Attachment_A-Statement_of_Work.pdf

PACE and WFIRST S/C TWTA SOW PACE-COMM-SOW-0021, Revision A

Reference: WFIRST-SOW-09805, Revision A

Effective Date: November 16, 2017 ii Check https://ipdtdms.gsfc nasa.gov to verify that this is the correct version prior to use

400-FORM-0002 (4/16/2014)

PACE and WFIRST Spacecraft (S/C)

Traveling Wave Tube Amplifier (TWTA)

Statement of Work (SOW)

Signature/Approval Page (Revision -)

Prepared By:

Mike Powers/Adan Rodriguez Arroyo

Reviewed By:

Bill Sluder

Beth Weinstein

Kevin Novo-Gradac

Jack Sanders

Gary Won

Tim Johnson

Mike Xapsos

Nicole Hackley

Michelle Rizzo

Craig Stevens

Dan McGuinness

Approved By:

Andre’ Dress

Electronic Signatures available online at: https://ipdtdms.gsfc.nasa.gov/ iii

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Preface

This document is under Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) Mission configuration control. Changes to this document require prior approval of the PACE

Configuration Control Board (CCB) Chairperson or designee. Proposed changes shall be submitted to the PACE Configuration Management Office (CMO), along with supportive material justifying the proposed change. Changes to this document will be made by complete revision.

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Change History Log

Revision Effective Date Description of Changes

(Reference the CCR & CCB/ERB Approval Date) Revision - 10/02/2017 Baseline Release following the approval of PACE-CCR-0149

(WFIRST-CIR-04540)

Revision A 11/16/2017 Updated following the approval of PACE-CCR-0195 v

Table of TBDs/TBRs/TBSs

Action Item

No.

Location Summary Individual/

Organization

Actionee vi

Table of Contents

1.0 Introduction

1.1 General Information

1.1.1 PACE Mission

1.1.2 WFIRST Mission

1.2 Scope

2.0 Applicable Documents

3.0 Management, Reporting, Reviews, and documentation

3.1 Program management

3.2 Reporting

3.3 Advanced Notifications

3.4 Reviews And Meetings

3.4.1 Kick-off Meeting

3.4.2 Design Reviews

3.4.3 Pre-Environmental Review (PER)

3.4.4 Pre-Ship Review (PSR)

3.4.5 Technical Interchange Meetings (TIM)

3.5 Documentation

4.0 Design And Analysis

4.1 Interface Control Documentation

4.2 Drawing Package

4.3 Computer Models

4.4 Structural Analysis Report

4.5 Structural Finite Element Model

4.6 Thermal Analysis Report

4.7 Thermal Model and Documentation

4.8 Worst Case Circuit Analysis Report

4.9 Parts Stress Analysis Report

4.10 Radiation Hardness Analysis Report

4.11 Reliability Analysis Report

4.12 Failure Modes And Effects Criticality Analysis Report

4.13 Error Analysis Report

5.0 Hardware Procurement/Manufacturing

5.1 General Requirements

5.2 Ka-Band Traveling Tube Amplifier (TWTA)

5.3 Connector Savers

5.4 Supporting Hardware

5.5 Ground Support Equipment

6.0 Performance Verification And Test

6.1 Verification Plan

6.2 Verification Test Procedures

6.3 Verification Test Reports

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7.0 Quality Assurance

7.1 General Requirements

7.1.1 Quality Assurance Plan/Manual

7.1.2 Surveillance of the Contractor

7.1.3 Anomaly Reporting

7.1.4 Configuration Management

7.1.5 Ground Support Equipment Interfaces

7.2 System Safety Requirements

7.3 Reliability Requirements

7.3.1 Stability Trending

7.3.2 Limited-Life Items

7.3.3 Control of Sub-Contractors and Suppliers

7.4 Reserved

7.5 Design Verification Requirements

7.5.1 Verification Requirements

7.5.2 Analysis, Trending, and Reporting of Test Data

7.5.3 Total and Failure-Free Operation hours

7.6 Workmanship Standards And Processes

7.6.1 General

7.6.2 New or Advanced Packaging Technologies

7.6.3 Workmanship: Use of Alternate Workmanship Standards

7.6.4 Electrostatic Discharge Control Requirements

7.6.5 Training and Certification of Contractor Personnel

7.6.6 Hardware Handling, Cleaning and Packaging

7.6.7 Splices, Circuit Board Trace Cuts, and Jumper Wires

7.6.8 Printed Circuit Board (PCB) Test Coupons

7.6.9 Use of Water Soluble Flux

7.6.10 Lead-Free and Tin Whisker Control Measures

7.7 EEE Parts Requirements

7.7.1 General

7.7.2 Plastic Encapsulated Microcircuits (PEMs)

7.7.3 Radiation Hardness

7.7.4 Parts Age Control

7.7.5 GIDEP Alerts and Problem Advisories

7.7.6 Reuse of Parts and Materials

7.7.7 Part Notification of Failure

7.8 Materials, Processes Requirements

7.8.1 Materials and Processes Control

7.8.2 Commercial-Off-The-Shelf (COTS), Vendor-Designed and Fabricated, and

Bilateral Agreement Furnished Hardware

7.8.3 M&P Usage Documentation

7.8.4 Materials Usage Agreements (MUAs)

7.8.5 Detailed Requirements

7.8.6 Materials Procurement Requirements

7.9 Contamination Control Requirements

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7.9.1 Contamination Control Plan

