Each system provides hydraulic pressure to

2.1 AUXILIARY POWER UNIT/

position hydraulic actuators for:
HYDRAULICS (APU/HYD)
1. Thrust vector control of the main
CONTENTS engines by gimbaling the three SSMEs
Description ........................................... 2.1-1
2. Actuation of various control valves on
Fuel System .......................................... 2.1-2
the SSMEs
Gas Generator and Turbine................ 2.1-5

Lubricating Oil..................................... 2.1-5

3. Movement of the orbiter aerosurfaces
Electronic Controller ........................... 2.1-6
(elevons, body flap, rudder/speed
Injector Cooling System...................... 2.1-9
brake)
APU Heaters ........................................ 2.1-11

Water Spray Boilers............................. 2.1-12

4. Retraction of the external tank/orbiter
Main Hydraulic Pump........................ 2.1-17
17-inch liquid oxygen and liquid
Hydraulic Reservoir............................ 2.1-20
hydrogen disconnect umbilicals with­
Hydraulic Accumulator...................... 2.1-20
in the orbiter at external tank jettison
Circulation Pump and Heat

Exchanger ...................................... 2.1-20

5. Main/nose landing gear deployment
Hydraulic Heaters ............................... 2.1-22
(system 1)/(system 1 or 2)
Operations ............................................ 2.1-22

6. Main landing gear brakes and anti-skid

7. Nose wheel steering (system 1 with

backup from system 2).

Each hydraulic system is capable of operation

when exposed to forces or conditions caused by
acceleration, deceleration, normal gravity, zero
gravity, hard vacuum, and temperatures
encountered during on-orbit dormant conditions.

Three identical, but independent, improved

auxiliary power units (APUs; also called IAPUs)
provide power for the orbiter hydraulic
systems. The APU is a hydrazine-fueled,
turbine-driven power unit that generates
mechanical shaft power to drive a hydraulic
pump that produces pressure for the orbiter’s
hydraulic system. Each unit weighs
approximately 88 pounds and produces
135 horsepower.

Each APU consists of a fuel tank, a fuel feed

system, a system controller, an exhaust duct,
Auxiliary Power Unit lube oil cooling system, and fuel/lube oil vents
and drains. Redundant electrical heater systems
Description and insulation thermally control the system
above 45° F to prevent fuel from freezing and to
The orbiter has three independent hydraulic maintain required lubricating oil viscosity.
systems. Each consists of a main hydraulic Insulation is used on components containing
pump, hydraulic reservoir, hydraulic bootstrap hydrazine, lube oil, or water to minimize
accumulator, hydraulic filters, control valves, electrical heater power requirements and to
hydraulic/Freon heat exchanger, electrical keep high surface temperatures within safe
circulation pump, and electrical heaters. limits on the turbine and exhaust ducts.
The three APUs and fuel systems are located in about 350 pounds. The fuel tank, which
the aft fuselage. Each APU fuel system supplies incorporates a diaphragm at its center, is
storable liquid hydrazine fuel to its respective serviced with fuel on one side and the
fuel pump, gas generator valve module, and gas pressurant (gaseous nitrogen) on the other. The
generator, which decomposes the fuel through nitrogen is the force acting on the diaphragm
catalytic action. The resultant hot gas drives a (positive expulsion) to expel the fuel from the
single-stage, dual pass turbine. The turbine tank to the fuel distribution lines and maintain a
exhaust flow returns over the exterior of the gas positive fuel supply to the APU throughout its
generator, cooling it, and is then directed operation. Each typical prelaunch fuel tank
overboard through an exhaust duct at the upper load is approximately 325 pounds. The fuel
portion of the aft fuselage near the vertical supply supports the nominal power unit
stabilizer. operating time of 90 minutes in a mission or any
defined abort mode, such as an abort once
The turbine assembly provides mechanical around, when the APUs run continuously for
power through a shaft to drive reduction gears approximately 110 minutes. Under operating
in the gearbox. The gearbox drives a fuel pump, load conditions, an APU consumes approxi­
a hydraulic pump, and a lube oil pump. The mately 3 to 3.5 pounds of fuel per minute
hydraulic pump supplies pressure to the
hydraulic system. The fuel pump increases the
fuel pressure at its outlet to sustain pressurized
fuel to the gas generator valve module and gas
generator. The lube oil system supplies
lubricant to the gearbox reduction gears and
uses the reduction gears as scavenger pumps to
supply lube oil to the inlet of the lube oil pump
to increase the pressure of the lube oil system.

The lube oil of each APU is circulated through a

heat exchanger in a corresponding water spray
boiler. Three water spray boilers (WSBs), one
for each APU, cool the lube oil systems. The
hydraulic fluid of each hydraulic pump driven
by an APU is also circulated through a Auxiliary Power Unit Locations
hydraulic heat exchanger in the corresponding
water spray boiler to cool hydraulic fluid during The fuel tanks are 28-inch-diameter spheres.
hydraulic system operation. The three WSBs Fuel tanks 1 and 2 are located on the port side of
are also located in the aft fuselage of the orbiter. the orbiter’s aft fuselage, and tank 3 is located
on the starboard side. Each fuel tank is serviced
Fuel System through its respective fill and drain service
connections, located on the corresponding side
The APU fuel system (one for each of the three of the aft fuselage. The gaseous nitrogen
APUs) includes the fuel tank and fuel isolation servicing connection for each fuel tank is located
valves, the fuel pump, and fuel control valves. on the same panel as the fuel servicing
The improved APUs use passive heat sinks and connections on the corresponding side of the aft
heat shields to minimize the effects of heat fuselage. The fuel tank is pressurized to 365 psi
soakback. prelaunch.

Fuel Tanks Each fuel tank’s temperature and gaseous

nitrogen pressure are monitored by the APU
The APU fuel tanks are mounted on supports controller and transmitted to the GPC, where
cantilevered from the sides of the internal quantity is calculated and transmitted to the
portion of the aft fuselage. The fuel is storable APU FUEL/H2O QTY meters on panel F8.
liquid anhydrous hydrazine. The hydrazine is When the switch below the meters on panel F8
stored in a fuel tank with a total capacity of is positioned to FUEL, the quantity in APU fuel
tanks 1, 2, and 3 is displayed simultaneously in
percent. The fuel quantity of 100 percent on the
meter is equivalent to 350 pounds. Fuel
pressure (psia) is shown on the FUEL PRESS
meter on panel F8. Fuel quantity in percent is
also displayed on the BFS SM SYS SUMM 2
display (FUEL QTY).

The gaseous nitrogen pressure in each fuel tank

exerts a force on the tank’s diaphragm to expel
the hydrazine fuel under pressure to the fuel
distribution system. Filters are incorporated
into each distribution line to remove any
particles. The fuel distribution line branches
into two parallel paths downstream of the filter.
An isolation valve is installed in each parallel
path, providing redundant paths to permit fuel
flow to the APU or to isolate fuel from the fuel APU Meters and Switches on Panel F8
supply tanks.

GN 2 Injector
Key:
H2 O cooling
- H2 O

- N2 H4 APU
controller
- Oil

Fuel tank
valves (2)
Fuel pump (3 ) GN2
R (rpm)
N2 H4
Gas Gear Hydraulic
Turbine main pump
GN 2 gen box

Fuel Pri. Sec.

