Draft SOW.pdf

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National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

RST-PROP-SOW-0050, Revision -

Roman Space Telescope (RST), Code 448

Delta-V Thruster Statement of Work

DRAFT

June 20, 2020 https://ipdtdms.gsfc.nasa.gov/

Delta-V Thruster Statement of Work RST-PROP-SOW-0050, Revision -i

Delta-V Thruster Statement of Work

Review/Signature/Approval Page

Prepared by:

Alison Rao

Approved by:

Electronic Approval available on-line at: https://ipdtdms.gsfc.nasa.gov/ ii

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 “WFIRST” and “RST” are completely interchangeable. For example, RST-MGMT-PROC-0024 is the same as WFIRST-

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 iii

Change History Log

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

Table of Contents

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Related Documentation

1.3.1 Applicable Documents

1.3.2 Reference Documents

2 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 Program Management

2.2 Reporting

2.3 Advanced Notifications

2.4 Reviews and Meetings

2.4.1 Kick-Off Meeting

2.4.2 Design Conformance Review

2.4.3 Qualification Test Readiness Review

2.4.4 Acceptance Test Readiness Review

2.4.5 Pre-Ship Review

2.4.6 Technical Interchange Meetings

2.5 Documentation

2.6 NASA/GSFC Furnished Data, Equipment, and Facilities

2.7 Existing Documentation and Analysis

3 DESIGN AND ANALYSIS

3.1 Interface Control Documentation

3.2 Drawing Package

3.3 CAD Models

3.4 Structural Analysis Report

3.5 Structural Finite Element Model

3.6 Thermal Analysis Report

3.6.1 Catalyst Bed Analyses

3.7 Thermal Model and Documentation

3.8 Error Analysis Report

3.9 User/Instruction Manual

3.10 Failure Mode, Effects and Criticality Analysis

3.11 Reliability Analysis

4 HARDWARE PROCUREMENT

4.1 General Requirements

4.2 Hardware Deliverables

4.3 Ground Support Equipment

5 PERFORMANCE VERIFICATION AND TEST

5.1 Verification

5.2 Verification Plan

5.3 Verification Methods

5.3.1 Inspection

v

5.3.2 Analysis

5.3.3 Test

5.4 Inspection Requirements

5.4.1 Visual Inspection

5.4.2 Physical Measurement

5.4.3 Documentation Search

5.5 Analysis Requirements

5.6 Test Requirements

5.6.1 Definitions

5.6.2 Thermal Cycle Prior to Structural Testing

5.6.3 Non-Destructive Examination

5.6.4 Verification Test Procedures

5.6.5 Verification Test Reports

5.6.6 Test Factors

5.6.7 Test Tolerances

5.6.8 Test Restrictions

5.6.8.1 Failure During Tests

5.6.8.2 Modification of Hardware

5.6.8.3 External Adjustment

5.6.8.4 Re-Test Requirements

5.7 Required Tests

5.7.1 Physical Inspection

5.7.2 Mass Properties Measurement

5.7.3 Proof Pressure Test

5.7.4 Performance Tests

5.7.5 Frequency Signature Survey

5.7.6 Static Loads/Strength Test

5.7.6.1 Sine Burst

5.7.6.2 Static Pull

5.7.7 Sine Vibration

5.7.8 Random Vibration

5.7.9 Shock

5.7.10 Thermal Vacuum Bake-out

5.7.11 Thermal Vacuum Test

5.7.11.1 Thermal Vacuum Test Parameters

5.7.11.2 Thermal Vacuum Test Profile

5.7.11.3 Thermal Cycling Testing - Ambient

5.7.12 Continuity/Hi-Pot Tests

5.7.13 Hot Fire Testing

5.7.14 Grounding

5.7.15 Alignment

5.7.16 Cleanliness

6 SAFETY AND MISSION ASSURANCE

6.1 General Requirements

6.2 Configuration Management

6.3 Training and Certification of Contractor Personnel

vi

6.4 Surveillance of the Contractor

6.4.1 Government Source Inspection

6.4.2 Supplier Source Inspection

6.4.3 Government Mandatory Inspection Points

6.5 Ground Support Equipment Interfaces

6.6 Design Verification Requirements

6.6.1 Verification Requirements

6.6.2 Analysis, Trending, and Reporting of Test Data

6.6.3 Limited Life Items

6.7 EEE Parts Requirements

6.7.1 General

6.7.2 Analyses

6.7.3 Parts Age Control

6.8 Materials, Processes Requirements

6.8.1 Materials and Processes Control

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

Agreement Furnished Hardware

6.8.3 M&P Usage Documentation

6.8.4 Materials Usage Agreements

6.8.5 Detailed Requirements

6.8.5.1 Flammability, Offgassing, and Compatibility Requirements

6.8.5.1.1 Toxic Offgassing (NASA-STD-6016A Section 4.2.1.2)

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

6.8.5.1.3 Oxygen Compatibility (NASA-STD-6016A Section 4.2.1.4)