7.9.2 Surface Cleanliness

7.9.3 Material Outgassing

7.9.4 Thermal Vacuum Bakeouts

7.10 METROLOGY

8.0 Handling, Storage, Packaging, Preservation, and Delivery

APPENDIX A. ABBREVIATIONS AND ACRONYMS

APPENDIX B. GSFC PCB SUBMITTAL AND MATERIAL SELECTION FORMS

APPENDIX C. LIST OF APPLICABLE DOCUMENTS

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List of Tables

Table Page

Table 4-1 FMEA Severity Categories

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1.0 INTRODUCTION

1.1 GENERAL INFORMATION

This document defines the work to be performed by the Contractor to deliver a Traveling Wave

Tube Amplifier (TWTA) that meets the requirements outlined in the specification (PACE-

COMM-SPEC-0053). As the TWTA procurement is a common buy between the PACE and

WFIRST Projects, this document will envelope the requirements of both PACE and WFIRST.

What follows is an introduction to both the PACE mission and the WFIRST mission.

1.1.1 PACE Mission

The Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission is a strategic climate continuity mission that was defined in the 2010 document Responding to the Challenge of Climate and

Environmental Change: NASA’s Plan for Climate-Centric Architecture for Earth Observations and Applications from Space (referred to as the “Climate Initiative”). The Climate Initiative complements NASA’s implementation of the National Research Council’s Decadal Survey of

Earth Science at NASA, NOAA, and USGS, entitled Earth Science and Applications from

Space: National Imperatives for the Next Decade and Beyond.

PACE will extend the high quality ocean ecological, ocean biogeochemical, cloud, and aerosol particle data records begun by NASA in the 1990s, building on the heritage of the Sea-Viewing

Wide Field-of-View Sensor (SeaWiFS), the Moderate Resolution Imaging Spectroradiometer

(MODIS), the Multi-angle Imaging SpectroRadiometer (MISR), and the Visible Infrared

Imaging Radiometer Suite (VIIRS). The mission will be capable of collecting radiometric and polarimetric measurements of the ocean and atmosphere, from which these biological, biogeochemical, and physical properties will be determined. PACE data products will not only add to existing critical climate and Earth system records, but also answer new and emerging advanced science questions related to Earth’s changing climate.

PACE is classified as a Category 2 mission, per the criteria in NASA Procedural Requirement

(NPR) 7120.5E, NASA Space Flight Program and Project Management Requirements. The mission classification is C according to NPR 8705.4B, Risk Classification for NASA Payloads.

The PACE observatory is comprised of two instruments, an Ocean Color Instrument (OCI) and a

Multi Angle Polarimeter (MAP). The OCI is the primary instrument on the observatory and is being developed at GSFC. The OCI is a hyper-spectral scanning (HSS) radiometer designed to measure spectral radiances from the ultraviolet to shortwave infrared (SWIR) to enable advanced ocean color and heritage cloud and aerosol particle science. The MAP is a second instrument on the PACE observatory, procured outside of GSFC. The MAP is a multi-band, multi-angle polarimeter planned to measure spectral polarized and unpolarized radiances to enable advanced

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cloud and aerosol particle science, as well as improved atmospheric correction for ocean color activities. This two-instrument PACE mission has the following multiple scientific goals:

Extending key systematic ocean biological, ecological, and biogeochemical climate data records and cloud and aerosol climate data records;

Making global measurements of ocean color data products that are essential for understanding the global carbon cycle and ocean ecosystem responses to a changing climate;

Collecting global observations of aerosol and cloud properties, focusing on reducing the largest uncertainties in climate and radiative forcing models of the Earth system;

and, Improving our understanding of how aerosols influence ocean ecosystems and biogeochemical cycles and how ocean biological and photochemical processes affect the atmosphere.

The PACE satellite is planned for a launch in 2022-2023. The PACE project office at the NASA

Goddard Space Flight Center (GSFC) is responsible for the satellite development, launch and operations. The mission is planned for launch into a Sun synchronous polar orbit at 676.5 km with an inclination of 98° and a 1 pm local ascending node crossing time. The spacecraft bus will host the OCI and MAP instruments. The GSFC PACE Project office will oversee the mission and the development of the satellite, launch vehicle, mission operations control center, and operations. The Headquarters Program Science will separately fund the science data processing system and competed science teams, which will include field-based vicarious calibration and data product validation efforts to support the Project science team.

NASA Headquarters has directed the mission development to be guided by a Design-to-Cost

(DTC) process. All elements of the mission, other than the cost, are in the DTC trade space. At the heart of the DTC process are the mission studies, performed across all the mission elements.

The mission studies will be used to define appropriate approaches within and across elements while maximizing science capabilities at a high cost confidence. Mission baseline requirements development is also embedded within the DTC process, as these requirements were not established at the onset of the mission concept development. Baseline mission requirements will be a product of the mission studies and will be defined by the project office as part of the DTC process.

The PACE mission consists of four major segments: space segment (SS), ground segment (GS), science data segment (SDS), and the launch segment (LS).

The space segment consists of the spacecraft bus, the OCI, and the MAP. The spacecraft and OCI are being developed and integrated at GSFC. The MAP is planned to be procured outside of GSFC. The spacecraft and instruments will be integrated as the

PACE observatory at GSFC.

