SSP_50102.pdf

SSP-50102

NASA/ASI BILATERAL INTEGRATION &

VERIFICATION PLAN

INTERNATIONAL SPACE STATION PROGRAM

January 24, 1997

NASANASA

National Aeronautics and Agenzia Spaziale Italiana Space Administration

International Space Station Rome, Italy Program Office Houston, Texas

SSP 50102 24 January 1997 i

PREFACE

The NASA/ASI Bilateral Integration and Verification Plan (BI&VP) is the document that defines the joint NASA and ASI integration and verification activities and identifies the organizational procedures involved in implementing the integrated verification requirements of the Mini Pressurized Logistics Module (MPLM) Segment. The goal of this document is also to ensure integration of the MPLM as part of the International Space Station (ISS).

The NASA/ASI Bilateral Integration and Verification Plan equally applies to the NASA and the Agenzia Spaziale Italiana (ASI). This document is under the control of the International Space Station Control Board (SSCB) with the concurrence of ASI. Any changes or revisions will be approved by the International Space Station Control Board and ASI.

Original Signed by Brinkley Original Signed by Rum

NASA

Space Station Program Manager

ASI

Program Manager

January 27, 1997 January 27, 1997

Date Date ii

CONCURRENCE

INTERNATIONAL SPACE STATION PROGRAM

NASA/ASI BILATERAL INTEGRATION AND VERIFICATION PLAN

January 24, 1997

Prepared by: W. J. Pattison ISSPO Verification

(NASA)

Original Signed by Pattison January 24, 1997 (Signature) (Date)

Checked by: William Arceneaux ISSPO Verification

(NASA)

Original Signed by Arceneaux January 24, 1997 (Signature) (Date)

Supervised by: Walt Wood Launch Package IPT

(NASA)

Original Signed by Wood January 24, 1997 (Signature) (Date)

Supervised by: Silvana Rabbia ASI

(ASI)

Original Signed by Rabbia January 24, 1997 (Signature) (Date)

DQA: Richard Wadle NASA

(Signature) (Date) iii

REVISION AND HISTORY PAGE

REV. DESCRIPTION PUB.

DATE

- Initial Release per SSCD 000574, EFF. 05-22-97 06-04-97 iv

TABLE OF CONTENTS

1. INTRODUCTION ........................................................................................................................... 0-1

1.1 PURPOSE AND SCOPE OF THE DOCUMENT....................................................................................... 0-1

1.2 PRECEDENCE...............................................................................................................................0-1

1.3 DOCUMENT EDITING, MAINTENANCE AND RELEASE AUTHORITY ................................................... 0-2

2. DOCUMENTS................................................................................................................................. 1-1

2.1 APPLICABLE DOCUMENTS............................................................................................................. 1-1

2.2 REFERENCE DOCUMENTS.............................................................................................................. 1-1

3. SYSTEM DESCRIPTION............................................................................................................... 2-1

3.1 U. S. SYSTEM DESCRIPTION......................................................................................................... 2-1

3.1.1 U. S. On-Orbit Segment (USOS) Description ....................................................................... 2-1

3.1.2 U. S. Ground System (USGS) Description............................................................................ 2-3

3.2 MPLM FLIGHT SYSTEM DESCRIPTION......................................................................................... 2-3

3.2.1 Structural/Mechanisms........................................................................................................ 2-4

3.2.2 Transport Modification Kit .................................................................................................. 2-5

3.2.3 Environment Control System ...............................................................................................2-5

3.2.4 Avionics System (AVS)......................................................................................................... 2-7

3.2.5 Software.............................................................................................................................. 2-7

3.2.6 Drag-on Equipment ............................................................................................................. 2-8

3.2.7 Active-to-Passive Reconfiguration....................................................................................... 2-8

3.2.8 Refrigerator/Freezer Racks ................................................................................................. 2-8

3.2.9 Mechanical Ground Support Equipment (MGSE) ................................................................ 2-9

3.2.10 Fluid Ground Support Equipment (FGSE)......................................................................... 2-9

4. INTEGRATION AND VERIFICATION ........................................................................................ 3-1

4.1 U.S. INTEGRATION AND VERIFICATION PROCESS........................................................................... 3-1

4.2 ASI VERIFICATION PROCESS........................................................................................................ 3-3

4.2.1 Joint Integration and Verification Program Approach......................................................... 3-5

4.2.2 ISSP Test & Verification Team..........................................................................................3-11

4.2.3 ASI Verification Responsibility ..........................................................................................3-11

4.3 RELATIONSHIP BETWEEN NASA AND ASI VERIFICATION MANAGEMENT .....................................3-11

4.4 NASA/ASI VERIFICATION PROCESSES........................................................................................3-12

4.4.1 Verification Requirements ................................................................................................. 3-13

4.4.2 Responsibility Assignment ................................................................................................. 3-16

4.4.3 Verification Procedures and Methods (including software)................................................3-17

4.4.4 Verification Traceability and Close-out.............................................................................3-19

4.4.5 Process Sampling..............................................................................................................3-25

4.4.6 Verification Certification...................................................................................................3-28

4.5 MPLM PROGRAM MILESTONE REVIEWS.....................................................................................3-29

5. SUBSYSTEM VERIFICATION ..................................................................................................... 4-1

5.1 SUBSYSTEM VERIFICATION APPROACHES...................................................................................... 4-1

