Tab_02_-_Statement_of_Work.pdf

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TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

Mars Entry, Descent and Landing Instrumentation (MEDLI2)

Backshell Pressure Transducer Statement of Work, Deliverable Item List & Schedule, and Sensor Specifications

MEDLI2-6006

Version 2

LANGLEY RESEARCH

CENTER

Hampton, Virginia

National Aeronautics and Space Administration ii

Table of Contents

1 Introduction

1.1 General Information

1.2 Scope

1.3 Applicable 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 (DCR)

2.4.3 Pre-Ship Review (PSR)

2.5 Documentation

3 Interface Control documentation

3.1 Drawing Package

3.2 ELECTRICAL Parts Stress Analysis

4 Hardware Procurement/Manufacturing

4.1 General Requirements

4.2 Pressure Transducers

4.3 CONNECTOR SAVERS

4.4 SUPPORTING HARDWARE

5 Performance Verification And Test

5.1 Qualification

5.2 Acceptance Verification Plan

5.3 Verification Methods

5.3.1 Inspection

5.3.2 Analysis

5.3.3 Test

5.4 Test Requirements

5.4.1 Measurement and Test Equipment

5.4.2 Test Tolerances

5.4.3 Test Restrictions

5.5 Acceptance Test Requirements

5.5.1 Performance Tests

5.5.2 External Leakage

5.5.3 Random Vibration

5.5.4 Proof Pressure Test

5.5.5 Shock

5.5.6 Thermal Cycling Testing

5.5.7 Cleanliness Verification

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5.6 Acceptance Test Procedures

5.7 Acceptance Test Reports

6 Quality Assurance

6.1 GENERAL REQUIREMENTS

6.1.1 Quality Assurance Plan/Manual

6.1.2 Surveillance of the Contractor

6.1.3 Anomaly Reporting

6.1.4 Configuration Management

6.2 System Safety Requirements

6.3 Reliability Requirements

6.3.1 Stability Trending

6.3.2 Limited-Life Items

6.3.3 Control of Sub-Developers and Suppliers

6.4 WORKMANSHIP STANDARDS AND PROCESSES

6.4.1 Workmanship Requirements

6.4.2 Electrostatic Discharge Control Requirements

6.4.3 Hardware Handling, Cleaning, and Packaging

6.4.4 Workmanship: Use of Alternate Workmanship Standards

6.5 EEE Parts Requirements

6.5.1 General

6.5.2 Custom Devices

6.5.3 Plastic Encapsulated Microcircuits

6.5.4 Parts Age Control

6.5.5 GIDEP Alerts and Problem Advisories

6.5.6 Reuse of Parts and Materials

6.5.7 Part Notification of Failure

6.6 Materials, Processes Requirements

6.6.1 Materials Selection Requirements

6.6.2 Materials Procurement Requirements

6.6.3 Dissimilar Metals

6.6.4 Welding

6.6.5 Interchangeability

6.6.6 Contamination Control Plan

6.6.7 Cleanliness

6.6.8 Material Outgassing

6.6.9 Thermal Vacuum Bake-outs

7 Handling, Storage, Packaging, Preservation, and Delivery 8 Appendix A. Abbreviations and Acronyms 9 Appendix B. MEDLI2 Material Selection Forms 10 Appendix C. List of Applicable and Reference Documents 11 Appendix D. Deliverable Item List & Schedule (DILS)

11.1 DILS

11.2 Proprietary Data

11.3 DELIVERABLES

12 Appendix E. Sensor Specifications

12.1 Purpose

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12.2 Scope

12.3 Transducer Constraints

12.3.1 Configuration

12.3.3 Interchangeability:

12.3.4 Parts, Materials, and Processes:

12.3.5 Electronic Parts Selection and Application:

12.3.6 Cleanliness

12.4 Design Goals

12.4.1 Design Life:

12.4.2 Temperature:

12.4.3 Non-operational Temperature – Low Temperature

12.4.4 Non-operational Temperature – High Temperature

12.4.5 Operational Temperature:

12.5 Mechanical Loading

12.5.1 Random Vibration Environment

12.5.2 Shock Environment

12.6 Functional Characteristics Needs:

12.6.1 Accuracy:

12.6.2 Static Error Band:

12.6.3 Temperature Error Effects:

12.6.4 Backshell Sensor Pressure Range:

12.6.5 Response Time:

12.6.6 Resolution:

12.6.7 External Leakage:

12.6.8 Input Voltage:

12.6.9 Input Current:

12.6.10 Load Impedance:

12.6.11 Output Impedance:

12.6.12 Output Voltage:

12.6.13 Zero Pressure Output Voltage:

12.6.14 Output Voltage Span:

12.6.15 Insulation Resistance:

12.6.16 Input/Output Isolation:

12.6.17 Proof Pressure:

12.6.18 Short Circuit:

12.6.19 Vibration Sensitivity:

12.6.20 Orientation Sensitivity:

List of Figures

Figure Page

Figure 1: Thermal Cycle Test Conditions Figure 2: Pressure Sensor 4-Point Mechanical Mounting

