GLAST Large Area Telescope: Performance & Safety Assurance WBS: 4.1.A Darren S. Marsh

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967 Section 17 1

GLAST Large Area Telescope:GLAST Large Area Telescope:

Performance & Safety Assurance WBS: 4.1.A

Darren S. MarshStanford Linear Accelerator CenterPerformance & Safety Assurance Manager

[email protected]

Gamma-ray Large Gamma-ray Large Area Space Area Space TelescopeTelescope



OutlineOutline

• Introduction• Organization• Requirements• Safety & Mission Assurance Program Reviews• Performance Assurance System• Workmanship & Inspection• Contamination Control• Nonconformance Reporting• Materials and Processes• Systems Safety



IntroductionIntroduction

• Performance & Safety Assurance is a program consisting of:– Quality Assurance

• Hardware• Software

– Systems Safety– EEE Parts Program– Materials & Processes Program– Contamination Control– Reliability & Risk Management Program– Design Verification– Technical Reviews



Performance Assurance Functional ResponsibilitiesPerformance Assurance Functional Responsibilities

FUNCTIONAL ELEMENT INSTITUTIONS (LEAD)

Hardware Quality SLAC (Marsh), GSFC (Kolecki), NRL (Virmani)

Flight Software Assurance SLAC (Sawyer)

Reliability Engineering

Continuous Risk Management

SLAC (Thurston, Horn)

SLAC (Marcellini, Horn)

EEE Parts Program NRL (Virmani)

Materials & Processes Program SLAC (Nordby, Tice)

Instrument Design Verification- Design Verification Planning- Analytical Design Verification- Functional Design Verification

SLAC (Horn)

SLAC (Klaisner)

SLAC (Bloom)

Systems Safety SLAC (O’Neill)

SLAC (Cullinan)

Configuration Management SLAC (Horn, Cramer)

Contamination Control



Performance & Safety Assurance RequirementsPerformance & Safety Assurance Requirements

LAT Documents

GLAST Project Office Documents

Requirements apply to all work by the LAT collaboration and their subcontractors and suppliers of deliverable space flight hardware and software

Contamination Control Plan

433 -PLAN -0010

LAT Mission Assurance Reqs 433 -MAR -0001

EEE Parts MGMT Plan

433 -PLAN -0004

LAT Flight S/W Mgmt. Plan

LAT -MD -00104

LAT Mechanical Parts Plan

LAT -SS -00107

LAT Quality Manual

LAT -MD -00091

Parts Program Control Plan

LAT -MD -00099

System Safety Program Plan

LAT -MD -00078

LAT Inst. Perf. Verification Plan LAT -MD -00408

Configuration Management Plan

LAT -MD -00068

LAT Contam. Control Plan

LAT -MD -00404

LAT Risk Mgmt. Plan

LAT -MD -00067

LAT Performance AssuranceImplementation Plan

LAT-MD- 00039



Safety & Mission Assurance Program ReviewsSafety & Mission Assurance Program Reviews

Fiscal Years

2000 2001 2002 2003 2004 2005 2006 2011

GLAST scheduled for launch in September 2006

BeginLAT I&T

CriticalDesignReview

PDR PER

PreShipReview

LAT ReadyFor S/C I&T

FABRICATION PHASE COMMISSIONINGPHASE

Build & TestFlight Units

ObservatoryI&T

Final DesignEngr’g Models

LAT I&T

Ops.

Prelim. & Sys. Design

Pre-PDR S&MA Survey

PDR Delta Baseline Review Pre-CDR S&MA

Survey



Results from GSFC Pre-PDR S&MA SurveyResults from GSFC Pre-PDR S&MA Survey

• Goddard Space Flight Center (GSFC) Office of System Safety and Mission Assurance (OSSMA) performed a survey of the LAT Program April 3-4, 2001– The goal of the survey was to evaluate the status of the

LAT Safety & Mission Assurance Program and give GSFC and LAT personnel the opportunity to discuss Safety & Mission Assurance documentation

– The SLAC survey did not result in any “Findings”, there were nine “Observations” and two “Commendations”

• Nearly all the recommendations identified in the survey were addressed– Documentation updated to reflect comments provided– Secured the necessary expertise in specific disciplines



Results from PDR/Baseline ReviewsResults from PDR/Baseline Reviews

Findings from January 2002 PDR/Baseline Review:• The Committee concluded that Performance & Safety

Assurance was at PDR level and recommended baselining• One RFA was generated from the review

