RST-PROP-SOW-0042_ACS Thruster_SOW DRAFT 20200531.pdf

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National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

RST-PROP-SOW-0042, Revision -

Roman Space Telescope (RST), Code 448

Attitude Control System (ACS) Thruster Statement of Work

DRAFT

May 31, 2020 https://ipdtdms.gsfc.nasa.gov/

ACS Thruster Statement of Work RST-PROP-SOW-0042, Revision -i

ACS 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. 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 Plan

5.2 Verification Test Procedures

5.3 Verification Test Reports

6 SAFETY AND MISSION ASSURANCE

v

6.1 General Requirements

6.2 Configuration Management

6.3 Training and Certification of Contractor Personnel

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) 19

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) . 20

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

vi

6.9 Contamination Control Requirements

6.9.1 Contamination Control Plan

6.9.2 Surface Cleanliness

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

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 attitude control system thrusters, from here on referred to as the ACS thrusters.

1.2 Scope

This Statement of Work (SOW) defines requirements that govern the management, development, testing, and delivery of the RST ACS 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 RST-PROP-LIST-0081.

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-0121 Attitude Control System Thruster Specification RST-PROP-LIST-0081 Attitude Control System Thruster Deliverable Items List and

Schedule

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

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

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 ACS 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 ACS thruster specification (RST-PROP-SPEC-0121) in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

• Program Management

• Quality Assurance

• ACS 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 ACS thruster specification RST-PROP-SPEC-0121 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 the DILS document, RST-PROP-LIST-0081.

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 ACS Thruster Specification, RST-PROP-SPEC-0121, 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 ACS Thruster Specification (RST-PROP-SPEC-0121) 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 ACS 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 ACS Thruster Specification (RST-PROP-SPEC- 0121). 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 RST-PROP-LIST-0081. 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.

The contractor shall provide a pre-launch catalyst bed heating analysis, which determines how long the catalyst bed heaters (single and both) can operate in the ground environment (air) without affecting the catalyst performance. The RST launch plan includes initiating catalyst bed heating shortly before launch to enable contingency spacecraft recovery maneuvers if needed.

The analysis shall include discussion of catalyst bed degradation indicators based on this launch configuration.

3.7 Thermal Model and Documentation

The contractor shall provide reduced Thermal Math Models (TMMs) for the ACS 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 ACS 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 ACS 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 ACS 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 ACS thrusters

4 HARDWARE PROCUREMENT

4.1 General Requirements

The contractor shall either procure or manufacture all components required to assemble, integrate, and test the ACS thrusters to support the delivery dates as called for in the contract (Section B Table) and listed in the DILS document, RST-PROP-LIST-0081.

The contractor shall assemble the quantities of ACS 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 ACS thruster.

4.2 Hardware Deliverables

The contractor shall provide the following hardware to meet the requirements of the RST ACS Thruster Specification (RST-PROP-SPEC-0121).

a) Seventeen (17) ACS Thruster Flight Units (DIL #59)

b) One (1) ACS Thruster Qualification Unit (DIL #60) if necessary to satisfy requirements in RST-PROP-SPEC-0121

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:

• Test Plugs (DIL #61)

• Alignment Hardware (DIL #61)

• Nozzle Covers (DIL #61)

5 PERFORMANCE VERIFICATION AND TEST

5.1 Verification Plan

A Verification Plan shall be generated by the contractor to describe the details of how the analyses, inspections, and verification tests identified in the RST ACS Thruster Specification RST-PROP-SPEC-0121 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 ACS 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)

5.2 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.

5.3 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.

6 SAFETY AND MISSION ASSURANCE

6.1 General Requirements

The Contractor shall comply with the applicable safety and mission assurance requirements documented in the RST Mission Assurance Requirements (MAR) (RST-SMA-REQ-0032). All corresponding deliverables shall be delivered as described in MAR Data Item Descriptions (DIDs). MAR sections 1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, and 14 and their associated DIDs apply except where noted as follows. Paragraphs 5.3.3.3, 5.3.3.4, 5.3.4, 5.3.6, 5.3.7, 5.3.8, 5.3.10, 6.3, 6.4, 6.6, 6.14, 9.8, and 11.4 also do not apply, and the individual requirements MAR-086 and MAR-090 in paragraph 6.5 and MAR-147 in paragraph 9.1 also do not apply. MAR sections 7 and 8 do not apply to this contract.