5.1.1 C&DH Early Design Compatibility and Stage Verification Approach.................................. 4-1

5.1.2 Thermal Control System (TCS) Verification Approach......................................................... 4-4

5.1.3 Environmental Control and Life Support System (ECLSS) Verification Approach................ 4-4

5.2 SUBSYSTEM JOINT TESTING.......................................................................................................... 4-5

5.2.1 Preparation for Joint C&DH Verification Testing at SVF.................................................... 4-5

5.2.2 Joint C&DH Verification Tests ............................................................................................4-5 v

5.3 ELECTRICAL INTERFACE STABILITY ANALYSIS .............................................................................. 4-6

6. SEGMENT VERIFICATION ......................................................................................................... 5-1

6.1 FLIGHT SYSTEM........................................................................................................................... 5-1

6.2 GROUND SUPPORT EQUIPMENT..................................................................................................... 5-3

7. INTERFACE VERIFICATION ...................................................................................................... 6-1

8. GROUND CHECK-OUT OF ON ORBIT ASSEMBLIES ............................................................ 7-1

8.1 DIGITAL PRE-ASSEMBLY (DPA) PROCESS..................................................................................... 7-1

8.1.1 DPA Validation At MPLM/NODE1 Interface....................................................................... 7-1

8.2 MASTER CABLING ........................................................................................................................ 7-2

8.2.1 Physical Check at MPLM Interface ..................................................................................... 7-3

9. SUPPORT EQUIPMENT ............................................................................................................... 8-1

10. FACILITIES .................................................................................................................................. 9-1

10.1 NASA SOFTWARE FACILITIES .................................................................................................... 9-1

10.1.1 Software Development and Integration Laboratory (SDIL)................................................ 9-1

10.2 MPLM VERIFICATION ACTIVITIES............................................................................................. 9-2

APPENDICES

Appendix A: Definition of Terms Appendix B: Abbreviations and Acronyms Appendix C: List of Candidates for Process Sampling

FIGURES

Figure 1-1: NASA/ASI Documentation............................................................................. 1-3 Figure 1-2: Verification Policy and Planning Documentation Tree.................................. 1-4 Figure 3-1: USOS System Diagram.................................................................................. 3-2 Figure 3-2: MPLM External Configuration (Isometric View without MDPS).................. 3-4 Figure 4-1: ISS Program Phases and Milestones including ASI Review Milestones........ 4-2 Figure 4-2: Summary of ASI Verification Process…….................................................... 4-5 Figure 4-3: MPLM Verification Control Document (VCD) Format (4 pages)………….. 4-6 Figure 4-4: Involvement in MPLM Verification Process………………………………... 4-13 Figure 4-5: MPLM Project - Requirements Flow Rationale…………………………….. 4-16 Figure 4-6: ASI Verification Traceability & Close-out Process (2 pages)………………. 4-20 Figure 4-7: NASA/Prime Verification Traceability Process……………………………... 4-23 Figure 4-8: ASI Verification Data Format for Transfer to PVIS (2 pages)………………. 4-26 Figure 5-1: MPLM-Node1 Configuration for Flights 6A, UF1 & UF2….......................... 5-2 Figure 5-2: MPLM-Node2 Configuration after Flight 10A…………................................ 5-2 Figure 6-1: MPLM Verification Model Philosophy……………………………………… 6-2

0-1

0 Introduction

0` 0 Purpose and Scope of the Document

The NASA/ASI Bilateral Integration and Verification Plan (BI&VP) documents the agreements between NASA and ASI for the integration and verification of the Italian Mini Pressurized Logistics Module (MPLM) Segment into the International Space Station (ISS) as established in the NASA/ASI Joint Management Plan (JMP), SSP 50076.

This document defines the Agenzia Spaziale Italiana (ASI) and the National Aeronautics and Space Administration (NASA) integration and verification activities and identifies the organizational elements involved in implementation of those activities including the responsibilities and involvement of both parties leading up to the delivery of the MPLM Segment. This plan also identifies support equipment, test support equipment and the required facilities.

The activities defined in this plan address the verification tasks required to comply with the requirements in the MPLM Segment Specification and to integrate the MPLM with the Space Station.

0` 1 Precedence

This document is prepared in compliance with the NASA/ASI Memorandum of Understanding (MOU), NASA/ASI Joint Management Plan (JMP) and the MPLM Segment Specification. The NASA/ASI documentation and relationship to other program documentation is shown in Figure 1-1. These documents are jointly developed by NASA and ASI. They are intended to document the agreed to joint policies and processes. The Bilateral Plans are prepared within the guidelines provided in those documents. The Bilateral Hardware/Software Exchange Agreement document reflects the bilateral agreements and decisions made as to the delivery or transfer of hardware and or software from one organization to another. It is a listing of actual hardware and software. The Bilateral Data Exchange document reflects the bilateral decisions and agreements for the exchange of data. The MOU, JMP, or the MPLM Segment Specification takes precedence in case of conflict with the NASA/ASI BI&VP.

The top level overall verification planning document for the International Space Station Program (ISSP) is documented in the Program Master Integration and Verification Plan (PMI&VP). The NASA/ASI BI&VP will comply with the NASA/ASI Joint Management Plan (JMP) and will receive source data from PMI&VP. The BI&VP will address the engineering and verification processes utilized. The verification documentation relationship between these documents and other verification documents is shown in the Verification Policy and Planning Documentation Tree (Figure 1-2).