Oil pump
tank
Pressure
relief valve Fuel control valves

Fuel test Overboard

line

Fuel pump seal cavity From water To water

drain catch bottle spray boiler spray boiler
049.cvs

Improved APU Fuel System Schematic

 APU FUEL TK VLV Switches and Circuit Breakers on Panel R2

Fuel Tank Isolation Valves from the solenoid if a valve fails open or shorts.
The valve heating profile, when the fuel is
Both isolation valves in each APU fuel stagnant, is gradual and, in the event of a failed
distribution system are electrically powered open valve or short, permits adequate time for
solenoid valves, which are controlled by the corrective action.
corresponding APU FUEL TK VLV 1, 2, 3
switches on panel R2. They are energized open Fuel Pump
when the corresponding switch is positioned to
OPEN; both valves are closed when the switch is Each APU fuel pump is a fixed-displacement,
positioned to CLOSE, or if electrical power is gear-type pump that discharges fuel at
lost. approximately 1,400 psi to 1,500 psi and
operates at approximately 3,918 rpm. A fuel
Each valve has a reverse relief function to filter is located at the fuel pump outlet, and a
relieve pressure on fuel trapped in the fuel relief valve relieves at approximately 1,725 psi
distribution line downstream of the fuel tank back to the pump inlet if the filter becomes
valves when both valves are closed. The valve clogged.
relieves the downstream pressure when the
pressure increases 40 psi to 200 psi above fuel Each fuel pump is driven by the turbine through
tank pressure due to heat soakback following the reduction gearbox. The fuel pump
APU shutdown. reduction gear is located in the lube oil system
gearbox, and a shaft from the reduction gear
The IAPU fuel tank isolation valves are cooled drives the fuel pump. Seals are installed on the
by fuel flow when the valves are open. Each shaft to contain any leakage of fuel or lube oil.
valve has redundant temperature measure- If leakage occurs through the seals, it is directed
ments (two per valve, four per APU). One to a drain line that runs to a 500-cubic
temperature reading for each valve is displayed centimeter catch bottle for each APU. If the
on the BFS SM SYS SUMM 2 display and the catch bottle were overfilled, it would relieve
APU/HYD, DISP 86 display (Ops 201) beside overboard at approximately 28 psia through a
the FU TK VLV AT and BT labels. There are drain port. On ascent or entry, the flight crew
two tank isolation valve circuit breakers per can monitor the catch bottle’s line pressure on
APU (one per valve) located on panel R2. These the BFS SM SYS SUMM 2 display (PMP LK P).
can be pulled to disconnect electrical power
 0001/ /079 SM SYS SUMM 2 5 008/23:29:22 Gas Generator and Turbine
BFS 000/00:00:00
CRYO TK 1 2 3 4 5 MANF1 MANF2
H2 PRESS 208 208 206 206 206 208 207 Each gas generator consists of a bed of Shell 405
O2 PRESS 816 815 814 814 814 815 815
HTR T1 -248 -248 -248 -248 -248 catalyst in a pressure chamber, mounted inside
T2 -248 -248 -248 -248 -248
APU 1 2 3 HYD 1 2 3 the APU exhaust chamber. When the hydrazine
TEMP EGT 942 942 942 PRESS 3064 3064 3064
B/U EGT 942 942 942 ACUM P 3080 3080 3080
fuel comes into contact with the catalyst, it
OIL IN 250
OUT 264
250
264
250
264
RSVR T 116 153 142 undergoes an exothermic reaction, decomposing
GG BED 511H 511H 511H QTY 72 74 71 into a hot gas at approximately 1,700° F. The
INJ 1271 1271 1271
SPEED % 99 102 101 W/B gas expands rapidly and makes two passes
FUEL QTY 59 60 62 H2O QTY 78 73 78
PMP LK P 14 14 14 BYP VLV BYP BYP BYP through a single-stage turbine wheel, passes
OIL OUT P 42 42 41
FU TK VLV over the outside gas generator chamber and
A T 63 65 62 THERM CNTL 1 28
B T 63 65 62 H2O PUMP P 23 63
exits overboard through its own independent
AV BAY
TEMP
1
97
2
97
3
83
FREON FLOW
EVAP OUT T
2384 2384
38 38
exhaust duct, located near the base of the
A4 14 27.439 27.435 26.324 31.873 18.48 vertical stabilizer. The temperature of the hot
051
gas at the exhaust duct is approximately 1,000° F.
APU Information on BFS SM SYS
SUMM 2 Display The shaft power from the spinning turbine is
sent to the hydraulic main pump associated
Fuel Control Valves with the APU via a speed reduction gearbox. It
is also used to drive the APU’s fuel pump and
The APU’s operating speed is controlled by the lubrication oil pump.
primary and secondary fuel control valves,
which are installed in series downstream of the The normal speed of the hydraulic main pump,
fuel pump. These are solenoid-operated pulser­ APU fuel pump, and APU lube oil pump are
type valves. In the normal APU operating 3,918 rpm, 3,918 rpm, and 12,215 rpm
mode, the primary control valve pulses to respectively. The lube oil system is necessary to
maintain the APU’s speed at about 74,000 rpm lubricate the APU gearbox and the fuel pump.
(103%), while the secondary control valve is
powered fully open. If the APU is taken to high The temperatures of the gas generator bed, the
via the APU SPEED SELECT switch on panel gas generator fuel injector, and the turbine
R2, the primary valve is unpowered and goes to exhaust gas are visible on the BFS SM SYS
fully open, while the secondary valve begins SUMM 2 CRT display (GG BED, INJ, TEMP
pulsing, and controls APU speed at about 81,000 EGT). While the APU is running, the gas
rpm (113%). If the secondary valve generator bed temperature transducer goes off-
subsequently fails open, the primary valve will scale high at approximately 500° F. On orbit,
begin pulsing to maintain APU speed at about when the APU is shut down, the gas generator
83,000 rpm (115%) in the backup speed control bed temperature transducer is useful for
mode. If the secondary valve loses power, it monitoring the bed temperature when the bed is
goes to the closed position and shuts down the kept warm by heaters.
APU. As noted above, the primary valve goes
to full open if it loses power, allowing the Lubricating Oil
secondary valve to take over automatically and
control at high speed (113%). The APU lube oil system is a scavenger-type
system with a fixed-displacement pump. Each
The crew can see APU speed on the BFS SM SYS APU turbine through its gearbox drives a lube
SUMM 2 display (APU SPEED %) in percent oil pump at 12,215 rpm. The system is
(100 percent = 72,000 rpm). The speed pressurized with gaseous nitrogen to provide
fluctuates due to the nature of the pulse- adequate suction pressure to start the lube oil
modulated fuel flow system. pump under zero-gravity conditions. Each lube
oil system has its own nitrogen gas storage
For safety reasons, each APU has an automatic vessel, which is pressurized to approximately
shutdown feature that will shut the APU down 140 psia. The pressurization system for each
if the speed falls below 80 percent (57,600 rpm) lube oil system has a valve controlled by its
or rises above 129 percent (92,880 rpm). corresponding APU controller. The gaseous
nitrogen pressurization valve for each power Electronic Controller
unit is energized open by its corresponding
controller when the gearbox pressure is below Each APU has its own digital controller. The
5.2 psi, plus or minus 1.3 psi, to ensure that controller detects malfunctions, controls turbine
gearbox pressure is sufficiently above the speed, gearbox pressurization, and fuel
requirements for proper scavenging and lube pump/gas generator heaters. Each controller is
pump operation. controlled by its corresponding APU CNTLR
PWR switch on panel R2. When the switch is
The pump increases the lube oil pressure to positioned to ON, 28-volt dc power is sent to
approximately 60 psi, directs the lube oil system that controller and APU. The controllers are
through the corresponding water spray boiler redundantly powered via dual internal remote
for cooling, and returns the lube oil to the power controllers. When the switch is posi­
accumulators and gearbox. The two accumula­ tioned to OFF, electrical power is removed from
tors in each lube oil system allow thermal that controller and APU.
expansion of the lube oil, accommodate gas
initially trapped in the external lube circuit, APU Start
maintain lube oil pressure at a minimum of
approximately 15 psia, and act as a zero-gravity, An APU/HYD READY TO START talkback
all-altitude lube reservoir. indicator for each APU is located on panel R2.
The talkback signals gray when that APU
The following information is transmitted to the hydraulic system is ready to start; that is, when
BFS SM SYS SUMM 2 display by the APU the APU gas generator temperature is above
controller via the GPC: lube oil pump outlet 190° F, APU turbine speed is less than 80
pressure (OIL OUT P) at approximately 45 psia, percent, WSB controller is ready, corresponding
outlet temperature at approximately 270° F and APU fuel tank isolation valves are open, and
return temperature from the water spray boiler corresponding hydraulic main pump is
(OIL IN, OUT) at approximately 250° F for each depressurized. When the APU is started, and
APU. The lube oil temperature of each APU is its turbine speed is greater than 80 percent of
also monitored on the APU OIL TEMP meter on normal speed, the corresponding indicator
panel F8. The APU is selected by the switch shows barberpole.
below the meter.
NOTE
A barberpole APU/HYD READY TO
HYDRAULIC APU
1
PRESSURE
2 3 1
QUANTITY
2 3
FUEL / H2O QTY
1 2 3
FUEL
EGT PRESS
OIL
TEMP START talkback will not inhibit a start.

PSIA PSIA % % % % ¡F PSIA ¡F

5
APU OPERATE 1, 2, 3 switches are located on
4 4 100 100 100 100 14

3 3 80 80 80 80
12 4 panel R2. When the switches are positioned to
10

2 2
60 60 60 60
8
3 START/RUN, the corresponding APU controller
1 1
40 40 40 40 6
4
2
activates the start of that unit and removes
0 0
20 20 20 20 2 1
electrical power automatically from the unit’s
0 0 0 0 0 0
X 1000 X 1000 X 100 X 100 gas generator and fuel pump heaters.

