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New ammonia tank installed after bolt troubles
BY WILLIAM HARWOOD
STORY WRITTEN FOR CBS NEWS "SPACE PLACE" & USED WITH PERMISSION
Posted: April 11, 2010


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Astronauts Rick Mastracchio and Clay Anderson ran into problems bolting a 1,700-pound ammonia coolant tank into place on the space station's power truss early Sunday. Finally, after multiple attempts over an hour and a half, Anderson drove a recalcitrant bolt home to clear the problem.

"Come on, baby. Come on!" he grunted as he drove the bolt with a power tool. "Get on there. Yeah, get 'er done! She's on."

"Thanks, Clay. Very good job," spacewalk coordinator Dottie Metcalf-Lindenburger called from the shuttle Discovery's flight deck.

The goal of Sunday's spacewalk was to remove a depleted ammonia coolant tank from the space station's main power truss and install a replacement. The old tank was successfully removed and tethered to an equipment cart. The astronauts then began work to install the new tank.

The massive tanks use spring-loaded bolts on four corners to engage receptacles on the power truss. Mastracchio and Anderson began attempting to line the bolts and receptacles up around 5:09 a.m. But they were unable to get one bolt - No. 4 - to engage.

After trying a variety of fixes, flight controllers told them to get a hammer and attempt to "pound" that corner into place.

"We don't think releasing bolt two is going to solve anything and it would be a step backwards," called Stan Love from mission control. "What we would like Rick and Clay to try next is to use the hammer to try to pound the bolt four corner down. And we'd like them to hammer on the flat part of the assembly where two of the plungers are."

But Mastracchio and Anderson objected that a hammer likely would not work, saying they already had applied more force than that by manually shoving on the tank in a bid to get all four bolts to engage.

"OK, stand down on the hammering," agreed spacewalk coordinator Dottie Metcalf-Lindenburger.

"Yeah, we're hitting it a lot harder than we can with a hammer," Mastracchio radioed. He suggested moving a foot restraint and repositioning the astronauts to apply more downward force to the ammonia tank.

Mission control then suggested backing out the bolts that were already engaged and try again from scratch, rocking the tank and using its momentum to help drive the bolts into the receptacles.

"OK, after talking about it, we're thinking if maybe Rick got back in the APFR (articulating portable foot restraint) to provide good steadying for the tank, if you could undo bolt two and with the tank now free try to re-seat it using its momentum. We think it might help to bias the tank away from the bad plunger on bolt four.

"That might work," Mastracchio said.

"So let me make sure I understand," Anderson said. "We're basically going to go back to the original situation and just try to use the momentum to try to slam it over bolt four."

The astronauts then repositioned themselves and made another attempt to engage the reluctant bolt.

"No joy," Anderson radioed after making multiple attempts to muscle the bolt into its receptacle.

Mission control then asked the crew to detach one bolt holding the tank in place and to try again, working the tank side to side.

"Ah, you've got to be kidding me!" Anderson exclaimed as bolt four suddenly engaged.

"Did it go in?" Metcalf-Lindenburger asked.

"Yes," Anderson laughed. "You have got to be kidding me! It went in there quicker than... now what do we do?"

Using a power screw driver, Anderson drove the bolt in, switching to a higher torque setting to finish the job. The spacewalkers then worked their way around to the rest of the bolts.

Because of the time lost getting the new tank in place, flight controllers told Mastracchio and Anderson to forego connecting ammonia lines to the tank and to defer bringing no-longer-needed debris shields into the station for return to Earth. Those tasks likely will be added to the crew's third spacewalk Tuesday.

The ammonia connections were deferred because if a leak occurred and an astronaut's suits was contaminated, there would not be enough time for a "bake out" cleaning procedure.

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