6.8.5.1.4 Electrical Wire Insulation Materials (NASA-STD-6016A Section 4.2.1.5) 30

6.8.5.1.5 Thermal Vacuum Stability (NASA-STD-6016A Section 4.2.3.6)

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

6.8.5.2 Processes

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

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

6.8.5.3 Material Nondestructive Evaluation (NDE)

6.8.5.3.1 Nondestructive Evaluation Plan (NASA-STD-6016A Section 4.2.5.1)

6.8.5.4 Special Materials Requirements

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

6.8.5.4.1.1 Liquid Locking Compounds (NASA-STD-6016A Section 4.2.6.6.1) . 31

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

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

6.8.5.4.4 Packaging (NASA-STD-6016A Section 4.2.6.8)

6.8.5.4.5 Shelf-Life Items

6.8.5.5 Verification

6.8.5.5.1 Solder Flux

6.8.5.5.2 Fasteners with Longitudinal Locking Elements

6.8.6 Materials Procurement Requirements

6.9 Contamination Control Requirements

6.9.1 Contamination Control Plan

6.9.2 Surface Cleanliness

vii

6.9.3 Thermal Vacuum Bakeouts

6.10 Safety Requirements

6.10.1 System Safety Program Plan

6.10.2 Operations Hazard Analysis

7 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY

APPENDIX A ABBREVIATIONS AND ACRONYMS

APPENDIX B DELIVERABLE ITEMS LIST AND SCHEDULE

1 INTRODUCTION

1.1 Purpose

The 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 RST Delta-V thrusters.

1.2 Scope

This Statement of Work (SOW) defines requirements that govern the management, development, testing, and delivery of the RST Delta-V thrusters. 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 Appendix B.

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 URL: https://ipdtdms.gsfc.nasa.gov/.

1.3.1 Applicable Documents

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 RST-PROP-SPEC-0122 Delta-V Thruster Specification RST-SMA-REQ-0032 RST Mission Assurance Requirements

541-PG-8072.1.2C Goddard Space Flight Center Fastener Integrity Requirements

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

GSFC EEE-INST-002 Instructions for EEE Parts Selection, Screening, Qualification, and Derating

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

GSFC-STD-7000A General Environmental Verification Standard (GEVS) for GSFC Flight Programs and Projects

NASA-STD-6008 NASA Fastener Procurement, Receiving Inspection, and

Storage Practices for Spaceflight Hardware

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

NASA-STD-8739.4 Workmanship Standard for Crimping, Interconnecting Cables, Harnesses, and Wiring

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.

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

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. (DIL #1) Areas of non-compliance need to be addressed by the contractor showing how they plan to meet the requirement(s) or why it will remain non-compliant.

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/Goddard Space Flight Center (GSFC) Contracting Officer’s Representative (COR) for all technical aspects of the Delta-V thruster 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

The contractor shall prepare and present to the NASA/GSFC COR monthly technical status reports. (DIL #3) The report shall be a summary presentation of the period's progress to include topics such as schedule overview, accomplishments, technical performance measures (e.g. mass and power), status of key milestones, a running action item log, risks, problem areas, challenges/issues, quality assurance issues/status, and activities on-going and planned.

The contractor shall generate a list of significant milestones that will enable the NASA/GSFC COR to ascertain program progress. (DIL #2)

The contractor shall report status verbally in weekly telecons with the NASA/GSFC COR.

2.3 Advanced Notifications

The contractor shall notify the NASA/GSFC COR at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, technical interchange meetings (TIMs), and deliveries at either the contractor’s or a subcontractor’s facility to allow timely participation by the NASA/GSFC Quality Assurance representative. (DIL #8) Event-specific notification requirements (such as failures, anomalies, etc.) are included in the appropriate sections in this

SOW.