FLIGHT CNTLR PWR RDR ALTM FIRE

HOLE
FUEL 1 To start the APU, fuel expelled from the
ON 1

2 hydrazine tank flows through the open tank

H2 O 3
valves and filter to the gas generator valve
(LL)

OFF 2
module, which contains a primary and
secondary fuel control valve in series. The
primary pulse control valve is normally open,
and the secondary pulse control valve is
APU OIL TEMP Meter and Switch on Panel F8 energized open. Fuel flowing through the
(NOTE: EGT indicator on meter is driven by pump bypass valve is directed to the gas
“TEMP EGT” transducer seen on BFS SYS generator, because the fuel pump is not being
SUMM 2 CRT display.) driven at that moment by the APU turbine.
The fuel in the gas generator decomposes The secondary fuel control valve normally stays
through catalytic reaction, creates hot gas, and fully open during the operation of the primary.
directs the hot gas to the single-stage turbine, If the primary valve loses power, it goes to the
which begins to rotate. The turbine’s fully open position, and the secondary valve
mechanical shaft drives the reduction gears, begins pulsing and controlling APU speed. If
rotating the fuel pump, lube oil pump, and the secondary valve loses power at any time, the
hydraulic pump. The fuel pump increases the APU is shut down. If the auxiliary power unit is
fuel pressure at its outlet and sustains taken to a high speed (by the APU SPEED
pressurized fuel to the gas generator valve SELECT switch on panel R2), the primary valve
module and gas generator. is unpowered and goes to the fully open
position while the secondary valve controls the
The startup logic delays the APU underspeed unit’s speed.
logic check for 10.5 seconds after the start
command is issued. This allows the APU to Each APU controller controls the speed of each
reach normal operating speed before the unit upon the activation of the APU SPEED
shutdown logic begins checking for a speed SELECT switch for each APU on panel R2. The
lower than 80 percent. The auto shutdown NORM position controls the speed at 74,160
capability of the controller can be disabled by rpm, 103 percent, plus or minus 8 percent. The
taking the APU AUTO SHUT DOWN switch on HIGH position controls the speed at 81,360 rpm,
panel R2 to INHIBIT. 113 percent, plus or minus 8 percent, with a
second backup of 82,800 rpm, 115 percent, plus
The startup logic does not delay the APU or minus 8 percent.
overspeed logic. If an overspeed is detected at
any time by the controller, the F7 and MASTER
APU Auto Shutdown
ALARM will annunciate. If the AUTO SHUT
DOWN on panel R2 is ENABLED, the controller The APU AUTO SHUT DOWN switches on
will automatically close the tank isolation valves panel R2 enable the automatic shutdown feature
and close the secondary control valve. in the associated APU controllers. When the
switch is positioned to ENABLE, each controller
CAUTION monitors its corresponding APU speed. If that
APU speed falls below 57,600 rpm (80 percent)
After an APU auto shutdown, the APU or rises above 92,880 rpm (129 percent), the
FUEL TK VLV switch must be taken to controller automatically shuts down that unit.
CLOSE prior to inhibiting auto shutdown Each shutdown command closes that unit’s
logic. Failure to do so can allow the fuel secondary fuel valve and the tank isolation
tank isolation valves to reopen and flow valves.
fuel to an APU gas generator bed that is
above the temperature limits for safe Ready
to Start
restart. Water Spray Boiler
Controller A or B
enabled Hydraulic main pump
pressure ­ normal
Steam vent temperature
above 130° F
APU Speed Control GN2 shutoff valve open Water APU fuel tank
boiler valves ­ open Panel R2
Hydraulic bypass valve controller
When the APU turbine speed exceeds the in proper position ready
control target (103 percent for NORMAL and APU Controller
113 percent for HIGH) the appropriate control Gas generator temperature

above 190° F

valve closes. The fuel is then diverted through a Turbine speed below 80%
APU controller
ready signal
bypass line back to the fuel pump inlet. When 053.cvs
the turbine speed drops below the control
target, the appropriate valve opens directing APU Ready-for-Start Talkback Indicator Logic
fuel to the gas generator and closing off the
bypass line. The primary fuel valve pulses to When an APU AUTO SHUT DOWN switch is
maintain APU speed. The frequency and positioned to INHIBIT, the automatic shutdown
duration of the primary fuel control valve pulses sequence for its APU controller is inhibited. If
are functions of the hydraulic load on the unit. the turbine speed falls below 80 percent or rises
above 129 percent APU UNDERSPEED or APU
CAUTION
OVERSPEED caution and warning lights on
panel F7 will be illuminated, and a tone will be An APU should not be restarted after an
generated, even though the APU AUTO SHUT overspeed shutdown. Uncontained over-
DOWN switch is in INHIBIT. speed and turbine wheel breakup could
occur if restart is attempted.

APU/HYD READY TO START Talkbacks, APU OPERATE Switches,

APU SPEED SELECT Switches, APU CNTLR PWR Switches, and
APU AUTO SHUT DOWN Switches on Panel R2
 28VA

CH1
A

CH2
Underspeed
Driver
CH4

CH3

28VB

Closes fuel
tank valves
28VA

CH1
B
C&W
Electronics
CH2 Yellow
O/S EXT 1A APU 2
Overspeed APU
O/S EXT 2A APU 3 +
Dri ver unders peed
O/S EXT 3C CH4
O/S EXT 1B PNL F7a2
C O/S EXT 2C O/S EXT 3B 12 Z5
L < 80%
CH3
O/S EXT 2B Z
E 6
5.2-2
O/S EXT 3A
28VB Yellow
APU 2
+ APU
APU 3 overspeed
PNL F7a2
28VA < 129%

CH1
Z
E 6
5.2-2
D Closes fuel
tank valves
CH2
S/O
Valve
Driver CH4

28VA CH3
CH1
E
28VB
CH2
PC
Valve
Dri ver CH4

CH3

28VB

Primary Secondary
valve valve 055.cvs

APU Overspeed/Underspeed Detection

Injector Cooling System hot APU must be restarted after it has been
recently shut down. The water cooling ensures
The gas generator injector water cooling system that the hydrazine will not detonate in the fuel
is used only when the normal cool-down period line leading into the injector due to heat
of approximately 180 minutes is not available. soakback from the gas generator. The injector is
The system sprays water to reduce the cooled by circulating water through it. The
temperature of the gas generator injector branch water from the gas generator injector is
passages to less than 400° F in the event that a exhausted into the aft fuselage.
 APU OPERATE
1 2 3
START/RUN
crew is safe to attempt a restart if the GG INJ
temperature is decreasing and at least 3.5
minutes of continuous injector cooling has been
INJECTOR COOL
completed. A Class 3 alarm with message "APU
Panel R2 1 (2) Cooldown" will annunciate 225 seconds
APU 1 after APU injector cooling is initiated
CONTROLLER
Vlv open cmd
APU1 CAUTION
Care must be taken not to delay in the OFF
GN2 H2O APU2 position when taking the APU OPERATE
switch to START/RUN. If cooldown is
terminated more than 2 to 3 seconds prior
APU3 to starting the APU, the injector branch
Control temperatures may increase above start
Valves 056.cvs limits, and detonation may occur without
another cooldown cycle.
APU Injector Cooling