List of Tables

Table Page

Table 5-1: Test Tolerances Table 5-2: Random Vibration Levels Table 11-1 HARDWARE DELIVERY AND SCHEDULE Table 11-2 DATA DELIVERY DOCUMENTATION AND SCHEDULE Table 12.5.2-1: Shock Spectrum ………………………………………………………………..44

1 INTRODUCTION

1.1 GENERAL INFORMATION

NASA intends on collecting measurements of low pressure data on a future Mars entry mission. These pressure measurements will be collected using a pressure transducer with previous space flight heritage that is capable of surviving space environments identified later in this document. NASA does not intend on qualifying a new design for this measurement.

1.2 SCOPE

This document defines the work to be performed by the contracted manufacturer in the fabrication and delivery of the Mars Entry, Descent, and Landing Instrumentation 2 (MEDLI2) Pressure Transducers. 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 Statement of Work (SOW) and the appendices.

1.3 APPLICABLE DOCUMENTS

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

2 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 PROGRAM MANAGEMENT

The contractor shall designate an individual(s) 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.

2.2 REPORTING

The contractor shall prepare and present to the NASA/LaRC Technical End User monthly technical status reports via a written email report. The report shall be a summary of the period's progress, schedule updates, problem areas, and activities on-going and planned. See Appendix D for reporting details.

2.3 ADVANCED NOTIFICATIONS

The contractor shall notify the NASA/LaRC TECHNICAL END USER at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, Technical Interchange Meetings, and deliveries at either the contractor’s or a sub-contractor’s facility to allow timely participation by the NASA/LARC Quality Assurance representative. 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 conduct a Kick-off Meeting at the Contractor’s facility prior to any activity identified in this SOW within thirty (30) days after award of the contract.

The Contractor shall provide to LaRC a Kick-off Presentation Package and all other required deliverables as specified in Appendix D. The Kick-off Meeting shall address program management, flight heritage, and quality assurance activities outlined in this SOW, as well as the performance and environmental requirements outlined in Appendix E. At a minimum, the Kick-off Meeting presentation package should cover the following areas:

Program Management Quality Assurance Flight Heritage Initial Program Schedule Release Manufacturing flow with government mandatory inspection points (section

6.1.2.3) Facilities

2.4.2 Design Conformance Review (DCR)

The Design Conformance Review can be combined with the Kick-Off meeting based on heritage designs.

The contractor shall organize and present a Design Conformance Review to a LaRC Review Team at the contractor’s facility prior to the manufacturing program, on a date defined in the contract. The contractor shall provide to LaRC a Design Conformance Review Presentation Package and all other required deliverable data in accordance with Appendix D. The Design Conformance Review shall address all design, drawings, analysis, and tests outlined in this SOW and Appendix E 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 shall cover the following areas:

Acceptance Test Plan Materials and Processes Interface Control Documentation Verification Approach System Safety Requirements

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

2.4.3 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 LaRC. This presentation shall demonstrate completion of all activities required for delivery of any hardware deliverable item to NASA/LaRC, and note any activities that are incomplete.

In particular, the contractor shall create and present a completed verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses) where applicable. All requirements that are not met shall be captured in the Deviations/Waivers etc. list and discussed with NASA/LaRC during the review.

A Data Delivery Package shall be made available for review during pre-ship reviews for each of the different hardware deliverables. 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, and part number

Appropriate approval signatures (e.g., contractor quality representative, contractor program manager, TECHNICAL END USER, NASA/LaRC

Representative, etc.)

Work orders for the final assembly and associated tests

As-Built Parts List

As-Built Final Interface Control Documentation (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

Anomaly Reports

List of As-Built Materials and Processes used

Verification matrix (including environmental), test data and reports

Photograph Documentation (Pre-Test and Post-Test)

Certificate of Conformance, with management signature

End Item Inspection Report

2.5 DOCUMENTATION

The contractor shall ensure the generation and delivery of all documentation as called for in this SOW and Appendix D.

In addition to that documentation specifically called for in the contract, upon request by the NASA/LaRC TECHNICAL END USER, the contractor shall make available a copy of any document or data generated during this contract performance for review by LaRC at either the contractor's facility or via the internet. This includes, but is not limited to, technical reports and memorandums, drawings, schematics, parts and materials data, test data, alerts, etc.

3 INTERFACE CONTROL DOCUMENTATION

The Contractor shall provide document(s) and/or drawing(s) that define, in detail, all electrical, thermal, and mechanical interfaces, including total mass, subject to review and approval by the NASA LaRC TECHNICAL END USER. These documents and/or drawings shall be reviewed and approved at the DCR.