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. (DIL #10)

The Contractor shall provide to the NASA/GSFC COR a Kick-off Presentation Package and all other required deliverables. (DIL #9) 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 Delta-V thruster specification (RST-PROP-SPEC- 0122) in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

• Program Management

• Quality Assurance

• Delta-V Thruster Design Description

• Preliminary Interface Control Documents

• Flight Heritage

• Facilities

• Qualification Verification Plan and Procedure

• Mechanical Analysis with Boundary Conditions

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

2.4.2 Design Conformance Review

The contractor shall organize and present a Design Conformance Review (DCR) to a GSFC Review Team at the contractor’s facility prior to the manufacturing program. (DIL #41)

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. (DIL #23) 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 Delta-V thruster specification RST-PROP-SPEC-0122 in sufficient detail to ensure that the proposed design conforms to all requirements and is ready for fabrication to begin. At a minimum, the design package should cover the following areas:

• Program Management

• Quality Assurance

• Electrical, Mechanical, and Environmental specifications

• Parts, including stress analysis

• Detailed architectural block diagrams for the different deliverable units

• Fabrication, Assembly, and Inspection Flow plan with customer Mandatory Inspection

Points (MIPs) identified

• Facilities

• Verification Test Plan (Including Performance Test Description)

• Qualification plans (if applicable)

• Qualification by similarity (if applicable)

• Materials and Processes List (as-designed)

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

• Mechanical/Structural analyses

• Thermal analyses

• Electrical Worst-Case analyses

• Failure Modes Effects Criticality Analysis

• Flight Heritage

• Specification Verification Matrix (per Section 6.6.1)

• Performance analysis (preliminary)

• Thruster operational constraints document (preliminary)

• Preliminary hot fire test matrix

The contractor shall prepare review minutes including, as a minimum, attendance, action items, action item accomplishment responsibility, and agreements. All items shall be in sufficient detail to be self-explanatory. A Design Conformance Review Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items. (DIL #42)

2.4.3 Qualification Test Readiness Review

The contractor shall hold a Qualification Test Readiness Review (QTRR) at the contractor's facility prior to starting qualification testing, if applicable. (DIL #48) The contractor shall demonstrate that all qualification hardware manufacturing steps are complete, show that all analysis verifications are complete, show readiness of all activities required for testing, and describe in detail any activities that are not yet ready with a completion schedule for each. In particular, the contractor shall present the updated specification verification matrix and all test procedures. The NASA/GSFC COR and customer technical team will attend the QTRR.

The QTRR package shall be delivered two (2) weeks prior to QTRR, unless otherwise stated.

(DIL #47) All Qualification Test Procedures shall be submitted to the NASA/GSFC COR for review four (4) weeks prior to QTRR (DIL #45).

At a minimum, the QTRR package shall address:

• Summary of qualification hardware manufacturing results

• Any non-conformances and problem reports

• 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

Review minutes shall be prepared and delivered to the NASA/GSFC COR within three (3) working days after the meeting. The minutes shall include at a minimum, attendance, action items, action item accomplishment responsibility, and agreements. (DIL #49) The scope of the QTRR shall include any testing that is performed during the assembly process (e.g., bubble point testing of the inlet filters).

2.4.4 Acceptance Test Readiness Review

The contractor shall hold an Acceptance Test Readiness Review (ATRR) at the contractor's facility prior to starting acceptance testing. (DIL #51) The contractor shall demonstrate that all hardware manufacturing steps are complete, show that all analysis verifications are complete, show readiness of all activities required for testing, and describe in detail any activities that are not yet ready with a completion schedule for each. In particular, the contractor shall present the updated specification verification matrix and all test procedures. The NASA/GSFC COR and customer technical team will attend the ATRR.

The ATRR package shall be delivered two (2) weeks prior to ATRR, unless otherwise stated.

(DIL #50) All Acceptance Test Procedures shall be submitted to the NASA/GSFC COR for review four (4) weeks prior to ATRR (DIL #45).

The specific pre-acceptance testing data shall also be provided at the ATRR.

At a minimum, the ATRR package shall address:

• Summary of hardware manufacturing results

• Any non-conformances and problem reports

• Any changes in design or manufacturing between qualification hardware and flight hardware

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

• Specification verification matrix

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

• All procedures required for the tests

• 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

• 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 NASA/GSFC COR within three (3) working days after the meeting. The minutes shall include at a minimum, attendance, action items, action item accomplishment responsibility, and agreements. (DIL #52)

2.4.5 Pre-Ship Review

The contractor shall hold a Pre-Ship Review (PSR) at the contractor's facility at the completion of verification tests and prior to the shipment of each hardware item to NASA/GSFC. (DIL #55)

This presentation shall demonstrate completion of all activities required for delivery of any hardware deliverable item to NASA/GSFC, and note any activities that are incomplete. In particular, the contractor shall present the completed specification verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses) where applicable. (DIL #56) Any requirements that are not met shall be identified in the Deviations/Waivers etc. list and discussed with NASA/GSFC during the review.

