost from WBS block 3.3.2.7,Operations Support

Parts Includes cost from WBS block 3.3.2.5.2,Spares

Facilities.. Includes cost from WBS block 3.3.2.4, Facilities.

Table 2(b), SRM and Stage (WBS 3.3)

Table 2(b) costs were derived by using the same rationale as describedabove, however costs are for the total program.

5 -2


629-6Vol II, Book 3

5.2 156-7 SRM, PARALLEL CONFIGURATION (Reference Subsection 3.2)

This subsection contains Table 2s for the following configurations:

5.2.1 Option I (with TVC and Thrust Termination)

5.2.2 Option II (without TVC and Thrust Termination)

5.2.3 Option III (with TVC)

5.2.4 Option IV (with Thrust Termination)

5 -3


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629-6Vol II, Book 3

Section 6

RECURRING COST PER ALTERNATE LAUNCH RATE

6.1 DESCRIPTION OF COSTING APPROACH

The recurring cost-per -launch is presented for each launch rate, includingthe basic mission model of 60. Data tables have been prepared for each ofthe alternate booster vehicles (options) of the baseline 156 -7 parallel configuration. A summary of the calculation method follows:

SRM/Stage. The recurring cost presented in this subsection encompasses880 Production SRMs to support 440 manned launches. Cost also includesthree nonrecurring SRMs for production facility start-up test.

The 880 production SRMs were preceded by 12 SRMs used for the unmannedbooster and the first five manned launches, which are part of the design,development, test and evaluation (DDT&E) phase of the program. Becausethese units are the same configuration as those in the production phase, theywill be manufactured on the same configuration of tools and will be part ofthe basic production run. They are included in the base for T 1 and the production learning application.

The first flight SRM in the production phase is thus identified as T16 summarized as follows:

SRM

Unmanned Booster (1)Manned Booster (5)Production Facilities Start-up MotorsProduction Motors

Quantity

210

3880

CumulativeQuantity

1 and 23 through 12

13 through 1516 through 895

The unit and attendant costs were laid on a 95 -percent cost curve. Thispercentage is deemed appropriate for a solid rocket program that encompasses a variety of hardware, systems engineering, program management,etc.

The production run quantity for stage is the same as the SRM in that theflight units in DDT&E are identified as the first 6 production units. Therefore, the first production phase unit is T 7 on a 90-percent production progress cost curve, for a total of 440 sets to T446'

6 -1


629-6Vol II, Book 3

Operation/Transportation. Unlike factory costs, which is learning oriented,operations effort is primarily a function of launch rate and the operationscosts are applied in the tables by the launches. The transportation cost takesinto effect shipping motors and hardware to KSC from factories located bothin the vicinity of KSC and the West coast. The cost is spread on an averagebasis.

Detailed calculations displaying the method and rationale used in derivingthe cost data on the tables is included in this section following the tables foreach optional configuration. As the details show, the recurring costs usedare the production amounts exclusive of the facilities and three productionfacilities start-up motors.

6 -2

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6.2.1.3 Costing Rationale/Detail

629-6Vol II, Book 3

OPTION I - BASIC wiTT & TVC

SRM PRODUCTION RECURRING

CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60

Year Qty 95% 95% CTF Cost $M

1979 32 CTF47 37.9745 CTF 15 13.0921 24.8824 $ 103.378

1980 48 CTF9573.0250 CTF47 37.9745 35.0505 145. 623

1981 64 CTF 159 117.7696 CTF95 73.0250 = 44.7446 185.898

1982 82 CTF241 173.1938 CTF 159 117.7696 55.4242 230.268

1983 100 CTF 341 238.9272 CTF241 173. 1938 65.7334 273.099

1984 118 CTF459 314.6826 CTF341 238.9272 75. 7554 314.737

1985 120 CTF 579 390.2446 CTF459 314.6826 75. 5620 313.934

1986 120 CTF699 464.6489 CTF579 390.2446 74.4043 309. 124

1987 120 CTF819 538.1099 CTF699 464.6489 73.4610 305.204

1988 76 CTF895 584.2166 CTF819 538. 1099 . 46. 1067 191. 557

Total 880 571. 1245 $2.372.822

T 1 = $4, 154,650

6-8


6.2.1,3 (Continued)

629-6Vol II, Book 3

OPTION I - BASIC wITT & TVC

STAGE PRODUCTION RECURRING

CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60


1979 16 CTF22 15.8624 CTF6 5. 1008 10.7616 $ 32.954

1980 24 CTF46 29.9246 CTF22 15.8624 = 14.0622 43.061

1981 32 CTF78 47.0255 CTF46 29.9246 17. 1009 52.366

1982 41 CTF 119 67.4425 CTF78 47.0255 20.4170 62. 520

1983 50 CTF 169 90.9413 CTF 119 67.4425 23.4988 71. 957

1984 59 CTF228 117.3471 CTF 169 90.9413 26.4058 80.859

1985 60 CTF288 143. 1472 CTF228 117.3471 = 25.8001 79.004

1986 60 CTF348 168. 1382 CTF288 143. 1472 24.9910 76.527

1987 60 CTF408 192.4802 CTF348 168. 1382 24.3420 74.539

1988 38 CTF446 207.6123 CTF408 192.4802 15. 1321 46.337

Total 440

6-9

202. 5115 $620. 124

T 1 = $3,062,166


6.2.1.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 40


1979 30 CTF4536.4692 CTF 15 13.0921 = 23.377 1 $ 97. 124

1980 48 CTF93

71. 5966 CTF45 36.4692 35. 1274 145.942

1981 64 CTF 157 116.3948 CTF93 71. 5966 44. 7982 186.121

1982 80 CTF237 170.5270 CTF 157 116.3948 = 54. 1322 224.900

1983 80 CTF317 223.2995 CTF237 170.5270 = 52.7725 219.251

1984 80 CTF397275.0862 CTF317 223.2995 = 51. 7867 215. 156

1985 80 CTF477 326.1019 CTF397 275.0862 51. 0157 211. 952

1986 80 CTF557 376.4860 CTF477 326.1019 50.3841 209.328

1987 80 CTF637 426.3360 ·CTF557 376.4860 49.8500 207. 109

1988 80 CTF717 475.7240 CTF 637426.3360 49.3880 205. 190

Total 702 462.6319 $1,922.073

T 1 = $4, 154,650

6 -10

LOCKHEED PRDPULSIDN COMPANJ

6.2.1.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 40

Year Qty 900/0 90% CTF Cost $M

1979 15 CTF2115. 2373 CTF6

5. 1008 10. 1365 $ 31. 040

1980 24 CTF45

29.365,8 CTF2115. 2373 = 14. 1285 43.264

1981 32 CTF 7746.5098 CTF45" 29.3658 17. 1440 52.498

1982 40 CTF l1766.4746 CTF77 46.5098 19.9648 61. 136

1983 40 CTF 157 85.4111 CTF 117 66.4746 18.9365 57.987

1984 40 CTF 197 103.6223 CTF 157 85.4111 18.2112 55.766

1985 40 CTF237 121.2772 CTF 197 103.6223 17.6549 54.062

1986 40 CTF 277 138.4836 CTF 237 121.2772 17.2064 52.689

1987 40 CTF317 155.3158 CTF277 138.4836 = 16.8322 51. 543

1988 40 CTF357 171. 8278 CTF317 155.3158 16.5120 50.562

Total 351

6-11

166.7270 $510.547

T1

= $3,062,166


6.2.1.3 (Continued)

629-6Vo1lI, Book 3



CUM TOTAL F AC TORS

(156-7 Para)

LAUNCH RATE OF 20

Year Qty 95% 95% = CTF Cost $M

1979 30 CTF45 36.4692 CTF 15 13. 0921 = 23.3771 $ 97. 124

1980 40 CTF85 65.8598 CTF45 36.4692 = 29.3906 122. 108

1981 40 CTF 125 94.2095 CTF85 65.8598 28.3497 117.783

1982 40 CTF 165 121. 8863 CTF 1~5 94.2095 27.6768 114.987

1983 40 CTF205 149.0674 CTF 165 121. 8863 = 27.1811 112.928

1984 40 CTF245 175.8574 CTF 205 149.0674 = 26. 7900 111.303

1985 40 CTF285 202.3247 CTF245 175.8574 = 26.4673 109.962

1986 40 CTF325 228.5181 CTF285 202.3247 = 26. 1934 108.824

1987 40 CTF365 254.4738 CTF325 228.5181 = 25.9557 107.837

1988 40 CTF405 280.2197 CTF365 254.4738 25.7459 106.965

Total ill 267.1276 $1, 109.821

T 1 =$4, 154,650

6-12


6.2.1.3 (Continued)