3.1 DRAWING PACKAGE

The contractor shall make a complete drawing package, including mechanical and electrical drawings at a minimum, for review at the contractor’s facility for Design Conformance Review (DCR).

3.2 ELECTRICAL PARTS STRESS ANALYSIS

If requested by the NASA LaRC TECHNICAL END USER, the contractor shall perform parts stress analyses on Electrical, Electronic, and Electromechanical (EEE) parts and devices to certify conformance with the derating requirements of EEE parts. The analyses shall be documented, and justification shall be included for all applications that do not meet the derating criteria. The Contractor shall use NASA document EEE-INST- 002, Instructions for EEE Parts Selection, Screening, Qualification, and Derating to establish criteria. Contractor derating guidelines may be considered in place of EEE- INST-002 guidelines but shall be submitted for approval. The results of these analyses shall be summarized in a Contractor format Parts Stress Analysis Report that will be provided to the NASA/LaRC TECHNICAL END USER for review.

4 HARDWARE PROCUREMENT/MANUFACTURING

4.1 GENERAL REQUIREMENTS

The contractor shall either procure or manufacture all components required to assemble, integrate, and test the pressure transducer to support the delivery dates specified in Appendix D.

The contractor shall provide a Fabrication, Assembly, and Inspection Flow plan at the Kick-off Meeting that shall include a step-by-step procedure that describes the method of fabrication, assembly, and inspection from piece parts to the completely assembled pressure transducers.

4.2 PRESSURE TRANSDUCERS

The contractor shall assemble, test, inspect, and deliver the quantities of the pressure transducer hardware identified in Appendix D. The contractor shall ensure the hardware meets the requirements noted in Appendix E.

4.3 CONNECTOR SAVERS

Flight Units shall be tested with connector savers to minimize mates and de-mates.

Connector savers shall be delivered with each Flight Unit.

Connector savers shall be vacuum compatible.

4.4 SUPPORTING HARDWARE

The contractor shall provide the following supporting hardware. See Appendix D for quantities.

a) Connector Savers

b) Mating connectors

c) ESD protective plastic caps

d) Pressure port protection caps

5 PERFORMANCE VERIFICATION AND TEST

5.1 QUALIFICATION

The Contractor shall provide a qualification report that demonstrates that the pressure transducer design is qualified for all requirements in Appendix E. It is expected that no qualification unit will be manufactured for the MEDLI2 project and that previous qualification data and design analysis will be used to satisfy MEDLI qualification requirements. Qualification by similarity shall be approved by the NASA LaRC/TECHNICAL END USER, and the qualification reports for any similarity items shall be made available to the TECHNICAL END USER.

5.2 ACCEPTANCE VERIFICATION PLAN

N/A

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 shall be by one or any combination of these three methods:

1) Visual inspection of the physical hardware

2) A physical measurement of a property of the hardware

3) A documentation search demonstrating hardware of an identical design has demonstrated fulfillment of a requirement.

5.3.1.1 Visual Inspection

Visual inspection of the physical hardware shall be performed to certify that the hardware has the properties/configuration specified in the requirement.

5.3.1.2 Physical Measurement

Physical measurement of hardware property (i.e. mass, dimensions, etc.) shall be performed to demonstrate the hardware meets specific requirement.

5.3.1.3 Documentation Search

Verification of requirements based on similarity shall include supporting rationale and documentation and shall be approved by the LaRC TECHNICAL END USER.

5.3.2 Analysis

Verification by analysis will be 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, and noted in the vendor provided verification matrices and approved by LaRC TECHNICAL END USER.

Analysis, including simulations where applicable, will also be used to guarantee that the pressure transducer will perform as expected under worst-case conditions.

Verification of performance or function through detailed analysis, using all applicable tools and techniques, is acceptable with LaRC TECHNICAL END USER approval.

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 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. Performance parameter measurements shall be taken prior to testing 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. Any requirement that exceeds previous qualification test data shall be presented to the MEDLI2 project as part of the verification planning process described in the SOW, for evaluation and a possible delta qualification test.

5.4.1 Measurement and Test Equipment

All measurement and test equipment used for calibration and/or verification of a requirement shall comply with the American National Standard for Calibration of Measurement and Test Equipment ANSI/NCSL Z540.3-2006 or equivalent.

5.4.2 Test Tolerances

Tolerances for the various mechanical test parameters are given in Table 5-1.

Test Test Parameter Tolerance

Temperature 2 C

Humidity 5% RH

Loads Steady-State (Acceleration): 5%

Static: 5%

Mass Properties Weight: 0.2%

Mechanical Response Spectrum: + 25%, - 10%

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

Table 5-1: Test Tolerances

5.4.3 Test Restrictions

5.4.3.1 Failure During Tests

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 shall be stopped if equipment fails during testing in cases where this failure will result in damage to the pressure sensors.