An End Item Data Package (EIDP) shall be made available for review during pre-ship reviews for each of the different hardware deliverables. (DIL #58) This package shall also be delivered with each end item with the level of detail required of that item. The package should be comprised of, but not limited to, the following data:

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

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

• Work orders for the final assembly and associated tests

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

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

• Problem/anomaly reporting (complete copies of report)

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

• Status of all action items from previous reviews

• Class I MRBs (complete copies of reports)

• List of As-Built Materials and Processes used

• Achieved surface cleanliness and outgassing rate data (when applicable)

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

• Hot fire test results

• Performance analysis (final)

• Thruster operational constraints document (final)

• List and status of all identified Life-Limited Items, including data regarding the life used and remaining

• Total number of mechanical cycles and remaining cycle life

• Trended Critical Parameters Data (when applicable)

• Specification verification matrix, test data and reports (including qualification test report)

• Acceptance test results

• Calibration data for thermal sensors

• List of Open Items with reason for item(s) being open and proposed closure date

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

• Certificate of Conformance, with management signature; includes manufacturer’s name and address; part number and revision number; batch identification such as date codes, lot codes, serializations; signature or stamp of authorized personnel; purchase order or contract number; contamination certificates of compliance, etc.

• End Item Inspection Report

• As-Built Configuration List

• Mate/Demate log (if applicable)

• Storage and Transportation Plans and Requirements

2.4.6 Technical Interchange Meetings

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. (DIL #4) 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 Appendix B.

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 NASA/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 NASA/GSFC Furnished Data, Equipment, and Facilities

N/A

2.7 Existing Documentation and Analysis

If analysis or documentation exists already for the flight unit that satisfies the requirements within the Delta-V Thruster Specification, RST-PROP-SPEC-0122, and the descriptions in Section 3, 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.

3 DESIGN AND ANALYSIS

The contractor shall perform analyses of the technical and environmental requirements specified in the Delta-V Thruster Specification (RST-PROP-SPEC-0122) 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 2.7.

3.1 Interface Control Documentation

The Contractor shall provide the following documents (DIL #11):

• Mechanical Interface Control Document (MICD), including physical characteristics, mounting interface, outline drawing, center of mass location, thermal coatings on surfaces

• Electrical Interface Control Document (EICD), including detailed description of each signal, interface circuits, telemetry description

3.2 Drawing Package

The contractor shall provide a drawing package that includes, but is not limited to: (DIL #24)

ELECTRICAL: assembly and interface drawings MECHANICAL: assembly and interface drawings

3.3 CAD Models

The contractor shall deliver the following computer models (DIL #25)

a) A Computer-Aided Design (CAD) file for the Delta-V thruster

b) A Mechanical Model in STEP file format

c) Thermal model (see Section 3.7)

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. (DIL #26) The effects of any thermal inputs shall be reflected in the analyses as appropriate. This analysis shall include a venting analyses for applicable flight components (such as thermal blankets and contamination enclosures) susceptible to pressure loadings to verify that positive strength margins exist at loads equal to the maximum pressure differential during launch. The results of these analyses shall be summarized in a contractor format Structural Analyses Report that will be provided to the NASA/GSFC COR for review.

3.5 Structural Finite Element Model

Contractors shall submit a finite element model that supports the conclusions in their structural analysis report. (DIL #27)

3.6 Thermal Analysis Report

The contractor shall provide a worst case thermal analysis (DIL #28) that illustrates that the device and/or the electronic parts junction temperatures are within the Electrical, Electronic, and Electromechanical (EEE) EEE-INST-002 de-rated operational temperature limits when subjected to the boundary conditions specified in the Delta-V Thruster Specification (RST-PROP-SPEC- 0122). This analysis shall be performed with the components operating at their maximum expected power dissipations. All analysis results shall be summarized in a thermal analyses report, to be provided for review as per Appendix B. This report shall contain a comprehensive list of each component’s maximum expected power dissipation, maximum case temperature, theta JC, maximum junction temperature, and de-rated operational temperature limit.

