Attachment A RST-SOW-PROP-0052-.pdf

RST-PROP-SOW-0052, Revision - Effective Date: November 13, 2020

National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

RST-PROP-SOW-0052, Revision -

Roman Space Telescope (RST), Code 448

Fill and Drain Valve Statement of Work (SOW)

GSFC RST CMO

November 13, 2020

Released

Roman Space Telescope Reviewed– Not Subject to Export Control

Propulsion Fill and Drain SOW RST-PROP-SOW-0052, Revision -ii

Fill and Drain Valve

Statement of Work (SOW) Review/Signature/Approval Page

Prepared by:

Eric Golliher

Approved by:

B. Forsbacka

Electronic approval is located on RST CM Tool iii

Preface This document is a Roman Space Telescope (RST) Configuration Management (CM)-controlled document.

Note: Prior to May 20, 2020, the project name was Wide Field Infrared Survey Telescope

(WFIRST).

For the purposes of configuration management, the prefixes “RST” and “RST” are completely interchangeable. For example, RST-MGMT-PROC-0024 is the same as RST-MGMT-PROC- 0024.

Changes to this document require prior approval of the applicable Configuration Control Board (CCB) Chairperson or designee. Proposed changes shall be submitted to the RST CM Office (CMO), along with supportive material justifying the proposed change.

In this document, a requirement is identified by “shall,” a good practice by “should,” permission by “may” or “can,” expectation by “will,” and descriptive material by “is.”

Questions or comments concerning this document should be addressed to:

RST Configuration Management Office Mail Stop 448 Goddard Space Flight Center Greenbelt, Maryland 20771 iv

Change History Log

Revision Effective Date Description of Changes (Reference the CCR & CCB/ERB Approval Date)