Otherwise, the test shall 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.

No replacement, adjustment, maintenance, or repairs are authorized during testing except external cleaning is allowed before cleanliness verification. 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 shall be included in the test report.

5.4.3.2 Modification of Hardware

Once the formal acceptance test has started, no alteration to the test configuration is to be permitted that might alter the test data results from the flight units under test. This includes cleaning, adjustment or re-calibration for all the test equipment involved with the formal acceptance test configuration setup.

5.4.3.3 External Adjustment

External cleaning is allowed before cleanliness verification.

5.4.3.4 Re-Test Requirements

If any event, including test failure, requires that a pressure transducer be disassembled and reassembled, then all tests performed prior to the event must 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.

5.5 ACCEPTANCE TEST REQUIREMENTS

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

Performance Testing External Leakage Random Vibration Proof Pressure Thermal Cycling Cleanliness

5.5.1 Performance Tests

The performance tests will be used to verify full compliance of each flight unit to its performance requirements, within the limitations of the environment and facilities. The performance test will be designed to verify unit performance in all modes and configurations and under varying input/output conditions. At a minimum, the following performances shall be verified periodically during performance testing.

Calibration over the Entire Pressure Range Pressure Output Range at Ambient (operational) Temperature Operational Voltage Power Consumption

5.5.2 External Leakage

The Contractor shall demonstrate the external leakage per Appendix E.

5.5.3 Random Vibration

Each pressure transducer shall be subjected to a random vibration test in each of three orthogonal axes of the unit under test, one axis being perpendicular to the mounting surface to the appropriate levels and durations shown in Table 5-2. During the test, the test input level can be reduced (notched) at critical frequencies, if required, to limit the random vibration loads and/or acceleration responses to 1.25 times design limit levels.

Notching will be limited to -12 dB of the original input and to a bandwidth of less than 100 Hz (notching beyond these limits will require MEDLI2 project approval).

The random vibration test tolerance spectral shape shall have a power spectral density within +/- 3 dB when measured in frequency bands of no more than 25 Hz in width.

Frequency (Hz) Test Level 20 – 40 +6 dB/oct 40 – 500 0.2 g2/Hz

500 – 2000 -6 dB/oct Overall 13.0 grms

Table 5-2: Random Vibration Levels

For the random vibration test, the unit under test will be attached to the vibration table using contractor provided hardware and conducted using contractor standard test procedures. The random vibration test duration shall be one (1) minute per axis.

During the random vibration test, the flight unit will be powered and the pressure signal monitored and recorded using recording instruments that have a response equal to or greater than the highest frequency of vibration. Performance and leakage tests shall be performed before the start of testing and after a test.

5.5.4 Proof Pressure Test

The proof pressure test will verify that the sensors performance did not degrade after exposure to the proof pressure value provided in Appendix E. Following the proof pressure test, a functional test shall be performed to verify that the sensor performance was not affected.

5.5.5 Shock

Refer to section 12.5.2 in Specifications.

5.5.6 Thermal Cycling Testing

Each pressure transducer shall be subjected to a thermal cycle test. The minimum number of cycles to be performed is three (3) as shown below in Figure 1. The temperature extrema are +70 C to -60C. The thermal cycle test can be conducted at a vendor specified pressure for the ambient conditions.

The rate of change from one temperature to the next shall be less than 5 degrees C per minute. The specified temperature extrema shall be maintained for a minimum of two

(2) hours before changing to the next temperature. The temperature measurement to be used for determining if at the proper test temperature shall be an internal temperature measurement. The tolerance for the temperature at each extrema shall be +/- 2 degrees C. During the thermal cycling test, the pressure transducer shall be powered on. If the thermal cycling test is performed at a pressure greater than 0.075 Pascals, then a pressure supply shall be connected to the pressure transducer with a vacuum source so the pressure transducer is measuring pressures in the sensing mid-range. During the test the pressure transducer measured pressure and the applied pressure shall be recorded and provided.

It is acceptable for all pressure transducers to be tested simultaneously in the same test facility.

Figure 1: Thermal Cycle Test Conditions

5.5.7 Cleanliness Verification

See Section 6.6.7 of this document.

5.6 ACCEPTANCE TEST PROCEDURES

The contractor shall generate Acceptance Test Procedures. The acceptance procedures shall be step-by-step instructions for performing tests outlined by the Acceptance 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.

Acceptance Test Procedures shall be contractor controlled documents and shall indicate all changes made after the initial release for review to NASA.

5.7 ACCEPTANCE TEST REPORTS

The contractor shall generate Acceptance Test Reports. The Acceptance Test Procedures and Test Data Sheets may be used to satisfy this requirement. 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 observed, and how they were resolved.