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The GS and associated Mission Operations Center (MOC) will be developed, integrated, and operated at GSFC. The GS provides for the command and control and health and safety monitoring of the PACE observatory on-orbit, as well as ensuring the science data are accounted for and delivered to the SDS. The MOC will contain the flight operations team (FOT) and is being managed by the PACE project through observatory commissioning. After commissioning, the FOT will be managed by the GSFC Earth

Science Mission Operations (ESMO) office. The MOC performs all real time operations and off-line operations functions, including planning and scheduling, orbit and attitude analysis, housekeeping telemetry data processing, monitoring/managing the spacecraft and instruments, first line health/safety for the instruments, and housekeeping archiving and analysis.

The SDS will be located at GSFC, but managed (separately from the project) by the

NASA Headquarters Earth Sciences Division. The SDS will ingest, apply calibration and science algorithms, and process the science data, provide science software development and algorithm integration, act as the science data interface to the science team, and deliver of all science data products to the NASA-assigned Distributed Active Archive

Center (DAAC).

The LS is planned for a launch vehicle to be selected and procured by the NASA Launch

Services Program at Kennedy Space Center (KSC).

In addition to utilizing GSFC institutional capabilities, the project will utilize the NASA/GSFC institutional capabilities such as the Flight Dynamics Facility (FDF), Near Earth Network

(NEN), Ocean Biology Processing Group (OBPG), Space Network (SN), and NASA Integrated

Services Network (NISN). PACE plans to generate 3.5 Terabits of science data daily. The data are downlinked from the observatory during 12-14 daily contacts via Ka-band communications to the NEN's ground stations. The observatory will also receive ground commands and transmit real-time housekeeping telemetry via a S-band 2-way link through the NEN during nominal operations. The observatory also has the capability of receiving ground commands and transmitting real-time housekeeping telemetry, via S-Band, through the SN during critical or contingency operations.

This document defines the work to be performed by the Contractor in the design, development, fabrication, and delivery of the PACE Ka-band Traveling Wave Tube Amplifier, from here on referred to as the TWTA.

1.1.2 WFIRST Mission

WFIRST, the Wide Field InfraRed Survey Telescope, is a strategic mission sponsored by

NASA’s Astrophysics Division that was recommended as the top priority large project by the

National Research Council’s Decadal Survey of Astronomy and Astrophysics, entitled “New

Worlds, New Horizons in Astronomy and Astrophysics.” WFIRST is a NASA Observatory

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designed to settle essential questions in the areas of dark energy, exoplanets, and infrared astrophysics.

The telescope has a primary mirror that is 2.4 meters in diameter (7.9 feet), and is the same size as the Hubble Space Telescope's primary mirror. WFIRST will have two instruments, the Wide

Field Instrument and the Coronagraph Instrument. WFIRST is designed for a 5-year mission and will launch on an EELV. The targeted launch date is the mid-2020s. After transfer trajectory, the

Observatory will operate at approximately one million miles from the Earth, in an orbit around the L2 point of the Sun-Earth System.

The Wide Field Instrument will have a field of view that is 100 times greater than the Hubble infrared instrument, capturing more of the sky with less observing time. As the primary instrument, the Wide Field Instrument will measure light from a billion galaxies over the course of the mission lifetime. It will perform a microlensing survey of the inner Milky Way to find

~2,600 exoplanets. The Coronagraph Instrument will perform high contrast imaging and spectroscopy of dozens of individual nearby exoplanets.

WFIRST is a wide-field near-infrared space telescope capable of performing imaging and spectroscopic sky surveys with multiple goals including gravitational microlensing surveys for exoplanets, large-area sky survey and deep surveys for research in dark energy. The WFIRST primary science objectives are:

1. Dark energy

WFIRST will answer basic questions about dark energy: Is cosmic acceleration caused by a new energy component or by the breakdown of General Relativity on cosmological scales? If the cause is a new energy component, is its energy density constant in space and time, or has it evolved over the history of the universe?

2. Exoplanets

WFIRST plans to complete a census of Exoplanets to help answer new questions about the potential for life in the universe: How common are solar systems like our own? What kinds of planets exist in the cold, outer regions of planetary systems? What determines the habitability of Earth-like worlds? This census makes use of a technique that can find exoplanets down to a mass only a few times that of the Moon.

WFIRST will also offer a Guest Observer program that supports community-based observing programs. While the baseline mission emphasizes the dark-energy and exoplanet measurements, the additional surveys carried out via the guest observer program will exploit

WFIRST's unique capabilities to substantially broaden the science return of the mission. The

Guest Observer program will provide broad support to many fields of astrophysics in the tradition of HST with the same astonishing results of new, creative, field-changing science.

In an extended mission, the Guest Observer program would likely become the dominant part of the WFIRST mission. HST has demonstrated that the combination of a powerful facility and peer-reviewed proposals has the greatest impact in advancing the extraordinarily broad field of astrophysics research and the WFIRST mission follows that model.

WFIRST is classified as a Category 1 mission, per the criteria in NASA Procedural Requirement

(NPR) 7120.5E, NASA Space Flight Program and Project Management Requirements. The mission classification is B according to NPR 8705.4B, Risk Classification for NASA Payloads.

1.2 SCOPE

The contractor shall provide the facilities, personnel, services, tools, equipment, and materials necessary to design, analyze, manufacture, test, and deliver the hardware and data in accordance with the requirements of this SOW and the documents referenced herein.