Revision - November 6, 2020 Initial Release per CCR-0290 v

Table of Contents

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Related Documentation

1.3.1 Applicable Documents [and Forms]

1.3.2 Reference Documents

2 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 Program management

2.2 Reporting

2.2.1 Program Plan and Schedule

2.2.2 Weekly Program Status Update

2.3 Advanced Notifications

2.4 Reviews and Meetings

2.4.1 Kick-off Meeting

2.4.2 Design Conformance Review (DCR)

2.4.3 Qualification Test Readiness Review (QTTR)

2.4.4 Acceptance Test Readiness Review (ATTR)

2.4.5 Pre-Ship Review (PSR)

2.4.6 Technical Interchange Meetings (TIM)

2.5 Documentation

2.6 Existing Documentation and Analysis

2.7 Qualification by Similarity Report

3 DESIGN AND ANALYSIS

3.1 Interface Control Documentation

3.2 Drawing Package

3.3 Computer Models

3.4 Structural Analysis Report

3.5 Reliability Analysis Report

3.6 Failure Modes and Effects Criticality Analysis Report

3.7 User/Instruction Manual

4 HARDWARE PROCUREMENT/MANUFACTURING

4.1 General Requirements

4.2 Hardware Deliverables

5 PERFORMANCE VERIFICATION AND TEST

5.1 Verification Plan

5.2 Verification Test Procedures

5.3 Verification Test Reports

6 SAFETY AND MISSION ASSURANCE

6.1 General Requirements

6.1.1 Surveillance of the Contractor

6.1.2 Government Source Inspection

6.1.3 Contractor Source Inspection

vi

6.1.4 Government Mandatory Inspection Points (MIPs)

6.1.5 Anomaly Reporting

6.1.6 Configuration Management

6.1.7 Workmanship: Use of Alternate Workmanship Standards

6.1.8 Training and Certification of Contractor Personnel

6.1.9 Hardware Handling, Cleaning and Packaging

6.1.10 GIDEP Alerts and Problem Advisories

6.1.11 Ground Support Equipment Interfaces

6.2 System Safety Requirements

6.3 Design Verification Requirements

6.3.1 Verification Requirements

6.3.2 Analysis, Trending, and Reporting of Test Data

6.4 Workmanship Standards and Processes

6.4.1 General

6.4.2 Workmanship: Use of Alternate Workmanship Standards

6.4.3 Training and Certification of Contractor Personnel

6.4.4 Hardware Handling, Cleaning and Packaging

6.5 Materials, Processes Requirements

6.5.1 Materials and Processes Control

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

Agreement Furnished Hardware

6.5.3 M&P Usage Documentation

6.5.4 Materials Usage Agreements (MUAs)

6.5.5 Detailed Requirements

6.5.5.1 Flammability, Offgassing, and Compatibility Requirements

6.5.5.1.1 Fluid Compatibility (NASA-STD-6016A Section 4.2.1.3)

6.5.5.1.2 Glycols (NASA-STD-6016A Section 4.2.3.9)

6.5.5.2 Processes

6.5.5.2.1 Adhesive Bonding (NASA-STD-6016A Section 4.2.4.5)

6.5.5.2.2 Additive Manufacturing (NASA-STD-6016A Section 4.2.4.11)

6.5.5.3 Material Nondestructive Evaluation (NDE)

6.5.5.3.1 Nondestructive Evaluation (NDE) Plan

6.5.5.4 Special Materials Requirements

6.5.5.4.1 Fastener Installation (NASA-STD-6016A Section 4.2.6.6)

6.5.5.4.1.1 Liquid Locking Compounds

6.5.5.4.2 Silver-Plated Fasteners (NASA-STD-6016A Section 4.2.6.6.2)

6.5.5.4.3 Contamination Control (NASA-STD-6016A Section 4.2.6.7)

6.5.5.4.4 Packaging (NASA-STD-6016 Section 4.2.6.8)

6.5.5.4.5 Shelf-Life Items

6.5.5.5 Verification

6.5.5.5.1 Fasteners with LL Longitudinal Locking Elements

6.5.6 Materials Procurement Requirements

6.5.7 Welding

6.6 Contamination Control Requirements

6.6.1 Contamination Control Plan

6.6.2 Surface Cleanliness

vii

6.6.3 Metrology

7 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY

APPENDIX A GSFC PCB SUBMITTAL AND MATERIAL SELECTION FORMS

APPENDIX B ABBREVIATIONS AND ACRONYMS

1 INTRODUCTION

1.1 Purpose

The Nancy Grace Roman Space Telescope (RST) is a mission responding to the 2010 National Research Council New Worlds, New Horizons (NWNH) Astronomy and Astrophysics Decadal Survey top priority recommendation in the large space mission category. The science program includes two dedicated investigations to tackle outstanding questions in dark energy research and exoplanet exploration, and includes a substantial General Observer program to enable targeted investigations of astrophysical phenomena to advance other goals from the Decadal Survey. A coronagraph instrument is included in the payload for purposes of advancing the present state of the art of coronagraph technology. This document defines the work to be performed by the Contractor in the design, development, fabrication, and delivery of the Roman Space Telescope (RST) Fill and Drain Valve.

1.2 Scope

This Statement of Work (SOW) defines requirements that govern the management, development, testing, and delivery of the RST Fill and Drain Valve. It 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 RST-PROP-LIST- 0115.

1.3 Related Documentation

In the event of a conflict between the SOW and the specification, the SOW shall take precedence.

The latest versions of all documents below shall be used unless otherwise specified in this SOW.

RST documents can be obtained from the RST CM Tool.

1.3.1 Applicable Documents [and Forms]

The following documents are referenced within this document and are directly applicable or contain policies or other directive matters that are binding for the contents of this document. In the event of conflict between an Applicable Document and the content of this document, the RST Project Configuration Change Board has the final authority for conflict resolution.

Document Number Title

541-PG-8072.1.2 GSFC Fastener Integrity Requirements

ANSI/NCSL Z540.1-

Calibration Laboratories & Measuring & Test Equipment General Requirements

ANSI/NCSL Z540.3-

Requirements for the Calibration of Measuring and Test Equipment

ASTM E-595-15 Standard test method for total mass loss and collected volatile condensable materials from outgassing in a vacuum environment http://gdms.gsfc.nasa.gov/

AWS D17.1 Specification for Fusion Welding for Aerospace Applications

GSFC-STD-1000G Rules for the Design, Development, Verification, and Operation of Flight Systems

ISO 17025-2005 General Requirements for the Competence of Testing and Calibration Laboratories

MIL-HDBK-6870 Inspection Program Requirements, Nondestructive for Aircraft and Missile Materials and Parts

MSFC-SPEC-445 Adhesive Bonding, Process and Inspection, Requirements for

NA GSFC 2013 01A GSFC NASA Advisory, Subject: Test Results for NAS1351 and NAS1352 fasteners using the LL longitudinal strip locking feature

NASA-STD-5005 NASA Technical Standards System

NASA-STD-5009 Standard NDE Guidelines and Requirements for Fracture Control Programs

NASA-STD-6008 NASA Fastener Procurement, Receiving Inspection, and Storage Practices for Spaceflight Hardware

NASA-STD-6016A Standard Materials and Processes Requirements for Spacecraft

NASA-STD-8739.6A Implementation Requirements for NASA Workmanship Standards

RST-PROP-SPEC-0123 RST Project Fill and Drain Valves Specification

RST-PROP-LIST -0115 RST Project Fill and Drain Valves Deliverable Items List and Schedule (DILS)

RST-SMA-REQ-0032 RST Mission Assurance Requirements

SAE AS9100D Quality Systems Aerospace - Model for Quality Assurance in Design, Development, Production, Installation, and Servicing

1.3.2 Reference Documents

The following documents are referenced herein and amplify or clarify the information presented in this document. These documents are not binding on the content of this document.