A single water tank located in the aft fuselage of

the orbiter serves all three APUs. The water The water tank supply is sufficient for about six
tank is 9.4 inches in diameter and loaded with 9 hot starts, two per APU. The unit’s injector
pounds (plus or minus 0.5 pound) of water. The temperature can be monitored on the BFS SM
water tank is pressurized with gaseous nitrogen SYS SUMM 2 display (INJ).
at a nominal pressure of 120 psi. The pressure
acts on a diaphragm to expel the water through Fuel Pump and Gas Generator
three 0.25-inch-diameter lines to three control Valve Module Cooling
valves. When the APU OPERATE switch on
The fuel pump and gas generator valve module
panel R2 for APU 1, 2, or 3 is positioned to
are cooled by passive cooling. The improved
INJECTOR COOL, the water valve of that unit
APUs have passive heat sinks and heat shields
opens and directs the water into the gas
to absorb conductive and radiant heat. This
generator injector to cool it.
prevents excessive heat soakback in the gas
If the injector branch (internal) temperature of generator valve and fuel pump assemblies.
an APU is above 400° F from heat soakback, or There are no water tanks or associated
if the catalytic bed heater temperature is above plumbing for this module with the APUs. The
430° F, the flight crew must cool the injector for crew has no requirement to do anything to
3.5 minutes before starting the APU. provide cooling. This passive cooling system, in
Operational data from hot APUs shows that the conjunction with active injector cooling, is used
GG INJ temperature does not accurately reflect to allow for contingency restarts in the event a
the drop in injector branch temperatures. The deorbit becomes necessary within approxi­
mately 180 minutes of APU shutdown.
 and the water lines from the fuel pump spray
CAUTION
manifold to the gas generator valve module.
An APU may not be restarted if the The heaters are divided into redundant A and B
temperature of the fuel pump is above 210° systems for each APU. The A AUTO switch
F or the temperature of the gas generator controls the A heater, and the A thermostat
valve module is above 200° F, because automatically controls the corresponding APU
hydrazine detonation may occur. fuel pump heater, maintaining fuel pump and
gas generator valve module temperatures at
about 100° F. The gas generator bed heater is
APU Heaters maintained between 360° and 425° F by a
compactor in the APU controller, which receives
The APU HEATER TANK/FUEL LINE/H2O its signal from the bed temperature transducer.
SYS 1A, lB, 2A, 2B, 3A, 3B switches on panel The gas generator temperature range ensures
A12 operate the thermostatically controlled efficient APU startup through efficient catalytic
heaters located on the corresponding APU fuel reaction. The B AUTO switch position provides
system and water system. The fuel tank, fuel the same capability for the B heater system. The
line, and water line heaters for each APU are gas generator and fuel pump heaters are
divided into redundant A and B systems for automatically deactivated by the corresponding
each unit. For example, for APU 1, 1A and 1B, controller at APU start. The OFF position of
the TANK/FUEL LINE/H2O SYS 1A switch each switch removes power from the respective
controls the A heaters, and the thermostats heater circuits. These heater switches also
provide automatic control. Only one set of provide redundant power to the gas generator
heaters is used at a time. The 1B switch controls and gearbox pressure signal conditioners for use
the 1B heaters, and the thermostats provide while the APU controller is off.
automatic control. The APU fuel tank and line
heater thermostats maintain the temperatures The lube oil system lines on each APU also have
between a nominal 55° F and 65° F. The water a heater system. These heaters are controlled by
system heater thermostats maintain the the APU HEATER LUBE OIL LINE 1, 2, 3
temperatures between 55° F and 65° F. The OFF switches on panel A12. The lube oil line heaters
position of each switch removes power from the for each APU are also divided into an A and B
respective heater circuits. system: e.g., for 1, A AUTO and B AUTO. The
A AUTO switch controls the A heater, and the
The APU HEATER GAS GEN/FUEL PUMP 1, thermostat automatically controls the
2, 3 switches on panel A12 operate thermostati­ corresponding lube oil system heater,
cally controlled heaters located on the maintaining the lube oil line in the temperature
corresponding APU, fuel pump, and gas range of 55° F to 65° F. The B AUTO switch
generator valve module, and provide power to position provides the same capability to the B
the gas generator bed heater. The thermostats heater system. The OFF position of each switch
control a series of heaters on the gas generator removes power from the respective heater
valve module, fuel pump, and all the fuel lines circuits.
 APU HEATER Controls on Panel A12

Water Spray Boilers Each WSB stores water in a bellows-type storage

tank pressurized by gaseous nitrogen providing
The water spray boiler (WSB) system consists of positive water expulsion to feed the boiler.
three identical independent water spray boilers, Hydraulic fluid passes through the boiler three
one for each APU and hydraulic system. The times. APU lube oil passes through the boiler
boilers are located in the aft fuselage of the twice. The hydraulic fluid tubes are sprayed
orbiter. Each WSB cools the corresponding APU with water from three water spray bars, and
lube oil system and hydraulic system by two water spray bars spray the APU lube oil.
spraying water onto their lines; as the water Separate water feed valves allow independent
boils off, the lube oil and hydraulic fluid are control of the hydraulic fluid spray bars and
cooled. The steam that boils off in each water APU lube oil spray bars. Redundant electrical
spray boiler exits through its own exhaust duct, controllers provide completely automatic
located on the starboard side of the vertical operation.
stabilizer.
The boiler system maintains APU lube oil
Each WSB is 45 by 31 inches long by 19 inches temperature at approximately 250° F and the
wide, and including controller and vent nozzle, hydraulic fluid in the range of 210° to 220° F.
weighs 181 pounds. They are mounted in the
orbiter aft fuselage between Xo 1340 and 1400, at The crew can see the WSB water quantity (H2O
Zo 488 minus 15, and at Yo plus 15. Insulation QTY), nitrogen tank pressure (N2 P), nitrogen
blankets cover each boiler. The boiler's water regulator pressure (REG P), and nitrogen tank
capacity is 142 pounds. temperature (N2 T) on the right side of the SM
APU/HYD (DISP 86) display on orbit.
 Water Spray Boiler Unit

2011/ /086 APU/HYD 4 000/02:36:12

000/00:00:00
APU 1 2 3 HYD 1 2 3
B/U EGT 313 313 310 B/U P 64↓ 64↓ 64↓
EGT 313 313 310 RSVR T 58 64 66
SPEED % 0L 0L 0L P 65 66 66
FUEL QTY 76 77 77 QTY 74 75 73
TK P 209 210 212 ACCUM P 2616 2624 2624
OUT P 209 210 212
TK VLV A CL CL CL
A T 61 62 62
B CL CL CL
B T 61 62 62 W/B 1 2 3
OIL T 64 63 62
OUT T 63 62 60 CNTLR A A A
OUT P 25 25 25 H2O QTY 100 100 100
GBX P 25 25 25 N2 P 2499 2506 2492
N2 P 141 142 140 T 57 58 55
BRG T 82 81 84 REG P 28 28 28
GG BED T 426 423 421 BYP VLV BYP BYP BYP
PUMP/VLV VENT T +122L +122L +122L
PMP T 94 92 90 TANK T + 57 + 58 + 55
VLV T 114 111 107 BLR T + 60 + 58 + 61
059

SM APU/HYD Display (DISP 86)

 Gaseous nitrogen Gaseous nitrogen
regulator and shutoff valve Steam
relief val ve Gaseous
nitrogen duct
Gaseous Water fill fill outlet
nitrogen
vent
Steam vent
Gaseous dump nozzle
P
nitrogen P Vent heaters
Steam vent
T
Tank Gaseous Hydraulic fluid
142 Pounds heaters nitrogen bypasses boiler
water tank when it decreases
Hydrau lic
(B) to 190°F. Hydraulic
Water T bypass / fl uid directed through
tank Secondary relief val ve water boiler at 210°F
T
controller Vent
Hydraulic fluid
208°F set-point
Water supply temperature
valve (hydrauli c) turns on
T T hydraulic-fluid
water feed valve
(A) Boiler
heaters
Pri mary Lube oil
control ler T T
250°F set-point
temperature turns
Water supply on APU lube oil
valve (lube) water feed valve

Lube oil Water fill/

drain drain
060.cvs

Water Spray Boiler (One of Three)

Nitrogen Supply System A single-stage regulator is installed between the

nitrogen pressure shutoff valve and the water
The gaseous nitrogen pressure for each WSB is
storage tank. The gaseous nitrogen regulator for
contained in a corresponding 6-inch spherical
each water spray boiler regulates the high-
pressure vessel. The pressure vessel contains
pressure nitrogen between 24.5 and 26 psig as it
0.77 pound of nitrogen at a nominal pressure of
flows to the water storage tank.
2,400 psi at 70° F. The gaseous nitrogen storage
system of each WSB is directed to its corre­ A relief valve is incorporated inside each
sponding water storage tank. Each storage nitrogen regulator to prevent the water storage
vessel contains sufficient nitrogen gas to expel tank pressure from exceeding 33 psig. The
all the water from the tank and allow for relief gaseous nitrogen relief valve opens between 30
valve venting during ascent. to 33 psig.
The nitrogen shutoff valve between the pressure
valve and water storage tank of each boiler Water Supply System
permits the pressure to reach the nitrogen
The water supply for each boiler is stored in a
regulator and water tank or isolates the nitrogen
positive-displacement aluminum tank contain­
supply from the water tank. Each nitrogen
ing a welded metal bellows separating the
valve is controlled by its respective BOILER N2
stored water inside the bellows from the
SUPPLY 1, 2, or 3 switch on panel R2. The
nitrogen expulsion gas.
nitrogen shutoff valve, which is latched open or
closed, consists of two independent solenoid
coils that permit valve control from either the
primary or secondary controller.
 BOILER Switches on Panel R2

Redundant pressure and temperature sensors two parallel lines: one line goes to the hydraulic
located downstream from the gaseous nitrogen fluid flow section and one to the lube oil section
pressure vessel and on the water tank for each of the WSB. The H2O spray valves in each
boiler transmit the pressures and temperatures feedline are controlled independently by the
through each controller to the systems manage- boiler controller.
ment general-purpose computer. The computer
computes the water tank quantity from the Temperature Control
pressure, volume, and temperature, and
transmits the water tank quantity to panel F8 for The two boiler controllers are operated by the
each boiler. The switch below the meter on respective BOILER CNTLR/HTR 1, 2, and 3
panel F8 is positioned to H2O to allow the water switches on panel R2. When the applicable
quantity of each boiler to be displayed on the switch is positioned to A, the A controller for
APU FUEL/H2O QTY 1, 2, or 3 meter. Water that boiler is powered; if it is positioned to B, the
quantity is available when either the A or B B controller is powered. The OFF position
controller is powered. removes electrical power from both controllers.