This SOW defines the contractor tasks, deliverables, responsibilities, and schedule, either within this document or by reference. More details for the Deliverable Items List and Schedule (DILS) are contained in PACE-COMM-LIST-0008. The contractor shall generate a matrix listing each section in this statement of work reflecting either compliance or non-compliance. (DIL #1) Areas of non-compliance need to be addressed by the contractor showing how they plan to meet the requirement(s) or why it will remain non-compliant.

2.0 APPLICABLE DOCUMENTS

All applicable and reference documentation identified in this document shall apply in the situations where they are specifically referenced. In the event of a conflict between the SOW and the specification, the SOW shall take precedence. See Appendix C for applicable documents.

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3.0 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

3.1 PROGRAM MANAGEMENT

The contractor shall designate a single individual who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract and ensure that all objectives are accomplished within schedule and cost constraints.

The contractor shall designate and identify by name a single individual who shall serve as a point of contact with the NASA/GSFC Contracting Officer’s Representative (COR) for all technical aspects of the TWTA contract.

The contractor shall establish and apply a program control system for managing all resources, controlling schedules, managing all engineering, manufacturing and procurement activities, configuration management, Quality Assurance, documentation control, and distribution.

3.2 REPORTING

The contractor shall prepare and present to the NASA /GSFC COR monthly technical status reports via telecon and a written report. (DIL #2). The report shall be a summary presentation of the period's progress to include topics such as schedule overview, accomplishments, technical performance measures (e.g. mass and power), status of key milestones, risks, problem areas, challenges/issues and activities on-going and planned as well as cost status.

3.3 ADVANCED NOTIFICATIONS

The contractor shall notify the NASA/GSFC COR at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, TIM’s, and deliveries at either the contractor’s or a sub-contractor’s facility to allow timely participation by the NASA /GSFC

Quality Assurance representative. (DIL #4) Event specific notification requirements (such as failures, anomalies, etc.) are included in the appropriate sections.

3.4 REVIEWS AND MEETINGS

3.4.1 Kick-off Meeting

The Contractor shall organize and hold a Kick-off Meeting at the Contractor’s facility prior to any activity identified in this SOW. (DIL #5)

The Contractor shall provide to GSFC a Kick-off Presentation Package and all other required deliverables. (DIL #6) The Kick-off Meeting shall address program management and quality assurance activities outlined in this SOW, as well as the performance and environmental requirements outlined in the TWTA specification in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

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Program Management

Quality Assurance

TWTA Design Description

Preliminary Interface Control Documents

Flight Heritage

Facilities

Qualification Verification Plan and Procedure

Mechanical Analysis with Boundary Conditions

3.4.2 Design Reviews

3.4.2.1 Design Conformance Review (DCR)

The contractor shall organize and present a Design Conformance Review to a GSFC Review

Team at the contractor’s facility prior to the manufacturing program, on a date defined in the

DILS. (DIL #7) The contractor shall provide to GSFC a Design Conformance Review

Presentation Package and all other required deliverable data prior to the review. (DIL #8) The

Design Conformance Review shall address all program management, design, drawings, analysis, manufacturing, test, and quality assurance activities outlined in this SOW and the PACE Project

TWTA Specification PACE-RF-SPEC-0053 in sufficient detail to ensure that the proposed design conforms to all requirements and is ready for fabrication to begin. At a minimum, the design package should cover the following areas:

Program Management

Quality Assurance

Electrical, Mechanical, and Environmental specifications

Parts, including stress analysis and radiation hardness assessment

Detailed architectural block diagrams for the different deliverable units

Manufacturing flow with inspection points

Facilities

Verification Test Plan (Including Performance Test Description)

Materials and Processes

Contamination Control (for items sensitive to contamination or with explicit surface cleanliness or outgassing requirements)

Mechanical/Structural analyses

Electrical Worst-Case analyses

Failure Modes Effects Criticality Analysis

Flight Heritage

Verification Matrix (per Section 7.5.1)

Review minutes shall be prepared and, as a minimum, shall include attendance, action items, action item accomplishment responsibility and agreements. All items shall be in sufficient detail to be self-explanatory. A Design Conformance Review Report shall be prepared following the

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review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items. (DIL #9)

3.4.3 Pre-Environmental Review (PER)

The contractor shall organize and conduct a Pre-Environmental Review (PER) at the contractor’s facility before the environment test program begins. (DIL #10) This presentation shall demonstrate overall conformance of the requirements specified in the PACE Project TWTA

Performance Specification (PACE-COMM-SPEC-0053) and this Statement of Work for this phase of the procurement. This presentation shall cover programmatic, technical, test and verification, and quality assurance topics, and address any changes made to the Verification

Matrix since DCR. (DIL #11) This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the testing of the hardware.

3.4.4 Pre-Ship Review (PSR)

The contractor shall hold a Pre-Ship Review at the contractor's facility at the completion of verification tests and prior to the shipment of each hardware item to NASA/GSFC. (DIL #12)

This presentation shall demonstrate completion of all activities required for delivery of any hardware deliverable item to NASA/GSFC, and note any activities that are incomplete. In particular, the contractor shall present the completed verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses) where applicable. (DIL

#13) Any requirements that are not met shall be identified in the Deviations/Waivers etc. list and discussed with NASA/GSFC during the review.