6 QUALITY ASSURANCE

6.1 GENERAL REQUIREMENTS

6.1.1 Quality Assurance Plan/Manual

The developer shall have a Quality Management System that is compliant with the requirements of SAE AS9100 Quality Systems – Aerospace – Model for Quality Assurance in Design, Development, Production, Installation and Servicing.

6.1.2 Surveillance of the Contractor

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

The contractor shall provide the LaRC representative with documents, records, equipment, and workings areas within their facilities that are required by the representative to perform their overview activities.

6.1.2.1 Government Source Inspection

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

The Government quality representative who has been delegated NASA quality assurance functions on this procurement shall be notified within 2 business days upon contractor receipt of any supplier/subcontractor orders. The Government representative shall also be notified 48 hours in advance of the time that articles or materials are ready for inspection or test.

6.1.2.2 Contractor Source Inspection

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

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

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

6.1.2.3 Government Mandatory Inspection Points (MIPs)

The Government or its representative will inform the Contractor of the MIPs at the Kick-off Meeting. In the event that proper notification has been made and 48 hours have elapsed without the MIP being accomplished, the contractor can waive the MIP after receiving NASA/LaRC TECHNICAL END USER approval.

6.1.3 Anomaly Reporting

Reporting of hardware anomalies to the NASA/LaRC TECHNICAL END USER shall begin no later than the first power application at the start of acceptance testing. The NASA LaRC TECHNICAL END USER shall be notified within 24 hours of each anomaly.

The contractor’s processes for review, disposition and approval of anomaly reports shall be described in their quality plan/manual or provided as a supplemental document. In addition, the contractor’s anomaly reporting document shall describe the members of the Material Review Board (MRB) and Failure Review Board (FRB). The MRB and FRB for any MEDLI2 pressure transducer anomalies shall include MEDLI2 LaRC participation.

The contractor shall provide the NASA LaRC Technical End User notice of MRB or FRB meetings related to MEDLI2 pressure transducer anomalies with at least 24 hours’ notice of the meeting. The NASA LaRC Technical End User may participate in the MRB or FRB meetings either remotely or in person at the contractor’s facility depending on the nature of the anomaly and the amount of notice available.

The contractor shall provide, as part of the monthly report, a list of all open anomaly reports and a separate list of the anomaly reports closed during the month. For each reported anomaly or nonconformance, there shall be a report that documents the investigation and engineering analysis needed to determine the cause and corrective actions to disposition the nonconformance, and identify any closed problem reports that do not have a definitive cause or corrective action. Reports shall be submitted to the NASA LaRC TECHNICAL END USER for review and approval of the disposition.

6.1.4 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 shall ensure all applicable changes are reviewed in a systematic manner to determine the validity and impact on performance, schedule, and cost.

All changes which affect the form, fit, function, external interfaces, or requirements as stated within this document and Appendix E, shall be submitted to the NASA LaRC Technical End User for approval prior to implementation of the change. NASA LaRC

Technical End User will provide a response within two (2) business days of receipt of the request for approval. The LaRC technical end user will contact the LaRC Office of Procurement for any major modifications to the specifications of the SOW that effect the intent of the SOW or value/funding of the contract.

All other changes shall be controlled and dispositioned by the contractor. NASA LaRC Technical End User reserves the right to review all other changes to the MEDLI2 Pressure Transducer documents 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/or performance requirements of the contract shall be dispositioned via a waiver or MRB, unless the affected item is reworked to restore compliance or is replaced with a fully compliant item. The contractor shall submit waivers to the NASA LaRC TECHNICAL END USER for final approval.

6.2 SYSTEM SAFETY REQUIREMENTS

N/A

6.3 RELIABILITY REQUIREMENTS

6.3.1 Stability Trending

The contractor shall track measurable parameters that relate to performance stability and repeatability. Selected parameters shall be monitored through acceptance testing.

These parameters will be compiled in the Trended Parameters List (TPL). These parameters shall include the calibration coefficients.

The reports will be delivered as a part of the Data Delivery Package and presented at the Pre-Ship Review (PSR).

6.3.2 Limited-Life Items

The contractor shall identify and manage limited-life items in a limited life items list.

Limited-life items include all hardware that is subject to degradation because of limited shelf life or expected operating times or cycles such that their expected useful life is less than twice the required life when fabrication, test, storage, and mission operation are combined.

The MEDLI2 Project TECHNICAL END USER shall approve the use of an item whose expected life is less than twice the mission design life. For materials that have exceeded their allowable shelf life, a waiver can be submitted to the LaRC TECHNICAL END USER for use.

6.3.3 Control of Sub-Developers and Suppliers

The contractor shall ensure that system elements obtained from sub-contractors and suppliers meet project reliability requirements.

6.4 WORKMANSHIP STANDARDS AND PROCESSES

The contractor’s workmanship program shall fully encompass 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.