Document Number Title

RST-SMA-LIST-0027 RST MAR Applicability Matrix

ASTM E-595-15 Standard test method for total mass loss and collected volatile condensable materials from outgassing in a vacuum environment

MSFC-SPEC-445A Adhesive Bonding, Process and Inspection, Requirements for

NASA-STD-8719.24 Rev A NASA Expendable Launch Vehicle Payload Safety Requirements

NASA-STD-5005 NASA Technical Standards System

2 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 Program management

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.

The contractor shall generate a matrix listing each section in this statement of work reflecting either compliance or non-compliance. (DILS #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.

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 constraints.

The contractor shall designate and identify by name a single individual to serve as a point of contact with the NASA/GSFC Contracting Officer’s Representative (COR) for all technical aspects of the Fill and Drain Valve 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, and documentation control.

2.2 Reporting

This section details the requirements for reporting to the NASA/GSFC COR.

2.2.1 Program Plan and Schedule

The contractor shall develop a detailed program plan and schedule to describe how the work will be conducted. The contractor shall develop the plans for these activities and the customer shall review and approve these plans. The contractor shall generate a list of significant milestones that will enable the NASA/GSFC COR to ascertain program progress. (DILS #2) The contractor shall develop a Program Plan that includes the elements given below at a minimum.

• How the program is to be managed

• The key management, technical and quality people on the program

• Any and all subcontractors and their role in the program

• How the contractor plans to manage their subcontractors

• The programmatic and technical risks

The contractor shall use the Program Plan described above to develop a detailed schedule for the program. The contractor shall deliver the program plan to the COR for review. The contractor shall incorporate comments made at the Kick-off Meeting from the customer into the Program Plan document and submit a final document to the COR for review and approval.

2.2.2 Weekly Program Status Update

The contractor shall prepare and present to the NASA/GSFC COR weekly technical status updates via teleconference or equivalent. The status update shall be a summary presentation of the weekly progress to include topics such as schedule overview, accomplishments, technical performance measures, status of key milestones, risks, problem areas, challenges/issues, quality assurance issues/status, and on-going and planned activities. Meeting minutes and action items shall be submitted to the NASA COR (DILS #3).

2.3 Advanced Notifications

The contractor shall notify the NASA/GSFC COR in advance of all mandatory hardware inspections, test activities, TIM’s, and deliveries at either the contractor’s or a subcontractor’s facility to allow timely participation by the NASA/GSFC Quality Assurance representative.

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

2.4 Reviews and Meetings

2.4.1 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. (DILS #5)

The Contractor shall provide to the NASA/GSFC COR a Kick-off Presentation Package and all other required deliverables. (DILS #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 Fill and Drain Valve specification in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

• Program Management

• Quality Assurance

• Fill and Drain Valve Design Description

• Preliminary Interface Control Documents

• Flight Heritage

• Facilities

• Qualification Verification Plan and Procedure, Qualification Report and Qualification by

Similarity (QBS) Report, if applicable

• Mechanical Analysis with Boundary Conditions

• Any long-lead items that need to be ordered prior to the Design Conformance Review

(DCR)

• Manufacturing Flow

Meeting minutes shall be prepared and delivered to the COR for review. The minutes shall include at a minimum, attendance, action items, action item accomplishment responsibility and agreements.

(DILS #7)

2.4.2 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. (DILS #8) The contractor shall provide to the NASA/GSFC COR a Design Conformance Review Presentation Package and all other required deliverable data prior to the review. (DILS #9) The Design Conformance Review shall address all program management, design, drawings, analysis, manufacturing, test, and quality assurance activities outlined in this SOW and the RST Fill and Drain Valve Specification RST-PROP-SPEC-0123 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 plan, risks, and schedule

• Qualification Test Plan, if applicable

• Program Management

• Quality Assurance

• Interface Control Documentation

• Mechanical, and Environmental specifications

• Parts, including stress analysis and radiation hardness assessment

• Detailed architectural block diagrams for the different deliverable units

• Fabrication, Assembly, and Inspection Flow plan

• 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

• Reliability Analysis

• Worst-Case analyses

• Flight Heritage

• Verification Matrix

• Acceptance Test Plan

• Final Qualification Report (if applicable)