Downstream of the water storage tank, the

feedwater lines to each water boiler split into
 APU FUEL/H2O QTY Meter and Switch on Panel F8

The BOILER PWR 1, 2, and 3 switches on panel boundary layer and promote enhanced turbu-
R2 enable (provide the automatic control lent heat transfer. Although the second pass is
functions) the specific controller A or B selected primarily a low-pressure drop return section,
for that boiler by the BOILER CNTLR/HTR 1, 2, approximately 15 percent of the unit's lube oil
and 3 switches on panel R2. When the applica- heat transfer occurs there. Three connected
ble controller A or B is enabled for that boiler, a spray bars feed the hydraulic fluid section,
ready signal is transmitted to the corresponding while two spray bars feed the power unit's lube
APU/HYD READY TO START indicator on oil section in each boiler.
panel R2 if the following additional conditions
are met: gaseous nitrogen shutoff valve is open, When the orbiter is in the vertical position on
steam vent nozzle temperature is greater than the launch pad, each boiler is loaded with up to
130° F, and hydraulic fluid bypass valve is in the 3.5 pounds of water, which is referred to as
correct position with regard to the hydraulic "pool mode" operation. When each APU/
fluid temperature. hydraulic system and WSB are in operation 5
minutes before lift-off, the APU lube oil tube
The core of each WSB is a stainless steel bundle is immersed in the boiler water
crimped-tube bundle. The hydraulic fluid sec- precharge. Liquid level sensors in each water
tion is divided into three 17-inch-long passes of boiler prevent the water feed valves from
smooth tubes (first pass-234 tubes, second pass- pulsing to avoid water spillage or loss. As the
224 tubes, and third pass-214 tubes). The lube vehicle ascends during launch, the lube oil
oil section of the APU comprises two passes system of the APU heats up, eventually the
with 103 crimped tubes in its first pass and 81 boiler water precharge boils off, and the boiler
smooth tubes in the second pass. The tubes are goes into the spray mode about 8 minutes after
0.0125 of an inch in diameter with a wall launch. The hydraulic fluid usually does not
thickness of 0.010 of an inch. Crimps located heat up enough during ascent to require spray
every 0.24 of an inch break up the internal cooling.
When the APU/hydraulic combination is at a differential pressure of 50 psi across the
started for atmospheric entry, the hydraulic boiler. A temperature controller bypass valve
fluid and power unit lube oil flow commences, allows the hydraulic fluid to bypass the boiler
fluid temperatures rise, and spraying is initiated when the fluid temperature decreases to 190° F.
as required. During the lower part of entry, At 210° F, the controller commands the bypass
when the boiler temperature reaches 188° F, the valve to direct the fluid through the boiler.
water spray boiler returns to the pool mode. When the hydraulic fluid cools to 190° F, the
The spray bars begin discharging excess water controller again commands the valve to route
to fill the boiler. When the water reaches the the fluid around the boiler. Bypass valve (BYP
liquid level sensors, the spray is turned off so VLV) status is available on the following
that the boiler is not overfilled. During entry, displays: SM SYS SUMM 2 (PASS AND BFS)
because the orbiter's orientation is different and PASS DISP 86 APU/HYD.
from that of launch, the boiler can hold up to 14
pounds of water. Heaters
The enabled controller of the operating WSB Each water boiler, water tank, and steam vent is
monitors the hydraulic fluid and lube oil outlet equipped with electrical heaters to prevent
temperature from the APU. The hydraulic fluid freeze-up in orbit. The water tank and boiler
outlet temperature controls the hydraulic fluid electrical heaters are activated by the corre­
H2O spray control valve, and the lube oil outlet sponding BOILER CNTLR/HTR 1, 2, and 3
temperature controls the lube oil water spray switches on panel R2. The A or B position of
control valve. Signals are based on a compari­ each switch selects the A or B heater system and
son of the hydraulic system fluid temperature to is automatically controlled by the corresponding
its 208° F set point and of the lube oil of the A or B controller. The steam vent heaters are
power unit to its 250° F set point. When the also activated by the BOILER CNTLR/HTR 1, 2
respective water feed valve opens, instantane­ and 3 switches but only if the BOILER PWR 1, 2
ous flows of 10 pounds per minute maximum or 3 switch on panel R2 is ON. The water tank
through the hydraulic section and 5 pounds per and boiler heaters are cycled on at 50° F and off
minute maximum through the lube oil section at 55° F. The steam vent heaters are not oper­
enter the water boiler through the correspond­ ated continuously in orbit; they are activated
ing spray bars to begin evaporative cooling of approximately two hours before APU startup.
the hydraulic fluid and APU lube oil. The steam The steam vent heaters are cycled on at 150° F
is vented out through the overboard steam vent. and cycled off at 175° F.

The separate water feed valves modulate the Main Hydraulic Pump
water flow to each section of the tube bundle
core in each WSB independently in 200-millisec- The main hydraulic pump for each hydraulic
ond pulses that vary from one pulse every 10 system is a variable displacement type. Each
seconds to one pulse every 0.25 of a second. operates at approximately 3,900 rpm when
driven by the corresponding APU.
Because of the unique hydraulic system fluid
flows, control valves are located in the hydraulic Each main hydraulic pump has an electrically
system fluid line section of each WSB. operated depressurization valve. The depres­
Normally, hydraulic system fluid flows at up to surization valve for each pump is controlled by
21 gallons per minute; however, the hydraulic its corresponding HYD MAIN PUMP PRESS 1,
system experiences 1- to 2-second flow spikes at 2, or 3 switch on panel R2. When the switch is
up to 63 gallons per minute. If these spikes positioned to LOW, the depressurization valve
were to pass through the boiler, pressure drop is energized to reduce the main hydraulic pump
would increase ninefold and the boiler would discharge pressure from its nominal range of
limit the flow of the hydraulic system. To 2,900 to 3,100 psi output to a nominal range of
prevent this, a relief function is provided by a 500 to 1,000 psi to reduce the APU torque
spring- loaded poppet valve that opens when requirements during the start of the APU. "APU
the hydraulic fluid pressure drop exceeds 48 psi Press Low" is one of the inputs required to get a
and is capable of flowing 43 gallons per minute gray READY TO START talkback.
 2 or PASS DISP 86 APU/HYD displays. A high-
NOTE
pressure relief valve in the filter module for
An APU cannot be successfully started each hydraulic system also relieves the hydrau-
with HYD MAIN PUMP PRESS posi- lic pump supply line pressure into the return
tioned to NORM. line in the event the supply line pressure
exceeds 3,850 psid.
After an APU has been started, the
corresponding HYD MAIN PUMP PRESS A separate pressure sensor (sensor A) in the
switch is positioned from LOW to NORM. This filter module for each hydraulic system
de-energizes the respective depressurization monitors the hydraulic system source pressure
valve, allowing that hydraulic pump to increase and displays the pressure on the HYDRAULIC
its outlet pressure from 500 to 1,000 psi to 2,900 PRESSURE 1, 2, and 3 meters on panel F8. This
to 3,100 psi. Each hydraulic pump is a variable hydraulic pressure sensor also provides an
displacement type that provides 0 to 63 gallons input to the yellow HYD PRESS caution and
per minute at 3,000 psi nominal with the APU at warning light on panel F7 if the hydraulic
normal speed and 69.6 gallons per minute at pressure of system 1, 2, or 3 is below 2,400 psi.
3,000 psi nominal with the APU at high speed.