6.4.1 Workmanship Requirements

The following workmanship standards shall apply to the pressure transducer.

Conformal Coating and Staking: NASA-STD-8739.1, Workmanship Standard for Staking and Conformal Coating of Printed Wiring Boards and Electronic Assemblies

Surface Mount Technology (SMT): NASA-STD-8739.2, Workmanship Standard for Surface Mount Technology

Hand Soldering Assemblies: NASA-STD-8739.3, IPC-J-STD-001 ES, or equivalent Soldered Electrical Connection

Crimping, Wiring, and Harnessing: NASA-STD-8739.4, Crimping, Interconnecting Cables, Harnesses, and Wiring

Printed Wiring Board (PWB) Design: Space Flight PWB designs shall not include features that prevent the finished board(s) from complying with the Class 3 Requirements of the appropriate manufacturing standard (e.g., specified plating thickness, internal annular ring dimensions, etc.).

o IPC-2221, Generic Standard on Printed Board Design o IPC-2222, Sectional Design Standard for Rigid Organic Printed Boards o IPC-2223, Sectional Design Standard for Flexible Printed Boards

Printed Wiring Board (PWB) Manufacture:

o IPC-A-600, Acceptability of Printed Boards (Class 3 requirements) o IPC-6011, Generic Performance Specification for Printed Boards (Class 3 requirements) o IPC-6012, Qualification and Performance Specification for Rigid Printed

Boards (Class 3/A requirements) o IPC-6013, Qualification and Performance Specification for Flexible Printed

Boards (Class 3 requirements)

6.4.2 Electrostatic Discharge Control Requirements

The contractor shall document and implement an Electro Static Discharge (ESD) Control Program suitable to protect the most ESD-sensitive instrument components at all levels of assembly and integration in accordance with the requirements of ANSI/ESD S20.20-1999.

All personnel who manufacture, inspect, test or otherwise process electronic hardware or who require unescorted access into ESD protected areas shall be certified as having completed the required training, appropriate to their involvement prior to handling any electronic hardware.

6.4.3 Hardware Handling, Cleaning, and Packaging

The handling of flight hardware shall be performed by qualified personnel in accordance with approved procedures that address cleaning, handling, packaging, tent enclosures, shipping containers, bagging, and purging. 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.

6.4.4 Workmanship: Use of Alternate Workmanship Standards

LARC 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 by the MEDLI2 Project TECHNICAL END USER. It must be established that the developer’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.

6.5 EEE PARTS REQUIREMENTS

6.5.1 General

It’s preferred that the Flight Unit parts be selected and processed in accordance with the requirements of EEE-INST-002, “instructions for EEE parts selection, screening, qualification and derating”. All application notes in EEE-INST-002 will apply.

The minimum acceptable EEE part grade available for Flight Unit use on MEDLI2 is Grade 2, with 100% Particle Impact Noise Detection (PIND) screening for cavity bodied devices and a sample Destructive Physical Analysis (DPA). This assumes that the radiation hardness requirements and system reliability goals are also being met.

Any parts that don’t meet Grade 1 or Grade 2 requirements shall require a Non Standard Parts Approval Request (NSPAR) using NASA Langley form LF-170 to be reviewed and approved by the NASA LaRC TECHNICAL END USER. The NSPAR must contain supporting information, which may include a source control drawing for review and approval to insure the component meets the application requirements. In the event that delivery of EEE parts prevent the “on time” delivery of these sensors, Grade 3 parts may be considered as an alternative with the submittal and approval of a

NSPAR.

The contractor shall maintain an EEE Parts Identification List and shall review proposed parts with the MEDLI2 TECHNICAL END USER. An As-Built Parts List (ABPL) shall be included as part of the end item data package.

6.5.2 Custom Devices

In addition to the applicable requirements of EEE-INST-002, custom microcircuits, hybrid microcircuits, MCM, ASIC and other non-standard application unique devices planned for Flight Unit shall be subjected to a parts-level design review (with LaRC participation). The design review shall address, at a minimum, de-rating of elements, method used to certify acceptable reliability, assembly and materials processes, methods for assuring adequate thermal matching of materials, and screening and qualification requirements.

6.5.3 Plastic Encapsulated Microcircuits

The use of Plastic Encapsulated Microcircuits (PEMs) is discouraged in the Flight Unit. However, when use is necessary to achieve unique requirements that cannot be found in hermetic high reliability microcircuits, plastic encapsulated parts must meet the requirements of NASA LaRC EEE-INST-002. All PEM(s) require NASA/LaRC TECHNICAL END USER review and concurrence. PEM usage shall be presented at the Design Conformance Review and Technical Interchange Meeting/s (TIM)s, as applicable.

6.5.4 Parts Age Control

Parts more than 5 years old require MEDLI2 TECHNICAL END USER concurrence.

Contractors shall present justification with inspection and test requirements.