Review minutes shall be prepared and delivered to the COR for review in the Design Conformance Review Report. The Design Conformance Review Report shall include, at a minimum: attendance, action items, action item accomplishment responsibility and agreements. (DILS #10)

2.4.3 Qualification Test Readiness Review (QTTR)

The contractor shall organize and conduct a Qualification Test Readiness Review at the contractor’s facility before the qualification test campaign begins, if applicable. (DILS #11) The presentation shall demonstrate overall conformance of the requirements specified in the RST Fill and Drain Valve Specification RST-PROP-SPEC-0123 and this Statement of Work for this phase of the procurement. This presentation (DILS #12) shall cover programmatic, technical, test and verification, metrology as discussed in Section 13 of the Mission Assurance Requirements document, and quality assurance topics, and address any changes made to the Verification Matrix since DCR. This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the testing of the hardware.

At a minimum, the QTRR package shall address:

• Summary of qualification hardware manufacturing results

• Any non-conformances and problem reports

• Risk Reduction Report

• Manufacturing lessons learned (for incorporation into flight build)

• As-built materials and processes, including as-built material certifications

• Specification verification matrix

• All procedures required for the qualification tests

• The list of tests to be conducted as part of the overall procedure

• Availability of facilities and personnel

• Special test equipment, e.g., for hot and cold tests

• Accuracy of instruments used to record test data

• How the tests are monitored and signed off

• Accept / reject criteria for each test

• How the data results are recorded and transmitted to the customer

• Any risks associated with each test including safety risks, risks in not obtaining accurate data, or any other risk which it is appropriate to discuss

All Qualification Test Procedures shall be submitted to the COR for review. (DILS #13)

Review minutes shall be prepared and delivered to the COR for review in the QTRR. The QTRR Report shall include, at a minimum: attendance, action items, action item accomplishment responsibility and agreements. (DILS #14)

2.4.4 Acceptance Test Readiness Review (ATTR)

The contractor shall organize and conduct an Acceptance Test Readiness Review at the contractor’s facility before the acceptance test campaign begins. (DILS #15) The presentation shall demonstrate overall conformance of the requirements specified in the RST Fill and Drain Valve Specification RST-PROP-SPEC-0123 and this Statement of Work for this phase of the procurement. This presentation (DILS # 16) shall cover programmatic, technical, test and verification, metrology as discussed in Section 13 of the Mission Assurance Requirements document, and quality assurance topics, and address any changes made to the Verification Matrix since DCR. This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the testing of the hardware. All Acceptance Test Procedures shall be submitted to the COR for review (DILS #17)

The ATRR package shall address:

• Summary of hardware manufacturing results

• Any non-conformances and problem reports

• Manufacturing lessons learned

• As-built materials and processes, including as-built material certifications

• Specification verification matrices

• All procedures required for the tests

• Availability of facilities and personnel

• The list of tests to be conducted as part of the overall procedure

• Special test equipment, e.g., for hot and cold tests

• Accuracy of instruments used to record test data

• How the tests are monitored and signed off

• Accept / reject criteria for each test

• How the data is recorded and transmitted to the customer

• Current hardware status, including build paperwork

• Any risks associated with each test, including safety risks, risks in not obtaining accurate data, or any other risk which it is appropriate to discuss

Review minutes shall be prepared and delivered to the COR for review. The minutes shall include at a minimum, attendance, action items, action item accomplishment responsibility and agreements. (DILS #18).

2.4.5 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. (DILS #19) This presentation package 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. (DILS #20) Any requirements that are not met shall be identified in the Deviations/Waivers list and discussed with NASA/GSFC during the review.

An End Item Data Package (EIDP) shall be made available for review electronically for each of the different hardware deliverables. (DILS #21) The electronic copies shall be text searchable.

Hard copies of the EDIP shall be made available at the contractor’s facility for the Pre ship Review at request of the customer. 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

• 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

• Achieved surface cleanliness

• Log of total operating time and failure-free operation, separated by primary/redundant sides, if any

• 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-Closure and Closed)

• Certificate of Conformance, with management signature

• End Item Inspection Report

• As-Built Configuration List

• Storage and Transportation Plans and Requirements

Review minutes shall be prepared and delivered to the customer. The minutes shall include at a minimum, attendance, action items, action item accomplishment responsibility and agreements.

(DILS #22).

2.4.6 Technical Interchange Meetings (TIM)

The contractor shall plan for and facilitate up to three (3) informal, face-to-face technical interchange meetings to be held at the contractor facilities. (DILS #23) 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.

