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[i]On April 21, 1968 on the mobile Service Structure of Launch Complex 34 (LC-34) at CCAFS there was an N2O4 spill of approximately one to two gallons during a dry-run using the new servicing equipment for the Apollo Service Propulsion System (SPS). A boilerplate Command and Service Module with a non-flight SPS was installed on the Saturn 1B launch vehicle ... The servicing dry-run was being completed in preparation for the scheduled October, 1968 launch of the first manned Apollo Program mission Apollo 7 ... The N2O4 spill occurred when a vacuum was applied to the Command Module Reaction Control System (RCS) propellant tank prior to the second dry-run servicing test. It was later determined that a quick disconnect (QD) servicing valve had become blocked during the initial dry-run test (proximate cause). When the vacuum pump was brought online for the second dry run, oxidizer was pulled into the pump's oil sump and then subsequently released out of the oil sump tank vent port. Technicians used the standard procedure at the time, which was to dilute the propellant using water. This, unfortunately, resulted in the formation of nitric acid. Approximately 400 gallons of water were used to dilute the N2O4 which ultimately ran down the side of the launch vehicle and into the instrument unit ring ... The damage to the vehicle was extensive and the delay was several weeks. The cleanup on the ground level of LC-34 took several days. A de-stack was completed to remove the instrument unit ring for repair. Most of the wiring in the instrument unit was removed and cleaned. Four cables were replaced and five connectors were rebuilt. Three of the outside antennas were also replaced along with the Saturn IB fin #4 and liquid oxygen bay three door. The forward skirt was removed from the Saturn IVB segment to allow for access inside the launch vehicle. The primary concern for the vehicle was long term corrosion. The vehicle design organization eventually became comfortable with proceeding to launch following several tests.[/i]
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