– Describe the LAT Metrology Program (S. Scott)• LAT Quality Procedure LAT-MD-00470, Inspection,

Measuring & Test Equipment, has been established to ensure that monitoring and measurement can be carried out and are carried out in a manner that is consistent with the monitoring and measurement requirements

Findings from the July 2002 Delta PDR/Baseline Review:• The Committee reaffirmed the decision to baseline the

Performance & Safety Assurance subsystem• No RFAs were identified for Performance Assurance



Results from GSFC Pre-CDR S&MA SurveyResults from GSFC Pre-CDR S&MA Survey

• Goddard Space Flight Center (GSFC) Office of System Safety and Mission Assurance (OSSMA) performed a survey of the LAT Program December 10-11, 2002 – The goal of the survey was to evaluate the status of the

LAT Safety & Mission Assurance Program and to assess the program’s readiness for the LAT CDR

– The SLAC survey did not result in any “Findings”, there were eight “Observations”

• Excerpt from the Survey Closeout Report– “It is the conclusion of this survey team that the LAT

Performance and Safety Assurance Program is CDR ready.”



LAT Performance Assurance SystemLAT Performance Assurance System

• LAT Performance Assurance Implementation Plan (PAIP), LAT-MD-00039, released and approved by GSFC

– Requirements for performance assurance elements are defined• LAT Quality Manual, LAT-MD-00091, completed and released

– LAT Quality Management System (QMS) is established, documented, implemented and aligned with the requirements of ISO 9001

• Documentation to ensure the effective planning, operation and control of assurance activities

– Configuration Management Plan, LAT-MD-00068– LAT EEE Parts Program Control Plan, LAT-MD-00099– LAT Contamination Control Plan, LAT-MD-00404– LAT Flight Software Management Plan, LAT-MD-00104– LAT Mechanical Parts Plan, LAT-SS-00107– LAT Continuous Risk Management Plan, LAT-MD-00067– LAT Instrument Performance Verification Plan, LAT-MD-00408

GOAL IS CONFORMANCE TO REQUIREMENTS



Performance Assurance ActivitiesPerformance Assurance Activities

• Collaborator/Supplier Surveillance Activities– Surveys of collaborators and key suppliers to evaluate

ability to produce quality flight hardware and ensure project requirements are met

– Review and approve specifications, travelers/work orders and NCRs

– Perform on-site source inspections to monitor or witness fabrication, assembly and/or integration & test activities

• Ensure contamination control requirements are met• Compliance to ESD requirements• Review travelers/routers, fabrication and workmanship

procedures• Equipment calibration review• Material handling and shelf life material storage



Fabrication, Assembly, Integration and Test ProcessFabrication, Assembly, Integration and Test Process

• Production Readiness Review (PRR)– Review of detailed fabrication and assembly plan using completed

drawings, process, tooling, and in-process test procedures• Fabrication, Assembly, Integration

– All work will be conducted in a controlled manner so that end item conforms to requirements

• Test Readiness Review– Evaluate the planned test/calibration program and test flow to assure

that it meets program needs• Comprehensive Performance Test Activities

– Instrument Performance Verification Plan, LAT-MD-00408, released and approved

– LAT Environmental Specification, LAT-SS-00788, released and approved

– Requirements traceability/verification matrix

Comprehensive Performance

Test Activities

Production Readiness

Review

Fabrication,Assembly,Integration

Test Readiness

Review

Test Readiness

Review



Delivery & Acceptance ProcessDelivery & Acceptance Process

• Pre-Ship Review– Assure the design of the item has been validated through

the environmental qualification and/or acceptance test program, that all open items have been dispositioned

• Flight Unit Delivery– Plans for shipping container, environmental control and

mode of transportation developed• Post-Ship Acceptance Test

– Verifies functionality of delivered hardware to integrator

Pre-Ship Review

Deliver Hardware to Integration

Site

Post Ship Acceptance

Test



Workmanship and Process ControlWorkmanship and Process Control

• LAT personnel working on flight hardware will be trained and certified to the following standards (or equivalent approved ESA standards):– NASA-STD-8739.1, Workmanship Standard for Staking and

Conformal Coating of Printed Wiring Boards and Electronic Assemblies

– NASA-STD-8739.2, Workmanship Standard for Surface Mount Technology

– NASA-STD-8739.3, Requirements for Soldered Electrical Connections

– NASA-STD-8739.4, Requirements for Crimping, Interconnecting Cables, Harness, and Wiring