2.5 Documentation

The contractor shall ensure the generation and delivery of all documentation as called for in the contract (Section B Table) and listed in the DILS document, RST-PROP-LIST-0115.

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.

2.6 Existing Documentation and Analysis

If analysis or documentation exists already for the flight unit that satisfies the requirements within the Fill and Drain Valve Specification, RST-PROP-SPEC-0123, then the analysis or documentation may not need to be redone, and the requirement can be satisfied by similarity and with the delivery of the previous analysis/documentation to the NASA/GSFC COR.

2.7 Qualification by Similarity Report

Any requirements that are verified through QBS shall be approved by the COR, and the qualification reports for any similarity items shall be made available to the COR. Any design differences to referenced QBS items shall be documented in this report. Any QBS items that are not accepted by the COR shall be re-verified through qualification testing. The QBS report shall contain detailed rationale for acceptance of each verification proposed for QBS, including test methods, data as supporting evidence of compliance and any risks identified in the QBS approach. Any differences to referenced QBS items shall be documented in this report. The QBS report shall be provided to the COR for review and approval (DILS #24).

3 DESIGN AND ANALYSIS

The contractor shall perform analyses of the technical and environmental requirements specified in the RST Fill and Drain Valve Specification (RST-PROP-SPEC-0123) to ensure compliance of the hardware fabrication and to assemble the documentation necessary to ensure its usability by NASA/GSFC users. Previous analyses may be submitted for the items below per Section 2.6.

3.1 Interface Control Documentation

The Contractor shall provide the following documents (DILS #25):

The Mechanical Interface Control Document shall provide document(s) and/or drawing(s) that define, in detail, all mechanical interfaces including the center of mass relative to an external reference, subject to review and approval by the NASA/GSFC COR.

The details of the mount hardware to RST spacecraft structure shall be agreed upon between the Contractor and NASA/GSFC COR at the Kick-off Meeting.

3.2 Drawing Package

The complete drawing package shall be available for review at the Contractor’s facility at DCR. (DILS #26)

3.3 Computer Models

The contractor shall deliver the following computer models (DILS #27)

a) A Computer-Aided Design (CAD) file for the Fill and Drain Valve

3.4 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 provided for the Flight Unit structure to ensure the capability to withstand and survive launch and ascent loads and worst case pressure conditions at the worst case temperature. (DILS #28) 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.

3.5 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. (DILS #29) 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.

3.6 Failure Modes and Effects Criticality Analysis Report

The contractor shall provide a FMECA (Failure Modes and Effects Criticality Analysis) to identify potential failures. (DILS #30) This report will refer to the applicable paragraphs of Section 6.5 of the Mission Assurance Requirements document, DID 6-2: MAR-081 through MAR-085 and MAR-087 through MAR-089. Note that MAR-090 and MAR-086 do not apply.

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

3.7 User/Instruction Manual

The Fill and Drain Valves Operational Constraints Document shall be presented at DCR to mitigate any issues. (DILS #31)

4 HARDWARE PROCUREMENT/MANUFACTURING

4.1 General Requirements

The contractor shall either procure or manufacture all components required to assemble, integrate, and test the Fill and Drain Valve to support the delivery dates as called for in the contract (Section B Table) and listed in the DILS document, RST-PROP-LIST-0115.

The contractor shall assemble the quantities of Fill and Drain Valve hardware described below.

The contractor shall provide a Fabrication, Assembly, and Inspection Flow plan at the DCR that includes a step-by-step procedure that describes the method of fabrication, assembly, and inspection from piece parts to the completely assembled Fill and Drain Valve.

4.2 Hardware Deliverables

The contractor shall provide the following hardware to meet the requirements of the RST Fill and Drain Valve Specification (RST-PROP-SPEC-0123).

a) Six (6) Liquid Fill and Drain Valves, 5 Flight and 1 Spare Units. (DILS #32)

b) Two (2) Gas Fill and Drain Valves, 1 Flight and 1 Spare Units. (DILS #33)

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

5 PERFORMANCE VERIFICATION AND TEST

5.1 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 RST Fill and Drain Valve Specification RST-PROP-SPEC-0123 will be performed. (DILS #34) 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 NASA/GSFC COR 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 Fill and Drain Valve.

This plan shall be a contractor controlled document and 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.

5.2 Verification Test Procedures

The contractor shall generate Verification Test Procedures and provide them to the NASA/GSFC COR. (DILS #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 indicate all changes made after the initial release for review to NASA.

5.3 Verification Test Reports

The contractor shall generate Verification Test Reports. (DILS #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.