Additionally, this report shall contain a thorough description of the computer models (or reference to the documentation required from Section 3.7 Thermal Model and Documentation) and the assumptions that were used to perform the analysis including boundary conditions, surface finish thermo-optical properties, interface conductances.

3.6.1 Catalyst Bed Analyses

The analyses described in this section may be included as part of the thermal analysis report (DIL #28) or may be a separate catalyst bed heating analysis report (DIL #30).

The contractor shall provide performance analyses for the catalyst bed heaters, including calculating time to reach minimum firing temperature from the minimum cold non-operational temperature. The analysis shall include warm-up predictions with a single catalyst bed heater operating and with both catalyst bed heaters operating.

3.7 Thermal Model and Documentation

The contractor shall provide reduced Thermal Math Models (TMMs) for the Delta-V thruster with fewer than 50 nodes per box, in Thermal Desktop/SINDA format or another format pre-approved by the RST Thermal group (DIL #29).

The thermal model documentation shall include:

• Labeled figures (drawings, cross-sections, etc) in sufficient detail to show all critical components and their relative locations within the Delta-V thruster

• Listing of all critical components, their material composition and relevant properties (density, specific heat, conductivity, etc)

• Listing of other relevant modeling assumptions (boundary conditions, interface conductances, thermo-optical properties, etc)

• Listing of component thermal dissipations for all operational and survival modes over which the hardware is intended to operate

If the contractor does not have the project-compatible software to create TMMs, then the contractor shall provide sufficient detailed information such that GSFC can create the TMMs.

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

3.8 Error Analysis Report

An Error Analysis shall be performed on the Delta-V thruster design that identifies all the factors that introduce error into the accuracy of the thruster, and shows that the component can meet its performance requirements in spite of the errors. Errors may include, but not be limited to: nozzle alignment error, valve response times, degradation of parts, thermal distortions and other effects, etc. An Error Tree shall be generated documenting ALL the sources of error, along with an Error Analyses Report and provided to NASA/GSFC COR for review. (DIL #31)

3.9 User/Instruction Manual

The contractor shall deliver procedures that describe the operation of the thruster and any operational constraints. Examples of items to include in the user/instruction manuals are long-term storage activities, operational constraints for voltage, temperature, number of cycles, hold open procedures, etc. (DIL #54)

3.10 Failure Mode, Effects and Criticality Analysis

The contractor shall perform and maintain a Failure Mode, Effects and Criticality Analysis (FMECA) that addresses the Delta-V thruster design and processes from project initiation through delivery, and includes likelihood, cause, detection/ mitigation, and effects of each interface and functional element failure mode. (DIL #32) 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.

3.11 Reliability Analysis

The contractor shall perform comparative numerical reliability assessments and reliability predictions (DIL #33) to:

a. Evaluate alternative design concepts, redundancy, cross-strapping approaches, and part substitutions as applicable

b. Identify the elements of the design that are the greatest detractors of system reliability

c. Identify those potential mission limiting elements and components that will require special attention in part selection, testing, environmental isolation, and/or special operations

d. Assist in evaluating the ability of the design to achieve the mission life requirement and other reliability goals and requirements as applicable

e. Evaluate the impact of proposed engineering change and waiver requests on reliability

f. Estimate the reliability (probability of success) of the Delta-V thrusters

4 HARDWARE PROCUREMENT

4.1 General Requirements

The contractor shall either procure or manufacture all components required to assemble, integrate, and test the Delta-V thrusters to support the delivery dates as called for in the contract (Section B Table) and listed in Appendix B.

The contractor shall assemble the quantities of Delta-V thruster hardware described below. The contractor shall present 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 Delta-V thruster.

4.2 Hardware Deliverables

The contractor shall provide the following hardware to meet the requirements of the RST Delta- V Thruster Specification (RST-PROP-SPEC-0122).

a) Nine (9) Delta-V Thruster Flight Units (DIL #59)

b) One (1) Delta-V Thruster Qualification Unit (DIL #60) if necessary to satisfy requirements in RST-PROP-SPEC-0122

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

4.3 Ground Support Equipment

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

• Two (2) Test Plugs (DIL #61)

• Two (2) Sets of Alignment Hardware (DIL #61)

• Nine (9) Nozzle Covers (DIL #61)

5 PERFORMANCE VERIFICATION AND TEST

5.1 Verification

The contractor will conduct a verification program that demonstrates the component design is qualified. The contractor will provide a verification matrix defining the method of verification for each specific requirement of this document.