0-2

0`2 Document Editing, Maintenance and Release Authority

The NASA/ASI BI&VP is controlled bilaterally, through approval signature, by the NASA Space Station Program Manager and the ASI Program Manager or their delegated authorities. The baseline BI &VP will be maintained by NASA Configuration Management Office. Changes to the baseline BI&VP must be disposition and approved by the NASA and ASI Space Station Managers or their authorized representatives following a review process in accordance with the process guidelines defined in

NASA/ASI JMP SSP 50076.

0-3

Management Plans

Memorandum of Understanding

Joint Management Plan

Multilateral Interface Control Plan

Space Station Documentation

Bilateral Data Exchange Agreements, Lists and

Schedules

Bilateral Hardware and Software Exchange

Agreements, Lists and Schedules

FIGURE 1-1: NASA/ASI Documentation

Bi-Lateral Implementation Plans

MPLM End Item Specification

Concept of Operations and Utilization

Vol. II, Mission Profiles and Scenarios

Concept of Operations and Utilization

Vol. I, Principles

Concept of Operations and Utilization

Vol. III, Pro cesses

Station Program Implementation Plan

(SPIP)

Space Station System Specification

MPLM Segment Specification

LLS GSE to

MPLM GSE

ICD

HOSC to ASI Gateway

ICD

Rack to

MPLM ICD

MPLM to

Shuttle ICD USOS to

MPLM ICD

CBM to Pressurized Element ICD

Hatch to Presurized

Element ICD

Refrigerator /Freezer to

MPLM ICD

LLS GSE to MPLM Flight

Hardware

ICD

Bilateral Integration and Verification Plan

Bilateral Safety & Product Assurance

Requirements

(Source: NASA/ASI Joint Management Plan SSP 50076)

ISPR to

LAB/JEM/APM

ICD

S

P 50102

24 January 1997

0-4

FIGURE 1-2: Verification Policy and Planning Documentation Tree

NASA/ASI

Bilateral Integration &

Verification Plan

(BI&VP)

SSP 50102

Program Master Integration & Verification Plan

(PMI&P)

D684-10020-1

Program Master Integration & Verification Plan

(PMI&P)

D684-10020-1

Integration & Verification Implementation Plan

(I&VIP)

D684-10025-1

Integration & Verification Implementation Plan

(I&VIP)

D684-10025-1

Product Group Master Verification Plans

(MVP)

Product Group Master Verification Plans

(MVP)

NASA/ASI

Joint Management Plan

(JMP)

SSP 50076

MPLM

Verification

Plan

MLM-PL-AI-0008

MPLM

Verification

Plan

MLM-PL-AI-0008

MPLM Subsystem Verification Plans

Process Data

Joint Activities

1-1

1 Documents

The following documents are specified in their current version and any major changes made to the specified documentation will be done with the visibility of both NASA and

ASI.

1` 0 Applicable Documents

Applicable documents are those documents which are considered authoritative in the context of this document. When no revision or date is specified, the latest revision is considered applicable. The applicable revision will be the one agreed between NASA and ASI per the ISSP change processing.

DOCUMENT NO. TITLE

No Number Memorandum of Understanding between the United States National Aeronautics and Space Administration and the Italian Space Agency for the Design, Development, Operation and Utilization of Two Mini Pressurized Logistics Modules and a Mini Laboratory for Space Station Freedom

SSP 50076 NASA/ASI Joint Management Plan

SSP 50125 NASA/ASI Bilateral Data Exchange Agreements

SSP 50219 NASA\ASI Bilateral Hardware and Software Exchange Agreements, Lists and Schedules

SSP 50017 Assembly Sequence and Manifest Document (AS&MD)

1` 1 Reference Documents

Reference documents are those documents which are sources of information which is helpful in developing the context of this document. Only documents called up in the text of this document are referenced here. When no revision or date is specified, the latest revision is considered applicable. The applicable revision will be the one agreed between NASA and ASI as per the ISSP change processing.

1-2

DOCUMENT NO. TITLE

D684-10020-1 Program Master Integration and Verification Plan

D684-10021 Program Verification Information System (PVIS) Process Document

D684-10056-1 Software Standards and Procedures Specification Document

NSTS 08117 Space Shuttle Requirements and Procedures for Certification of Flight Readiness

NSTS 14046 Payload Verification Requirements

SW684-10022 Program Verification Information System (PVIS) Software Requirements Specification

SSP 30233 Space Station Requirements for Materials and Processes

SSP 30459 ISS Interface Control Plan

SSP 41000 System Specification for ISS

SSP 41164 Italian Mini-Pressurized Logistics Segment Specification

SSP 41172 Environmental Qualification and Test Requirements

SSP 41174 ISS ICWG Operating Procedures

SSP 50011 Concept of Operations and Utilization Document

SSP 50021 Safety Requirements for ISSP

SSP 50108 ISSP Certificate of Flight Readiness Process Document

SSP 50182 NASA/ASI Bilateral Safety and Product Assurance Requirements

SSP 50226 Mini-Pressurized Logistics Module (MPLM) to the Software Development and Integration Laboratory (SDIL) Interface Control Document Part 1

SSP 50123 Appendix Q Configuration Management Handbook

KSC-ISS-LSU-311 Resupply and Return Processing Plan

1-3

MLM-PL-AI-0003 Electromagnetic Compatibility (EMC) Control Plan

MLM-PL-AI-0008 MPLM Verification Plan

MLM-PL-AI-0011 MPLM Configuration and Data Management Plan

MLM-RP-AI-0130 MPLM Flight System End Item Specification to Segment Specification Traceability report