An End Item Data Package (EIDP) shall be made available for review during pre-ship reviews for each of the different hardware deliverables. (DIL #14) This package shall also be delivered with each end item with the level of detail required of that item. The package should be comprised of, but not limited to, the following data:

The deliverable item name, serial number, part number, and classification status (e.g., flight, non-flight, ground support)

Appropriate approval signatures (e.g., contractor’s quality representative, product design lead, government Representative)

Work orders for the final assembly and associated tests

As-Built vs. As Designed Parts List, (EEE parts, includes serialization/revisions)

As-Built Final Drawing Package (including rework instructions, if any)

Problem/anomaly reporting (complete copies of report)

Deviations/Waivers/shortages/open items/non-conformances and their dispositions, with supporting rationale

Status of all action items from previous reviews

Class I MRBs (complete copies of reports)

List of As-Built Materials and Processes used

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Achieved surface cleanliness and outgassing rate data (when applicable)

Log of total operating time and failure-free operation

List and status of all identified Life-Limited Items

Trended Critical Parameters Data (when applicable)

Verification matrix (including environmental), test data and reports

Photograph Documentation (Pre and Post conformal coating, Pre-Closure and Closed)

Certificate of Conformance, with management signature

End Item Inspection Report

As-Built Configuration List

Mate/Demate log

Printed circuit board coupon results

Storage and Transportation Plans and Requirements

3.4.5 Technical Interchange Meetings (TIM)

The contractor shall plan for and facilitate up to five (5) informal, face-to-face technical interchange meetings to be held at the contractor facilities. (DIL #15) These TIMs shall support review and coordination of technical issues including, but not limited to, parts, test plans, test procedures, software changes, design modifications, and design analyses.

3.5 DOCUMENTATION

The contractor shall ensure the generation and delivery of all documentation as called for in the contract and listed in the DILS document, PACE-COMM-LIST-0008.

In addition to that documentation specifically called for in the contract, upon request by the

NASA/GSFC COR, the contractor shall make available a copy of any document or data generated during this contract performance for review by GSFC at either the contractor's facility or via the internet. This includes, but is not limited to, technical reports and memorandums, drawings, schematics, studies, analyses, parts and materials data, test data, alerts, etc.

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4.0 DESIGN AND ANALYSIS

The contractor shall perform analyses of the technical and environmental requirements specified in the PACE Project TWTA Performance Specification (PACE-COMM-SPEC-0053) to ensure compliance of the hardware fabrication and to assemble the documentation necessary to ensure its usability by NASA/GSFC users.

4.1 INTERFACE CONTROL DOCUMENTATION

The Contractor shall provide the following documents (DIL #16):

Mechanical Interface Control Document (MICD), including physical characteristics, mounting interface, outline drawing, thermal coatings on surfaces

Electrical Interface Control Document (EICD), including connector identification, connector pinouts, detailed description of each signal, interface circuits, command description, command sequencing/timing

4.2 DRAWING PACKAGE

The contractor shall provide a drawing package that includes, but is not limited to: (DIL #17)

ELECTRICAL: assembly and interface drawings (board level schematics available on request)

MECHANICAL: assembly and interface drawings

4.3 COMPUTER MODELS

The contractor shall deliver a Computer-Aided Design (CAD) file for the TWTA (DIL # 18)

4.4 STRUCTURAL ANALYSIS REPORT

The purpose of the structural analyses is to demonstrate compliance with the mechanical/structural design and test requirements. Structural analyses verify the structural integrity of the flight hardware by assessing the size and location of applied loads, load paths, and critical failure modes. A Structural Analysis shall be performed on the Flight Unit structure to ensure the capability to withstand and survive launch and ascent loads. (DIL #19) The analysis shall also address loads on any lift points as well. For metallic elements whose strengths are to be qualified by analysis (rather than by test, subject to NASA/GSFC approval), margins of safety will be 2.0 on yield and 2.6 on ultimate. Beryllium and composite materials shall not be qualified by analysis alone. The effects of any thermal inputs shall be reflected in the analyses as appropriate. This analysis shall include a Venting analyses for applicable flight components (such as thermal blankets and contamination enclosures) susceptible to pressure loadings to verify that positive strength margins exist at loads equal to twice those induced by the maximum pressure differential during launch. The results of these analyses shall be summarized in a contractor format Structural Analyses Report that will be provided to the NASA/GSFC COR for review.

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4.5 STRUCTURAL FINITE ELEMENT MODEL

Contractors required to submit finite element models (per PACE-COMM-SPEC-0053, Section

6.3, 11.5) to the spacecraft shall submit model documentation that describes the following: (DIL

#20)

1. The version of the model, including date of creation

2. A list of element, node, property, and material identification (ID) numbers

3. A description of the nonstructural mass represented on each property card

4. A description of units

5. A description of the local reference coordinate system

6. The results of satisfying the following model validity checks

Equilibrium/grounding

Rigid body equilibrium/grounding checks using the NASTRAN

GROUNDCHECK case control statement to assess the presence of mechanisms, overconstraints, etc. for all six model degrees-of-freedom for the various constraint sets.

Free-free dynamics (showing rigid body modes)

In the unconstrained condition, the deployed on-orbit model should have six rigid body modes with frequencies below 0.005 Hz, with a goal of 0.0005 Hz, and the ratio of the lowest elastic mode frequency and the highest rigid body mode frequency should be greater than 100, with a goal of 1000. In their unconstrained condition, the stowed dynamics and thermal distortion models should have six rigid body modes with frequencies below 0.001 Hz, with a goal of 0.0001 Hz.

Unit gravity loading (each axis)

With the model constrained at appropriate interfaces, and 1G inertial loadings applied separately in three orthogonal directions, the sum of constrained forces in the loading direction should be within 0.01% of the model weight. The magnitude of the sums orthogonal to the loading direction should be less than 1.0 N.