5.2 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 Delta-V Thruster Specification RST-PROP-SPEC-0122 will be performed. (DIL #35) Verification tests shall demonstrate the thrusters meet 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, and data analysis methods, and give the sequence of the tests.

The plan shall include a verification matrix summarizing how all requirements in the specification are verified (analysis, inspection, test, per the definitions in the specification) and listing all tests that will be performed on the Delta-V thrusters.

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.

If any individual test plans are created in addition to the master Verification Plan, such as for Thermal Vacuum testing, those plans shall also be provided. (DIL #34)

5.3 Verification Methods

Verification methods include inspection, analysis, as well as environmental, functional, and performance testing, or a combination of these techniques.

5.3.1 Inspection

Verification by inspection includes (but is not limited to) visual inspection, simple physical manipulation, gauging, measurement, and documentation examination.

5.3.2 Analysis

Verification by analysis is used to show design margins. Also, when the particular tests required for verification are impractical, risky, unacceptably long, or prohibitively expensive, analysis may be used instead of testing, as noted in the verification matrices and approved by the

NASA/GSFC COR.

Analysis, including simulations where applicable, is also used to guarantee that the thruster and its components will perform as expected under worst-case conditions.

5.3.3 Test

Verification by test includes, but is not limited to, the evaluation of performance by use of special equipment or instrumentation, simulation techniques, and the application of established principles and procedures to determine compliance with requirements.

5.4 Inspection Requirements

Verification by inspection is by one of these three methods: 1) visual inspection of the physical component; 2) a physical measurement of a property of the component, or; 3) a documentation search demonstrating components of an identical design have demonstrated fulfillment of a requirement (also known as Qualification by Similarity).

5.4.1 Visual Inspection

Visual inspection of the physical component is performed by a qualified inspector to certify that the component has the properties/configuration specified in the requirement.

5.4.2 Physical Measurement

Physical measurement of component property (i.e. mass, dimensions, etc.) is performed by a qualified inspector to demonstrate the component meets a specific requirement.

5.4.3 Documentation Search

Verification of requirements based on similarity will include supporting rationale and documentation and be approved by the NASA/GSFC COR.

5.5 Analysis Requirements

Verification of performance or function through detailed analysis, using all applicable tools and techniques, is acceptable with NASA/GSFC COR approval. Detailed descriptions of the minimum required analyses, as well as analysis requirements, are provided in the SOW.

5.6 Test Requirements

This section provides general test requirements on how testing is to be performed in the process of verifying that the deliverable item meets its requirements.

a. Performance parameter measurements are taken to establish a baseline that can be used to assure that there are no data trends established in successive tests that indicate a degradation of performance trend within specification limits that could result in unacceptable performance in flight.

b. Any requirement that exceeds previous qualification test data are presented to the

NASA/GSFC COR as part of the verification planning process described in the SOW, for evaluation and a possible delta qualification test.

5.6.1 Definitions

The hardware definitions are reproduced here from Section 1.8 of GEVS (GSFC-STD-7000A).

Prototype Hardware: “Hardware of a new design; it is subject to a design qualification test program; it is not intended for flight.” The purpose of the tests on this hardware is to prove that a new design meets one or more of its design requirements. Qualification testing is performed at maximum expected flight levels plus a margin. Test durations are typically longer than for acceptance tests.

Protoflight Hardware: “Flight hardware of a new design; it is subject to a qualification test program that combines elements of prototype and flight acceptance verification; that is, the application of design qualification test levels and flight acceptance test durations.” The purpose of the test on this hardware is to prove that a new design meets one or more of its design requirements. Protoflight testing is performed at maximum expected flight levels plus a margin.

Test durations are typically the same as for acceptance tests.

Follow-On (Acceptance) Hardware: “Flight hardware built in accordance with a design that has been qualified either as prototype or as protoflight hardware; follow-on hardware is subject to a flight acceptance test program.” The purpose of the test on this hardware is to prove that a particular flight unit has been manufactured properly. The design has already been proven during a qualification or protoflight test program. Acceptance testing is performed at maximum expected flight levels.

5.6.2 Thermal Cycle Prior to Structural Testing

Flight hardware made of composites or flight hardware with bonded joints shall undergo thermal cycling to hot and cold survival temperatures a minimum of 5 cycles prior to structural testing.

5.6.3 Non-Destructive Examination

NDE of critical weldments shall be performed pre- and post-proof test.