6 SAFETY AND MISSION ASSURANCE

6.1 General Requirements

The Contractor shall comply with the applicable safety and mission assurance requirements documented in the RST Mission Assurance Requirements (MAR) (RST-SMA-REQ-0032). All corresponding deliverables shall be delivered as described in MAR Data Item Descriptions (DIDs).

Sections 1, 2, 3 and 4 apply.

Section 5 applies with the exception of:

Section 5.3.3.3 does not apply

Section 5.3.3.4 does not apply Section 5.3.4 does not apply Section 5.3.6 does not apply Section 5.3.7 does not apply Section 5.3.8 does not apply Section 5.3.10 does not apply

Section 6 applies with the exception of:

Section 6.3 does not apply Section 6.4 does not apply Section 6.5 MAR-082, MAR-086 and MAR-090 do not apply Section 6.6 does not apply Section 6.7 does not apply Section 6.14 does not apply Sections 7 and 8 do not apply Section 9 applies with the exception of:

Section 9.1 does not apply Section 9.3 does not apply Section 9.4 does not apply Section 9.5 does not apply Section 9.6 does not apply

Section 9.7 does not apply Section 9.8 does not apply

Section 10 does not apply Sections 11, 12, 13, 14 and 15 apply

The Contractor’s plan for compliance with the MAR shall be documented in the RST-specific Mission Assurance Implementation Plan (MAIP) or Quality Assurance Plan, DID 3-1. (DILS #37)

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

6.1.1 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 NASA/GSFC representative.

The contractor shall provide the NASA/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. The contractor will refer to Section 3.6 of the Mission Assurance Requirements document for surveillance of the contractor.

6.1.2 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 contractor will refer to Section 3.6 of the Mission Assurance Requirements document for surveillance of the contractor.

6.1.3 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 will refer to Section 3.6 of the Mission Assurance Requirements document for surveillance of the contractor.

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.

• 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.

6.1.4 Government Mandatory Inspection Points (MIPs)

The contractor shall plan for GMIPS, which will be discussed during the kick off meeting. The NASA/GSFC COR may request additional MIPs if a specific process prohibits inspection at the DCR and then add as required. The contractor shall provide work instructions, procedures, drawings, etc. that are appropriate for the activities. The contractor will refer to Section 3.8 of the Mission Assurance Requirements document for Government Mandatory Inspection Points. The following are examples of activities that may be subject to GMIPS:

- Unit and component level assembly – witness final assembly

- Mechanical – final assembly and acceptance test

- Rework and repairs to flight hardware

- Pre-Ship Inspection/Data Review

6.1.5 Anomaly Reporting

The contractor shall have a documented process for anomaly reporting and disposition. The process will establish an anomaly review board (ARB) whose membership will include a government representative as a voting member with approval authority for proposed actions on all major nonconformances. (DILS #38)

The process shall require major anomalies to be submitted to the ARB and the government. The contractor shall report major hardware anomalies beginning with the first application of power at the component level, and major mechanical system anomalies beginning with the first operation.

Major anomalies are those that have resulted in hardware damage or potential damage to hardware. Examples of major anomalies are exceedance of test limits resulting in overstress and unexpected system responses. The contractor shall assess the failure risk ratings and failure effect risk ratings for major anomalies and shall identify those that have a failure effect risk rating of 2 or 3 and a failure corrective action risk rating of 3 or 4 as a significant residual risk in the risk list.

The process shall allow the contractor to disposition minor anomalies with an appropriate subset of the ARB. Minor anomalies are those that have not resulted in hardware failure or have caused no damage or stress to hardware. Examples of minor anomalies are those that can be resolved immediately, procedural errors, database problems, operator errors, and exceedance of test limits that do not affect the end item.

6.1.6 Configuration Management

The contractor’s Configuration Management (CM) system (available for review on request) shall control the design and hardware/software by means of drawings, specifications, and other documents and ensure all applicable changes are reviewed in a systematic manner to determine the validity and impact on performance, schedule and cost. The contractor’s Configuration Management system shall have a change classification and impact assessment process that ensures Class I changes are forwarded to the CO for approval prior to release/incorporation.

(DILS #39) Class I changes are defined as changes that affect form, fit, function, external interfaces, or requirements as stated within this document and the Fill and Drain specification.

All other changes are considered to be Class II changes and shall be controlled and dispositioned by the contractor. All Class II changes shall be provided to the NASA/GSFC COR for review purposes. (DILS #40) NASA/GSFC reserves the right to review all Class II changes for technical content to ensure the proper classification has been assigned. Any flight item that is found to be non-compliant with the quality, workmanship and performance requirements of the contract shall be dispositioned via a waiver or Materials Review Board (MRB), unless the affected item is reworked to restore compliance or is replaced with a fully compliant item. The contractor shall submit Waivers and MRBs to the NASA/GSFC COR for final approval.