6.5.5 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 MEDLI2. The contractor shall review and disposition all GIDEP Alerts for relevancy and impact. In addition, the contractor shall review and disposition any NASA Alerts and Advisories provided to the developer by the MEDLI2 Project. Alert applicability, impact, and corrective actions shall be documented and status provided to the MEDLI2 Project on a monthly basis.

6.5.6 Reuse of Parts and Materials

Any reuse of mechanical components along with EEE parts and materials shall be logged and verified that they meet the original design requirements. In addition, the Contractor shall inform NASA/LaRC TECHNICAL END USER of any mechanical and/or parts reuse including those installed in an assembly and then removed.

6.5.7 Part Notification of Failure

The contractor shall provide failure-reporting data to NASA/LaRC TECHNICAL END USER within 72 hours of part failure determination.

6.6 MATERIALS, PROCESSES REQUIREMENTS

6.6.1 Materials Selection Requirements

To qualify material for flight use, the material must have a satisfactory flight heritage relevant to MEDLI2 requirements or meet the following applicable selection criteria as defined herein for:

Vacuum outgassing 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 B, or an equivalent form. The contractor shall review proposed materials and processes with the NASA/LaRC TECHNICAL END USER. An As-Built Materials List (ABML) shall be included as part of the end item data package, using the form in the Appendix B, or an equivalent form. Pure Tin, Zinc, and Cadmium are not acceptable for flight use.

6.6.1.1 Vacuum Outgassing of Polymeric Materials

Only materials that have a total mass loss (TML) less than 1.00% and a collected volatile condensable mass (CVCM) less than 0.10% shall be approved for use in a vacuum environment. Material vacuum outgassing shall be determined in accordance with ASTM E-595. If a material exceeds these maximum limits, the contractor shall be required to either replace with a compliant material or bring it into compliance via a vacuum bake-out, or to submit a Material Usage Agreement (MUA) for its usage. See Appendix B for MUA form and example. Exception may be approved by NASA/LaRC TECHNICAL END USER if materials are contained within hermetically welded sensor case.

6.6.1.2 Stress Corrosion Cracking of Inorganic Materials

Materials used in structural applications shall be highly resistant to stress corrosion cracking (SCC) as specified in MSFC-STD-3029. A Material Usage Agreement (MUA) and a SCC evaluation form shall be submitted, contractor format acceptable, for each material usage that does not comply with the MSFC-STD-3029 SCC requirements.

6.6.1.3 Process Selection Requirements

Materials and manufacturing process information shall be provided on the material list.

6.6.2 Materials Procurement Requirements

Raw materials purchased by the contractor and its developers shall be accompanied by a Certificate of Compliance and, where applicable, the results of nondestructive, chemical, and physical tests. When requested, this information shall be made available to the NASA LaRC TECHNICAL END USER for review.

6.6.3 Dissimilar Metals

To avoid electrolytic corrosion, dissimilar metals shall not be used in direct contact unless protection against corrosion has been provided in accordance with MIL-STD-

889. Variances from this policy must be submitted to the NASA/LaRC TECHNICAL END USER for approval.

6.6.4 Welding

Welding shall be performed and inspected per vendor/NASA approved procedure according to MIL-STD-2219A with Change 1. Control of weld filler material shall also be per vendor and NASA approval. Test records such as dye penetrant, x-rays, etc. shall all be retained. At a minimum, the Contractor shall maintain a heritage internal process that contains a weld schedule including settings and configuration demonstrating a repeatable performance.

6.6.5 Interchangeability

Each pressure transducer shall be directly interchangeable physically and functionally with other items of the same part number.

6.6.6 Contamination Control Plan

The contractor shall prepare a Contamination Control Plan (CCP) that describes the procedures that will be followed to control contamination. The CCP shall establish the implementation and describe the methods and procedures that will be used to measure and maintain the levels of cleanliness required during each of the various phases of the item’s lifetime. The contamination potential of material and equipment used in cleaning, handling, packaging, tent enclosures, shipping containers, bagging (e.g., anti-static film materials), and purging shall be described in detail at each phase of assembly, integration, test, and launch. The CCP shall define the use of protective covers and purges, vent locations and paths, and environmental constraints. The contractor shall submit their CCP to the MEDLI2 Project for review and approval.

6.6.7 Cleanliness

All hardware cleanliness shall be verified to meet the requirements in section 12.3.6 of Appendix E prior to delivery to LARC.

6.6.8 Material Outgassing

All materials shall be screened against the measured materials in NASA Reference Publication 1124, Outgassing Data for Selecting Spacecraft Materials. Individual material outgassing data shall be considered valid for use for MEDLI2 if the material was processed in the same manner as the material in the Reference Publication (mix ratio, temperature, post cure bake-out, etc.) based on each component’s operating conditions. Established material outgassing data shall be verified and shall be provided to the MEDLI2 Project for review and approval upon request.

