Separation Ring System_Draft Statement of Work.pdf

Effective Date:

Expiration Date:

Check https://ipdtdms.gsfc.nasa.gov to verify that this is the correct version prior to use

400-FORM-0002 (4/16/2014)

National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

MSR-CCRS-SD-SOW-0005, Revision

Mars Sample Return - Capture, Containment and

Return System (CCRS) Project

NASA/GSFC Code 435

MSR CCRS

Partial Jettison 818mm (32”) Separation System

Statement of Work (SOW)

MSR-CCRS CMO

1/2022

DRAFT

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

MSR CCRS Separation System SOW MSR-CCRS-SD-SOW-0005

Revision DRAFT

Effective Date: XX/XX/XXXX ii

Partial Jettison 818mm (32”) Separation System Statement of Work

Signature/Approval Page Prepared by:

CCRS Separation System RE

Code 540

Reviewed by:

CCRS Chief Safety and Mission

Assurance Officer

Code 383

CCRS Project Systems Engineer

Code 599

CCRS GSFC Flight Manager

Code 484

CCRS Structures/Deployables PDL

Code 543

Approved by:

CCRS Project Manager

Code 435 iii

*** Electronic signatures are available on-line at: https://ipdtdms.gsfc.nasa.gov*** iv

Preface

This document is a Mars Sample Return (MSR) Capture, Containment and Return System

(CCRS) Project configuration control board (CCB) controlled document. Changes to this document require prior approval of the CCB Chairperson or designee. Proposed changes shall be submitted in the Technical Data Management System (TDMS) via a configuration change request (CCR) along with supportive material justifying the proposed change. Changes to this document will be made by complete revision.

All of the requirements in this document assume the use of the word "shall" unless otherwise stated.

Questions or comments concerning this document should be addressed to:

CCRS Configuration Management Office

Mail Stop: 435

Goddard Space Flight Center

Greenbelt, Maryland 20771

GSFC-DL-CCRS-TDMSCM-Admin@mail.nasa.gov v

Change History Log

Revision Effective Date Description of Changes

(Reference the CCR & Approval Date) vi

Table of TBDs/TBRs/TBSs

Action Item

No.

Location Summary Individual/

Organization

Actionee vii

Table of Contents

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

1.1 MSR CCRS Overview ..................................................................................................... 1-1

1.2 Scope ................................................................................................................................ 1-2

1.3 Terminology ..................................................................................................................... 1-3

1.4 Basic Description ............................................................................................................. 1-3

1.5 Angular Capability ........................................................................................................... 1-4

1.6 Verb Application .............................................................................................................. 1-4

1.7 Changes ............................................................................................................................ 1-4

1.8 Applicable Documentation .............................................................................................. 1-4

2 MANAGEMENT, REPORTING, DOCUMENTATION, AND REVIEWS ........................ 2-1

2.1 Program Management ...................................................................................................... 2-1

2.2 Reporting.......................................................................................................................... 2-1

2.3 Advanced Notifications ................................................................................................... 2-1

2.4 Reviews and Meetings ..................................................................................................... 2-1

2.4.1 Kickoff Meeting ....................................................................................................... 2-1

2.4.2 Design Conformance Review (DCR) ....................................................................... 2-2

2.4.3 Pre-Test Review (PTR) ............................................................................................ 2-3

2.4.4 Pre-Ship Review (PSR) ............................................................................................ 2-3

2.4.5 Technical Interchange Meetings (TIM) ................................................................... 2-4

2.4.6 Training .................................................................................................................... 2-4

2.5 Documentation ................................................................................................................. 2-4

2.7 Existing Components ....................................................................................................... 2-5

2.7.1 Existing Documentation and Analysis ..................................................................... 2-5

2.7.2 Use of Inherited Products ......................................................................................... 2-5

3 DESIGN AND ANALYSIS .................................................................................................. 3-1

3.1 Design Documentation..................................................................................................... 3-1

3.1.1 Interface Control Documentation ............................................................................. 3-1

3.1.2 3-1

Heritage Documentation ...................................................................................................... 3-1

3.2 Drawing Package ............................................................................................................. 3-1

3.3 Computer Models............................................................................................................. 3-1

3.3.1 NASTRAN Model .................................................................................................... 3-1

3.3.2 Finite Element Model Requirements .................................................................. 3-1

3.3.3 Model Documentations ....................................................................................... 3-2

3.3.4 Model Checks ..................................................................................................... 3-2