A contractor QA representative shall be a member of the Configuration Control Board. The QA activities shall be defined in the Configuration Management Plan and described in detail in the QA Plan. Related portions of the plans shall be cross-referenced.

6.1.7 Workmanship: Use of Alternate Workmanship Standards

NASA/GSFC recognizes that the contractor may have an established workmanship program equivalent to the specific standards cited herein. In these instances, the contractor may use existing standards upon review and approval on-site by the NASA/GSFC COR. (DILS #41)

It must be established that the contractor’s workmanship program fully encompasses the specific requirements of this chapter. It is the contractor’s responsibility to list all deviations from the baseline workmanship standards and to provide data supporting their position/rationale.

6.1.8 Training and Certification of Contractor Personnel

All personnel performing work on flight hardware requiring a prerequisite set of skills and competency shall be certified as having completed the required training, appropriate to their involvement.

6.1.9 Hardware Handling, Cleaning and Packaging

The handling of flight hardware shall be performed by qualified personnel in accordance with procedures that address cleaning, handling, packaging, tent enclosures, shipping containers, bagging, and purging. These procedures are documented in the Contamination Control Plan (see Section 7.9.1). Compatible packaging shall be selected so that hardware is not contaminated or otherwise degraded during shipping or storage. All personnel working on flight hardware shall be certified as having completed the required training and competency certifications prior to handling any flight hardware. This includes, but is not limited to, workmanship, clean room and ESD awareness courses.

6.1.10 GIDEP Alerts and Problem Advisories

Contractors shall keep sufficient selection and usage records for all flight parts and materials adequate to determine applicability of any issued Government Industry Data Exchange Program (GIDEP) alerts relevant to items used on RST. The contractor will refer to Section 14 of the Mission Assurance Requirements document on GIDEP.The contractor shall review and disposition all GIDEP Alerts for relevancy and impact and shall notify the COR and CSO of applicable GIDEPs. In addition, the contractor shall review and disposition any NASA Alerts and Advisories provided to the contractor by the NASA/GSFC COR. Alert applicability, impact, and corrective actions shall be summarized and status provided to the NASA/GSFC COR. (DILS #42)

6.1.11 Ground Support Equipment Interfaces

Mechanical and electrical ground support equipment (GSE) and associated software that directly interface with flight deliverable items shall be assembled and maintained to mitigate potential risk to flight hardware. Parts and materials selection and reporting requirements are exempted as long as deliverable flight item contamination requirements are not compromised. However, all GSE interfaces to flight hardware shall be flight quality (connectors, baseplates, etc.).

6.2 System Safety Requirements

The contractor shall supply detailed descriptions of the design, test, operation and inspection requirements for all flight hardware and materials, ground support equipment, and their interfaces necessary for a valid identification, assessment, control and mitigation of documented hazards. This includes technical information concerning hazardous and safety critical equipment, systems, operations, handling and materials. For all identified hazards, the contractor shall also document hazard controls, verifications and tracking methods. (DILS #43)

The contractor shall provide technical support for safety working group and technical meetings as necessary in conjunction with TIMs.

6.3 Design Verification Requirements

6.3.1 Verification Requirements

The contractor shall implement a program to verify all requirements specified in the RST Fill and Drain Valves Specification (RST-PROP-SPEC-0123).

The contractor shall provide a verification matrix defining the method of verification for each specific requirement of the RST Fill and Drain Valves Specification (RST-PROP-SPEC-0123).

In-process production evaluation tests and environmental stress screening tests shall also be considered to be verification tests.

6.3.2 Analysis, Trending, and Reporting of Test Data

The contractor shall properly record and maintain a log of open/close cycles for each seat in the valve.

6.4 Workmanship Standards and Processes

6.4.1 General

The contractor shall implement a workmanship program to assure that workmanship meet mission objectives for quality and reliability per the requirements.

6.4.2 Workmanship: Use of Alternate Workmanship Standards

NASA/GSFC recognizes that the contractor may have an established workmanship program equivalent to the specific standards cited herein. In these instances, the contractor may use existing standards. . These standards shall be available for review at vendor location.

6.4.3 Training and Certification of Contractor Personnel

All personnel performing work on flight hardware requiring a prerequisite set of skills and competency shall be certified as having completed the required training, appropriate to their involvement.