Enforced displacement/rotation (all 6 degrees-of-freedom)

Grounding forces will be determined by applying unit rigid body displacements and rotations to a stiffness matrix of the unsupported model, and determining the resultant grid point forces. Full capability of NASTRAN GROUNDCHECK case control can be used to determine grounding forces and moments. Grounding forces should be less than 1.0 N, and moments less than 0.5 N-m.

Matrix Conditioning Checks

The maximum ratio of any diagonal term to its corresponding term of the triangular factor matrix should be less than 5.0E7. The evaluation should be performed in a static decomposition with restraints applied to remove rigid body modes. A negative value of NASTRAN Param, Bailout, and forcing program execution with near singularities will not be used.

In NASTRAN static analysis (for instance unit gravity and thermal load checks), epsilon is a measure of the error in the load predicted from the product of

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stiffness matrix and solution set displacement compared to the actual input load vector . Epsilon should be less than 1.0E-8.

Unit increase temperature (if required)

When thermal stress assessment are performed, model checks are needed to ensure proper results. Remove all rigid elements (if not assigning thermal expansion values), equate all material coefficients of thermal expansion and reference temperatures, assign a uniform temperature field and allow for expansion/contraction of the model in all 6 degree-of-freedom. Results should show minimal element force generation and uniform expansion/contraction.

7. Mass Properties (CG location, Inertias, and total model mass)

Contractors required to submit finite element models (per PACE-COMM-SPEC-0053, Section

6.3, 11.5) to the spacecraft shall adhere to the following:

1. Model submitted as a MacNeal Schwendler Corporation (MSC)/ NASA Structural

Analysis (NASTRAN) data deck

2. All model property and material cards have descriptive names

3. Models submission is "full" model with no symmetry assumptions made to reduce model size

4. Model includes no "Super Elements"

5. Model submission includes an explicit Single Point Constraint set

6. Until actual hardware mass properties are verified and final, the finite element model is adjusted to the maximum allocated mass for each subsystem and component

4.6 THERMAL ANALYSIS REPORT

The Contractor shall perform a worst case thermal analysis that illustrates that the device and/or the electronic parts junction temperatures are within the Electrical, Electronic, and

Electromechanical (EEE) EEE-INST-002 (DIL #21) de-rated operational temperature limits when subjected to the boundary conditions specified in the TWTA Performance Specification

(PACE-COMM-SPEC-0053). This analysis shall be performed with the components operating at their maximum expected power dissipations. By analysis or by similarity to other flight qualified parts, contractor shall also prove that start up at the minimum non-operational temperature will not cause damage to any parts. All analysis results shall be summarized in a thermal analyses report, to be provided for review as per the contract schedule. This report shall contain a comprehensive list of each component’s maximum expected power dissipation, maximum case temperature, theta JC, maximum junction temperature, and de-rated operational temperature limit. Additionally, this report shall contain a thorough description of the computer models (or reference to the documentation required from section 4.7 (Thermal Model and

Documentation) of this document) and the assumptions that were used to perform the analysis including boundary conditions, surface finish thermo-optical properties, interface conductances.

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4.7 THERMAL MODEL AND DOCUMENTATION

The Contractor shall provide reduced Thermal Math Models (TMMs) for the TWTA with less than 50 nodes per box. (DIL #22) The TMMs shall be delivered in an agreed upon format. If the contractor does not have the project-compatible software to create TMMs, then the contractor shall provide sufficient detailed information such that GSFC can create the TMMs.

Documentation shall be provided including detailed descriptions of all aspects of the model necessary for GSFC to run and/or recreate the TMMs.

4.8 WORST CASE CIRCUIT ANALYSIS REPORT

The contractor shall perform worst-case analyses (WCA) for newly designed or modified circuits. (DIL #23) This element has been identified as warranting a Worst Case Analysis, since it has performance critical or function critical components for which excessive operating variations could compromise mission performance. They include control loops that require adequate phase and gain margin to operate properly, sensitive analog circuitry, power supply or switching circuitry, Field Programmable Gate Arrays, motor and actuator systems, and electro-mechanical elements that require torque margin to operate over life and environmental variations. The result is “reliability is designed into the hardware” for long term trouble-free field operation (i.e., removal of adverse operational circuit behavior due to unanticipated component stress drift).

WCA shall be performed during the design phase by the design engineer. The Worst Case

Analysis Report shall include the following:

Address worst case conditions performed on each component.

Discuss how each analysis includes the mission life.

Discuss consideration of critical parameters at maximum and minimum limits.

The effect of environmental stresses on the operational parameters being evaluated.

The results of these analyses shall be summarized in a Contractor format Worst Case Circuit

Analysis Report that will be provided to the NASA/GSFC COR for review.

4.9 PARTS STRESS ANALYSIS REPORT

The contractor shall perform parts stress analyses on Electrical, Electronic, and

Electromechanical (EEE) parts and devices as employed in the circuit designs of the Flight Item to certify conformance with the derating requirements of EEE parts. (DIL #24) The analyses shall be documented, and justification shall be included for all applications that do not meet the derating criteria. The Contractor shall use NASA document EEE-INST-002, Instructions for

EEE Parts Selection, Screening, Qualification, and Derating to establish criteria. Contractor derating guidelines may be considered in place of EEE-INST-002 guidelines but shall be submitted for approval. (DIL #25) The results of these analyses shall be summarized in a

Contractor format Parts Stress Analysis Report that shall be provided to the NASA/GSFC COR for review.