MLM-RP-AI-0131 MPLM FGSE End Item Specification to Segment Specification Traceability report

MLM-RP-AI-0132 MPLM MGSE End Item Specification to Segment Specification Traceability report

MLM-SR-AI-0004 Test Requirements Specification

MLM-SR-AI-0001 Electromagnetic Compatibility (EMC) Specification

MLM-SY-AI-0001 MPLM Flight System End Item Specification

MLM-SY-AI-0003 Mechanical Ground System End Item Specification

MLM-SY-AI-0002 Fluid Ground System End Item Specification

2-1

2 System Description

The International Space Station (ISS) is an international endeavor being developed by the National Aeronautical and Space Administration (NASA), the National Space Development Agency of Japan (NASDA), the European Space Agency (ESA), the Agenzia Spaziale Italiana (ASI), the Canadian Space Agency (CSA), and the Russian Space Agency (RSA). The ISS consists of pressurized modules and unpressurized systems and elements that form a human base in low earth orbit. The ISS provides science capabilities for micro-gravity, materials, life science research and development, earth and stellar observation as well as other technology development and demonstration by United States and the International Partners.

The ISS is comprised of the U.S. On-orbit Segment (USOS), U.S. Ground Segment (USGS), ASI Italian Mini-pressurized Logistics Modules (MPLM), ESA Attached Pressurized Module (APM), NASDA Japanese Experiment Module (JEM), RSA Russian Segment (RS), and the CSA Canadian Mobile Servicing System (MSS).

The ISS development is accomplished in stages using a pre-defined sequence of assembly flights. Every physical station configuration in each stage shall be verified.

The assembly sequence flight numbers will be used to reference the verification reporting. Changes within an assembly stage shall be considered in the verification of that stage. The following represents a brief description of the relevant hardware for the USOS, USGS and MPLM systems and interfaces involved in the verification process.

2` 0 U. S. System Description

2` 0 ` 0 U. S. On-Orbit Segment (USOS) Description

The United States On-orbit Segment (USOS) is an earth orbiting facility which houses experiment payloads, distributes resource utilities, and supports permanent human habitation for conducting research and science experiments in a micro-gravity environment. The USOS supplies the following services and capabilities to ISS: electric power generation , distribution and control; primary communications and data links to ground support facilities; environmental control and life support; thermal control and heat rejection; data processing; stowage and transportation; house keeping; personal hygiene; food preparation and storage; extravehicular activity access; payload utilities;

attitude control; pointing support and robotics system control. The USOS System Diagram is shown in Figure 3-1.

The U.S. pressurized modules contain equipment to provide laboratory, habitation, logistics resupply, and overall station command and control functions. The U.S.

2-2

T he rm al

C up ol a

Port

N od e

NADIR

NADIR

N od e

Zenith

Zenith

AFT

FWD

AFT

FWD

M ul tip le

In te rf ac es

M P

LM

a nd U

S G

S In te rf ac es

M T

S

S

S

S

S

P

P

P

P

PMA - 1

A irl oc k

U S

L A

B G N

C P

M C

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C

PMA - 2

E V

A A id s

A P

C U

I

U

LC

/A tta ch ed

P ay lo ad s

N od e

M P

LM

S

Z

P

U

LC

/A tta ch ed

P ay lo ad s

S

FIGURE 3-1: USOS System Diagram

R es up pl y/ R et ur n C on ta in m en t

PMA - 3

H A

B A

MPLM

N ot e

MPLM

N ot e

N O

T E

S

1.

M

P

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w ill c on ne ct to N od e

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ir) fo r fli gh ts

A

, U F

-1 a n d

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-2 o nl y.

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w ill c on ne ct to N od e

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-3 a nd s ub se qu en t u til iz at io n fli gh ts

2-3 pressurized elements includes the U.S. Laboratory Module (LAB), the U.S. Habitation Module (HAB), the Node 1, the Node 2, the Airlock, and the Cupola. The Nodes are pressurized, environmentally controlled elements that serve to connect the LAB, the HAB, and the International Partners' modules. With four radial ports and two axial ports each, the nodes are the building blocks for the pressurized elements for the station.

Node 1 serves as the initial berthing port for the MPLM until assembly flight of Node 2.

Then, Node 2 will become the primary berthing location for the Pressurized Mating Adapter (PMA), the forward end of the LAB, the APM, the JEM, and the MPLM when it arrives at the Station on a resupply mission. It contains equipment for primary-to-secondary power conversion and plumbing and cable runs to other elements.

The U.S. unpressurized elements includes the Integrated Truss Assembly (ITA), the Unpressurized Cargo Carriers ( UCC), the Photovoltaic (PV) power modules, the Solar Dynamics module, and the external central Thermal Control Subsystem (TCS).

2` 0`1 U. S. Ground System (USGS) Description

The United States Ground Segment (USGS) consists of the ground facilities, hardware, and software utilized in performance of the ground based support functions to the on-orbit Space Station. The USGS provides the capability for the integration and verification of the ISS products (hardware, software, displays, procedures and data). The USGS provides ground based monitoring and command and control of the Station and user payloads. The USGS provides the capability for training, operations planning, logistics, and for the processing of station equipment, payloads and waste returned from orbit.

