Dated but important:
http://www.isro.org/newsletters/scripts/...009jun2009
S P A C E I N D I A [center]World-Class Solid Propellant Plant Commissioned at Satish Dhawan Space Centre SHAR[/center] The Solid Propellant Plant (SPP) at Satish Dhawan Space Centre (SDSC) SHAR, set up for manufacturing S200 solid boosters of GSLV Mk-III, was commissioned on December 18, 2008 with the successful casting of Head-End Segment (HES). Subsequently, in February 2009, the Nozzle-End-Segment (NES) and in April 2009 the Middle Segment (MS) were also processed. Thus, processing of all the three segments for the first static test of S200 booster has been completed. The S200 booster segments with 3.2 m dia. stand as the second largest of their kind in the world.
Some of the solid propellant plants in the world had faced teething problems and some of the large size segments were rejected due to processing glitches.
Thus, processing of such large solid propellant booster segments without any hitch in the maiden attempt itself is a commendable achievement by the SPP team. This testifies to the professional maturity of the team in planning, establishing and operationalising the plant.
All the three segments are now undergoing various post-cure operations like propellant trimming, inhibition and non-destructive testing (NDT). Preliminary NDT of HES and NES shows that the segments are in good condition. Evaluation of mechanical, interface and ballistic properties of HES and NES has been completed and results are well within the specifications. Viscosity values of final mix slurry were made available on-line throughout the programme. Information pertaining to the overall programme, including the total number of final mix batches processed, total number of batches made at each station, unloading time of each batch at respective stations, etc., was also displayed in-situ in the mixing control room.
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Propellant Slurry being transferred to master hopper
SPP and its constituent facilities
SPP has 53 buildings spread over 6 Sq Km area, interconnected with roads of 18 Km length. All the non-scritical operations and plant maintenance are taken care by operation and maintenance contractor, M/s Premier Explosives Limited. Automation and remote operation with built-in safety features in most of the facilities enable processing of large quantity of propellant (around 100 tons) within 24 Hrs. The annual capacity of the plant is to produce 900 ton of solid propellant required for 12 segments (delivery of four S200 boosters). Of the three segments of S200, the middle segment carries maximum propellant (about 98 tons).
The major constituent facilities of SPP are:
- Hardware Insulation and Lining
- Raw Materials Storage and Preparation
- Propellant Mixing Stations and Pre-mix storage
- Casting and Curing.
- Bowl Cleaning and Bowl Preparation
- Propellant Machining
- Segment Inhibition and Tilting
- Non-destructive Testing
- Integrated Sample Processing
- Analytical and Physical Testing Lab
- Segment Storage Magazine
- Material Handling and Maintenance
- Electrical Sub-stations and Standby DG Stations
- Fire Fighting and Protection System
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Middle segment being loaded on to the transporter
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Middle segment being tranported to Curing Facility
State-of-the-art facilities
Though the propellant processing technology adapted at SPROB (which produces S139 boosters for PSLV and GSLV) and SPP is more or less same, the quantity of propellant produced and the size of segments handled in SPP are three times more than that processed by SPROB. As large quantities of raw materials are to be handled for processing propellant for S200 segments, a need was felt to adopt bulk packing for storage and handling of major raw materials. Ammonium Perchlorate constituting 68% of solid propellant is being received from APEP, Aluva (VSSC) in flexible intermediate bulk containers (FIBC) of 1000 kg capacity as against the old practice of 40 kg drums to minimise the number of containers handled during storage and processing. Liquid ingredients, namely, HTPB resin and plasticizer DOA, are received and stored in large sized tankers of 12 ton/8 ton capacity. Required quantity of these ingredients are transferred and weighed into bins using pneumatically operated double diaphragm pumps in closed loop batch weighing system.
SPP has five mixing stations. Of them, four will be in operation during final mixing. The fifth station will be contingent hot standby to meet the requirement of uninterrupted casting 100 tons of propellant within 24 hours. The casting facility is designed for continuous casting with two transfer cars to receive the bowls, tilt and transfer the propellant slurry into the master hopper which feeds the slurry to segment hardware. All operations in mixing and casting facilities are fully automated using the state-of-the-art PLC systems to avoid manual errors in operation. Integrated Sample Processing Facility (ISPF) carries out propellant mixing, casting, decoring, end trimming and inhibition of Agni motors for ballistic evaluation and cartons for the evaluation of mechanical/physical/interface properties. Radiographic inspection of segments takes place in horizontal attitude along the segment length using PLC programmable floor based LINAC handling system and film positioning system, without any manual intervention.
SPP has set-up a centralised data acquisition and control system in major operational areas, namely, raw material preparation, propellant mixing and propellant casting. Import systems like AP grinder, vertical mixer, Vertical Turning Mill (VTM) and linear accelerator are indigenised.
Built-in Safety
This plant is equipped with a modern fire fighting system comprising of four pumps of 410 cubic metres per hour capacity each, 2460 cubic meters of water storage, 17 km length of outdoor piping (80 NB to 600 NB) spread over the entire plant and fitted with 154 hydrant points. Eleven deluge systems and four sprinkler systems are provided in areas where propellant is processed.
With the twin objective of meeting the stringent safety requirements and reducing the manpower, the following 'process automations' are introduced in the plant:
- Blasting, degreasing and resin lining of S200 hardware
- Raw material feeding, bowl lid lifting and slurry spill collection in propellant mixing
- Slurry feeding, continuous casting, segment handling with (grab) tackle, bowl cleaning
- Agni motor decoring and Agni/carton trimming
All the facilities of SPP have undergone rigorous test and evaluation (T&E) process by expert committees proving their intended performance. These facilities were evaluated by three levels of safety committees.
Successful commissioning of this world-class solid propellant plant and successful realisation of all the three segments for S200 booster are the significant milestones in the progress of 'SHAR Facilities for GSLV Mk-III' (SFG) project.