The Contractor’s plan for compliance with the MAR shall be documented in a RST-specific Mission Assurance Implementation Plan (MAIP) or Quality Assurance (QA) Plan. (DIL #12) The MAIP or QA Plan shall include a list of key sub-tier suppliers. The MAIP or QA Plan shall also include a MAR compliance matrix that identifies variances and acceptance rationale for processes, procedures, and standards that are proposed as alternatives to those specified by the MAR Appendix C.

The Contractor shall have a documented closed-loop system for identifying, reporting, reviewing, and correcting product nonconformance and anomalies. The nonconformance/anomaly process may be included within the MAIP or QA Plan (DIL #12) or may be submitted as a unique DIL. (DIL #13)

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

The Contractor shall document and implement a Lead Free Control Plan that meets the requirements of GEIA-STD-0005-1 and GEIA-STD-0005-2 for tin-based solders and surface finishes that are less than 3% lead by weight and comply with the Level 2C requirements set.

(DIL #14)

6.2 Configuration Management

The contractor’s Configuration Management (CM) system (available for review on request) shall control the design and hardware/software by means of drawings, specifications, and other documents and ensure all applicable changes are reviewed in a systematic manner to determine the validity and impact on performance, schedule, and cost. The contractor’s Configuration Management system shall have a change classification and impact assessment process that ensures Class I changes are forwarded to the NASA/GSFC COR for approval prior to release/incorporation. (DIL #5) Class I changes are defined as changes that affect form, fit, function, external interfaces, or requirements as stated within this document and the ACS Thruster specification.

All other changes are considered to be Class II changes and shall be controlled and dispositioned by the contractor. All Class II changes shall be provided monthly to the NASA/GSFC COR for review purposes. (DIL #6) NASA/GSFC reserves the right to review all Class II changes for technical content to ensure the proper classification has been assigned. Any flight item that is found to be non-compliant with the quality, workmanship, and performance requirements of the contract shall be dispositioned via a waiver or Materials Review Board (MRB), unless the affected item is reworked to restore compliance or is replaced with a fully compliant item. The contractor shall submit Waivers and MRBs to the NASA/GSFC COR for final approval.

(DIL #7)

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

6.3 Training and Certification of Contractor Personnel

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

6.4 Surveillance of the Contractor

The work activities and operations of the contractor and all sub-tier suppliers shall be subject to evaluation, review, survey, and inspection by a customer representative.

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

6.4.1 Government Source Inspection

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

The quality representative who has been delegated customer quality assurance functions on this procurement shall be notified immediately upon contractor receipt of any sub-tier suppliers’ orders. The customer representative shall also be notified 48 hours in advance of the time that articles or materials are ready for inspection or test.

6.4.2 Supplier Source Inspection

The contractor shall ensure that its procurement documents impose the applicable requirements on all its suppliers, and ensure those requirements are flowed down to all subsequent sub-tier suppliers.

The contractor shall perform source inspection at their suppliers’ and sub-tier suppliers’ facilities in accordance with the procurement documentation or when one or more of the following conditions exist:

• Processes, end-item controls, and tests that are destructive in nature prevent the contractor from verifying quality after delivery to the contractor's facility.

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

• Qualification tests are to be performed by the sub-tier supplier or supplier.

• Products are shipped directly from the source to the customer, bypassing the supplier's inspection facilities.

6.4.3 Government Mandatory Inspection Points

The required Government Mandatory Inspection Points (MIPs) are outlined in this section. The customer may request additional MIPs, as required. 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/GSFC COR approval.

MIPs shall be reviewed during fabrication flow discussions at the major reviews as described in Section 2.4. Completed and upcoming MIPs shall be included in monthly status reports to ensure clear communication of MIP status.

