GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
GLAST Large Area Telescope:
Gamma-ray Large
Area Space
Telescope
Pre-Environmental Test Review
Integration and Test
Ken Fouts
SLAC
Integration and Test
Presentation 8 of 12
1
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Overview
• Review Current Status
– LAT Instrument Configuration
– Procedure Status
• Review Plan for Environmental Test
– Organization
– Pathfinding Summary
– LAT I&T Operations at NRL
– EGSE/MGSE Readiness
– Test Configurations and flow
• Schedule Review
Integration and Test
Presentation 8 of 12
2
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Current Configuration
• As built configuration
– LAT-DS-1624 LAT Top Assembly
– Radiators
– ACD, Radiator & LAT MLI
Integration and Test
Presentation 8 of 12
3
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
I&T Process Procedures
Document
Title
Status
LAT-PS-03263-01
Fastener Installation and Torqueing Procedure
Released
LAT-PS-04727-01
Connector Mate and Demate
Released
LAT-MD-04601-01
LAT I&T eLog Book Implementation Plan
Released
LAT-PS-03291-01
Flight Hardware Bag and Purge Procedure
Released
LAT-PS-04436-01
AeroGo Bearing Reference Guide
Released
LAT-PS-04511-04
LAT Data Collection Procedure
Released
LAT-MD-01533-01
LAT EGSE Plan
Released
I&T Standard Processes will continue to be used at NRL
Integration and Test
Presentation 8 of 12
4
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Key Documents for Environmental Test
Document
Title
Status
LAT-PS-6898
LAT Environmental Test Implementation Plan
In Signoff
LAT-PS-07929-01
LAT Shipping Container Procedure
Released
LAT-PS-07728
LAT Environmental Test Handling Procedure
In Signoff
LAT-MD-02717-01
LAT Environmental Test Sequence
Released
LAT-MD-01196-03
LAT Dynamics Test Plan
Released
LAT-MD-01600-03
LAT Thermal Vacuum Test Plan
Released
LAT-MD-02726-01
LAT EMI/EMC Test Plan
Released
LAT-DS-7411
LAT Environmental Test Wiring Diagram
Released
Key Environmental Test Planning has been completed
Integration and Test
Presentation 8 of 12
5
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Environmental Test Configuration Drawings
Drawing
Title
Status
LAT-DS-06188
Acoustic Test Configuration Assembly
Released
LAT-DS-06185
Thermal-Vacuum Test Configuration Assembly
Draft
LAT-DS-06187
Horizontal Vibration Test Configuration Assembly
Released
LAT-DS-06190
Vertical Vibration Test Configuration Assembly
Released
LAT-DS-06186
Handling Configuration Assembly
Released
LAT-DS-06184
Transport Configuration Assembly
Released
LAT-DS-06189
EMI/EMC Test Configuration Assembly
Released
LAT-DS-06191
Mass Properties Configuration Assembly
Draft
LAT Instrument Configuration for Environmental Tests is documented
Integration and Test
Presentation 8 of 12
6
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
I&T Documentation
Test Performance and
Operation Plan
LAT-MD-02730
Drawings
Test Sequence
LAT-MD-00676
(Mechanical Assembly,
Cabling, EGSE/MGSE
interface, etc.)
LAT Environmental Test Plans
I&T Operating
Processes and
Procedures
Assembly Instruction
Data Sheet (AIDS)
Electronic Logbooks
(Component installation,
Mate/Demate, Etc.)
QA and
Archive
Non-Conformance
Report (NCR)
CM processes for document control, release and completion will be maintained.