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4.10 RADIATION HARDNESS ANALYSIS REPORT

The contractor shall perform a Radiation Hardness Analysis on the TWTA design to determine the effects of Total Ionizing Dose (TID), Displacement Damage Dose (DDD) and Single Event

Effects (SEE) on performance. (DIL #26) The analysis shall address all the requirements contained in PACE-COMM-SPEC-0053. The results of these analyses shall be summarized in a

Contractor format Radiation Hardness Analyses Report that will be provided to the NASA/GSFC

COR for review.

4.11 RELIABILITY ANALYSIS REPORT

The contractor shall provide a numerical reliability assessment of the component, using reliability data from historical on-orbit performance, life-testing, or data books, such as MIL-

HDBK-217F. (DIL #27) The results of this analysis shall be summarized in a Contractor format

Reliability Analysis Report that will be provided to the NASA/GSFC COR for review.

4.12 FAILURE MODES AND EFFECTS CRITICALITY ANALYSIS REPORT

The contractor shall perform an FMECA (Failure Modes and Effects Criticality Analysis) to identify potential failures with severity categories 1, 1R, 1S, 2, 2R, 3, and 4 per Table 4-1. (DIL

#28)

The FMECA shall be updated throughout the development life cycle to address design changes that result in changes to failure modes, causes, effects, system impact, or to mitigation status and corresponding retention rationale. FMECA shall be performed at the interface and functional level of the component.

The contractor shall prepare and maintain a critical items list (CIL) for severity categories 1, 1R, 1S, and 2 per Table 4-1.

The contractor shall:

Analyze failure modes resulting in severity categories 1, 1R, 1S, or 2 to determine the potential cause, corresponding mitigation actions, and retention rationale.

For each item on the CIL that is not addressed by having a Corrective Action taken which reduces the severity category to a 2R, 3 or 4, there shall be a retention rationale prepared/recorded which contains data that supports the premise that the risk presented by inclusion of the item in the design has been minimized by one or more of the following: detailed evaluation of probability of occurrence; proper design controls, inspections, and tests; and that no adverse failure history exists. The rationale also will contain data that describes operational constraints caused by occurrence of the failure and any measures that can be taken to restore the function on orbit.

Identify and assess common cause failure modes and causes for category 1R and 2R items

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Address flight hardware and software that is designed, built, or provided by their organization or subcontractors, from project initiation through launch and mission operations.

Address the ground system that interfaces with flight equipment to the extent necessary to assure the integrity and safety of flight items.

Identify and address safety critical software.

Table 4-1 FMEA Severity Categories

Category Severity Severity Description

1 Catastrophic Failure modes that could result in serious injury, loss of life

(flight or ground personnel), or loss of launch vehicle.

1R Failure modes of identical or equivalent redundant hardware items that could result in Category 1 effects if all failed.

1S Failure in a safety or hazard monitoring system that could cause the system to fail to detect a hazardous condition or fail to operate during such condition and lead to Category 1 consequences.

2 Critical Failure modes that could result in loss of one or more mission objectives as defined by the GSFC project office.

2R Failure modes of identical or equivalent redundant hardware items that could result in Category 2 effects if all failed.

3 Significant Failure modes that could cause degradation to mission objectives.

4 Minor Failure modes that could result in insignificant or no loss to mission objectives

We are considering the loss of a single string component to be a category 2 and the loss of a redundant component to be a 2R.

The results of these analyses shall be summarized in a Contractor format Failure Modes And

Effects Criticality Analysis Report that shall be provided to the NASA/GSFC COR for review.

4.13 ERROR ANALYSIS REPORT

An Error Analysis shall be performed on the Flight Unit TWTA Design that shall identify all the factors that introduce error into the accuracy of the TWTA, and shows that the system can meet its performance requirements in spite of the errors. Errors may include, but not be limited to:

Alignment error, radiation effects, electronic noise, degradation of parts, optical distortions, thermal distortions, quaternion algorithm calculations, etc. An Error Tree shall be generated documenting ALL the sources of error, along with an Error Analyses Report and provided to

NASA/GSFC COR for review. (DIL #29)

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5.0 HARDWARE PROCUREMENT/MANUFACTURING

5.1 GENERAL REQUIREMENTS

The contractor shall either procure or manufacture all components required to assemble, integrate, and test the flight TWTA to support the delivery dates as called for in the contract and listed in the DILS document, PACE-COMM-LIST-0008.

The contractor shall assemble the quantities of TWTA hardware described below. The contractor shall provide a Fabrication, Assembly, and Inspection Flow plan at the DCR that shall include a step-by-step procedure that describes the method of fabrication, assembly, and inspection from piece parts to the completely assembled TWTA. (DIL #32)

5.2 KA-BAND TRAVELING TUBE AMPLIFIER (TWTA)

The contractor shall provide the following hardware to meet the requirements of the PACE

Project TWTA Specification (PACE-COMM-SPEC-0053).

One (1) Protoflight Traveling Wave Tube Amplifier

Two (2) Flight Traveling Wave Tube Amplifier

The contractor shall include in the proposal the cost to purchase all hardware including all supporting hardware.

5.3 CONNECTOR SAVERS

Flight Units shall be tested with connector savers to minimize mates and de-mates. Connector savers shall be delivered with each Flight Unit.