5.6.4 Verification Test Procedures

The contractor shall generate Verification Test Procedures (acceptance testing and qualification testing as applicable) and provide them to the NASA/GSFC COR. (DIL #45) 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. The Thermal Vacuum Test Procedure shall include the contents listed in Section 6.9.3 for the Chamber Configuration.

5.6.5 Verification Test Reports

The contractor shall generate Verification Test Reports. (DIL #57) These reports shall document the results of each test that was performed, what test levels were achieved, what performance requirements were verified, what anomalies were seen, and how they were resolved. The Thermal Vacuum Test Report may include the Bakeout results (see Section 6.9.3) if it can be delivered by the delivery date for Bakeout Test Results.

5.6.6 Test Factors

The following test factors and durations, shown in Table 5-1, shall be used for prototype, protoflight, and follow-on flight hardware.

Table 5-1 Test Factors and Durations

Test Prototype Protoflight Acceptance Structural Loads

Level Duration

Centrifuge Sine Burst(1)

1.25 X Limit Load

1 Minute

5 Cycles Full Level

1.25 X Limit Load

30 Seconds

Limit Load(2)

30 Seconds

Random Vibration Level Duration

Limit Level +3dB

2 Minutes/Axis

Limit Level +3dB

1 Minute/Axis

Limit Level

1 Minute/Axis Sine Vibration

Level Sweep Rate(3)

1.25 X Limit Level

Octaves/Minute/Axis

1.25 X Limit Level

Octaves/Minute/Axis

Octaves/Minute/Axis

Shock Actual Device Simulated

2 Actuations

1.4 X Limit Level

2 Actuations/Axis

2 Actuations

1.4 X Limit Level

1 Actuations/Axis

1 Actuation

1 Actuation/Axis

(1) Test levels for Beryllium structure are 1.4x limit level for both qualification and acceptance testing. Composite structure, including metal matrix, requires acceptance testing to 1.25 x limit level.

(2) As a minimum, the test level will be equal to or greater than the workmanship level.

(3) The sweep direction should be evaluated and chosen to minimize the risk of damage to the hardware. If a sine sweep is used to satisfy the loads or other requirements, rather than to simulate an oscillatory mission environment, a faster sweep rate may be considered, e.g., 6-8 oct/min to reduce the potential for over stress.

(4) Shorter durations may be used in static testing if necessary to protect the hardware from damage due to facility limitations. If a shorter duration is used then the dwell time at load must be sufficient to demonstrate that the target loading condition has been achieved within the specified tolerances, all test measurements have been recorded, and the structure is stable under the applied loading condition.

5.6.7 Test Tolerances

Verification tests shall meet the tolerances for the various mechanical parameters given in Table 5-2.

Table 5-2 Test Tolerances

Test Test Parameter Tolerance Temperature ± 2 °C Humidity ± 5% RH Loads Steady-State (Acceleration): ± 5% Static: ± 5% Mass Properties Weight: ± 25g

Center of Gravity: ± 5 mm Moments of Inertia ± 1 % Products of Inertia ± 5 %

Test Test Parameter Tolerance

Mechanical

Response Spectrum:

Simulated (f ≤ 3kHz) Simulated (f ≥ 3kHz)

Shaker

± 6 dB

+9/-6 dB ± 3 dB

Shock Time History: ± 10% Pressure >1.3 x 104 Pa (> 100 mm Hg): ± 5%

1.3 x 104 to 1.3 x 102 Pa (100 mm Hg to 1 mm Hg): ± 10%

1.3 x 102 to 1.3 x 101 Pa (1 mm Hg to 1 micron): ± 25%

< 1.3 x 101 Pa (< 1 micron): ± 80% Vibration Sinusoidal: Amplitude ± 10% Frequency ± 2% Random: RMS Level ± 10%

Accel. Spectral Density ± 3 dB

5.6.8 Test Restrictions

5.6.8.1 Failure During Tests

a. When a failure (non-conformance or trend indicating that an out-of-spec condition will result) occurs, determination will be made as to the feasibility and value of continuing the test to its specified conclusion. The test will be stopped if equipment fails during testing in cases where this failure will result in damage to the equipment.

b. Otherwise, the test will be completed to obtain as much information as possible. If corrective action is taken, the test will be repeated to the extent necessary to demonstrate that the test item’s performance is satisfactory. If corrective action taken as a result of failure affects the validity of previously completed tests (e.g., redesign of a component), prior tests will be repeated.