Integration and Test
Presentation 8 of 12
7
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
LAT Environmental Test Organization
Ken Fouts
I&T Manager
E. Grove, Deputy
B. Raynor
NRL Resource
Manager
Dynamics Test
J. Ku
EMI/EMC
M. Lovellette
Rqmts & Planning
K. Fouts
N. Johnson
TVAC
J. Armiger
NRL Operations
P. Dizon
Environmental Test Management Team is in place work planning and scheduling
Integration and Test
Presentation 8 of 12
8
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
LAT I&T Team
Subsystem I&T Support
ACD – Martin Kocian/Dave
Thompson
CAL - Eric Grove
DAQ – Gregg Thayer
Elec - Dave Nelson
FSW - Mike DeKlotz
SAS - Richard Dubois
TKR -Hiro Tajima
Controls - Shannon Leone
QA - Doug Bartholomew
LAT Integration and Test
Ken Fouts, Manager (SU-SLAC)
Eric Grove, Deputy Manager (NRL)
Larry Wai
LAT I&T Data Manager
WBS 4.1.9, 4.1.9.1
Brian Grist
Eliazar Ortiz
Jeff Tice
Electrical Lead Engineer
Mechanical Lead Engineer
Material Logistics Lead
John Canfield, S&E Associate - Electrical
Phuc Hoang, S&E Technician - Electrical
Albert Nguyen, Electrical Engineer
Roger Williams, S&E Associate - Electrical
Drew Roberts, Electrical Engineering Contractor
Patrick Young, Electrical Engineer
Mechanical
Design Support
Marc Campell,
Manager (SU-SLAC)
WBS 4.1.9.4
Leo Manger, S&E Associate - Mechanical
Dave Kiehl, S&E Technician - Mechanical
Tom Neiland, S&E Technician - Mechanical
Mark Molini, S&E Associate - Mechanical
Online
Software
Particle Test
Ric Claus,
Manager (SU-SLAC)
WBS 4.1.9.5
Manager (SU-SLAC)
WBS 4.1.9.7
Gary Godfrey,
Domi Celestino, Inventory Clerk
Science
Verification,
Analysis, and
Calibration
Anders Borgland, Manager
(SU-SLAC)
WBS 4.1.9.9
Bill Olson
Jim Panetta
Mechanical Engineer
Engineering Physicist
Arthur Scholz
Mechanical Engineer
Selim Tuvi
Eric Charles
Software Developer
Software Developer
Lester Miller
Warren Focke
Engineering Physicist
Engineering Physicist
LAT Collaboration
I&T Coordination
Eduardo do couto e
silva
(SU-SLAC)
LAT I&T Team has a proven track record for safe program execution
Integration and Test
Presentation 8 of 12
9
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Pathfinding Summary (1 of 2)
LAT Pathfinding Activity Documented in LAT-MD-07727
Objective: Identify and mitigate mechanical operations/handling risk.
• Pathfinder Lifting Operations
– Installation into and Removal from Shipping Container with the GPR.
– Installation into and removal from the Test Stand with GPR
– Onto and off of the Vibe Table with the GPR
– Test Stand Turnover with Complete Mass Simulator and SLAC lift
slings
– Installation of the rotated test stand and LAT onto the TVAC
table/Trolley
• Pathfinder Move Operations
– Transport weighted shipping container
– Move LAT in the test stand from clean tent to Sine Vibe.
– Move LAT and test stand from clean tent to EMI test chamber.
– Move LAT and test into Acoustic test chamber.
– Move LAT and test stand TVAC staging area and into chamber.
LAT-PS-07728 LAT Handling Procedure was developed during Pathfinding
Integration and Test
Presentation 8 of 12
10
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Pathfinding Summary (2 of 2)
• Pathfinding Miscellaneous Operations/Installations
– Radiator installation/removal procedures including timed trial runs
(adhesive pot life)
– TVAC prep work – mount S/C simulator sink plate
– TVAC configure – another rotation and install on Table/Cart
• Improved handling procedures for installation and use of test
stand extensions
– Installation of TVAC STE – heater cages, ACD sink plates
– Transport into TVAC chamber and working around LAT and STE inside
chamber.
– TVAC cable installation and routing
Pathfinding activity mitigated potential risk for critical handling operations
Integration and Test
Presentation 8 of 12
11
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
I&T Operating Plan
• The detailed LAT I&T schedule is maintained in MS Project by the I&T Scheduler.
