GLAST LAT Project
Gamma-ray Large
Area Space
Telescope
CDR/CD3 Review May 12-16, 2003
GLAST Large Area Telescope:
Performance & Safety Assurance
WBS: 4.1.A
Darren S. Marsh
Stanford Linear Accelerator Center
Performance & Safety Assurance Manager
Marsh@SLAC.Stanford.Edu
Document: LAT-PR-01967
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Outline
•
•
•
•
•
•
•
•
•
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Introduction
Organization
Requirements
Safety & Mission Assurance Program Reviews
Performance Assurance System
Workmanship & Inspection
Contamination Control
Nonconformance Reporting
Materials and Processes
Systems Safety
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Introduction
• 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Performance Assurance Functional Responsibilities
FUNCTIONAL ELEMENT
INSTITUTIONS (LEAD)
Hardware Quality
SLAC (Marsh), GSFC (Kolecki), NRL (Virmani)
Flight Software Assurance
SLAC (Sawyer)
Reliability Engineering
SLAC (Thurston, Horn)
Continuous Risk Management
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)
Contamination Control
Configuration Management
Document: LAT-PR-01967
SLAC (Cullinan)
SLAC (Horn, Cramer)
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Performance & Safety Assurance Requirements
GLAST Project Office Documents
LAT Mission
Assurance Reqs
433 -MAR -0001
EEE Parts
MGMT Plan
433 -PLAN -0004
Contamination
Control Plan
433 -PLAN -0010
LAT Performance Assurance
Implementation Plan
LAT-MD- 00039
LAT Documents
LAT Quality
Manual
LAT -MD -00091
System Safety
Program Plan
LAT -MD -00078
Configuration
Management Plan
LAT -MD -00068
Parts Program
Control Plan
LAT -MD -00099
LAT Contam.
Control Plan
LAT -MD -00404
LAT Risk Mgmt.
Plan
LAT -MD -00067
LAT Mechanical
Parts Plan
LAT -SS -00107
LAT Flight S/W
Mgmt. Plan
LAT -MD -00104
LAT Inst. Perf.
Verification Plan
LAT -MD -00408
Requirements apply to all work by the LAT collaboration and their subcontractors and suppliers of
deliverable space flight hardware and software
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Safety & Mission Assurance Program Reviews
Fiscal Years
2000
2001
2002
Pre-PDR
S&MA Survey
2003
2004
2005
PDR Delta
Baseline Review Pre-CDR S&MA
Survey
PDR
Critical
Design
Review
PER
Begin
LAT I&T
2006
2011
LAT Ready
For S/C I&T
PreShip
Review
Ops.
Prelim. & Sys. Design
Final Design
Engr’g Models
Build & Test
Flight Units
LAT I&T
FABRICATION PHASE
Observatory
I&T
COMMISSIONING
PHASE
GLAST scheduled for launch in September 2006
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Results 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Results 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Results 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.”
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
LAT 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Performance 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Fabrication, Assembly, Integration and Test Process
Production
Readiness
Review
•
•
•
•
Fabrication,
Assembly,
Integration
Test
Test
Readiness
Readiness
Review
Review
Comprehensive
Performance
Test Activities
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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Delivery & Acceptance Process
PreShip
Review
Deliver
Hardware to
Integration
Site
Post Ship
Acceptance
Test
• 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Workmanship 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Contamination 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Nonconformance 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
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Nonconformance Reporting Process
Observatory
Office
GLAST Project
Office
IPO
End Item Data
Package
ACD
ELEX
F RB
F RB
End Item Data
Package
Operations Data
NCR/CA
NCR/CA
CAL
NCR/CA
NCR/CA
NCR/CA
End Item/Traveler Data Package
TKR
F RB
MRB
MRB
MRB
MRB
MRB
Program Records Database
MECH
LAT
Observatory
IOC
Operations
Nonconformances will be reported to GSFC in accordance with MAR requirements
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
LAT 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)
Submitted
ACD
CAL
Elec
I&T
Mech
TKR
Total
97
48
24
0
114
57
340
SLAC IPO
GSFC
Pending
Accepted Approved
97
97
0
48
48
0
22
22
2
0
0
TBD
113
113
1
48
48
9
328
328
12
Total Materials Count on LAT M&P List
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
LAT 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
ACD
CAL
Elec
I&T
Mech
TKR
Total
Inorganic Materials
SLAC IPO
GSFC
Submitted
Pending
Accepted Approved
36
36
36
0
13
13
13
0
6
4
4
2
0
0
0
TBD
74
74
74
0
19
19
19
0
148
146
146
2
Inorganic Materials Count on LAT M&P List
ACD
CAL
Elec
I&T
Mech
TKR
Total
Polymer and Composite Materials
SLAC IPO
GSFC
Submitted
Pending
Accepted Approved
47
47
47
0
29
29
29
0
12
12
12
0
0
0
0
TBD
25
24
24
1
33
24
24
9
146
136
136
10
Polymer and Composite Materials Count on LAT M&P List
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
LAT 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
ACD
CAL
Elec
I&T
Mech
TKR
Total
Lubricants
SLAC IPO GSFC
Submitted
Pending
Accepted Approved
1
1
1
0
0
0
0
0
2
2
2
0
0
0
0
TBD
4
4
4
0
2
2
2
0
9
9
9
0
Lubricant Count on LAT M&P List
ACD
CAL
Elec
I&T
Mech
TKR
Total
Processes
SLAC IPO
GSFC
Submitted
Pending
Accepted Approved
13
13
13
0
6
6
6
0
4
4
4
0
0
0
0
TBD
11
11
11
0
3
3
3
0
37
37
37
0
Processes on LAT M&P List
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Materials 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
ACD
CAL
Elec
I&T
Mech
TKR
Total
Materials Pending Approval
Lacking Needs
Tested
Material
Change
Total
Info for
Qual
for OutID is TBD
Material
Pending
Approval Testing
gassing
0
0
0
0
0
0
0
0
0
0
0
0
0
2
0
0
0
2
TBD
TBD
TBD
TBD
TBD
TBD
0
1
0
0
0
1
0
0
0
0
9
9
0
3
0
0
9
12
Materials Pending Materials Branch Approval
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
Systems 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.
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
LAT Hazard Analysis
Risk Priority:
Subsystem
Hazards
Hazards Group
RAV*
Electronics
Electrical short circuit or overload
Electrical
8
Mechanical
Structural failure
Collision
8
Mechanical
Rupture of heat pipes
Hazardous Materials
10
Calorimeter
Mechanical damage to
calorimeter
Hazardous Materials
17
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.
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GLAST LAT Project
CDR/CD3 Review May 12-16, 2003
LAT Operating and Support Hazard Analysis
Subsystem
Hazards
I&T
Electronics
Power distribution system
overload or short circuits
Structural failure or improper use
of MGSE
I&T
Risk Priority:
Hazards Group
RAV*
10
Electrical
Collision
8
ALL
Personnel contact with sharp edges,
pinch points, or rotating fixture
Occupational
10
Electronics
Electrostatic discharge
Electrical
10
Electronics
Electromagnetic interface
Electrical
10
Unacceptable
Undesirable (Acceptable With Proper Controls)
Operation Permissible
• 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.
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