629-6Vol II, Book 3

OPTION I - BASIC w / TT & TVC


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 20


1979 15 CTF21 15.2373 CTF6 5. 1008 10. 1365 $ 31. 040

1980 20 CTF41 27.1114 CTF21 15.2373 11.8741 36.360

1981 20 CTF61 38. 1093 CTF41 27.1114 10.9979 33.677

1982 20 CTF81 48.5666 CTF61 38. 1093 10.4573 32.022

1983 20 CTF 101 58.6369 CTF81 48.5666 10.0703 30.837

1984 20 CTF 121 68.4079 CTF 101 58.6369 9.7710 29.920

1985 20 CTF 141 77.9363 CTF 121 68.4079 9. 5284 29.178

1986 20 CTF 161 87.2614 CTF 141 77.9363 9.3251 28. 555

1987 20 CTF 181 96.4122 CTF 161 87.2614 9. 1508 28.021

1988 20 CTF201 105.4107 CTF 181 96.4122 8.9985 27.555

Total ill

6 -13

100.3099 $307.165

T 1 = $3.062,166


6.2.1.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 10


1979 20 CTF3528.8636 CTF 15 13.0921 = 15.7715 $ 65.525

1980 20 CTF5543.9511 CTF35 28.8636 = 15.0875 62. 683

1981 20 CTF7558.6323 CTF55 43.9511 = 14.6812 60.995

1982 20 CTF9573.0250 CTF75 58.6323 = 14.3927 59.797

1983 20 CTF 115 87. 1947 CTF95

73.0250 = 14. 1697 58.870

1984 20 CTF 135 101. 1830 CTF 115 87.1947 13.9883 58. 116

1985 20 CTF 155 115.0190 CTF 135 101. 1830 13.8360 57.484

1986 20 CTF 175 128.7231 CTF 155 115.0190 13.7041 56.936

1987 20 CTF 195 142.3121 CTF 175 128.7231 = 13.5890 56.458

1988 20 CTF215 155.7985 CTF 195 142.3121 13.4864 56.031

Total 200 142.7064 $592.895

T 1 = $4, 154,650

6 -14


6.2.1.3 (Continued)

629-6Vol II. Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 10


1979 10 CTF 16 12.0398 CTF6 5. 1008 6.9390 $ 21. 248

1980 10 CTF26 18.3227 CTF 16 12.0398 6.2829 19. 239

1981 10 CTF36 24.2461 CTF26 18.322'7 5.9234 18. 138

1982 10 CTF46 29.9246 CTF36 24.2461 5.6785 17.389

1983 10 CTF56 35.4189 CTF46 29.9246 5.4943 16.824

1984 10 CTF66 40. 7667 CTF56 35.4189 5.3478 16.376

1985 10 CTF76 45.9930 CRF66 40.7667 5.2263 16.004

1986 10 CTF86 51. 1163 CTF76 45.9930 = 5. 1233 15. 688

1987 10 CTF96 56. 1501 CTF86 51. 1163 5. 0338 15.414

1988 10 CTF 106 61. 1051 CTF96 56. 1501 4.9550 15. 173

Total 100 56.0043 $171.493

T l = $3,062, 166

6-15


6.2.1.3 (Continued)

OPTION I - BASIC WITH T. T. AND TVC

RECURRING AND FIRST UNIT COST

WBS

SRM (WBS 3.3.2) - Incl 3 PPQ's

629-6Vol II, Book 3

COST

Total SRM

Less:

STAGE

FacitiliesTransportationSupport Equipment SparesFlight Test SupportOperations Support

Recurring SRM lncl 3 PPQ's

3.3.2

3.3.2.43.3.2.7.23.3.2.53.3.2.63.3.2.7. 1

$2,545.691M

25.700M)80.702M)51. 242M)

1. 433M)3.536M)

$2,383.078M

StructuresAvionicsPower

Recurring Stage

OPERATION

Support Equipment SparesFlight Test SupportOperations SupportInstallation Assembly and CheckoutMajor Ground Test

Recurring Operations

3.3. 13. 3. 33.3.5

3.3.2.53.3.2.63.3.2.7.13.3.63.3.7

$ 384. 516M184. 120M

50. 888M

$ 620. 124M

$ 51. 242M1. 433M3.536M

188. 494M120.401M

$ 365. 106M

TRANSPOR T ATION 3.3.2.7.2 $ 80.702M

Total Recurring Cost - Inc1 3 PPQ'sR econcil. w / WBS - Facilities

TOTAL PRODUCTION

6 -16

$3,449.010M25.700M

$3,474. 710M


629-6Vol II, Book 3

6.2.1.3 (Continued)

OPTION I - BASIC WITH TT & TVC

CTF895' @ 95%

CTF 12, @ 95%

T 1 = $2.383. 078M .;. 573.5927 =

584.2166

( 10.6239)

573.5927

$4. 15465M

3 PPQ'sCTF 15' @ 95%

CTF 12' @ 95%

13'. 0921

10.6239)

2.4682 x $4. 15465M = $ 10.255M

880 Prod. CTF895' @ 95%

CTF 15' @ 95%

CTF880' T 16 ..... 895

584.2166

( 13.0921)

571. 1245 x $4. 15465M = $2,372.823M

TOTAL PRODUCTION INCL PPQ

T, STAGE

$2, 383. 078M

CTF446' @ 90%

CTF6' @ 90%

CTF440

, T7

_446

T 1 = $620. 124M ~ 202.5115 =

207.6123

5. 1008)

202.5115

6-17

$3,062. 166M


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629-6Vol II, Book 3

OPTION II . _ BASIC (W /0 TT & TVC)


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60


1979 32 CTF47 37.9745 CTF 15 13.0921 24.8824 $ 88. 991

1980 48 CTF95 73.0250 CTF47 37.9745 = 35.0505 125.356

1981 64 CTF 159 117.7696 CTF95 . 73.0250 = 44. 7446 160.027

1982 82 CTF241 173.1938 CTF 159 117.7696 55.4242 198.222

1983 100 CTF341 238.9272 ~TF241 173. 1938 = 65. 7334 23:>.092

1984 118 CTF459 314.6826 CTF341 238.9272 = 75. 7554 270. 936

1985 120 CTF579 390.2446 CTF459 314.6826 = 75.5620 270.244

1986 120 CTF699 464. 6489 CTF579 390.2446 74.4043 266. 103

1987 120 CTF819 538. 1099 CTF699 464.6489 73.4610 262. 730

lQ~Jl 76 CT~~95 584..2166 CTF819 538. 109') 4(,.lOG7 164.899

Total 880 571. 1245 $2,042.600

Tl = $3, 5.'b, 452

6-23


6.2.2.3 (Continued)

629-6Vol II, Book 3

OPTION II - BASIC (W/0 TT & TVq


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60

Year Qty 90% 90% :: CTF Cost $M

1979 16 CTF2215.8624 CTF6 5. 1008 :: 10.7616 $ 30.898

1980 24 CTF46 29.9246 CTF22 15.8624 :: 14.0622 40.374

1981 32 CTF7847.0255 CTF46 29.9246 17. 1009 49. 099

1982 41 CTF 119 67.4425 CTFn~ 47.0255 :: 20.4170 58.620

1983 50 CTF 169 90.9413 CTF 119 67.4425 :: 23.4988 61.468

1984 59 CTF228 117.3471 CTF 169 90.9413 :: 26.4058 75. 814

1985 60 CTF288 143.1472 CTF228 117.3471 :: 25.8001 74.076

1986 60 CTF348 168. 1382 CTF288 143.1472 :: 24.9910 71. 753

1987 60 CTF40'1 192.4802 CTF348 168.1382 :: 24.3420 69.889, .... 1""1'"

~" Gl.c-44 6 2u,.oi23 CTF408 192.4802 :: 15. 1321 43.446~700 JO

Total 440=

6- 24

Tl

:: 2,871,130

202.5115 $581.431


6.2.2.3 (Continued)

629-6Vol II, Book 3

OPTION II - BASIC (W /0 TT & TVC)


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 40


1979 30 CTF45 36.4692 CTF 15 13.0921 = 23.3771 $ 83.607

1980 48 CTF93

71. 5966 CTF45 36.4692 = 35. 1274 125. 631

1981 64 CTF 157 116.3948 CTF93

" 71. 5966 = 44. 7982 160.219

1982 80 CTF237 170.5270 CTF 157 116.3948 = 54. 1322 193.601

1983 80 CTF317 223.2'995 CTF237 170.5270 = 52.7725 188. 738

1984 80 CTF397275.0862 CTF317 223.2995 = 51.7867 185.213

1985 80 CTF477 326.1019 CTF397275.0862 = 51. 0157 182.455

1986 80 CTF557 376.4860 CTF477 326.1019 = 50.3841 180. 196

1987 80 CTF637426.3360 CTF 557 376.4860 49.8500 178.286

1988 80 CTF717 475.7240 CTF637 426.3360 = 49.3880 176.634

Total 702 462.6319 $1,654.580

T 1 = $3,576,452

6 - 25


6.2.2.3 (Continued)