If during a test sequence, a test item is operated in excess of design life and wears out or becomes unsuitable for further testing from causes other than deficiencies, a spare will be substituted, and previously completed tests will be repeated to the extent necessary.

c. No replacement, adjustment, maintenance, or repairs are authorized during testing. This requirement does not prevent the replacement or adjustment of equipment that has exceeded its design operating life during tests, provided that after such replacement, the equipment is tested as necessary to assure its proper operation. A complete record of any exceptions taken to this requirement will be included in the test report.

5.6.8.2 Modification of Hardware

Once the formal acceptance test has started, cleaning, adjustment, or modification of test hardware is not permitted.

5.6.8.3 External Adjustment

The thruster shall be designed so that no external adjustments are required after start of acceptance or qualification testing.

5.6.8.4 Re-Test Requirements

If any event, including test failure, requires that the thruster be disassembled and reassembled, then all tests performed prior to the event will be considered for repeat. If the unit has multiple copies of the same build, then all units must be examined to determine if the problem is common. If all copies require disassembly for repair, then each must receive the same test sequence.

5.7 Required Tests

The following tests are required for each thruster to provide assurance that the thruster meets all of its requirements. Each test or demonstration is described below:

• Physical Inspection

• Mass Properties

• Proof Pressure

• Performance Testing (Pre-Environmental)

• Sine Sweep Survey

• Static Load/Strength

• Sine Vibration

• Random Vibration

• Shock (deferred to higher level if warranted by shock assessment)

• Thermal Vacuum Bake-Out

• Thermal Vacuum Cycling

• Performance Testing (Pre-Hot Fire)

• Hot Fire Testing

• Harness Hi-Pot Testing

• Performance Testing (Final)

• Grounding

• Alignment

• Cleanliness

5.7.1 Physical Inspection

Each flight unit will be physically inspected for conformance to the thruster design, including workmanship, envelope, and marking.

5.7.2 Mass Properties Measurement

Measurement of the weight and center of gravity of each flight hardware component will be made to show compliance with requirements and to provide accurate data for the observatory mass properties control program. Center of gravity at the component level will be referenced to the component-to-spacecraft mounting interface.

5.7.3 Proof Pressure Test

Proof pressure testing is to be performed per the test requirements of NASA-STD-8719.24, which applies to pressure vessels, lines, and fittings. The proof pressure test will verify internal pressure containment per NASA-STD-8719.24. Following the proof pressure test, a leak test will be performed to verify that the proof pressure test did not damage or degrade the components.

5.7.4 Performance Tests

The performance testing suite is a group of tests that are repeated during the acceptance test program to ensure the health of the test article. Performance testing will include leakage verification and electrical performance tests, as well as any other tests that the supplier deems necessary to verify the continued health of the test article. Electrical performance tests will include testing at the minimum and maximum operating voltage extremes. These tests occur before and after environmental testing and after hot fire testing.

5.7.5 Frequency Signature Survey

a. Frequency signature test will be conducted on each thruster before and after vibration testing in each axis. This can be conducted in one of two ways: low-level signature random, or low-level sine sweep.

b. This test will be performed immediately preceding the sine/random vibration tests and will be repeated after the sine/random vibration tests to verify that the modal signature of the unit under test (first resonant frequency) is within 5% of the pre-test frequency. In this case, the unit has passed and the test can continue. If the post-test frequencies are between 5% and 10% of the pre-test frequencies, the cause of the shift should be investigated (test bolt torques, etc.) before determining whether failure has occurred or success has been achieved and whether the test can continue. A shift of greater than 10% indicates failure, and the test should be terminated, and the failure documented. In either case when the shift is greater than 5%, the NASA/GSFC COR is to be notified.

c. Frequencies will be verified and reported up to 200 Hz, at a minimum. Thus, if the low-level test is done as a sine sweep rather than a low-level random, the sweep should be completed to at least 200 Hz. Low-level random should be done for the full random vibe frequency range of 20 Hz to 2000 Hz. Pre- and post-frequency signature surveys will be verified and reported as follows:

• Sine vibration – frequency range of 0 – 200 Hz for signature tests

• Random vibration – frequency range of 0 – 2000 Hz for signature tests

5.7.6 Static Loads/Strength Test

Strength testing is used to verify the component strength and structural integrity, and it can be done using a variety of techniques, such as sine burst, static pull, or centrifuge testing.

a. Structural design loads are applied to prototype or protoflight hardware. There is no requirement to strength test flight hardware that has already been strength tested through…