Main pump outlet pressure (HYD PRESS) can

be seen by the crew on the BFS SM SYS SUMM

HYD MAIN PUMP PRESS 1, 2, 3 Switches on Panel R2

 Reservoir

T
Thermal
control WSB
valve T cntlr
Freon/hyd
heat exch
Water
GN2 spray
boiler
Accumulator
M
Hydraulic Circulation Hyd bypass
APU
main pump pump valve

350 0p 2500 PSIG

psig Cl
Unloader P
3000
valve
psig Open. P>2563 psig Priority
P
Close. P<2050 psig valve
(relieves
at 3000
Open P 2600> psig
psid)
Reseat P 2600< psig

Pressure
Return
NOTE: The system is shown in normal operation Pressure
- APU on Return
- Circ pump off 064.cvs

Hydraulic System (Control Section)

HYDRAULIC PRESSURE and QUANTITY Meters on Panel F8

(Driven by different sensor than CRT)
Hydraulic Reservoir Circulation Pump and Heat Exchanger

Hydraulic reservoir pressure is maintained The circulation pump is actually two fixed-
using an accumulator bootstrap mechanism. displacement gear-type pumps in tandem,
The bootstrap uses a variable area piston driven by a single motor. One is a high pres­
assembly to convert high pressure to the sure, low-volume pump (2,500 psig), which is
accumulator to lower pressure in the reservoir used to maintain accumulator pressure while
(roughly 40:1). This reservoir pressure the hydraulic system is inactive in orbit. The
maintains adequate hydraulic inlet pressure at other is a low pressure, high-volume pump (350
both the main pump and circulation pump to psig), which is used to circulate hydraulic fluid
prevent cavitation during startup and operation. through the orbiter hydraulic lines while the
When the main hydraulic pump is in operation, hydraulic system is inactive in orbit in order to
the high-pressure side of the piston and the warm up cold spots. The hydraulic fluid is
bootstrap accumulator are pressurized to 3,000 circulated through a Freon/hydraulic fluid heat
psig from the main pump discharge line. When exchanger to pick up heat from the orbiter Freon
the main hydraulic pump is shut down, the coolant loops. A temperature-controlled bypass
priority valve closes, and the bootstrap valve directs the hydraulic fluid through the
accumulator maintains a pressure of heat exchanger if the temperature at the heat
approximately 2,500 psi. The 2,500 psi on the exchanger inlet is less than 105° F. The bypass
high side results in a main pump inlet (low side) valve bypasses the fluid around the heat
pressure of approximately 62 psia. The exchanger if the temperature is greater than 115° F.
minimum inlet pressure to assure a reliable
main pump start is 20 psia (which corresponds An unloader valve at the circulation pump
to a high-pressure side of 800 psi). This pre­ outlet directs the high pressure output from the
vents the main pump from cavitating (not circulation pump into the accumulator until the
drawing hydraulic fluid), which could damage accumulator pressure is greater than 2,563 psia,
the pump. then redirects the high pressure output to
combine with the low pressure output to the
The quantity in each reservoir is 8 gallons. The hydraulic lines.
hydraulic fluid specification is MIL-H-83282,
0001/ /079 SM SYS SUMM 2 5 008/23:29:22

which is a synthetic hydrocarbon (to reduce fire BFS 000/00:00:00

CRYO TK 1 2 3 4 5 MANF1 MANF2

hazards). The reservoir provides for volumetric H2 PRESS 208 208 206 206 206 208 207

expansion and contraction. The quantity of each O2 PRESS

HTR T1
816 815 814
-248 -248 -248
814 814
-248 -248

815 815

reservoir is monitored in percent on the T2 -248 -248 -248 -248 -248

APU 1 2 3
HYD 1 2 3

HYDRAULIC QUANTITY meters on panel F8. TEMP EGT 942 942 942
PRESS 3064 3064 3064

B/U EGT 942 942 942

ACUM P 3080 3080 3080

A pressure relief valve in each reservoir protects OIL IN 250 250 250
RSVR T 116 153 142

OUT 264 264 264

the reservoir from overpressurization and GG BED 511H 511H 511H

QTY 72 74 71

relieves at 120 psid. INJ

SPEED %
1271 1271 1271

99 102 101
W/B

FUEL QTY 59 60 62
H2O QTY 78 73 78

PMP LK P 14 14 14
BYP VLV BYP BYP BYP

OIL OUT P 42 42
41

Hydraulic Accumulator FU TK VLV

A T 63 65
62
THERM CNTL 1 28

B T 63 65 62
H2O PUMP P 23 63

The accumulator is a piston type precharged AV BAY

TEMP
1
97
2
97
3

83

FREON FLOW
EVAP OUT T
2384 2384

38 38

with gaseous nitrogen at 1,650 to 1,750 psi. The A4 14 27.439 27.435

26.324 31.873 18.48

051

gaseous nitrogen capacity of each accumulator

is 96 cubic inches, and the hydraulic volume is BFS SM SUMM 2 Display
51 cubic inches. (Hydraulic System Values)
 HYD CIRC PUMP Switches on Panel R2

Each circulation pump can be manually turned repressurization of the hydraulic accumulator
on or off with the corresponding HYD CIRC when the pressure lowers to a value of 1,960 psi.
PUMP switch on panel R2. If the switch is In this contingency, the circulation pump will
placed in GPC, the pump will be activated and first receive the highest priority to operate and
deactivated by the SM GPC according to a will be turned ON while other circulation
control software program based on certain pumps are operating in thermal mode (this
hydraulic line temperatures and/or accumula- means that two pumps can be operating
tor pressure. This program activates the simultaneously). After the pump has been
appropriate circulation pump when any of the repressurized, the accumulator above 1,960 psi,
control temperatures drop below either 0° F, or - or a period of 2 minutes (this value can be
10° F, depending on their locations, and changed by Mission Control Center uplink) has
deactivates the circulation pump when all of the elapsed, the circulation pump will be com-
control temperatures for that system are greater manded to OFF. It is possible to run all three
than 20° F, or after 15 minutes for system 1 and circulation pumps at the same time to
10 minutes for systems 2 and 3. The repressurize accumulators.
activation/deactivation limits for these control
temperatures can be changed during the flight The circulation pump is automatically discon-
by crew or Mission Control. nected when its corresponding APU Run
command is issued by the APU controller. Each
The program also includes a timer to limit the circulation pump can be powered by one of two
maximum time a circulation pump will run, and orbiter main electrical buses, selectable by the
a priority system to assure that only one HYD CIRC PUMP POWER switches on panel A12.
circulation pump is on at a time (because of
excessive power usage if more than one The crew can see circulation pump outlet
circulation pump is on). Each circulation pump pressure as well as the hydraulic line and
uses 2 kW of electrical power. This software component temperatures on the PASS SM HYD
will also automatically provide for the THERMAL display, DISP 87.
 Hydraulic System Controls on Panel A12

2011/ /087 HYD THERMAL 4 000/02:36:29

APU start is delayed as long as possible to save
000/00:00:00

CIRC PUMP CONTROL

fuel. At T minus 6 minutes 15 seconds, the pilot
HYD
1
2
3
LINE TEMPS 1
2
3

CIRC PMP P 64
66
66
ELEVON LOB+

94 + 61 + 59 begins the prestart sequence. The pilot confirms
CIRC PMP P 64
66
66
ELEVON LOB+

94 + 61 + 59
PMP BDY
T+ 61 + 47 + 47 LIB+ 94 + 61 + 61 that the WSB is activated, then activates the
RSVR
T+ 58 + 64 + 66 RIB+ 94 + 61 + 61
ACCUM
P2616 2624 2624 ROB+ 94 + 59 + 61 APU controllers and depressurizes the main
HX IN
T+ 75 + 75 + 75 RD/SB PDU+ 97 + 59 + 59
OUT
T+ 59 + 54 + 54

FUS+ 97 + 59 + 59 hydraulic pump. Depressurizing the main

SW VLV PR S1 S2

BDYFLP PDU+

97 + 59 + 59
FUS+ 97 + 59 + 59
pump reduces the starting torque on the APU.
ELEV L OB
IB
3*
2*
1
1
2

L BRAKE WHL
FUS
+ 70 + 45
+ 70 + 45
The pilot then opens the fuel tank valves and
R IB
OB
3*
2*
1
1
2