629-6Vol II, Book 3

OPTION II - BASIC (W/0 TT & TVC)


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 40

Year .9!r 90% 90% = CTF Cost $:&1

1979 15 CTF21 15.2373 CTF6 5. 1008 = 10. 1365 $ 29.103

1980 24 CTF4529.365,8 CTF21 15.2373 = 14. 1285 40.565

1981 32 CTF 7746.5098 CTF45' 29.3658 = 17. 1440 49.223

1982 40 CTF 11766.4746 CTF

77 46.5098 = 19.9648 57.322

1983 40 CTF 157 85.4111 CTF 117 66.4746 = 18.9365 54.369

1984 40 CTF 197 103.6223 CTF 157 85.4111 = 18.2112 52.287

1985 40 CTF237 121. 2772 CTF 197 103.6223 = 17.6549 50.690

1986 40 CTF277 138.4836 CTF237 121. 2772 = 17.2064 49.402

1987 40 CTF317 155.3158 CTF277 138.4836 = 16.8322 48.327

l°Q Q 40 CTF357 17Lf:l?7R CTF~i'l 15S.31Sg = Ib.51tO 47.408

Total 351

6-26

166.7270 $478.676

T 1 = $2,871, 130


6.2.2.3 (Continued)

629-6Vol II, Book 3

OPTION II - BASIC (W/0 TT &: TVC)


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 20


1979 30 CTF45 36.4692 CTF 15 13.0921 = 23.3771 $ 83.607

1980 40 CTF85 65.8598 CTF45 36.4692 = 29.3906 105. 114

1981 40 CTF 125 94.2095 CTF85 65.8598 = 28.3497 101. 391

. 1982 40 CTF 165 121. 8863 CTF 125 94.2095 = 27.6768 98.985

1983 40 CTF205 149. ct674 CTF 165 121. 8863 = 27. 1811 97.212

1984 40 CTF245 175.8574 CTF205 149.0674 :: 26. 7900 95.813

1985 40 . CTF285 202.3247 CTF245 175.8574 = 26.4673 94.659

1986 40 CTF325 228.5181 CTF285 202.3247 = 26. 1934 93.679

1987 40 CTF365 254. 473R CTF325 228.518J = 25.9557 92.829

1988 40 CTF405 280.2197 CTF365 254.4738 25.7459 92.079

Total ~

6-27

267. 1276 $955.368

T1 = $3,576,452


6.2.2.3 (Continued)

629-6Vol II, Book 3

OPTION II - BASIC (W /0 TT 8< TVC)


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 20

Year Qty 90% 90% ::: CTF Cost $iiii

1979 15 CTF21 15.2373 CTF6 5.1008 ::: 10. 1365 $ 29. 103

1980 20 CTF41 27.1114 CTF21 15.2373 ::: 11.8741 34.092

1981 20 CTF61 38. 1093 CTF41 27.1114 ::: 10.9979 31. 576

1982 20 CTF81 48.5666 CTF61 38. 1093 ::: 10.4573 30.024

1983 20 CTF 101 58.6'369 CTF81 48.5666 ::: 10.0703 28.913

1984 20 CTF 121 68.4079 CTF 101 58.6369 ::: 9.7710 28.054

1985 . 20 CTF 141 77.9363 CTF 121 68.4079 ::: 9.5284 27.357

1986 20 CTF 161 87.2614 CTF 141 77.9363 ::: 9.3251 26.774

1987 20 CTF 181 96.4122 CTF J61 87.2614 9. 1508 26.273

1988 20 CTF201 105.4107 CTF 181 96.4122 ::: 8.9985 25.836

Total ,ill

6-28

100.3099 $288.002

. T l ::: $2, 871,130


6.2.2.3 (Continued)

629-6Vol II, Book 3

OPTION II - BASIC (W10 TT 8< TVC)


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 10


1979 20 CTF3528.8636 CTF 15

13.0921 = 15.7715 $ 56.406

1980 20 CTF5543.9511 CTF35 28.8636 = 15.0875 53. 960

1981 20 CTF7558.6323 CTF

5543.9511 = 14.6812 52.507

1982 20 CTF9573.0250 CTF

7558.6323 = 14.3927 51.475

1983 20 CTF 115 87. 1-947 CTF95

73.0250 = 14.1697 50.677

1984 20 CTF 135 101. 1830 CTF 115 87. 1947 = 13.9883 ·50.028i

1985 20 CTF 155 115.0190 CTF 135 101. 1830 = 13.8360 49.484

1986 20 CTF 175 128.7231 CTF 155 115.0190 = 13.7041 49.012

1987 20 CTF 195 142.3121 CTF 175 128.7231 = 13. 58QO 48.600

l';1HH lU CTF215 155.7985 CTF 195 142.3121 = 13.4864 48.233

Total 200 142.7064 $510.382

T 1 =3,576,452

6-29


6.2.2.3 (Continued)

629-6Vol II, Book 3

OPTION II - BASIC (W /0 TT & TVC)


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 10

Year Qty 900/0 900/0 = CTF Cost $M

1979 10 CTF 16 12.0398 CTF 6 5. 1008 = 6.9390 $ 19.923

1980 10 CTF26 18.3227 CTF 16 12.0398 = 6.2829 18.039

1981 10 CTF36 24.2461 CTF26 18.3227 = 5.9234 17. 007

1982 10 CTF46 29.9246 CTF36 24.2461 = 5.6785 16.304

1983 10 CTF56 35.41'89 CTF46 29.9246 = 5.4943 15.775

1984 10 CTF66 40. 7667 CTF56 35.4189 '" 5.3478 15.354

1985 10 CTF76 45.9930 CRF66 40. 7667 = 5.2263 15.00:'

1986 10 CTF86 51. 1163 CTF 76 45.9930 = 5. 1233 14.710

1987 10 CTF9656. 1501 CTFS6 51. 1163 = 5.0338 14.453

10P~ In r'T"T;- to1 ll\c:.l r""rn...-:" 56.1501 4.9550 14.226- - - lOb --. _._-~ •• 96

Total 1?0

6-30

T1

= $2,871, 130

56.0043 $160.796


6.2.2.3 (Continued)

OPTION II - BASIC (W/O TT AND TVC)

RECURRING AND FIRST UNIT C05T

WBS

SRM (WBS 3.3.2) Incl 3 PPQ's

629-6Vol II, Book 3

COST

Total SRM

Less:

STAGE

FacilitiesOperations SupportSupport Equipment SparesFlight Test Support

Recurring Incl 3 PPQ's

3.3.2

3.3.2.43.3.2.73.3.2.53.3.2.6

$2,214.040M

25.700M)84. 238M)51. 242M)

1. 433M)

$2,051. 427M


Recurring State

OPERATION

Support Equipment SparesFlight Test SupportOperations SupportInstallation Assembly and CheckoutMajor Ground Test


TRANSPOR TATION

Total Recurring Cost - Incl 3 PPQ's

FACILITIES

TOTAL PRODUCTION

6-31

3.3.13.3.33.3.5

3.3.2.53.3.2.63.3.2.7. 13.3.63.3.7

3.3.2.7.2

$ 378. 979M157.677M44. 781M

$ 581. 437M

$ 51. 242M1. 433M3. 536M

169. 645M108. 361M

$ 334.217M

$ 80.702M

$3,047. 783M

25.700M

$3,073.483M


629-6Vol II, Book 3

6.2.2.3 (Continued)

OPTION II - BASIC (w/o TT & TVC)

T 1 - SRM

I. CTF895' @ 95%

CTF 12 , @ 95%

584.2166

( 10; 6239)

CTF883' T 13 ~ 895 573.5927

T1

= $2,051.427M';' 573.5927 = $3,576.452

II. 3 PPQ's

CTF 15' @ 95%

CTF 12' @ 95%

CTF3, T13~ 15

III. 880 Production

CTF895' @ 95%

CTF I5 , @ 95%

13.0921

10.6239)

2.4682 x $3,576,452

584.2166

( 13.0921

$ 8.827M

CTF880' T 16 -+895 571. 1245 x $3,576,452 $2,042. 600M

TOTAL SRM RECURRING INCL 3 PPQ's (PRODUCTION)