The USGS also provides support to other functions. The USGS provides external interface functional support to the Space Shuttle Orbiter space transportation system, launch/landing site facilities, ground communication systems, and orbiting communication systems.

2` 1 MPLM Flight System Description

The MPLM Flight System is a pressurized module, used to re-supply and return ISS containerized cargo requiring a pressurized environment; the cargo can either be passive only, or include cold cargo accommodated in Refrigerator/Freezer-Refrigerator (R/FR) racks. The MPLM will be launched on the Orbiter in one of two configurations: passive or active. The active configuration is based upon the need to supply power, cooling and 1553B data interface from the Orbiter to the MPLM in support of an active (powered) R/FR on the MPLM. The passive configuration means the MPLM racks will be in a passive mode not requiring power, cooling and the 1553B data interface. Figure 3-2 provides an isometric view of the MPLM external configuration.

2-4

The MPLM Flight System is capable of accommodating up to sixteen cargo storage racks (ISPRs); moreover, five rack locations are provided with the interfaces of utility lines (coolant, electrical power and data), to support the accommodation of R/FR racks.

The MPLM Ground Systems support the MPLM Flight System during ground processing.

FIGURE 3-2: MPLM External Configuration (Isometric View without MDPS)

2 1̀̀0 Structural/Mechanisms

The MPLM Flight System primary structure includes the following elements:

• cylindrical shell, which consists of two sections interfacing through a central ring; each section includes aluminum alloy waffle panels, linked together by means of longitudinal welds;

• three forged rings (two external rings and one central ring) and two machined rings (intermediate rings);

• sixteen box-shaped longeron assemblies;

• the FWD cone shell, which consists of aluminum alloy waffle panels welded together, plus one F/T plate;

2-5

• the bulkhead, which includes the penetrations for the utility lines to/from the Space Station;

• the Hatch;

• the aft cone shell, formed by aluminum alloy waffle panels welded together and one forged ring;

• the Aft Access Closure (AAC);

• the flight fittings (two main fittings, two stabilizer fittings and one keel fitting);

• the Rack Attachment Blocks, used to connect the racks accommodated in the module interior to the cylindrical shell longerons.

The MPLM Flight System secondary structure includes the following elements:

• the Meteoroid and Debris Protection System (MDPS), which consists of a single bumper shield, provided with openings in proximity of the grapple fixtures, of the atmosphere control valves and generally of any equipment arranged externally on the module shell;

• the FWD cone support structure, which includes three independent honeycomb panels, connected to the primary structure, used to support most of the MPLM Flight System equipment;

• four standoffs, which mainly provide support for diffusers, grids, lights, ducting, piping and electrical harness; the standoffs also allow rack on-orbit tilting by insertion of dedicated hinge mechanisms;

• close-out panels, to meet Human Factor Engineering requirements, and light panels for fire suppressant containment;

• bracketing, needed to support some equipment.

The MPLM Flight System includes the following mechanisms:

• the Passive Common Berthing Mechanism (PCBM), to interface with the Active Common Berthing Mechanism (ACBM) installed on the ISS Node 1 and Node 2 nadir ports;

• two Flight Releasable Grapple Fixtures (FRGF), to allow the on-orbit deployment and berthing to the Space Station, and the retrieval and the re-insertion into the Orbiter cargo-bay.

2` 1̀ 1 Transport Modification Kit

To accept and route the Orbiter mission hardware resources, the MPLM Flight System accommodates a Transport Modification Kit, which consists of two Payload Disconnect Assemblies (ROEU and ROFU PDA’s), each supported by a dedicated truss structure installed on the FWD cone shell.

2` 1̀ 2 Environment Control System

2-6

The Environment Control System (ECS) includes the Environmental Control and Life Support Subsystem (ECLSS) and the Thermal Control Subsystem (TCS).

The ECLSS performs the following functions:

• Atmosphere Control and Supply (ACS): the hardware dedicated to this function consists of two Depressurization Assemblies (depressurization in the event of a contamination or a fire), three Positive Pressure Relief Assemblies (relief in the event of isolated module internal over-pressure), five Negative Pressure Relief Valves (automatic relief in the event of a depressurized module return to ground) and three Total Pressure Sensors (module internal pressure monitoring).

• Atmosphere Revitalization System (ARS): a sampling line provided with filter and shut-off valve leads the air sampled inside the MPLM Flight System to the Space Station.

• Fire Detection and Suppression (FDS): the MPLM Flight System contains a cabin smoke detector to detect a fire event and fire suppression ports to allow the crew members for discharging the fire suppressant contained in a Portable Fire Extinguisher (PFE) into the compartment affected by the fire event.

• Temperature and Humidity Control: a ventilation system including one cabin fan, ducting, diffusers, grids and one temperature sensor, ensures the air circulation inside the MPLM flight System cabin and in the FDS compartments (to ensure smoke detection); intermodule ventilation lines, each with a dedicated IMV shut-off valve, are provided to supply the module with revitalized air from the ISS and to return heat loaded air to the Space Station.

The Thermal Control Subsystem (TCS) includes the Active Thermal Control Subsystem (ATCS) and the Passive Thermal Control Subsystem (PTCS).

The ATCS collects the heat loads rejected by the R/FR’s (when included in the flight manifest) and by the cold plate cooled MDM and transfers them to the Orbiter or to the Space Station. This function is performed by means of a water loop, which includes one WPP, one on/off valve, one modulating valve, one differential pressure sensor, one cold plate, hard and flex pipes and quick disconnects.