– Schedules will be updated daily via the afternoon meeting with progress from that day.
• NRL Operations
– Normal work time will be 7:00am-8:00pm. “Shifts” will run nominally 7:00am-4:00pm
and 12:00am-8:00pm. Shifts will be adjusted to go around the clock as the need
arises.
– Daily morning meeting at 7:00am and afternoon meeting at 3:00pm.
– Daily phone tag-up to SLAC at 4:00pm.
– Minimum staff when the instrument is under test is 2 LAT Electrical Test staff
members.
– TVAC will be staffed 24/7
– Extended shifts and/or Saturdays will be used to maintain schedule as required.
• LAT Instrument Handling
– LAT will be configured in the portable clean tent whenever possible.
– The LAT will be bagged to maintain cleanliness when outside of the controlled
environment.
– Cleanroom and ESD protocol will be maintained during all LAT handling operations.
NRL Operating plan is similar to SLAC Operations
Integration and Test
Presentation 8 of 12
12
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Troubleshooting in I&T
• No troubleshooting will be done without appropriate disposition on an NCR.
• When an anomaly occurs:
– The test set-up is frozen
– The instrument and test equipment is safed.
– The test set-up and instrument configuration is reviewed and
documented by the Test Conductor.
– Test conductor notifies the TD, Subsystem Engineer and QA.
• QA initiates an NCR with information from TC and convenes MRB.
– At a minimum, MRB consists of the Test Director, Test Conductor,
Subsystem Engineer and QA.
• MRB will provide detailed disposition for troubleshooting.
• The test procedure will be redlined or a separate procedure will be written
(as defined by MRB) to document the troubleshooting activity defined in
the disposition.
Troubleshooting will be done in accordance with the I&T Implementation Plan
Integration and Test
Presentation 8 of 12
13
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Problem Resolution in I&T
Problem Observed
Inspection, Testing,
Data Analysis
(HW, SW, Data)
Issue
Closed
False Alarm!
Corrective
Actions
Test Conductor
Error
No
Non Conformance
Report (NCR)
Test
Procedure/Set Up
Error
Flight HW
Damaged
Test Equipment
Problem
Categorize
by
Test Conductor
and/or
Test Director
Yes
Possible
Flight HW Failure
HW MRB
Troubleshoot
HW
Root Cause Identified
Corrective Actions
Possible
Flight SW
Failure
SW JIRA
Troubleshoot
SW
Root Cause Identified
Corrective Actions
CCB Action
Problem Resolution will continue to use the NCR process
Integration and Test
Presentation 8 of 12
14
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Network Configuration for LAT Operations at NRL
VSC and Power Rack will move with the LAT Instrument
Integration and Test
Presentation 8 of 12
15
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
LAT I&T CCB Controls Test Configuration
•
LAT-MD-03492 LAT I&T CM/CCB
Procedure establishes the process for
configuration control of flight and test
software installed on the LAT and EGSE
test stations.