6.4.4 Hardware Handling, Cleaning and Packaging

The handling of flight hardware shall be performed by qualified personnel in accordance with procedures that address cleaning, handling, packaging, tent enclosures, shipping containers, bagging, and purging. These procedures are documented in the Contamination Control Plan (see Section 7.9.1). Compatible packaging shall be selected so that hardware is not contaminated or otherwise degraded during shipping or storage. All personnel working on flight hardware shall be certified as having completed the required training and competency certifications prior to handling any flight hardware. This includes, but is not limited to, workmanship, clean room and ESD awareness courses.

6.5 Materials, Processes Requirements

6.5.1 Materials and Processes Control

Materials, processes, and lubrication approval by the RST Materials and Processes Engineer (MPE) is required for each usage or application in spaceflight hardware with criteria, including Data Deliverables, as follows. The contractor shall ensure the relevant requirements are flowed to vendors.

All Materials and Processes (M&P) shall be defined by standards and specifications, and be selected from government, industry, and subcontractor specifications and standards. There is a preference for the use of active government or industry specifications.

The MPE shall be a voting member of subcontractor M&P Control Boards, if established.

To qualify material for flight use, the material must have a satisfactory flight heritage relevant to PACE requirements or meet the following applicable selection criteria as defined herein for:

• Stress corrosion cracking (SCC)

• Manufacturing process selection

The contractor shall create and maintain a Materials and Processes Identification List (M&P) using the forms in the Appendix, or an equivalent form. The contractor shall review proposed materials and processes with the NASA/GSFC COR. An As-Built Materials List (ABML) shall be included as part of the EIDP, using the form in the Appendix, or an equivalent form. Pure Tin, Zinc, and Cadmium are not acceptable for flight use.

6.5.2 Commercial-Off-The-Shelf (COTS), Vendor-Designed and Fabricated, and Bilateral Agreement Furnished Hardware

The use of any hardware, including those listed above, for which a detailed M&P list (as defined herein) is not available and/or an M&P List is not available for review and approval will be treated as non-compliant. A Materials Usage Agreement (MUA) shall be prepared and submitted to define what measures are taken to ensure that all M&P in the hardware are acceptable for use. Supporting rationale may include documentation supporting qualification of heritage flight hardware per GSFC-STD-1000G (Rule 1.11), documentation supporting Safety and Mission Assurance (SMA) acceptance of hardware, hermetic sealing, vacuum bake-out, material changes for known non-compliant materials, etc. The disposition of the MUA will be coordinated through the MPE.

6.5.3 M&P Usage Documentation

The Materials and Processes List shall be provided per the RST MAR, RST-SMA-REQ-0032.

The list of Processes will include those processes that ensure a repeatable/controlled process that produces a consistent and reliable product. An As-Built Materials List (ABML) shall be included as part of the end item data package, see Section 6.5.6. Sample forms are available upon request.

The lists shall include the following information in an electronically searchable format:

• Non-Metallics Usage List – Material Identification (including full specification, manufacturer, and part number), Mix Formula, Cure, Amount, Expected Environment, Special Reason for Selection, Outgassing Values (including reference source and test reference), Usage, MUA Number (if applicable).

• Metallics Usage List – Materials Identification (including full specification), Condition, Surface Finish and/or Coating, Application, Expected Environment, Stress Corrosion Cracking Rating, Corrosion Rating, Usage, MUA Number (if applicable), complete fastener part number (identifying material, condition, finish, locking element).

• Lubrication Usage List – Component Type, Size and Material; Component Manufacturer and Manufacturer Identification; Proposed Lubrication System and Amount of Lubricant;

Type and Number of Wear Cycles; Speed, Temperature and Atmosphere of Operation;

Type of Loads and Amount; Other Details.

• Material Processes Utilization List – Process Type; Contractor Specification Number;

Military, ASTM (American Society for Testing and Materials), Federal or Other Specification; Description of Material Processed; Application.

The Materials and Processes List shall include references to Materials Usage Agreements (MUAs) at entries for non-compliant materials and processes (see 6.5.4).

6.5.4 Materials Usage Agreements (MUAs)

MUAs shall be submitted for all M&P that are technically acceptable but do not meet M&P requirements. (DILS #44) The MUA shall include sufficient information to demonstrate that the application is technically acceptable. The contractor will refer to Section 11.2 of the Mission Assurance Requirements document for MUAs.

6.5.5 Detailed Requirements

Detailed Requirements in Section 4.2 of NASA-STD-6016A are applicable to all RST flight hardware, except as specified below. The contractor shall ensure the relevant requirements are flowed to vendors.

6.5.5.1 Flammability, Offgassing, and Compatibility Requirements

6.5.5.1.1 Fluid Compatibility (NASA-STD-6016A Section 4.2.1.3) Heritage usage may be solely considered when assessing compatibility.

6.5.5.1.2…