– NASA-STD-8739.7, Electrostatic Discharge Control



Workmanship & Inspection Requirements Workmanship & Inspection Requirements

• A work order/traveler will define the steps for QA inspection– Quality records will be maintained and reviewed

• Mandatory inspections points (MIP) will be performed for integration & test at predefined inspection points– To screen out defects caused by workmanship, design,

assembly, etc.– To prevent unacceptable products from entering the next

stage of production– A final inspection verified that the hardware/software

deliverables meet requirements and are properly documented



Contamination ControlContamination Control

• Cleanroom environments– LAT assembly, integration & test activities will be

performed in class 100,000 environment– LAT personnel are trained in contamination control

• Monitoring, recording, and inspections– Continuous temperature, %RH, and multiple port airborne

particle count monitoring– Fallout witness plates, tape lifts, and/or NVR solvent

rinses/swabs are planned– Visual inspections of hardware and cleaning as required

prior to each closeout activity• LAT Contamination sensitive hardware (calorimeter, tracker,

and ACD) shall meet Level 750B surface cleanliness per MIL-STD-1246



Contamination Control (Con’t.)Contamination Control (Con’t.)

• Additional requirements– Calorimeter Cesium Iodide crystals shall not be exposed to

>45% relative humidity– ACD photomultiplier tubes are shall not be exposed to

excessive helium levels as specified in LAT Contamination Control Plan

• Atmosphere Control using GN2 and/or dry air– ACD requires purge if measured helium levels exceed 10

ppm• GN2 will be filtered and certified to Grade B, 99.99%

pure per MIL-P-27401– Dry air flow to calorimeter as required will limit Cesium

Iodide crystals exposure to humidity < 45% RH



Contamination Control (Con’t)Contamination Control (Con’t)

• Materials selection– Select materials that satisfy outgassing of ≤ 1% TML and ≤

0.1% CVCM• Bakeout

– Plan is to do a vacuum bakeout of LAT at 40˚C at start of thermal-vacuum test

– The parameters of subsystem or component bakeouts (e.g., temperature, duration, and pressure) will be individualized depending on materials used, the fabrication environment, and the established contamination allowance.

– Required thermal vacuum testing of flight hardware shall be performed and outgassing rates shall be monitored to achieve required outgassing levels



Nonconformance ReportingNonconformance Reporting

• All nonconformances will be reported through a nonconformance & corrective action (NCR/CA) system – The LAT will ensure that product which does not conform

to requirements is identified and controlled to prevent its unintended use or delivery

– Action will be taken to eliminate the cause of nonconformance in order to prevent recurrence

– Close-out of all nonconformance reports shall be verified• Work stopped until the nonconformance is reviewed and

dispositioned by Material Review Board (MRB)– Records of the nature of nonconformities and any

subsequent action taken, including concessions obtained, shall be maintained

– When nonconforming product is corrected it shall be subject to re-verification to demonstrate conformity to the requirements



Nonconformance Reporting ProcessNonconformance Reporting Process

Nonconformances will be reported to GSFC in accordance with MAR requirements

TKR CAL ACD ELEX MECH

End Item/Traveler Data Package

Program Records Database

IPO

LAT IOCOperations

End Item DataPackage

MR

B

MR

B

MR

B

MR

B

MR

B

Operations Data

FR

B

FR

B

Observatory

End Item DataPackage

FR

B

GLAST ProjectOffice

ObservatoryOffice

NC

R/C

A

NC

R/C

A

NC

R/C

A

NC

R/C

A

NC

R/C

A



LAT Materials and PartsLAT Materials and Parts• Material requirements

– Source: 433-MAR-0001, “Mission Assurance Requirements”

– LAT: LAT-SS-00107-01, “Mechanical Parts Plan”

• Material Usage Agreement (MUA) needed for non-compliant materials

– All materials have been assessed by GSFC materials branch to be compliant to standards and used in conventional methods

– Currently the project requires no MUA’s

• Relevant procedures and guidelines for material selection

– Metallic Materials for Stress Corrosion Cracking Resistance in Sodium Chloride Environment (MSFC-STD-3029)

– Fastener Integrity Requirements (541-PG-8072.1.2)

– Standard Test Method for Total Mass Loss and Collected Volatile Condensable Materials for Outgassing (ASTM-E-595)

SubmittedSLAC IPO Accepted

GSFC Approved

Pending

ACD 97 97 97 0CAL 48 48 48 0Elec 24 22 22 2I & T 0 0 0 TBDMech 114 113 113 1TKR 57 48 48 9Total 340 328 328 12