•
LAT I&T CCB is held on an as needed
basis and requires the following
minimum representation:

I&T Manager (CCB Chair)

I&T Electrical Test Lead

Systems Engineering

Online Manager

Flight Software

Quality Assurance

DAQ Electronics
Software packages listed below are
controlled by CCB in the locations listed
LAT I&T CCB has been successful in controlling software installation/changes
Integration and Test
Presentation 8 of 12
16
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Environmental Test MGSE/STE
• Transport Container
– Manufacture complete; Analyses complete
– Proof test complete
– Demo Road Test complete
– Available at SLAC
• Test Interface Plate
– Complete
• Test Stand/Spreader Bars
– Complete, used in pathfinding
• TVAC Sink Plates – ACD & S/C Simulator
– Complete, used in pathfinding 2
• TVAC Cal-Rod Cage
– Complete, used in pathfinding 2
• Acoustic Simulator
– Complete
• Mass Properties Plate
– Load Cell Interface in manufacture – Complete
All MGSE has been used in dry run or pathfinding activity
Integration and Test
Presentation 8 of 12
17
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
GPR, Lift Fixture Proof Test at SLAC
Rotation Stand w/ GPR Proof Test
Integration and Test
Presentation 8 of 12
Proof Test of the 4x4 Lift Fixture
and GPR
18
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Facilities
• Thermal Vacuum Test
– Cables and Port Plates – complete
– Mechanical analyses complete
– Trolley (cart) – complete, used in pathfinding
– Chamber rails upgrade – complete and proof tested
– Pathfinding 2 – complete
– Chamber refurb, cleaning and recommissioning - complete
– GSE bakeout and STE Validation – ECD: 5/16/06
• Acoustic Test
– Ramp manufacture complete
• Vibration Test
– Expander head load frame procurement - delivered
– Load frame manufacture – complete
– Installation and proof test - complete
• EMI/EMC Test
– Ramp manufacture – complete, used in pathfinding
NRL Facility has been upgraded to meet LAT Operational Requirements
Integration and Test
Presentation 8 of 12
19
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Environmental Test Sequence
Baseline
C
F
Rev date: 24 April 2006
Ship to
NRL
S
NRL
Post-Ship
at SLAC
Receive,
Unpack
Sine Vibe
C
L
L
Pre
Pre-TV
C
S
T-Bal
L
S
T-Cycle
L
C
L
L
Mount
Radiators
EMI/EMC
T
L
E
L
Acoustic
L
L
Post- Axis
Final
C
F
S
Remove
Radiators
Weight
CG
Pack LAT
Ship to
Spectrum
TESTING IN THERMAL VAC CHAMBER
Integration and Test
Presentation 8 of 12
L Limited Performance Test
F LAT Functional and FSW Test
C Comprehensive Performance Test
T TCS Functional Test
S SVAC Test
E EMI/EMC Emissions/Susceptibility Test
20
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Sine Vibe Configuration
Integration and Test
Presentation 8 of 12
21
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Vibration Facility Layou
Integration and Test
Presentation 8 of 12
22
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Radiator Installation
Radiator flange access
Radiator installation test
Integration and Test
Presentation 8 of 12
23
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
EMI/EMC Test Configuration
Integration and Test
Presentation 8 of 12
24
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
EMI Chamber Layout
Integration and Test
Presentation 8 of 12
25
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Acoustic Test Configuration
Integration and Test
Presentation 8 of 12
26
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Acoustic Test Layout
Integration and Test
Presentation 8 of 12
27
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
TVAC Configuration
Integration and Test
Presentation 8 of 12
28
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Thermal STE
Heater Cage Configuration
S/C Sink Plate Configuration
Installation of ACD Sink Plate Panels (5)
Integration and Test
Presentation 8 of 12
29
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
TVAC Layout
Integration and Test
Presentation 8 of 12
30
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Environmental Test Schedule (1 of 3)
Integration and Test
Presentation 8 of 12
31
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Environmental Test Schedule (2 of 3)
Integration and Test
Presentation 8 of 12
32
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Environmental Test Schedule (3 of 3)
Integration and Test
Presentation 8 of 12
33
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Staffing Plan
• Current staffing plan for NRL:
– Single long shift 5-6 days per week for Sine Vibe, Acoustic,
EMI/EMC tests.
– 24/7 staffing for TVAC duration.