T 1 STAGE

$2.051. 427M

CTF 446' @ 90%

CTF6' @ 90%

T 1 = $581. 437M :- 202.5115 =

207.6123

5. 1008)

202.5115

6-32

$2,871. 130


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629-6Vol II, Book 3

OPTION III - BASIC WITH TVC


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60

Year Oty 95% 95% = CTF Cost $M

1979 32 CTF4737.9745 CTF 15

13.0921 = 24.8824 $ 101.564

1980 48 CTF9573.0250 CTF47 37 ..9745 = 35.0505 143.068

1981 64 CTF 159 117.7696 CTF9573.0250 = 44.7446 182.638

1982 82 CTF241 173.1938 CTF 159 117.7696 = 55.4242 226.230

1983 100 CTF341 238.92.72 CTF241 173.1938 = 65. 7334 268.310

1984 118 CTF459 314.6826 CTF341 238.9272 = . 75.7554 309.2.17

1985 120 CTF579 390.2446 CTF459 314.6S26 = 75.5620 308.428

. 1986 120 CTF699 464. 6489 CTF579 390.2446 74.4043 303. 702

1987 120 CTFS19538.1099 CTF699 464.6489 = 73.4610 299.852,

lClRR 76 r'T'l<' 584.2166 C'I'F819 538. 1~~? . • L ln / - 188. 198.- ~- 895 '"Xv. ~VVI

Total 880 571. 1245 $2, 331. 207

T 1 = $4,081,785

6 -3 8


6.2.3.3 (Continued)

629-6VallI, Book 3

OPTION 1lI - BASIC WITH TVC


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60

Year Qty 90% 90% ::; CTF Cost $M

1979 16 CTF22 15.8624 CTF6 5. 1008 ::; 10.7616 $ 32.419

1980 24 CTF46 29.9246 CTF22 15.8624 ::; 14.0622 42.363

1981 32 CTF78 47.0255 CTF46 29.9246 17.1009 51.517

1982 41 CTF 119 67.4425 CTF78 47.0255 ::; 20.4170 61. 506

1983 50 CTF 169 90.9413 CTF 119 67.4425 ::; 23.4988 70. 790

1984 59 CTF228 117.3471 CTF 169 90.9413 26.4058 79.547

1985 60 CTF288 143. 1472 CTF228 117.3471 ::; 25.8001 77.723

1986 60 CTF348 1&8. 1382 CTF288 143. 1472 ::; 24.9910 75.285

1987 60 CTF408 192.4802 CTF318 168. 1382 ::; 24.3420 73.330,,...1"1 .... 38 CTF446 207.6123 CTF408 192.40u2 b. Ut.l 45.585... ..,uv

Total 440

6-39

202.5115 $610.065

\ ::; $3,012,496


6.2.3.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 40


1979 30 CTF45 36.4692 CTF 15 13.0921 = 23.3771 $ 95.420

1980 48 CTF93 71. 5966 CTF45 36.4692 = 35. 1274 143.382

1981 64 CTF 157 116.3948 CTF93 71. 5966 = 44. 7982 182.857

1982 80 CTF237 170.5270 CTF 157 116.3948 = 54. 1322 220. 956

1983 80 CTF317 223.2995 CTF237 170.5270 = 52.7725 215.406

1984 80 CTF397 275.0862 CTF317 223.2995 = 51. 7867 211. 382i

198,5 80 CTF477 326. 1019 CTF397 275.0862 = 51. 0157 208.235

1986 80 CTF557 376.4860 CTF477 326.1019 = 50.3841 205.657

1987 80 CTF637 426.3360 CTF 557 376.4860 = 49.8500 203.477

l'JtlM 80 CTF717 475.7240 CTF637 426.3360 = 49.3880 201. 591

Total

6 -40

T 1 = $4,081, 785

462.6319 $1,888.363

LOCKHEED PRDPULSIDN CDMPANJ

6.2.3.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 40

Year .9!l 90% 90% :: CTF Cost $M

1979 15 CTF2115.2373 CTF6 5. 1008 :: 10. 1365 $ 30.536

1980 24 CTF45 29.365:8 CTF21 15.2373 :: 14. 1285 42.562

1981 32 CTF7746.5098 CTF45 29.3658 :: 17. 1440 51. 646

1982 40 CTF 117 66.4746 CTF77 46.5098 :: 19.9648 60. 144

1983 40 CTF 157 85.4.111 CTF 117 66.4746 :;: 18.9365 57.046

1984 40 CTF 197 103.6223 CTF 157 85.4111 :: 18.2112 54.861

1985 40 CTF237 121. 2772 CTF 197 103.6223 :: 17.6549 53.185

1986 40 CTF277138.4836 CTF237 121. 2772 :: 17.2064 51. 834

1987 40 CTF317 155.3158 CTF277138'.4836 :: 16.8322 50.707

!?88 40 CTF357 171.f:l2.78 CTF:;n 155.3158 16.5120 49. 742

Total 351 166. 7270 $502,263

T 1 :: $3,012,496

6-41


6.2.3.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL F AC TORS

(156-7 Para)

LAUNCH RA TE OF 20

Year Qty 95% 95% = CTF Cost $1:1

1979 30 CTF4536.4692 CTF 15 13.0921 = 23,3771 $ 95.420

1980 40 CTF8565.8598 CTF45 36.4692 = 29.3906 119.966

1981 40 CTF 125 94.2095 CTF85

65.8598 = 28.3497 115.717

. 1982 40 CTF 165 121.8863 CTF 125 94.2095 27.6768 112.971

1983 40 CTF205149.0674 CTF 165 121. 8863 = 27.1811 110.947

1984 40 CTF245 175.8574 CTF205 149.0674 = 26. 7900 109.351,198,5 40 CTF285 202.3247 CTF245 175.8574 = 26.4673 108.034

198,6 40 CTF325 228.5181 CTF285202.3247 = 26. 1934 106.916

1987 40 CTF365 254.4738 CTF325 228.5181 = 25.9557 105. 946

1988 40 CTF405 280.2197 CTF365254.4738 = . 25.7459 105.089

Total ~

6 -42

267. 1276 $1,090.357

T 1 = $4,081,785


6.2.3.3 (Continued)

629-6Vol II, Book 3

OPTION ill- BASIC WITH TVC


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 20


1979 15 CTF21 15.2373 CTF6 5. 1008 = 10. 1365 $ 30.536

1980 20 CTF41 27. 1114 CTF21 15.2373 11. 8741 35.771

1981 20 CTF61 38. 1093 CTF41 27. 1114 = 10.9979 33.131

1982 20 CTF81 48.5666 CTF61 38. 1093 = 10.4573 31.503

1983 20 CTF 101 58.6369 CTF81 48.5666 = 10.0703 30.337

1984 20 CTF 121 68.4079 CTF 101 58.6369 = 9.7710 29.435

1985 . 20 CTF 141 77.9363 CTF 121 68.4079 = 9. 5284 28.704

1986 20 CTF 161 87.2614 CTF 141 77.9363 = 9.3251 28.092

]987 20 CTF 18J 96.4122 CTF 161 87.2614 = 9. 1508 27.567

1988 20 CTFZOI 105.4107 CTF 181 96.4122 = 8.9985 27. 108

Total ,ill

6 -43

100.3099 $302. 184

T 1 = $3,012,496


6.2.3.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 10

Year Qty 95% 95% - , CTF Cost $M

1979 20 CTF3528.8636 CTF 15 13.0921 = 15.7715 $ 64.376

1980 20 GTF5543.9511 CTF35 28.8636 = 15.0875 61.584

1981 20 CTF7558.6323 CTF55

43.9511 = 14.6812 59.926

1982 20 CTF95

73.0250 CTF 7558.6323 = 14.3927 58.748

1983 20 CTF 115 87.1'947 CTF95

73.0250 = 14. 1697 57.838

1984 20 CTF 135 101. 1830 CTF 115 87.1947 = 13.9883 ' 57.097

1985 20 CTF 155 115.0190 CTF 135101. 1830 = 13.8360 56.476

1986 20 CTF 175 128.7231 CTF 155 115.0190 = 13.7041 55.937

1987 20 CTF 195 142.3121 CTF 175 128. 7231 = B.5890 55.467

l':!IHS 20 CTF215 155.7985 CTF 195 142.3121 = 13.4864 55.049

Total 200 14'2.7064 $582.498

T1

= $4,081,785

6-44

LOCKHEED PRDPULBION COMPANJ

6.2.3.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 10


1979 10 CTF 16 12.0398 CTF6 5. 1008 = 6.9390 $ 20.904

1980 10 CTF26 18.3227 CTF 16 12.0398 = 6.2829 18. 927

1981 10 CTF36 24.2461 CTF26 18.3227 = 5.9234 17.844

1982 10 CTF46 29.9246 CTF36 24.2461 = 5.6785 17. 106

1983 10 CTF56 35.4189 CTF46 29.9246 = 5.4943 16.552

1984 10 CTF66 40. 7667 CTF56 35.4189 '" 5.3478 16.110

1985 10 CTF76 45.9930 CRF66 40. 7667 = 5.2263 15. 744

198'6 10 CTF86 51. 1163 CTF76 45.9930 = 5. 1233 15.434

1987 10 CTF96 56.1501 CTF86 51. 1163 = 5.0338 15.164IOIlR I" r'T'r. 61. I05l CTF96 56. ~5J 1 - .~ ,. - ....... 14.927- - - 106 ~. 7JJU