3.3.5 Solid Model .............................................................................................................. 3-2

3.4 Structural Analysis Report ............................................................................................... 3-2

3.5 Mass Properties Analysis Report ..................................................................................... 3-3

3.6 Separation Analysis Report.............................................................................................. 3-3

3.7 Thermal Analysis Report ................................................................................................. 3-3

3.8 Reliability Analysis Report .............................................................................................. 3-3

3.9 Failure Modes And Effects Analysis Report ................................................................... 3-4 viii

3.10 Safety Analysis Report .................................................................................................... 3-4

3.11 User/Instruction Manuals ................................................................................................. 3-4

4 HARDWARE PROCUREMENT/MANUFACTURING ..................................................... 4-1

4.1 General Requirements ...................................................................................................... 4-1

4.2 Deliverable Milestones .................................................................................................... 4-1

4.3 Support Hardware ............................................................................................................ 4-1

4.4 Ground Support Equipment Description ......................................................................... 4-1

5 PERFORMANCE AND VERIFICATION ........................................................................... 5-1

5.1 Verification Plan .............................................................................................................. 5-1

5.2 Verification Test Procedure ............................................................................................. 5-1

5.3 Verification Test Reports ................................................................................................. 5-1

6 QUALITY ASSURANCE ..................................................................................................... 6-2

6.1.1 Quality Assurance Plan/Manual ............................................................................... 6-2

6.1.2 Surveillance of Seller ............................................................................................... 6-2

Government Source Inspection ........................................................................................ 6-2 Sell Source of Inspection ................................................................................................. 6-2

Government Mandatory Inspection Points (MIPs) .......................................................... 6-3

6.1.3 Anomaly Reporting .................................................................................................. 6-3

6.1.4 Configuration Management ...................................................................................... 6-3

6.1.5 Ground Support Equipment Interfaces ..................................................................... 6-4

6.2 System Safety Requirements ........................................................................................... 6-4

6.3 Reliability Requirements ................................................................................................. 6-4

6.3.1 Stability Trending ..................................................................................................... 6-4

6.3.2 Limited-Life Items ................................................................................................... 6-4

6.3.3 Control of Sub-Developers and Suppliers ................................................................ 6-5

6.4 Design Verification Requirements ................................................................................... 6-5

6.4.1 Verification Requirements ....................................................................................... 6-5

6.5 Workmanship Standards And Processes .......................................................................... 6-5

6.5.1 Workmanship: Use of Alternate Workmanship Standards ..................................... 6-5

6.5.2 Training and Certification of Seller Personnel ......................................................... 6-6

6.5.3 Hardware Handling, Cleaning and Packaging ......................................................... 6-6

6.6 Materials, Processes Requirements .................................................................................. 6-6

6.6.1 Materials and Processes Control .............................................................................. 6-6

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

Agreement Furnished Hardware .............................................................................. 6-6

6.6.3 M&P Usage Documentation .................................................................................... 6-7

6.6.4 Materials Usage Agreements (MUAs) ..................................................................... 6-7

6.6.5 Detailed Requirements ............................................................................................. 6-7

6.6.5.1 Thermal Vacuum Stability(NASA-STD-6016 Section 4.2.3.6) ......................... 6-8

6.6.5.2 Adhesive Bonding (NASA-STD-6016 Section 4.2.4.3) ..................................... 6-8

6.6.5.3 Nondestructive Evaluation (NDE) Plan (NASA-STD-6016 Section 4.2.5.1) .... 6-8

6.6.5.4 Fastener Installation (NASA-STD-6016 Section 4.2.6.5) .................................. 6-8

6.6.5.5 Contamination Control (NASA-STD-6016 Section 4.2.6.6) .............................. 6-9

6.6.5.6 Packaging (NASA-STD-6016 Section 4.2.6.7) .................................................. 6-9 ix

6.6.5.7 Shelf-Life Items .................................................................................................. 6-9

6.6.5.8 Fasteners with LL Longitudinal Locking Elements ........................................... 6-9

6.6.6 Materials Procurement Requirements .................................................................... 6-10

6.7 CONTAMINATION CONTROL REQUIREMENTS .................................................. 6-10

6.7.1 Surface Cleanliness ................................................................................................ 6-10

6.7.2 Material Outgassing ............................................................................................... 6-10

6.7.3 Thermal Vacuum Bakeouts .................................................................................... 6-10

6.8 METROLOGY .............................................................................................................. 6-10