The PTCS protects the MPLM Flight System from the external environment influences, minimizes the heat leakages/gains and prevents condensation inside the MPLM Flight System.

The PTCS equipment includes:

• the thermal control coating (MPDS external surface finish);

• the Multi-Layer Insulation (MLI), composed by blankets which cover all the

MPLM Flight System shell, including the Hatch and the CBM external/internal surfaces;

• insulation material, which covers all ATCS equipment;

2-7

• items which reduce (washers) or increase (fillers) the thermal conductivity at interface level;

• heaters arranged on the shell external surface, to prevent internal condensation and ATCS loop water freezing;

• heaters arranged externally on each depressurization assembly, to prevent icing inside the non-propulsive vent during the depressurization;

• heaters arranged on the ROFU PDA, to prevent water freezing in the jumpers.

2` 1`3 Avionics System (AVS)

The Avionics System performs electrical power distribution and conditioning, module illumination, data management and processing.

The electrical power distribution equipment includes:

• one Power Distribution Box (PDB), which distributes electrical power to all subsystem equipment (except for the shell heaters) depending on the user interface characteristics;

• one Heater Control Unit (HCU), which distributes electrical power to the shell heaters;

• one battery, which supplies the ROFU PDA heaters during the transfer phases (when the MPLM is manifested with R/FR racks).

The module general illumination is accomplished by means of eight General Luminaire Assemblies, switched on/off by one remote control assembly. The emergency illumination, which ensures the egress in case of loss of power, is provided by the Emergency Egress Lighting System, which consists of one Emergency Lighting Strip and one Emergency Lighting Power Supply.

The data management and processing provides the capabilities to monitor and control the MPLM Flight System equipment and the R/FR racks (when included in the flight manifest). The hardware dedicated to this function is the Multiplexer/Demultiplexer (MDM), which requires cold plate cooling; a backplane is used to support the harness-side plug connectors to be mated with the MDM receptacle connectors.

Electrical harness (cabling, connectors, backshells, MIL-STD-1553B components) is provided to accomplish power distribution and data transfer.

2`1`4 Software

The Flight Operational Software of the MPLM Flight System, running on the MDM computer provides the following functions:

• status polling and commanding of the R/FR’s (when included in the flight manifest), in behalf of either the Orbiter or the Space Station;

2-8

• monitoring and commanding of the ECS powered equipment and the electrical power distribution equipment;

• detection and isolation of predefined equipment failures, to prevent catastrophic hazardous events and failure propagations;

• function status data assessment;

• detection and isolation of fire events, by processing failure data;

• monitoring of the MPLM Flight System internal pressure.

2` 1 ` 5 Drag-on Equipment

The equipment accommodated into the MPLM Flight System after berthing to the ISS and removed before deberthing are called drag-on equipment. The drag-on equipment includes:

• one Portable Fire Extinguisher (PFE), used as the manual fire suppression system;

• one Portable Breathing Apparatus (PBA), which provides respirable atmosphere to the crew members in the event of a hazardous atmosphere condition;

• Intravehicular Activity Restraints & Mobility Aids, used to assist crew member operations and work activities.

2` 1`6 Active-to-Passive Reconfiguration

The MPLM Flight System active-to-passive internal reconfiguration is performed by removing the R/FR Kit, which includes:

• the Water Pump Package;

• the on-off valve;

• some hard and flex ATCS lines;

• and, by reconfiguration of MPLM CSCI.

Moreover, in the passive configuration, the Battery and the ROFU PDA are not installed.

2` 1̀ 7 Refrigerator/Freezer Racks

The Refrigerator/Freezer-Refrigerator (R/FR) racks will have power, data, coolant, and structural/mechanical interfaces with the MPLM. The R/FR is fully compatible with the International Standard Payload Rack (ISPR) attachment mechanisms and envelopes.

R/FRs provide module services for cold storage and freezing of food and supplies. R/FR units also support science specimens and samples.

The R/FR will support the following functions at the interface to the MPLM:

• Structural/Mechanical Attachment

2-9

• Return Coolant

• Receive Supplied Coolant

• Receive Power

• Supply Data

• Receive data

The MPLM will provide the following functions to the R/FR:

• Structural/Mechanical Attachment

• Supply Coolant

• Receive Returned Coolant

• Control Coolant Supply

• Supply Power

• Control Power

• Supply Data

• Receive Data

2` 1 `8 Mechanical Ground Support Equipment (MGSE)

ASI will supply the following ground support equipment: support structure lightweight floor, MDPS handling kit, pads and protective covers, and Aft access closure support fixture.

2`1`9 Fluid Ground Support Equipment (FGSE)

The water servicer kit (WSK) is used to vacuum fill, drain and dry the TCS loop and to store, prepare, circulate, de-aerate, adjust and sample cooling water. It provides helium and gaseous nitrogen to TCS for proof and leak test and nitrogen to WPP accumulator.

The gas leakage test stand is used to provide helium and gaseous nitrogen to the ECLSS loops and valve, of the MPLM for functional leak tests. The USOS/NSTS Thermal Simulator (UNTS) will simulate the Orbiter water supply and return, heat rejection capability, OPHX, ROFU and Transport Modification Kit (TMK) delta pressure and controls the water temperature at the Orbiter and MPLM inlet I/F. The thermal simulator is also used to simulate the USOS heat rejection and to control the water temperature at the USOS and MPLM inlet I/F.