Total 100

6 -45

T1 =$3, 0 12, ,~t96

56,0043 $168.712


6.2.3.3 (Continued)



WBS

SRM (WBS 3.3.2) Inc. 3 PPQ's

629-6Vol II, Book 3

COST

Total SRM

Less:

STAGE

FacilitiesOperations SupportSupport Equipment SparesFlight Test Support

Recurring Ins;:l 3 PPQ's

3.3.2

3.3.2.43.3.2.73.3.2.53. 3. 2. 6

$2,503.895M

25.700M)84. 238M)51. 242M)

1. 433M)

$2, 341. 282M


Recurring Stage

OPERATION

Support Equipment SparesFlight Test SupportOperations SupportInstall, Assemble and CheckoutMajor Ground Test


TRANSPOR TA TION

Total Recurring Incl 3 PPQ's

FACILITIES

TOTAL PRODUCTION

6 -46

3.3. 13.3.33.3.5

3.3.2.53.3.2.63.3.2.7.13.3. 63.3.7

3.3.2.7.2

$ 378. 979M181. 216M49.870M

$ 610.065M

$ 51. 242M1. 433M3.536M

184. 124M117. 993M

$ 358.928M

$ 80.702M

$3,390.977M

25.700M

$3,416.677M

LOCKHEEO PROPULSION COMPA.... )

629-6Vol II, Book 3

6.2.3.3 (Continued)


T 1 - SRM

1. CTF895' @ 95%

CTF 12' @ 95%

584.2166

( 10. 6239)

CTF883' T 13- 895 573.5927

T 1 =$2,341. 282M :- 573.5927 =

II. 3 PPQ's

$4.081.785

CTF 15' @ 95%

CTF I2 , @ 95%

CTF3 , Tn --. 15

III. 880 Production

CTF895' @ 95%

CTF 15' @ 95%

13.0921

10. 6239)

2.4682 x $4,081,785

584.2166

( 13.0921)

$ 10.075M

CTF880' T 16~ 895 571. 1245 x $4,081,785 = $2,331. 207M

TOTAL SRM PRODUCTION RECURRING INCL 3 PPQ's

T 1 STAGE

$2, 341. 282M

CTF446' @ 90%

CTF6' @ 90%

T 1 = $610.065 : 202.5115 =

207.6123

5. 1008)

202.5115

6-47

$3.012,496


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629-6Vol II, Book 3

OPTION IV - BASIC WITH THRUST TERM


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60


1979 32 CTF47 37.9745 CTF 15 13.0921 24.8824 $ 90.804

1980 48 CTF9573.0250 CTF47 37.9745 35.0505 127.911

1981 64 CTF 159 117.7696 CTF95

73.0250 44.7446 163. 287

1982 82 CTF241 173.1938 CTF 159 117.7696 = 55.4242 202.261

1983 100 CTF341 238.92.72 CTF241 173.1938 = 65.7334 239.882

1984 118 CTF459 314.6826 CTF341 238.9272 = 75.7554 276.456

1985 120 CTF579 390.2446 CTF459

314.6826 = 75.5620 275.750

1986 120 CTF699 464.6489 CTF579 390.2446 74.4043 271. 525

1987 120 CTF819 538. 1099 CTF699 464. 6489 73.4610 268.083

l':'lH~ 7(., r'T'l< 584.2166 C'T'"!:' 538. 1:;;; . 4£". lJ~7 168.258- - - 895 ~~ 819

Total 880 571. 1245 $2,084.217

T 1 = $3,649,321

6-53


6.2.4. 3 (Continued)

629-6Vol II, Book 3

OPTION IV - BASIC wtTH THRUST TERM


CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 60


1979 16 CTF2215.8624 CTF6 5. 1008 = 10.7616 $ 31. 433

1980 24 CTF46 29.9246 CTF22 15.8624 = 14.0622 41.073

1981 32 CTF7847.0255 - CTF46 29.9246 = 17. 1009 49.948

1982 41 CTF 119 67.4425 CTF78 47.0255 = 20.4170 59.634

1983 50 CTF 169 90.9-413 CTF 119 67.4425 = 23.4988 68.635

1984 59 CTF228 117.3471 CTF 169 90.9413 26.4058 77.126

1985 60 CTF288 143. 1472 CTF228 117.3471 = 25.8001 75.357

1986 60 CTF348 168. 1382 CTF288143. 1472 = 24.9910 72.994

1987 60 CTF408 192.4802 CTF348 168. 1382 24.3420 71. 098

1980 38 CTi--446

207.u123 CTF408 192.'toVG = 15. 1321 44. 198

Total 440

6-54

202.5115 $591.496

T 1 = $2, 920,802


6.2.4.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 40


1979 30 CTF45 36.4692 CTF 15 13.0921 = 23.3771 $ 85.311

1980 48 CTF9371. 5966 CTF45 36.4692 = 35. 1274 128.191

1981 64 CTF 157 116.3948 CTF93

71. 5966 = 44. 7982 163.483

1982 80 CTF237 170.5270 CTF 157 116.3948 = 54. 1322 197.546

1983 80 CTF317 223.2995 CTF237 170.5270 = 52.7725 192.584

1984 80 CTF397 275.0862 CTF317 223.2995 - 51.7867 188.986

1985 80 CTF477 326.1019 CTF397

275.0862 = 51. 0157 186. 173

1986 80 CTF557 376.4860 CTF477 326.1019 = 50.3841 183.868

1987 80 CTF657 426.3360 CTF ':;57 376.4860 _. 49.8500 181.919

1988 80 CTF717 475.7240 CTF637 426.3360 49.3880 180.233

Total 7.02

6-55

T 1 = $3,649,321

462.6319 $1,688. Z94


6.2.4.3 (Continued)