– SLAC will average 14 people including
• I&T Management
• I&T Electrical
• I&T Mechanical
• Mechanical Design
• Online
• SVAC
• QA
• DAQ
Integration and Test
Presentation 8 of 12
34
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Staffing Plan (1 of 2)
5/1/2006 5/29/2006
6/5/2006 6/12/2006 6/19/2006 6/26/2006
Sine Vibe TestInstall Radiators
EMI Test
Acoustic Test
7/3/2006 7/10/2006 7/17/2006 7/24/2006 7/31/2006
TVAC Prep
TVAC Open Door
8/7/2006 8/14/2006 8/21/2006 8/28/2006
TVAC Test
Remove Radiators
Wt & CG
9/4/2006
Ship
I&T Electrical
B. Grist
J. Canfield
D. Roberts
P. Hoang
P. Young
R. Williams
A. Nguyen
Sub-Total
1
1
1
1
1
5
1
1
1
1
1
5
1
1
1
1
1
1
5
1
1
1
1
5
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
5
1
1
1
1
1
5
1
1
1
1
1
1
5
1
1
1
1
5
1
1
1
1
1
5
1
1
1
1
1
1
5
1
1
1
1
5
1
1
1
1
1
1
1
1
1
1
5
5
1
1
1
1
4
1
1
1
1
1
5
I&T Mechanical
E. Ortiz
L. Manger
T. Neiland
D. Kiehl
M. Molini
Sub-Total
1
1
1
1
3
1
1
1
4
1
1
1
1
4
1
1
1
1
3
1
1
1
1
1
3
1
4
1
1
1
1
3
1
1
1
4
1
0
0
0
1
1
1
4
1
1
1
1
4
QA
J. Cullinan
D. Bartholomew
YC Liew
E. Rodriguez
J. Marshall
Sub-Total
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
I&T Online
R. Claus
J. Panetta
S. Tuvi
L. Miller
Sub-Total
1
1
1
1
1
Integration and Test
Presentation 8 of 12
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
35
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Staffing Plan (2 of 2)
5/1/2006 5/29/2006
6/5/2006 6/12/2006 6/19/2006 6/26/2006
Sine Vibe TestInstall Radiators
EMI Test
Acoustic Test
7/3/2006 7/10/2006 7/17/2006 7/24/2006 7/31/2006
TVAC Prep
TVAC Open Door
8/7/2006 8/14/2006 8/21/2006 8/28/2006
TVAC Test
Remove Radiators
Wt & CG
9/4/2006
Ship
I&T SVAC
A. Borgland
E. Charles
W. Focke
Sub-Total
As Required
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
2
1
0
0
0
1
1
1
1
1
1
3
1
1
3
1
1
2
1
1
2
1
1
2
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
2
2
3
1
0
0
0
0
Mech/Thermal
M. Campell
B. Olson
J. Ku
J. Goodman
J. Wang
Sub-Total
3
3
1
3
2
1
1
4
0
0
0
0
0
0
DAQ
J. Thayer
G. Thayer
Sub-Total
System Engineering
P. Hascall
R. Baun
R. Bright
R. Bielawski
Sub-Total
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Management
K. Fouts
L. Klaisner
D. Horn
Sub-Total
Integration and Test
Presentation 8 of 12
1
0
1
0
0
0
0
1
0
1
1
0
1
1
0
1
0
36
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Environmental Test Staffing Summary
SLAC Staffing at NRL
18
EMI Test
Vibe Test
Acoustic Test
WT/CG
TVAC Test
Ship
16
14
Total FTE at NRL
12
10
8
6
4
2
Integration and Test
Presentation 8 of 12
00
6
4/
2
9/
20
06
8/
28
/
20
06
21
/
8/
20
06
8/
14
/
00
6
8/
7/
2
20
06
7/
31
/
20
06
7/
24
/
20
06
17
/
7/
20
06
10
/
7/
3/
20
06
7/
20
06
6/
26
/
20
06
19
/
6/
20
06
6/
12
/
00
6
5/
2
6/
5/
29
/
20
06
0
37
GLAST LAT Project
May 25, 2006: LAT Pre-Environmental Test Review
Summary
• The LAT baseline performance has been demonstrated post
shipment to NRL.
• The LAT instrument as-built configuration is in accordance with
current engineering.
• Documentation, preparation and pathfinding for handling and
configuring the LAT for Environmental Test have been completed.
• All EGSE and MGSE has been identified and its use has been
demonstrated.
• LAT I&T has completed the necessary preparation to begin the LAT
Instrument Environmental Test.
Integration and Test
Presentation 8 of 12
38