Total Materials Count on LAT M&P ListTotal Materials Count on LAT M&P List



LAT M&P List: Inorganic, Polymer and Composite MaterialsLAT M&P List: Inorganic, Polymer and Composite Materials

• Inorganic materials– Inorganic materials submitted to LAT IPO

as of 29 April 2003• Polymers and Composites

– Polymer and composite materials submitted to LAT IPO as of 29 April 2003

Inorganic Materials


GSFC Approved

Pending


Inorganic Materials Count on LAT M&P ListInorganic Materials Count on LAT M&P List

Polymer and Composite Materials


GSFC Approved

Pending


Polymer and Composite Materials Count on LAT M&P ListPolymer and Composite Materials Count on LAT M&P List



LAT M&P List: Lubricants and ProcessesLAT M&P List: Lubricants and Processes

• Lubricants– Lubricants used only in static applications,

largely for bolts– No moving parts within the LAT– Lubricants submitted to LAT IPO as of 29

April 2003• Processes

– M & P list collects process information for all heat treating and surface treatment processes

– Processes submitted to LAT IPO as of 29 April 2003

Lubricants


GSFC Approved

Pending


Lubricant Count on LAT M&P ListLubricant Count on LAT M&P List

Processes


GSFC Approved

Pending


Processes on LAT M&P ListProcesses on LAT M&P List



Materials List Pending ItemsMaterials List Pending Items

• Pending items as of 29 April 2003• Reasons for status

– Specific material not yet chosen– Waiting for “TBD’s” to be filled in– Outgassing testing in progress

• Mechanical Parts Review Board will evaluate materials once missing information is collected from test results or work with manufacturer

• Final step is to validate materials list– Cross-check against drawing list– Check for missing materials and processes

Materials Pending Approval

Material ID is TBD

Lacking Info for

Approval

Needs Qual

Testing

Change Material

Tested for Out-gassing

Total Pending

ACD 0 0 0 0 0 0CAL 0 0 0 0 0 0Elec 0 2 0 0 0 2I & T TBD TBD TBD TBD TBD TBDMech 0 1 0 0 0 1TKR 0 0 0 0 9 9Total 0 3 0 0 9 12

Materials Pending Materials Branch ApprovalMaterials Pending Materials Branch Approval



Systems SafetySystems Safety

• The purpose of the LAT Systems Safety Program is to identify the hazards of the LAT and impose design requirements and establish controls to reduce the associated risk to acceptable levels.

• Established and implemented System Safety Program Plan (SSPP), LAT-MD-00078

– Complies with EWR 127-1, Eastern and Western Range Safety Requirements

– LAT Preliminary Hazard Analysis, LAT-MD-00366

• Identifies safety critical areas, assesses risk, and establishes requisite hazard controls

– LAT Operating and Support Hazard Analysis, LAT-MD-01968

• Evaluates activities for hazards or risks introduced into the system by operational and support procedures and evaluates the adequacy of operational and support procedures used to eliminate, control, or abate identified hazards or risks.



LAT Hazard AnalysisLAT Hazard Analysis

17Hazardous MaterialsMechanical damage to

calorimeterCalorimeter

10Hazardous MaterialsRupture of heat pipesMechanical

8CollisionStructural failureMechanical

8Electrical Electrical short circuit or overloadElectronics

RAV*Hazards GroupHazardsSubsystem

Risk Priority: Unacceptable Undesirable (Acceptable With Proper Controls) Operation Permissible

• Hazard controls have been identified and established • Verification of hazard controls will be on-going

*The Risk Assessment Value (RAV) is derived from MIL-STD-882D, Standard Practices for System Safety.



LAT Operating and Support Hazard AnalysisLAT Operating and Support Hazard Analysis

ElectricalElectromagnetic interfaceElectronics

ElectricalElectrostatic dischargeElectronics

OccupationalPersonnel contact with sharp edges, pinch points, or rotating fixtureALL

8CollisionStructural failure or improper use of MGSEI&T

10Electrical

Power distribution system overload or short circuits

I&T Electronics

RAV*Hazards GroupHazardsSubsystem

10

10

10

• All hazard identified in Preliminary Hazard Analysis apply to

Operating and Support Hazard Analysis

*The Risk Assessment Value (RAV) is derived from MIL-STD-882D, Standard Practices for System Safety.

Risk Priority: Unacceptable Undesirable (Acceptable With Proper Controls) Operation Permissible