629-6VollI, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RATE OF 40

Year .9!r 900/0 900/0 = CTF Cost $M

1979 15 CTF2115.2373 CTF6 5. 1008 = 10. 1365 $ 29.607

1980 24 CTF4529.365,8 CTF21 15.2373 = 14. 1285 41.267

1981 32 CTF7746.5098 CTF45 29.3658 = 17. 1440 50.074

1982 40 CTF 11766.4746 CTF77 46.5098 = 19.9648 58.313

1983 40 CTF 157 85.4.111 CTF 117 66.4746 = 18.9365 55.310

1984 40 CTF 197 103.6223 CTF 157 85.4111 = 18.2112 53. 191

1985 40 CTF237 121. 2772 CTF 197 103.6223 = 17.6549 51.566

1986 40 CTF277138.4836 CTF237 121.2772 17.2064 50.256

1987 40 CTF317 155.3158 CTF277 138.4836 = 16.8322 49. 164

l?~!! ~O CTF357 171.87.78 CTF317155.3158 = 16.1)120 48.228

Total 351

6-56

166. 7270 $486. 976

T1 = $2, 920,802


6.2.4.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 20


36.4692I

1979 30 CTF45 CTF 15 13.0921 = 23.3771 $ 85.311

1980 40 CTF85 65.8598 CTF45 36.4692 = 29.3906 107.256

1981 40 CTF 125 94.2095 CTF85 65.8598 = 28.3497 103.457

1982 40 CTF 165 121. 8863 CTF 125 94.2095 27.6768 101. 002

1983 40 CTF205149.0674 CTF 165 121.8863 = 27.1811 99. 193

1984 40 CTF245175.8574 CTF205 149.0674 26. 7900 97. 765

1985 40 CTF285202.3247 CTF245 175.8574 = 26.4673 96.588

1986 40 CTF325 228.5181 CTF285 202.3247 = 26. 1934 95.588

1987 40 CTF365 254.4738 CTF325 228.5181 = 25.9557 94.721

1988 40 CTF405 280.2197 CTF365 254.4738 25.7459 93.955

Total l2..Q

6-57

267.1276 $974.836


6.2.4.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 20


1979 15 CTF21 15.2373 CTF6 5. 1008 = 10. 1365 $ 29.607

1980 20 CTF41 27.1114 CTF21 15.2373 = 11.8741 34.682

1981 20 CTF61 38. 1093 CTF41 27.1114 = 10.9979 32. 123

1982 20 CTF81 48.5666 CTF61 38. 1093 = 10.4573 30.544

1983 20 CTF 101 58.6369 CTF81 48.5666 = 10.0703 29.413

1984 20 CTF 121 68.4079 CTF 101 58.6369 = 9.7710 28.539

1985 . 20 CTF 141 77.9363 CTF 121 68.4079 = 9.5284 27.831

1986 20 CTF 161 87.2614 CTF 141 77.9363 = 9.3251 27.237

19R7 20 CTF 181 96.412? CTF 161 87.2614 9. 1508 26.728

1988 20 CTF201 105.4107 CTF 181 96.4122 = 8.9985 26.283

Total ,ill

6-58

100.3099 $292.987

·T1 = $2, 920, 802

LOCKHEEO PROPULSION COMPANVI

6.2.4.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 10


1979 20 CTF3528.8636 CTF 15 13.0921 = 15.7715 $ 57.555

1980 20 CTF5543.9511 CTF35 28.8636 = 15.0875 55.059

1981 20 CTF75

58.6323 CTF55

43.9511 = 14.6812 53.576

1982 20 CTF95

73.0250 CTF75

58.6323 = 14.3927 52.524

1983 20 CTF 115 87.1947 CTF95

73.0250 = 14. 1697 51. 710

1984 20 CTF 135 101. 1830 CTF 115 87. 1947 :::: 13.9883 . 51. 048

1985 20 CTF 155 115.0190 CTF 135 101. 1830 13.8360 50.492

1986 20 CTF 175 128.7231 CTF 155 115.0190 = 13.7041 50.011

1987 20 CTF 195 142.3121 CTF 175 128. 7231 = 13.5890 49.591

1988 20 CTF215 155.7985 CTF 195 142.3121 = 13.4864 49.216

Total . 200

6-59

142.7064 $520.782

T 1 = $3,649,321


6.2.4.3 (Continued)

629-6Vol II, Book 3



CUM TOTAL FACTORS

(156-7 Para)

LAUNCH RA TE OF 10


1979 10 CTF 1612.0398 CTF6

5. 1008 = 6.9390 $ 20.267

1980 10 CTF26 18.3227 CTF lb 12.0398 = 6.2829 18. 351

1981 10 CTF3624.2461 CTF26

18.3227 = 5.9234 17.301

1982 10 CTF46 29.9246 CTF3624.2461 = 5.6785 16.586

1983 10 CTF5635.4189 CTF46 29.9246 = 5.4943 16.048

1984 10 CTF6640. 7667 CTF56 35.4189 ;; 5.3478 15.620

1985 10 CTF76

45.9930 CRF6640.7667 = 5.2263 15.265

1986 10 CTF8651. 1163 CTF76 45.9930 = 5. 1233 14. 964

1987 10 CTF96

56.1501 CTF86 51. 1163 = 5. 0338 14. 703

19f18 10 CTF 106 61.!051 r""'T""" 56. ~::: l 4.9::;::;.1 . 14.473~.~ 96

Total 100 56.0043 $163.57.8

T 1 = $2,920,802

6-60


6.2.4.3 (Continued)

OPTION IV - BASIC WITH T. T.


WBS

SRM (WBS 3.3.2) Inel 3 PPQ's

629-6VallI, Book 3

COST

Total SRMLess: Facilities

Support Equipment SparesFlight Test SupportOperation Support

Recurring Inel 3 PPQ's

STAGE


Recurring Stage

OPERATION

Support Equipment SparesFlight Test SupportOperation SupportInstall, Assemble and CheckoutMajor Ground Test


TRANSPOR TATION

Total Recurring Incl 3 PPQ's

FACILITIES

TOTAL PRODUCTION

6-61

3.3.23.3.2.43.3.2.53.3.2.63.3.2.7

3.3. 13.3.33.3.5

3.3.2.53.3.2.63.3.2.7.13.3.63.3.7

3.3.2.7.2

3.3.2.4

$2,255.837M( 25.700M)( 51. 242M)( 1. 433M)( 84. 238M)

$2,093. 224M

$ 384.516M161. 181M45. 799M

$ 591. 496M

$ 51. 242M1. 433M3.536M

173.414M110.769M

$ 340. 394M

$ 80.702M

$3, 105. 816M

25.700M

$3. 131. 516M


6.2.4.3 (Continued)

OPTION IV - BASIC WITH T. T.

629-6Vol II, Book 3

Tl

- SRM

I. CTF895' @ 95% 584.2166

CTF 12' @ 95% ( 10.6239)

CTF883 , Tn _895 573.5927

T 1 :: $2,093. 224M :- 573.5927 :: $3,649,321

II. 3 PPQ's

CTF 15' @ 95% 13.09'21

CTF 12' @ 95% 10.6239)

CTF3 , Tn ---..15 2.4682 x $3,649,321 :: $ 9.007M

III. 880 Production

CTF895' @ 95% 584.2166

CTF IS' @ 95% ( 13.0921)

CTF880' T 16 - 895 571. 1245 x $3,649,321 $2,084.217M

TOTAL SRM PRODUCTION RECURRING INCL 3 PPQ's $2,093. 224M

T l STAGE

CTF 446' @ 90%

CTF6' @ 90%

Tl

:: $591.496 ~ 202. SUS ::

207.6123

5. 1008)

202. SUS

6-62

$2,920.802

LOCKHEEO PROPULSION COMPANVI

629-6Vol II, Book 3

Section 7

PROGRAM COST ESTIMATING RELATIONSHIPS (CERS), TABLE 3

Table 3 is presented in three subsections: 7.1 Total Program costs as afunction of gross weight, 7.2 Production/Operations cost as a function ofproduction rate, and 7.3 DDT&E costs as a function of full-s cale firings(GTH) and Flight-Test Motors (FTMs).

(7.1) Total Program costs = f (Booster Vehicle gross weight)

The costs presented are the cost-per-pound of total grossweight for DDT&E, and production quantities for 10, 20,40, and 60 launches per year. These costs are for thetotal Booster Vehicle (WBS 3.3).

(7.2) Production/Operations cost = f (Production Rate)

These costs represent the total Booster Vehicle (WBS 3.3)recurring costs with 3 PPQs for launch rates of 10, 20,40, and 60 launches per year.

(7.3) DDT&E Costs = f (GTH and FTH)

These costs represent the total Booster Vehicle (WBS 3.3)less Facilities and those costs that are part of Operations(WBS 3.3.2.5, 3.3.2.6. 3.3.2.7, 3.3.6, and 3.3.7).

7-1


7.1 SRM 156-7 TOTAL PROGRAM COST = F(Booster Vehicle Gross Weight)

629-6Vol II, Book 3

Cost Per Pound

SRMs w/Stage 9 12 203~~ 393~:< 705~:< 883~:<

Maximum Launch Rate 10/yr 20/yr 40/yr 60/yr

OPTION I (w/TVC & TT)DDT&E $7.66 $3.60Production $2.66 $2.55 $2.44 $2.40Operations 1. 64 .49 .46 .39 .36

OPTION II (w/o TVC & TT).DDT&E 7.02 3.23Production 2.38 2.27 2. 18 2. 14Operations 1. 56 .46 .44 .37 .34

OPTION III (wi TVC)DDT&E 7.63 3.57Production 2.63 2.52 2.41 2.37Operations 1. 63 .49 .46 • 38 .35

OPTION IV (w/TT)DDT&E 7. 10 3.27Production 2.41 2.30 2.21 2. 17Operations 1. 58 .47 .44 .37 .34

~:< Includes 3 Production Facilities Start -up Motors

7 -2


629-6Vol II, Book 3

7.2 PRODUCTION/OPERATIONS COSTS = F (Production Rate)

(Cost in Millions)

SRMs w/Stage~' 203 393 705 883

Maxmium Launch Rate 10/yr 20/yr 40/yr 60/yr

OPTION I (w/TVC & TT)Production $3. 766 $3.606 $3.451 $3.389Operations . 697 .654 .549 .505

OPTION II (w/o TVC & TT)Production 3.306 3.164 3.026 2.972Operations .646 .607 .510 .470

OPTION III (w / TVC)Production 3.700 3.543 3.391 3.331Operations .688 .645 .541 .498

OPTION IV (w/TT)Production 3.371 3.226 3.086 3.030Operations .657 .616 .518 .477

* Includes 3 Production Facilities Start-up Motors

7 -3


629 -6,Vol II, Book'3

7.3' DDT&E COST = F (Number of GTH or Full-Scale Firings and FTH)