3-1

3 Integration and Verification

3` 0 U.S. Integration and Verification Process

The verification process for U.S. elements is put in place to implement and control processes that confirm that the ISS is compliant with specifications, properly functions as an integrated unit and will serve its intended purpose. The Bilateral Integration and Verification Plan (BI&VP) is the documentation of the joint integration and verification activities established to ensure that the MPLM complies with the MPLM Segment Specification, applicable ICDs and the integration of the MPLM with the ISS.

Figure 4-1 depicts the ISS program phases and their relationship to program milestones as it relates to the MPLM and also identifies the different verification activities that occur during each phase. The verification activities described within this document encompass the phases up to the Final Acceptance Review.

During the Performance and Functional Requirements Compliance Phase, specification requirements are defined, stage-assembly configurations are defined and developed from end items, and unique stage assembly configuration designs are qualified. The following activities occur through development and documentation of requirements. Typical reviews planned for ISSP are: System Requirements Reviews (SRR), System Design Reviews (SDR), Preliminary Design Reviews (PDR), Critical Design Reviews (CDR), and Stage Integration Reviews (SIR).

A Functional Configuration Audit (FCA) is conducted to ensure specification requirements have been met. Closure of requirements is either by test, demonstration, inspection, or analysis. This FCA is based on the results of the verification activities initiated during the Performance and Functional Compliance Phase. For the MPLM Program this is called Qualification Review (QR).

The Flight Article Acceptance Phase is completed when the MPLM Final Acceptance Review/Physical Configuration Audit (FAR/PCA) is completed, ensuring each assembled configuration has been verified and is ready for assembly into the launch package.

In accordance with NASA/ASI Memorandum of Understanding, the MPLM (Flight and GSE) hardware and software will be shipped and delivered to KSC by ASI, who will also be responsible for the post-delivery inspection with the assistance of NASA, to ensure the equipment was not damaged or changed during shipment.

P 50102

24 January 1997

3-2

FIGURE 4-1: ISS Program Phases and Milestones including ASI Review Milestones

Define Requirements

Design and Development

Qualification Acceptance

Launch Pkg Processing

On-orbit

A&CO

On-orbit Operations

Post Landing

MPLM

CDR

ISS

SIR

MPLM

QR

MPLM

FAR/PCA

ORR FRR

ISS

IDR

(PDR)SDR

MPLM

PDR

SRR

Determine Specification, Design, Performance & Acceptance Requirements Compliance

MPLM Verification and Integration

Conduct Checkouts & Demonstrations

� CoFR # 1 & # 2 Signed � On-orbit assembly to previous stage

� Conduct Station and Payload Increment operations

� Conduct MPLM post landing operations and checkouts

Operations & Utilization Phase

Assembly & Checkout Phase

Flight Article Acceptance

Phase

Performance & Functional Requirements Compliance Phase (System, Segment, Stage, End Item, ICD, IRD Development)

NASA TaskNASA/ASI Joint Tasks

LAUNCH

Qualification Procedures Development & Verification

Assembly, Operation and Payload Procedures Development & Verification

S/W

IPR

3-3

The Assembly and Checkout Phase encompasses Launch Package Processing and the On- Orbit assembly and checkout functions for the first flight of each MPLM. Appropriate reviews will be held by NASA to ensure that the necessary checkout demonstrations, and tests have been completed. After ISSPO acceptance of the MPLM at KSC, the data from the ASI FAR and other joint reviews will support the endorsement statements for CoFR 1 and CoFR 2. The ISS CoFR 1 precedes the Payload Readiness Review (PRR) and CoFR 2 precedes the Flight Readiness Review (FRR). Refer to SSP 50108, Appendix C for the ASI ISS CoFR process requirements.

Included in the assembly and checkout phase are post delivery verification testing activities conducted by KSC with support from ASI. These testing activities are to demonstrate MPLM functionality and may include abbreviated subsets of the acceptance tests performed at the factory under the MPLM verification program. Details of this testing will be provided in the Resupply and Return Processing Plan (KSC-ISS-LSU-

311) to be developed by NASA with ASI provided requirements.

Verification data developed during the first three phases is used to support the Operations and Utilization Phase. This phase encompasses the developing ISS on-orbit configuration. As new stage assemblies are added, each requires unique verification requirements and integration activities.

Integration occurs during each program phase and is tailored to the activities within each time interval preceding each major program review. Integration concludes for each stage when the stage is assembled on-orbit and certified ready for operational use.

3` 1 ASI Verification Process

ASI responsibility for the MPLM verification encompasses Development phase, Performance and Functional Requirements Compliance (qualification), and Flight Article Acceptance. The primary objectives to be accomplished by the verification program during the above phases include:

• support the design development

• certification that the design fulfills all specified requirements and therefore is qualified

• demonstration that the delivered hardware and software, is free of workmanship defects and performs as specified

A basic assumption of the MPLM development and verification program is that both deliverable configurations (active and passive) will be verified through the qualification and acceptance phases. Verification will start at the equipment /component level and progress through the various intermediate levels; assembly, subsystem, and element verification. To achieve the above objectives, verification will be an incremental integrated process. The verification process begins with the translation of design and

3-4 performance requirements (documented in the specifications) into verification requirements, i.e. with the allocation of these requirements to the appropriate method of resolution. With this determination, the objectives and conditions for analysis and/or testing/demonstration/ inspection are established forming the basis for preparation of plans, specifications and procedures. The results of the analysis, inspection, demonstration and test activities are evaluated against the established requirements.