R BRAKE WHL+ 62 + 70 + 61
FUS+ 40 + 67 + 61
looks for three APU ready-to-start indications
RUD/SPDBK 1* 2 3
NG
UPLK+ 40
MFUS 1+ 40
(gray talkbacks). At T minus 5 minutes, the
TIRE PRESS
MFUS 2+ 40 pilot starts the three units by setting the APU
MG LEFT RIGHT
MG L
UPLK+ 40
IB 377 377 377 377
MG R
UPLK+ 40 OPERATE switches to START/RUN and checks
OB 378 378 376 376
FUS+ 40
NG 369 369 364 364
the hydraulic pressure gauges for an indication
068
of approximately 800 psi. Then the pilot
SM HYD THERMAL Display (DISP 87) pressurizes the main pump and looks for
approximately 3,000 psi on the gauges. All three
The SM APU/HYD display (DISP 86) shows the hydraulic main pump pressures must be greater
hydraulic system pressure, reservoir tempera­ than 2,800 psi by T minus 4 minutes, or the
ture, reservoir quantity (in percent), and automatic launch sequencer will abort the launch.
hydraulic accumulator pressure.
The APUs operate during the ascent phase and
Hydraulic Heaters continue to operate through the first OMS burn.
At the conclusion of the main engine purge,
Areas of the hydraulic lines that cannot be
dump, and stow sequence, the APUs and WSBs
warmed by fluid circulation while the system is
are shut down. The same sequence applies for a
inactive on-orbit are warmed by heaters. These
delayed OMS-1 burn. If an abort once around is
heaters are automatically controlled by thermo­
declared, the APUs are left running, but the
stats to maintain the hydraulic line temperatures
hydraulic pumps are depressurized to reduce
in a specified range. Each heated area has
fuel consumption. The units are left running to
redundant heaters (A and B), which are con­
avoid having to restart hot APUs for deorbit
trolled by the HYDRAULIC HEATER switches
and re-entry.
on panel A12.
Six hours after lift-off, or as soon as they are
Operations required, depending on the environment, the
The WSB controllers are powered up at launch gas generator/fuel pump heaters are activated
minus 8 hours, and the boiler water tanks are and are in operation for the remainder of the
pressurized in preparation for APU activation. orbital mission. The fuel and water line heaters
The controllers activate heaters on the water are activated immediately after APU/HYD
tank, boiler, and steam vent to assure that the SHUTDN in the post OMS-1 timeframe to prevent
water spray boiler is ready to operate for launch. the lines from freezing as the APUs cool down.
Two hours after lift-off, the steam vent heaters At 45 minutes before deorbit, the WSB water
of the WSBs are turned on and left on for about tanks are pressurized, the APU controllers are
1.5 hours to eliminate all ice from the steam activated, and the main hydraulic pumps are set
vents. to low pressure. The pilot opens the fuel tank
valves and looks for three gray APU/HYD
Two hours and twenty minutes into the flight, READY TO START talkbacks. The pilot then
while in the Post Insertion Checklist, the closes the fuel tank valves. This procedure takes
hydraulic thermal conditioning is enabled by place while the crew is in contact with the
taking the hydraulic circulation pumps to GPC. ground so that flight controllers can observe
Further, the HYD CIRC PUMP POWER APU status. Five minutes before the deorbit
switch(es) on panel A12 will be configured to burn, one APU (selected by Mission Control) is
distribute electrical loads when appropriate. started to ensure that at least one unit will be
operating for entry. The hydraulic pump is left
While the vehicle is in orbit, the hydraulic in low-pressure operation. The APU operates
circulation pumps are in the GPC mode-- through the deorbit burn. At 13 minutes before
automatically activated when hydraulic line entry interface (400,000-foot altitude), while the
temperatures become too low and automatically orbiter is still in free fall, the other two APUs are
deactivated when the lines warm up started, and all three hydraulic pumps are
sufficiently. pressurized to normal. Two main engine
hydraulic isolation valves are cycled open and
On the day before deorbit, one APU is started to
then closed to ensure that the engines are
supply hydraulic pressure for flight control
stowed for entry. Two minutes later, if
system checkout. (Hydraulic pressure is needed
required, the aerosurfaces are put through an
to move the orbiter aerosurfaces as part of this
automatic cycle sequence to make sure warm
checkout.) The associated WSB controller is
hydraulic fluid is available in the aerosurface
activated, landing gear isolation valves 2 and 3
drive units.
are closed, and one APU (selected by the
Mission Control Center) is started. The After touchdown, a hydraulic load test may be
hydraulic main pump is set to normal pressure done to test the response of the auxiliary power
(approximately 3,000 psi), and aerosurface drive units and hydraulic pumps under high load
checks are made. After about 5 minutes, the (i.e., high flow demand) conditions. This test
checks are complete, and the APU is shut down. cycles the orbiter aerosurfaces with one
Normally, the unit does not run long enough to hydraulic system at a time in depressed mode
require WSB operation. The landing gear (the remaining two APUs and hydraulic pumps
isolation valves on hydraulic systems 2 and 3 have to drive all the aerosurfaces). This is
are reopened after the APU is shut down. typically done on the first flight of a new
vehicle. Then the main engine hydraulic
At 2.5 hours before the deorbit burn, the boilers'
isolation valves are opened again, and the
steam vent heaters are activated to prepare the
engines are set to the transport position. At this
system for operation during atmospheric entry.
point, the hydraulic systems are no longer
At about the same time, the landing gear isolation
needed; the APUs and WSBs are shut down.
valves on hydraulic systems 2 and 3 are closed,
and the circulation pumps are turned off.
APU/HYD Caution and Warning Summary
Placing the APU AUTO SHUT DOWN switch
in INHIBIT only inhibits the automatic
shutdown of that APU if its turbine speed is

The yellow APU TEMP caution and warning less than 80% or more than 129%. The APU
light on panel F7 is illuminated if the APU 1, UNDERSPEED or APU OVERSPEED light
2, or 3 lube oil temperature is above 290° F. will always illuminate, and a tone will be
generated.

The yellow APU OVERSPEED light is
illuminated if APU 1, 2, or 3 turbine speed is
The yellow HYD PRESS light illuminates
more than 92,880 rpm (129%). If the APU when hydraulic system 1, 2, or 3 drops below
AUTO SHUT DOWN switch on panel R2 is in 2,400 psi for any reason.
ENABLE, an automatic shutdown of that
APU will occur.
The blue SM ALERT illuminates, and the
C/W tone is sounded if turbine speed falls

The yellow APU UNDERSPEED light is below 80% or rises above 129%.
illuminated if APU 1, 2, or 3 turbine speed is
less than 57,600 rpm (80%). If the APU
The red BACKUP C/W ALARM illuminates if
AUTO SHUT DOWN switch for that APU is hydraulic pressure of system 1, 2, or 3 drops
in ENABLE, an automatic shutdown will below 2,400 psi.
occur.

O2 PRESS H2 PRESS FUEL CELL FUEL CELL FUEL CELL

REAC STACK TEMP PUMP
(R)
O2 HEATER MAIN BUS AC AC
CABIN ATM
(R) TEMP UNDERVOLT VOLTAGE OVERLOAD

FREON AV BAY/
IMU FWD RCS RCS JET
LOOP CABIN AIR
(R)
H2O LOOP RGA/ACCEL AIR DATA LEFT RCS RIGHT RCS
(R) (R)

LEFT RHC RIGHT/AFT LEFT OMS RIGHT OMS

(R) RHC (R)

PAYLOAD FCS (R)

GPC OMS KIT OMS TVC
WARNING (R) SATURATION (R)

PAYLOAD FCS
PRIMARY C/W MPS
CAUTION CHANNEL (R)

BACKUP C/W APU APU APU

HYD PRESS
ALARM (R) TEMP OVERSPEED UNDERSPEED

070

APU/HYD Caution and Warning Lights on Panel F7

 APU/HYD Summary Data restarted for entry: one APU prior to the
deorbit burn, and the other two prior to entry

The APU is a hydrazine-fueled, turbine- interface.
driven power unit that generates mechanical
shaft power to drive a hydraulic pump that
Each APU fuel tank load is approximately
produces pressure for the orbiter's hydraulic 325 pounds of hydrazine.
system.

APU/HYD controls are located on Panel R2;

The three orbiter hydraulic systems provide heater controls are on panel A12.
pressure to position hydraulic actuators for:
gimbaling SSMEs, actuating SSME control
CRTs that display APU/HYD information
valves, moving orbiter aerosurfaces, retract­ include the PASS and BFS SM SYS SUMM 2
ing ET disconnect umbilicals, deploying display (DISP 79), APU/HYD display (DISP
landing gear, and providing brake power, 86), HYD THERMAL (DISP 87), and
anti-skid, and nose wheel steering. APU/ENVIRON THERM (DISP 88).

The APUs are located in the aft fuselage of
Several meters for monitoring APU/HYD
the orbiter. parameters are located on panel F8.

Each APU/HYD system has an independent
APUs can be manually shut down and
water spray boiler for APU lube oil and restarted after completion of a full injector
hydraulic fluid cooling. Water is used after water cooling cycle (3.5 minutes), or after
APU shutdown for injector cooling if a hot approximately 180 minutes of passive cooling
restart is required. The APUs share a central on orbit.
supply tank for injector cooling.