( Cos t in Millions)

Development PFRT TOTAL

GTH Qty Unit Cost Total Qty Unit Cost Total Qty Unit Cost Total

OPTION I 5 $19.611 $98.055 4 $14. 562 $58'.248 9 $17.367 $156.303(w/TVC&TT)

Option II 5 17.404 87.018 4 13. 168 52.672 9 15.521 139. 690(w/o TVC & TT)

OPTION III 5 19. 169 95.846 4 14.460 57.840 9 17.076 153.686(w/TVC)

OPTION IV 5 17.782 88.911 4 13.349 53.396 9 15.812 142.307(wITT)

156-6 SERIES 5 22.560 112.801 4 17.510 70.040 9 20. 316 . 182.841(w/TVC & TT)

FTH

OPTION I (w/TVC & TT) 12 13.025 156.303

OPTION II (w/o TVC & TT) 12 11. 641 139. 690

OPTION III (w/TVC) 12 12.807 153.686

OPTION IV (wITT) 12 11. 859 142.307

156- 6 SERIES (wI TVC & TT) 18 10. 158 182. 841

7-4


629-6

V 01 II, Book 3

Appendix A

MISCELLANEOUS COST BACK-UP DATA

A. 1 INTRODUCTION

The following cost data are supplied to clarify possible questions that mightarise while reading the text of this book.

Section A.2 contains contract evaluation reports in LPC' s behalf regardingprevious LPC 156 -inch LSM contracts and testing conducted at LPC'sPotrero Proving Ground, California.

Section A. 3 is concerned with the information disclosed in the NASA/Headquarters briefing on 23 February 1972.

The cost bands, discussed in Section I, Introduction. are shown on threefinancial charts contained in this Appendix; Cost versus Total Impulse,and the final two charts in this Appendix showing cost effect of total boostervehicle weight. Our potential reductions fall within these bands and are inline with our program projections as discussed in the 23 Feb 72 NASA/Headquarters presentation.

A-I


629-6V 01 II, Book 3

A.2 CONTRACT EVALUATION REPORTS

EVALUATION

Lockheed Propulsion Company's performance on Contract AF 04(695)-364is noted below. This contract effort involved the design fabrication andtest firing of two (2) segmented 156- inch diameter solid propellant rocketmotors with jet tab thrust vector control. Period of performance - 1964.

Department of Defense Terminal ContractorPerfor mance Evaluation Report

(1) Strong Points. Corporate program management during theperiod of performance was good, with close working relationship between the program manager, technical director, manufacturing, and test personnel. The organization employed wasvery effective in keeping management on top of the technicaldifficulties as they were encountered. Excellent workingrelationship existed between the contractor, subcontractors,and the Air Force Systems Program Office. The contractorhas been very prompt in submitting reports on or before duedates. The quality and content of reports have been excellent.The contractor used sound engineering approaches that resultedin cost savings to the program.

(2) Weak Points. No significant weak points were encountered.during the perfor mance of this contract.

A-2


629-6Vol II, Book 3

EVALUATION

Lockheed Propulsion Company's performance on Contract AF 04( 695) -772is noted below. This contract effort involved the design, fabrication andtest firing of two (2) flightweight 156-inch solid propellant rocket motorswith liquid injection thrust vector control. Period of performance 1965-1966.

Department of Defense Terminal ContractorPerformance Evaluation Report

(1) The results obtained by the Lockheed Propulsion Company insatisfying the technical and schedule requirements of this contractare considered excellent in all respects. Two 156 -inch diametermotors of advanced configuration were designed, fabricated, andsuccessfully tested well within the time period specified.

As a direct result of the contractor's efforts, several highlysignificant advancements in the large solid motor state-of-theart were achieved. For example, large submerged nozzleswere tested for the first time, thus permitting a significantreduction in overall motor length. A nozzle-mounted omniaxialthrust vector control system was developed and tested at amotor thrust level twice that of any previous system. The highburn rate propellant (0.8 in./ sec) developed is a particularlysignificant advancement in that the increased burn rate wasachieved with no degradation in performance or increase inunit cost. Significant cost reductions are pos sible with themastic insulation demonstrated.

This was the first firm fixed price contract awarded underProgram 623A for the demonstration test of a large solidpropellant motor. Since the contract was tightly negotiated,cost performance became heavily incentivized and firmfinancial control was exercised by Lockheed management.

A-3

LOCKHEED PROPULBIDN CDMPANV

629-6Vol II, Book 3

:;-1JUI1IIU.... lln.. "·=.CONTRACTOR PERFO'RMANCE

,. 'TRACTC,t,/'f'A""E .,NO l.OCATION..-I '.j,) REPORT CONTROl. '<1'.\1801., '\'l ~:.o .............. ~i:

DD-l&.l.(SAJl'D: O(l('EVALUATION REPORT LOCKHEED PROPULSICi~ CQ?~ANY Z. OA TE (",um • -1-0). -...__.'

REDLArmS, CALIFORNIA 1 APR 165 - 31 1':,,\;, r ~JlSUMMARY DATA3-= CONTRACTOR S. PROJECT OFFiCER •. (;t] ENGINEERING DEV.

FRA1!K V. ~NETTI o OPE'-ATION AL. SYSTEMS DEY

Uu'lG!: ~LID f.!OTOR PROGRA!'1 HAI-JAGER DOTHER

I. CO..... NO. AGENCY. OFFICE A .... D L.OCATION e. 0 PBR'ODlc7. CONTRACT NUMBER

AFSC-SSD-SSBS CC TER",N"L

LOS ANGF.LES AFS. AFUPO LOS ANGELES. CALIF. AF OJ..( 695 )-71'ORIGIN"L CONTR"CT D ..TEISI

• OR,QINALL,.Y aCHED- 10. CURRENTLY aCHED- t 1. ACTUAL eOMPL.ETION 12. TYPE OF0, UL.EO COMPLETION DATE ULEO COMPLETION DATE DATa. CONTRACT

~. :;:; 10 65 I~ ~;~;;:v;965 31 f.!ARCH 1q66 31 MARCH 1q66 It; , Qf,f, o CPFF

13. ORIGINAL. CONTRACT PRICE , •. CURRBNT CONT....CT PRICB (I MillIon.) U· ACTUAL. COST DCPII'(I MIIII_) (, MI/llano)

DFPI

5.500 '5.'510 ".",n gg I'P

,e. PItO.JEC T N AM&: 17. RaT !Ii a: 131!1O.lECT NUhU!£R .e. MAJO R END I TEht o OTHER

LARGE SOLID PROPELLANT LARGE SOLm HOTORMOTOR pnOGRA11 623.\ DEMONSTRATION TEST

.e. IIRIEF DESCRIPTION (Wh., II Ie, It. purpose. '.chnol.,.y In.olY.d):

•• BRIEF .T"TE..ENT 01' CH .. R"CTERISTIC' OF .... JOR END ITE". This effort is a continuation or" priorI!'I. pro.:;rams involving development and demonstration test of 156-inch dia;lleter solidpropellant rocket motors and related advanced technology. This contract required thedeSign) 'fabrication, and static test firing of one (1) segmented 15b-inch motor a11done (1 monolithic 156-inch motor. Both rotors were nighi; confieured and incorpora-ted a nozzle mounted liquid injection thrust vector control 'system, a deep submergednozzle, high burn rate propellant, and reused case components.

b • STATE.OP-THIE.ART ADVANCES REQUIREO OR NOT; COMPARATIVE DIFFICULTV: TEtCHNOL.OGY THAT MUST BE DEVEL.OPEO:

. Advancements in the state-of-the-art were required and successfUlly accomplishedin the fol,lo¥.ing ar~as:

_.---==-

1) Large deep submerged nozzles.. 2) High burn rate propellant

3) Nozzle mounted liquid injection thrust vector control systellis4) ~astic insulation

~, ~fort is .iudged hi~h1v difficult. because the contractor had to accolllPlishil-WO 15 inch motor Ilrlnj3S reqUlrlng state-ol-t.ne-art ac1vancemelll,,~ .1.11 Clo rt:J.Clol.lVe.l.YshoN. t.jmp- unnp-l".<l . YP-n

C'. uro:, ..... c. .... uc.,.."'c. • 'uHNI:tHc.u lC,"IUI~t.l!ENT. DATA OR OTHER SUPPORT.

Availability of motor case co~nents from earlier 156-inch motor firinfspermitted reuse of these items as G • Case components for the segmented me or werereused without modification. Components for the monolithic case required ~~ensive

:nodification. In addition, certain items of an industrial facilities nature wereprovided, the largest of which was a tlolO-hundred (200) ton crane excess to therequirements of a related program. No funding was required for these items of a~acility nature since they were GFP excess to other program requirements.