5.4 SUPPORTING HARDWARE

The Contractor shall provide the following supporting hardware:

One set of the mating half of the external connectors for each delivered flight unit, plus two additional sets per contract delivery schedule

Electrostatic Discharge flight protective caps, as applicable

Closeout caps for test connectors

5.5 GROUND SUPPORT EQUIPMENT

The Contractor shall provide Ground Support Equipment to support Integration and Test activities at the Observatory level. Ground Support Equipment includes:

Shipping container(s)

Drill template

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6.0 PERFORMANCE VERIFICATION AND TEST

6.1 VERIFICATION PLAN

A Verification Plan shall be generated by the contractor to describe the details of how the analyses, inspections, and verification tests identified in the PACE Project TWTA Performance

Specification, PACE-COMM-SPEC-0053, will be performed. (DIL #33) Verification tests shall demonstrate the item meets all of the specified performance requirements over the specified range of environments, measure performance parameters and reveal inadequacies in manufacturing and assembly such as workmanship or material problems. Any requirement that exceeds previous qualification test data shall be presented to the PACE project as part of the planning process for evaluation and a possible delta qualification test.

The plan shall state the purpose of each test, state acceptance criteria, describe in detail the test method, set up, instrumentation, data analysis methods (if applicable), and give the sequence of the tests. The plan shall include a verification matrix summarizing how all requirements are verified (analysis, inspection, test, per the definitions in the Spec.), and listing all tests that will be performed on the TWTA.

This plan shall be a contractor controlled document and shall indicate all changes made after the initial approval by the NASA/GSFC COR. After Verification Plan approval, no changes shall be made without written NASA/GSFC COR approval.

If any individual test plans are created in addition to the master Verification Plan, such as for

Thermal Vacuum testing, those plans shall also be provided. (DIL #34)

6.2 VERIFICATION TEST PROCEDURES

The contractor shall generate Verification Test Procedures and provide them to GSFC. (DIL

#35) The verification procedures shall be step-by-step instructions for performing tests outlined by the Verification Test Plan. The procedures shall define the environmental conditions for the tests, required equipment and facilities, test constraints, use of diagnostic or performance test software, operating conditions, tolerance on all input stimuli, data to be recorded and pass/fail limits.

Verification Test Procedures shall be contractor controlled documents and shall indicate all changes made after the initial release for review to NASA. The Thermal Vacuum Test Procedure shall include the contents listed in Section 7.9.4 for the Chamber Configuration.

6.3 VERIFICATION TEST REPORTS

The contractor shall generate Verification Test Reports. (DIL #36) These reports shall document the results of each test that was performed, what test levels were achieved, what performance requirements were verified, what anomalies were seen, and how they were resolved. The

Thermal Vacuum Test Report may include the Bakeout results (see Section 7.9.4) if can be delivered by the delivery date for Bakeout Test Results as specified in the DILS.

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7.0 QUALITY ASSURANCE

7.1 GENERAL REQUIREMENTS

7.1.1 Quality Assurance Plan/Manual

The contractor shall have a Quality Management System that is compliant with the requirements of SAE AS9100 Quality Systems - Aerospace - Model for Quality Assurance in Design, Development, Production, Installation and Servicing or equivalent, as documented in a Quality

Assurance Plan. The Plan shall be delivered to the NASA/GSFC COR for approval, and GSFC shall be notified of any changes to the QA program. (DIL #37)

7.1.2 Surveillance of the Contractor

The work activities and operations of the contractor, subcontractors, and suppliers are subject to evaluation, review, survey, audit, and inspection by GSFC representative.

The contractor shall provide the GSFC representative with documents, records, equipment, and a suitable work area within their facilities that are required by the representative to perform their overview activities.

7.1.2.1 Government Source Inspection

The Government may elect to perform inspections at a supplier's facilities. The following statement shall be included on all procurement documents: “All work on this order is subject to inspection and test by the Government in accordance with the inspection clauses in the contract.”

The Government quality representative who has been delegated NASA quality assurance functions on this procurement shall be notified immediately upon contractor receipt of any supplier/subcontractor orders. The Government representative shall also be notified 48 hours in advance of the time that articles or materials are ready for inspection or test.

7.1.2.2 Contractor Source Inspection

The contractor shall ensure that its procurement documents impose the applicable requirements on subcontractors and other suppliers. The subcontractor and other suppliers shall in turn impose the requirements on their procurement sources.

The contractor shall perform source inspection at the subcontractor's or supplier's facilities in accordance with the procurement documentation or when one or more of the following conditions exist:

In process, end item controls, or tests that are destructive in nature prevent the contractor from verifying quality after delivery to the contractor's facility.

It is not feasible or economical for the contractor to determine the quality of procured articles solely by inspections or tests performed at the contractor’s facility.

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Qualification tests are to be performed by the subcontractor or supplier.

Products are shipped directly from the source to NASA, by-passing the contractor's inspection facilities.

7.1.2.3 Government Mandatory Inspection Points (MIPs)

The contractor shall plan for GMIPS. The contractor shall provide work instructions, procedures, drawings, etc. that are appropriate for the activities. The following are examples of activities that may be subject to GMIPS:

- Circuit card assemblies

- Final solder inspection before conformal coating and staking

- Post conformal coating

- Pre-closure of boxes

- Harness – pre integration (pre staking or potting)

- Unit and component level assembly – witness final assembly

- Mechanical – final assembly and acceptance test

- Software acceptance test

- Rework and repairs to flight hardware

- Pre-Ship Inspection/Data…