The three APUs are started 5 minutes before

lift-off. They continue to operate throughout
the launch phase, and are shut down after the
main engine propellant dump and stow are
completed (post OMS-1). The APUs are

APU/HYD Rules of Thumb

APU fuel usage rates vary with loading, but

average 1% per minute (3 to 3.5 lbs/minute).
Usage rates are reduced by about half if the
hydraulic main pump is taken to low pres­
sure (HYD MAIN PUMP PRESS switch on
panel R2 set to LOW), as is done during the
abort once around deorbit coast period.

The APU injector cooling tank shared by all

three APUs contains enough water for 21
minutes of continuous flow. This is enough
for six complete 3.5-minute hot restart
injector cooling cycles.

If all water spray boiler cooling is lost to the

lube oil after an APU reaches full operating
temperatures, only 2 to 3 minutes of operat­
ing time are available before bearing seizure
occurs.
 APU
fuel
tank
valves
T
N2
P
H4 GN2
T (2 in P
TB gray indicates: Fuel pump paral lel)
GGT > 190°F Control power T Q (COMP)
APU speed < 80% Auto shut down
Fu tk vlvs - OP Speed select GEAR BOX I/F WITH
Hyd mn pump P ­ Low Oper start FUEL PUMP
APU
Wb ok when: Rdy to control APU OIL PUMP
Cntrl A(B) ­ ENA start TB overspeeed
HYD PUMP
Vent T > 130°F
GN2 vlv - OP Inj cooling APU
Hyd byp vlv - BYP underspeed

T T P R (RPM) GN 2

Hyd main pump

3000
GN 2 Gas gen Turbine Gear box X X
psia

X
H20

X
WB Boiler N 2 supply
cntlr Boiler cntlr/htr Oil pump

X
APU temp
Boiler power L

X
T
Exhaust L

X
T T L

X
L L L L L L L L L L PLT
L
L L L L L L L L L L

X
X X

X
L L
GN 2 Bypass
Q valve X Freon
L L Reservoir
X

X
T > 105°F hx
X
P

X
L L
P
X

X
X X

X
X X

X X

X X
X X

X X

X X

X X
X

X X

X
X

L L Circ
pump
X

X
X

X
X
X

X X X
L L T 2500 400
X

P
X

psia psia
X

X
X
X

L L
X

P
X

X
L L
X X X

Z Z Z
Z Z Z
Z Z Z
X X X

X X X

Q
X

X
Z

X X
H2O (Comp)
X

L L
X

L L X X X X X X X
X

X
X

T P
L L
X
X

X X
X

L L
Priority valve
X
X

closes at 2600 psia

WB on at L L X X X X X X X P Hyd press
X

> 250°F
X

TL L P X X X X X
X

X
X

X X
X
X

Isol
L L X X
X

vlvs
X
X
X

L L Brakes Elev
X

T L SS M E Lg rudder
(Sys 1) spd brk
Vent T ET umb nws only bdy flp
X

X
X

X X X
Byp vlv
X
X

< 190°F
X

X
X

X X X X X X X X X X X X X
071.cvs

APU/Hydraulic Overview
Panel R2
Panel F8
Panel A12
 0001/ /079 SM SYS SUMM 2 5 008/23:29:22 2011/ /087 HYD THERMAL 4 000/02:36:29

BFS 000/00:00:00 000/00:00:00

CRYO TK 1 2 3 4 5 MANF1 MANF2

CIRC PUMP CONTROL

H2 PRESS 208 208 206 206 206 208 207 HYD

1
2
3
LINE TEMPS 1
2
3

O2 PRESS 816 815 814 814 814 815 815 CIRC PMP P 64
66
66
ELEVON LOB+ 94 + 61 + 59

HTR T1 -248 -248 -248 -248 -248 CIRC PMP P 64

66
66
ELEVON LOB+ 94 + 61 + 59

T2 -248 -248 -248 -248 -248 PMP BDY T+ 61 + 47

+ 47
LIB+ 94 + 61 + 61

APU 1 2 3
HYD 1 2 3 RSVR T+ 58 + 64
+ 66
RIB+ 94 + 61 + 61

TEMP EGT 942 942 942

PRESS 3064 3064 3064
ACCUM P2616 2624 2624
ROB+ 94 + 59 + 61

HX IN T+ 75 + 75
+ 75
RD/SB PDU+ 97 + 59 + 59

B/U EGT 942 942 942

ACUM P 3080 3080 3080

OUT T+ 59 + 54
+ 54
FUS+ 97 + 59 + 59

OIL IN 250 250 250

RSVR T 116 153 142
BDYFLP PDU+ 97 + 59 + 59

OUT 264 264 264

SW VLV PR S1 S2
FUS+ 97 + 59 + 59

GG BED 511H 511H 511H

QTY 72 74 71
ELEV L OB 3* 1 2
L BRAKE WHL
+ 70 + 45

INJ 1271 1271 1271

IB 2* 1 3
FUS
+ 70 + 45

SPEED % 99 102 101

W/B R IB 3* 1 2
R BRAKE WHL+ 62 + 70 + 61

FUEL QTY 59 60 62
H2O QTY 78 73 78 OB 2* 1 3
FUS+ 40 + 67 + 61

PMP LK P 14 14 14
BYP VLV BYP BYP BYP RUD/SPDBK 1* 2 3
NG UPLK+ 40

OIL OUT P 42 42 41
MFUS 1+ 40

FU TK VLV
TIRE PRESS
MFUS 2+ 40

A T 63 65 62
THERM CNTL 1 28 MG LEFT RIGHT
MG L UPLK+ 40

B T 63 65 62
H2O PUMP P 23 63 IB 377 377 377 377
MG R UPLK+ 40

AV BAY 1 2 3
FREON FLOW 2384 2384 OB 378 378 376 376
FUS+ 40

TEMP 97 97 83
EVAP OUT T 38 38 NG 369 369 364 364

A4 14 27.439 27.435
26.324 31.873 18.48 068

051

DISP 79 SM SYS SUMM 2 Display SM HYD THERMAL Display (PASS DISP 87)
(PASS and BFS)

2011/ /086 APU/HYD 4 000/02:36:12 2011/ /088 APU/ENVIRON THERM 4 000/02:36:51

FREON LOOP 1 2
000/00:00:00

000/00:00:00
ACCUM QTY 27 27
H2O LOOP 1 2

APU 1 2 3 HYD 1 2 3

FREON FLOW 2193 2190

PUMP OUT P 64 62

B/U EGT 313 313 310 B/U P 64↓ 64↓ 64↓ PL HX FLOW 290 286
OUT T 64 63

EGT 313 313 310 RSVR T 58 64 66 AFT CP FLOW 279 278

P 3OL 38

SPEED % 0L 0L 0L P 65 66 66 RAD IN T 97 96
ICH FLOW 564L 777

FUEL QTY 76 77 77 QTY 74 75 73 RAD OUT T 38 38

OUT T 41 38

TK P 209 210 212 ACCUM P 2616 2624 2624 EVAP OUT T 38 38

CAB HX IN T 42 38

OUT P 209 210 212 EVAP TEMP DUCT NOZ

ACCUM QTY 45 55

TK VLV A CL CL CL HI LOAD INBD 259

APU FUEL T 1 2 3

A T 61 62 62 OUTBD 259 312

TK SURF + 69 + 67 + 68

B CL CL CL TOPPING FWD 257

TK HTR + 70 + 68 + 69

B T 61 62 62 W/B 1 2 3 AFT 257

TEST LN 1 + 62 + 62 + 63

OIL T 64 63 62 L 162 50
TEST LN 2 + 62 + 63 + 63

OUT T 63 62 60 CNTLR A A A R 162 50

FEED LN + 57 + 58 + 58

OUT P 25 25 25 H2O QTY 100 100 100 EVAP FDLN T A B

PUMP IN + 57 + 58 + 58

GBX P 25 25 25 N2 P 2499 2506 2492 FWD 80 80

DRN LN 1 + 62 + 62 + 63

N2 P 141 142 140 T 57 58 55 MID 1 80 80

DRN LN 2 + 62 + 62 + 63

BRG T 82 81 84 REG P 28 28 28 MID 2 79 75

OUT + 92 + 90 + 88

GG BED T 426 423 421 BYP VLV BYP BYP BYP AFT 75 79
BYP LN +108 +106 +102

PUMP/VLV VENT T +122L +122L +122L TOPPING 75 79

GG SPLY LN 113 111 107

ACCUM 75 79

PMP T 94 92 90 TANK T + 57 + 58 + 55

HI LOAD 75 79
H2O LN INJ+ 71 92 + 72

VLV T 114 111 107 BLR T + 60 + 58 + 61

059
078

SM APU/HYD Display (PASS DISP 86) APU/ENVIRON THERM (PASS DISP 88)