DOWNGRADED AT 3 YE:~R INTERVAL~,

DECLASSIFIED AFTER 12 YEARS.DOD DIR 5200.10

THIS PAGE IS UNCLASSIFIED(I1.ddlllonal epae. I. requited, continue on ,.".t•• ald•• )

>0. EV ..LU .. TORN .... E (TYPod) ISlC;N .. TURE •. ,I ITITLE IDATE

HAllOLD l'T. ROBBINS / ':"----;. \

COLOi.JEL, U~F V~.·././ ?'C' ~/~" 1<>.- i DrrC:::CTOr., rp..(XmJ':,: (23A I2. J'v'LY lC)tl

DO ,~~~"'..1446 ..FSC I..AFBI 196)

A-4


629-6Vol II, Book 3

A. 3 NASA COST BRIEFING SUMMAR Y

Key Baseline costs are summarized on the chart below. The total programcost for the Booster Vehicle (Work Breakdown Structure Item 3.3) is $ 3.66billion. These values result in a total program cost per launch of $ 8.2million, or a recurring cost per SRM of $ 2. 9 million.

TOTAL BOOSTER VEHICLE COST

$M

TOTAL

189.8

3,474.7

3,664.5

STAGE

48.2

929.0

977. 2

~141. 6

2,545.7

2,687. 3

DEVELOPMENT

PRODUCTION

TOTAL BOOSTER VEHICLE PROGRAM COST

TOTAL VEH ICLE COST/LAUNCH 8. 2AVERAGE-RECURRING SRM COST 2. 9/MOTOR (5. 8IVEHICLE)

BOOSTERVEHICLEWBS 3.3

SRM

WBS 3. 3. 2

IBOOSTER llSYSTEM

I WBS 3.0 JL_ r -

I

A further analysis of LPC's Baseline cost is summarized in the figure below.The costs of various SRMs are plotted versus the total impulse (total energy)in the motor. The various data points on the left half of the chart representactual cost history from major solid rocket motor development and production programs. The triangles represent the development phase, thecircles reflect the first production buy, and the squares denote subsequentproduction buys. The development phase of each of these programs comprised more than 50 rocket motors, with further production learning indicated by the decreasing cost for each production buy.

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629-6Vol II, Book 3

The triangles located in the center of the chart represent the actual co st ofthe large solid motor programs conducted by Lockheed Propulsion Company.These programs, designated "120- 1 and 156 -1 through 156 - 5, were singlemotor programs, with each motor a different configuration. The costs showninclude all nonrecurring expenses such as design, tooling, and test.

The Baseline SRM development and production costs are shown at the extremeright side of the chart. The development cost appears to be reasonable, butconservative, considering that the Baseline program has 25 developP"lentmotors as compared to the one-of-a-kind large solid motor development costspreviously discussed. The Baseline production cost also appears to berealistic, based on experience. Experience (shown on the left half of thechart) also indicates that production motors may well fall into the lower halfof the cost bands. An individual SRM cost of $ L 8 million, or a recurringbooster vehicle launch cost of $ 6 million, appears to be feasible bas ed onexperience.

SOLI D ROCKET MOTORCOST VERSUS TOTAL IMPULSE

t::> DEVELOPMENTo FI RST PRODUCTIONo FOLLOW-ON PRODUCTION

~

10 e----r----~~~-E.CHOHE.()F•••KIHO..; /'"

. 1156-1 .. t:::t SRM DEVELOPMENT./

"/;~./ 1....... """'-70 SRM P~ODUCTIOH

;~/'"1.0 1------+---------IJf--..,,£-----7"=-----h....::.--~-_+_----___l

~ B I~ A...~ ;tl~ '0c::: ww/8 BASELI NE

.0:: 1"-1 <)/VI t-------:r------',MF-~o~"y=--I__+- --+ +- ----j0.1 {'; J

II

0.01 L..--J...._..l....-............L..

6.,.--....I.---l---L....l...J'="7---JL---l.......l--.J....L,,....-...L.--l.--l.....Ll_....l--_L...-J......w

10 10 108 109TOTAL IMPULSE ILBF-SECI

A-6

LOCKHEED PROPULSION CDMPANJ

LPC 156-INCH DIAMETER EXPERIENCE COMPARISON

629-6V 01 II, Book 3

TOTAL PROGRAM COSTS

L-71 L-72 156-5 156-6 HGV TOTAL

DESIGN $1.571 $0.409 $0.737 $0.333 $0 .304 $ 3.354

MANUFACTURING 2.380 1.017 2.349 1.566 1.440 8.752

TEST 0.526 0.192 0.366 0.166 0.157 1.407

TOTAL $4.477 $1.618 $3.452 $2.065 $1.901 m.5l3

TOTAL IMPULSE (X 100) 100 140 160 60 30 490

PROPELLANT WEIGHT 0.423 0.626 0.687 0.273 0.156 2.165

SRM DEVELOPMENT COST COMPARISON

ALLPREVIOUS BASELINE156-INCH SRM

TOTAL COST m.5l3M $141.608M

SRM QUANTITIES 5 25

COST I SRM $2.7M $5.7M

COST/# SEC TOTAL IMPULSE $0.03 $0.02

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629-6Vol II, Book 3

A cost analysis also was performed to determine the peak developmentfunding requirements. Results are shown in the graph below. The estimatefor total Space Shuttle funding indicates a peak level of $1 billion per year.By comparison, the peak funding requirements for the 156-inch solid rocketmotor baseline program are small, reaching a maximum of $ 50 million peryear. These costs reflect the total booster vehicle development program.

ANNUAL FUND INGDEVELOPMENT REQU I REMENTS

(BOOSTER VEHICLE)

1.500..----..----,-----,-----,-----,------,-------,

ESTIMATED NASA BUDGETTOTAL SHUTTLE$5.5 BIlLi ON

TOTAL'$i89M(3.4%)

1979: I

1975 1976 1977 1978$30M I $40M I $50M I $38M I

ISRM BOOSTER

VEH IClE $REQU I REMENTS

~

ClVl;ZZ::::>0LL.:=i....J ....J«::::>a:lZz~ - 0.500

oCY 1973 1974

FYFUND ING $12M I $19M IBOOSTER VEHICLEDEVELOPMENT REQU IREMENTS

An analysis was also conducted to determine the variation of program costsas a function of booster lift-off weight. The range of lift-off weights consideredreflects the variation noted in the inputs received by LPC from the individualPhase B system contractors. The first figure following shows the effect ontotal program costs and cost per launch. It can be noted from the graph thatLPC's baseline design is at the conservative end, and that the effect of therange of contractor inputs for booster lift-off weight can affect the costs byas much as 20 percent. This amount of variation can result in bringing thetotal program cost down to $ 3. 0 billion, and the total cos t per launch to $ 6. 7million.

The second figure shows the same effect on the total recurring cost and thetotal recurring cost per launch. In this case, the total recurring cost, andcost per launch, can also vary as much as 20 percent, down to $ 2.75 billiontotal cost and to $6.75 million per launch.

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'LOCKHEEO PROPULSION COMPANJ

629-6Vol II, Book 3

COST EFFECT OF BOOSTER VEHICLE WEIGHTTOTAL PROGRAM (WBS LEVEL 3.3)- 445 LAUNCHES

5.0

6.0

7.0

9.0

8.28.0

·COSTILAUNCH($M)

CUMULATIVE EFFECT

2. 241---;-~--

2.0 1=--.1----------------'---1

3.0

3.66

TOTAL PROGRAM($ B)

4.0

1. 8 1. 92 2. 0 2. 2 2. 4 2. 6 2. 8

. BOOSTER LIFTOFF WEI GHT ILB X 10-6)

3.0

COSTEFFECT OF BOOSTER VEH ICLE WEI GHTRECU RR ING (W BS LEVEL 3. 3) - 440 LAUNCHES

6.0

8.07.8

7.0

COST/LAUNCH($Ml

9.0

5.0

2. 0 f=~::::-=-==--=-===-=--=-=-=-=--==-=-===--=-==~ 4. 6PHASE B CONTRACTOR INPUTS - .45 KLB .65 KLB• • •• ••

3.0

~ CUMULATIVE EFFECTTOTAL RECURRI NG

($ B)

4.0

3. 45

1. 8 1. 92 2.0 2. 2 2. 4 2. 6 2. 8 3. 0

BOOSTER LIFTOFF WEIGHT ILB X 10-6)

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technical report cost estimating data · 2013-08-31 · lpc document no. 629-6 vol ii, book 3 data...

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