6.6.9 Thermal Vacuum Bake-outs

Thermal vacuum bake-out will be performed at LaRC.

7 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY

Products shall be stored, preserved, marked, labeled, and packaged to prevent loss of marking, deterioration, contamination, excessive condensation and moisture, or damage during all phases of the program. Stored and stocked items shall be controlled in accordance with documented procedures and be subject to quality surveillance.

Contractor is responsible for providing an acceptable shipping container that protects the hardware appropriately.

While in a shipping container, the pressure transducer shall be wrapped in a non-ESD-generating vapor barrier with redundant maximum humidity indicators. Packaging materials and methods shall not degrade the molecular or particulate cleanliness of the item.

The shipping container shall also include redundant shock indicators and one (1) humidity indicator and shall be capable of prolonged shipping conditions. The contractor shall document what action NASA LaRC is to take if the shock sensors are tripped when hardware arrives at the NASA LaRC receiving area. A copy of this document shall be included with shipping documentation.

By executing the act of product shipment, the supplier certifies that the product complies with all contract requirements. Prior to shipping, quality assurance personnel shall ensure that:

Fabrication, inspection, and test operations have been completed and accepted.

All products are identified and marked in accordance with requirements.

The accompanying documentation (developer's shipping and property accountable form) has been reviewed for completeness, identification, and quality approvals.

Evidence exists that preservation and packaging are in compliance with requirements.

Packaging and marking of products, as a minimum, comply with Interstate Commerce Commission rules and regulations and are adequate to ensure safe arrival and ready identification at their destinations.

The loading and transporting methods are in compliance with those designated in the shipping documents.

Integrity seals are on shipping containers and externally observable shock or humidity monitors do not show excessive environmental exposure.

In the event of unscheduled removal of a product from its container, the extent of re-inspection and retest shall be as authorized by NASA or its representative.

Special handling instructions for receiving activities, including observation and recording requirements for shipping-environment monitors are provided where appropriate.

Shipping documentation and containers shall contain appropriate measures (signs/warnings) to ensure that the item’s packaging is only removed or opened inside of a cleanroom.

The contractor’s quality assurance organization shall verify prior to shipment that the above requirements have been met and shall sign off appropriate shipping documents to provide evidence of this verification. The contractor shall ship Free On Board (F.O.B.) destination to NASA/LaRC Hampton, Virginia. The contractor has the responsibility for any damage incurred during shipment.

8 APPENDIX A. ABBREVIATIONS AND ACRONYMS

Abbreviation/ Acronym Definition

A Approve ANSI American National Standards Institute CCB Change Control Board CCR Configuration Change Request C&DH Command and Data Handling CDR Critical Design Review CM Configuration Management CMO Configuration Management Office CO Contracting Officer CVCM Collected Volatile Condensable Mass DCR Design Conformance Review DILS Deliverable Item List & Schedule DPA Destructive Physical Analysis EDL Entry, Descent, and Landing EEE Electrical, Electronic, and Electromechanical EMC Electro Magnetic Compatibility EMI Electro Magnetic Interference ERD Environmental Requirements Document ESD Electrostatic-Discharge FSO Full Scale Output FRB Failure Review Board GSE Ground Support Equipment I Information LaRC Langley Research Center ICD Interface Control Document MEADS Mars Entry Atmospheric Data System MEDLI2 Mars Entry, Descent, and Landing Instrumentation 2 MIP Mandatory Inspection Point MPE Maximum Predicted Environment MRB Material Review Board MTBF Mean Time Between Failure MUA Materials Usage Agreement NASA National Aeronautics and Space Administration NPPL NASA Preferred Parts List QBS Qualified By Similarity Pa Pascal PSIA Pounds per Square Inch (Absolute) PEMs Plastic Encapsulated Microcircuits PER Pre-Environmental Review PIL Parts Identification List

Abbreviation/ Acronym Definition

PIND Particle Impact Noise Detection PSR Pre-Ship Review QA Quality Assurance QBS Qualified By Similarity R Review RTD Resistive Temperature Device SCC Stress Corrosion Cracking S/C Spacecraft SOW Statement of Work TBR To Be Refined TML Total Mass Loss TIM Technical Interchange Meeting TPL Trended Parameters List TPS Thermal Protection System

9 APPENDIX B. MEDLI2 MATERIAL SELECTION FORMS

MATERIAL USAGE AGREEMENT

(MUA)

USAGE AGREEMENT NO.:

PAGE OF

PROJECT:

: ORIGINATOR: ORGANIZATION:

DETAIL

DRAWING

NOMENCLATURE USING ASSEMBLY NOMENCLATURE

MATERIAL & SPECIFICATION MANUFACTURER & TRADE NAME

USAGE THICKNESS WEIGHT EXPOSED AREA…