Confirmation of the satisfaction of each requirement provides an increment in the verification process. A summary of the ASI verification process is presented in Figure 4-

2. The flow shown is valid for qualification and acceptance considering that analysis and inspection of documents are clearly applicable only for qualification purposes.

The MPLM development program is partitioned into several milestones that are described in paragraph 4.5 Development Milestones.

The practical implementation of the verification program is accomplished by establishing and maintaining the Verification Control Documents (VCDs). VCDs are those documents used to plan, control and report status/completion of verification activities.

VCD structure is shown in Figure 4-3 and the document will be prepared as required indicating:

• specification text

• verification method at the applicable level

• applicable verification phase

• applicable execution document (specification, procedure, etc.)

• verification reporting document (verification report, inspection report, analysis report, test/demonstration report)

• supporting information (approved request for waivers, comments, etc.)

VCDs will be established for each equipment/component, each subsystem of the module and for the MPLM element. The VCD data will be part of the Verification Data Base (VDB) whose automation will be maximized. Format and content of this Data Base, to be delivered to NASA, are detailed in paragraph 4.4.4.6 PVIS Data Format.

For ISS common equipment and software (PBA, PFE, PCBM, Hatch, MDM hardware, software and firmware, MATE hardware and software, Lights and ISS Common Software), the ISSP verification approach will be used and is not the responsibility of ASI. Reference to the applicable ISS common equipment verification documents will be included in the subsystem VCD's.

The ASI - provided End Items verification campaign is considered concluded when the module is accepted and delivered to NASA.

3-5

Specification Requirements

H/W Design Manufacturing and

Assembly

Verification Control

Next Step

Verification Criteria

Selection & Planning

Is Verification

Criteria Met ?

Analysis and

Assessment Execution

Integration and Test

Execution

Engineering Implementation

- Test

- Demonstration

- Inspection

- Anal ysis (including similarity)

- Inspection on Documents

Req.'s Close-out Yes

No

S/W Design

FIGURE 4-2: Summary of ASI Verification Process

3 1̀̀0 Joint Integration and Verification Program Approach

NASA and ASI are jointly responsible for the following:

• exchange of data, hardware and software per agreed to bilateral agreements (Bilateral Hardware and Software Exchange Agreements, Lists and Schedules and Bilateral Data Exchange Agreement)

• monitoring NASA-ASI bilateral activities maintaining NASA-ASI data exchange agreements

• supporting joint testing of agreed to interfaces/subsystems

NASA is responsible for:

• Management of the implementation of the ISSP verification process

• Conducting ISS System program verification functions

• Certification that the on-orbit ISS is ready to support the MPLM

• Obtaining CoFR endorsements for Shuttle Launch Packages

3-6

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FIGURE 4-3: MPLM Verification Control Document (VCD) Format (page 1 of 4)

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FIGURE 4-3: MPLM VCD Format (page 2 of 4)

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FIGURE 4-3: MPLM VCD Format (page 3 of 4)

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FIGURE 4-3: MPLM VCD Format (page 4 of 4)

3-10

• Integration and verification of the MPLM into the launch package during launch processing at KSC

• Integration of the MPLM into the integrated ISS

• Verification of all NSTS/USOS utility ports to MPLM

• Verification of control and data capabilities needed to support the MPLM

• Establishing and maintaining the ISS requirement and verification traceability from the top level system specification to the MPLM Segment Specification

• Providing Certificate of Qualification (COQ) and Acceptance Data Package

(ADP) for NASA GFE hardware and software incorporated or used for the

MPLM

• Maintaining the NASA-ASI bilateral data, and hardware/software exchange agreements.

• Upon delivery of the MPLM to NASA, NASA will be responsible for the MPLM and MPLM Ground Support Equipment provided by ASI

• ISS end to end system verification and launch package verification

• Providing items specified as NASA-supplied on the Verification Intersite

Deliverable List

ASI responsibilities:

• Qualification and Acceptance Verification of the MPLM element

• Verification of ASI provided GSE

• Apply the requirements of the ISSP CoFR processes and endorsements (as negotiated) to the MPLM

• Integrating verification reviews into MPLM program reviews

• Providing requirement compliance and verification data from the MPLM

Segment specification down to the End Item (EI) specification

• Certification of MPLM

• Integration, Qualification, Verification and Acceptance of the MPLM and

ASI provided Ground Systems.

• Providing verification data to the ISSP verification team

• Support activities at the ISSP Software Verification Facility (SVF) as specified herein

• Support activities at the Kennedy Space Center (KSC)

• Generating and providing Acceptance Data Packages for the MPLM on end item delivery

• Providing items designated as ASI supplied on the Verification Intersite

Deliverables List

• Providing test and checkout requirements for launch/landing site processing

• Provide Software Independent Verification and Validation (IV&V) as agreed to in SSP 50182, NASA/ASI Bilateral Safety and Product Assurance Requirements. This software IV&V program is an ASI activity that is intended to satisfy NASA IV&V requirements.

3-11

3`1` 1 ISSP Test & Verification Team

The Integrated Test and Verification (IT&V) Team in the Vehicle Office of the SSPO is responsible for ISSP verification.