At a minimum, the following activities shall be considered MIPs for the thruster contract:

• Inspect 100% solder

• Inspect 100% crimps

• Inspect 100% conformal coating, staking, and potting

• Rework inspection

• Pre-closure inspection

• Pre-ship inspection / data review

At a MIP, the contractor shall make available for review/inspection the hardware, waivers, non-conformance reports, non-destructive evaluation results, and any other documentation that will enable the customer to evaluate the completeness of the hardware at the MIP. The customer may choose to be present for the MIP event, may choose to review documents remotely, or may waive the MIP entirely. The MIPs in this section shall apply to both qualification and flight hardware.

6.5 Ground Support Equipment Interfaces

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

6.6 Design Verification Requirements

6.6.1 Verification Requirements

The contractor shall implement a program to verify all requirements specified in the RST ACS Thruster specification (RST-PROP-SPEC-0121).

The contractor shall provide a verification matrix defining the method of verification for each specific requirement of the ACS Thruster specification (RST-PROP-SPEC-0121), per Section 5.1 of this SOW. (DIL #35)

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

6.6.2 Analysis, Trending, and Reporting of Test Data

The contractor shall properly record, maintain, and analyze test information during the normal test program to assess performance and flight worthiness and to aid in the identification and analysis of flight hardware failures and problems. Trended data shall be included as part of the

EIDP. (DIL #58)

6.6.3 Limited Life Items

The contractor shall implement a plan to identify and manage limited life items, including moving mechanical components and bonded joints as applicable. The contractor shall prepare and maintain a list of life-limited items and their predicted impact on operation during flight.

(DIL #36) The list shall include expected life, required life, duty cycles, expected life to required life ratio, and rationale for selecting and using the item. The list may include such items as structures, thermal control surfaces, electromechanical mechanisms, seals, and valves. The environmental or application factors that may affect the items include such things as atomic oxygen, solar radiation, shelf-life, extreme temperatures, thermal cycling, wear, and fatigue.

6.7 EEE Parts Requirements

6.7.1 General

The contractor shall meet the EEE Parts requirements per Section 10 of the RST MAR, RST-

SMA-REQ-0032.

The contractor shall submit an EEE Parts Control Plan (PCP) that addresses the system requirements for mission lifetime and reliability. (DIL #15)

6.7.2 Analyses

The contractor shall perform parts stress and derating analyses for electrical, electronic, and electromechanical (EEE) parts in accordance with GSFC EEE-INST-002 Instructions for EEE Parts Selection, Screening, Qualification, and Derating. (DIL #37)

The contractor shall perform Worst-Case Analyses (WCA) on the ACS thruster design to assure the design meets critical performance and life requirements, since excessive operating variations could compromise mission performance. (DIL #38) Elements that may warrant worst case analysis may include: sensitive analog circuitry, motor and actuator systems, and electro-mechanical elements that require torque margin to operate over life and environmental variations. Adequate margins in electronic circuits and electro-mechanical devices can be verified by analysis, testing or both.

6.7.3 Parts Age Control

Parts more than 5 years old, comparing the part Lot Date Code (LDC) to the Project DCR date, require NASA/GSFC COR approval for use. (DIL #39) Parts drawn from inventory having lot date codes older than 5 years, shall be reviewed by the Government to determine the need for re-screen. Parts stored in conditions where moisture or ESD are not controlled shall not be used.

Contractors shall present justification with inspection and test requirements.

6.8 Materials, Processes Requirements

6.8.1 Materials and Processes Control

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

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

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

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

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

6.8.3 M&P Usage Documentation

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

The list of processes will include those processes that ensure a repeatable/controlled process that produces a consistent and reliable product. The contractor shall provide an As-Designed Materials & Processes List thirty (30) calendar days prior to DCR. (DIL #16) An As-Built Materials List (ABML) shall be included as part of the end item data package, and submitted for review thirty (30) calendar days prior to PSR. (DIL #58) Sample forms are available upon request.

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

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

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

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

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

Type of Loads and Amount; Other Details.

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

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

The Materials and Processes List shall include references to MUAs at entries for non-compliant materials and processes (see 6.8.4).

Wire, cable, and connectors shall meet the requirements of this document and be reported on the M&P List, as well as the parts identification list and as-built parts list. All other standard and nonstandard EEE parts shall be exempt from these requirements and reporting on the Materials and Processes List.