7 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY ............. 7-1

Appendix A Abbreviations and Acronyms

Appendix B List of Applicable Documents……………………………………………………….

x

List of Figures

Figure 1-1: MSR Architectural Overview .................................................................................. 1-1

Figure 1-2: CCRS Functional Description (Reference Only) ..................................................... 1-2 Figure 1-3: CCRS Shown pre- and post-Jettison (Reference Only) ............................................ 1-3

List of Tables

Table 3-1 Inherited Product Data Requirements .................................................................. 2-5 Table 3-2 Inherited Product Supplementary Information.................................................... 2-6

1-1

1 INTRODUCTION

This document defines the work to be performed by the Seller in the design, development, fabrication, and delivery of the CCRS Separation System.

1.1 MSR CCRS Overview

MSR is an effort to bring samples of Martian rocks and soil back to Earth, where they can be investigated in unprecedented detail, using all the capabilities of terrestrial laboratories. It is part of NASA's Mars Exploration Program, a long-term effort of robotic exploration of the Red

Planet. NASA is collaborating with its various centers and the European Space Agency (ESA) to develop the advanced technologies and hardware needed for the campaign.

The sample return mission architecture is designed to continue the work begun by NASA's Mars

2020 rover. The 2020 rover will collect samples on Mars and stash them on the planet’s surface for subsequent return to Earth. A follow-on campaign will include NASA-led Sample Retrieval

Lander (SRL) that would launch the retrieved samples into Mars orbit, and an ESA-led Earth

Return Orbiter (ERO) that would rendezvous with the samples in Mars orbit and bring them back to Earth (Figure 1-1).

Figure 1-1: MSR Architectural Overview

CCRS is the payload on the ERO, shown in Error! Reference source not found.Error!

Reference source not found..

The main functions of CCRS are:

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• Capture, containing and orientating the Orbiting Sample (OS)

• Transferring contained OS to the CCRS clean zone

• Performing Earth Entry System (EES) in-flight assembly

• Jettisoning the contaminated module for Planetary Protection

• Protect EES from micro meteoroid damage

• Precision separation of EES from ERO

• Delivery of EES with contained OS to Utah Test and Training Range (UTTR)

Figure 1-2: CCRS Functional Description (Reference Only)

1.2 Scope

The Seller 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.

This SOW defines the Seller 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 MSRCCRS-SD-LIST-0011.

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1.3 Terminology

The term “Buyer” refers to code 210, who is the procuring authority from the Government.

The term “Seller” or “Vendor” or “Supplier” refers to the manufacturer and provider of the

CCRS Separation System defined in this SOW.

The term “Government” refers to the NASA Goddard Space Flight Center (GSFC).

The term “GSFC” refers to the NASA Goddard Space Flight Center (GSFC) or GSFC CCRS project.

1.4 Basic Description

The Separation System is an integral part of the Capture, Containment and Return System (CCRS).

It is responsible for restraining the Capture Enclosure (CE) during launch, cruise, and Capture and

Containment (CCM) robotic operations while in Martian orbit. The Separation Ring system is intended to facilitate jettison of the contaminated Capture Enclosure after capture and assembly of the Martian sample container into the Earth Entry System (EES). To facilitate robotic operations, the jettison system requires a hollow inner diameter for robotic access to pass the Contained

Orbiting Sample (C-OS) into the Assembly Enclosure (AE).

In its most basic description, the Sep System can be imagined as a 818mm (32”) hollow cylinder that provides a deployable structural load path between the CCRS Capture Enclosure (CE) and

CCRS Assembly Enclosure (AE). This interface needs to be strong enough to properly address launch loads while also remaining capable of providing precise and controlled ejection energy into the CE during the ejection event to jettison the mass without recontacting elements of the

CCRS and Earth Return Orbiter (ERO) Satellite System. CCRS consists of the Capture

Enclosure (CE) and the Assembly Enclosure (AE) that attach to the top of the ERO deck via two deployable kickstands on the CE side and four Titanium flexures on the AE side for launch. The

CE will be secured to the AE for launch using the Separation System assembly described herein.

Figure 1-3: CCRS Shown pre- and post-Jettison (Reference Only)

The design envelope for these components will be controlled by Mechanical Interface Control documents.

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Note: Images shown in Error! Reference source not found.Error! Reference source not found.

and Figure 1-3 are notional design concepts for reference only. These do not represent a flight proven design.

1.5 Angular Capability

As a result of surrounding hardware, volumes, and mass properties of the jettisoned module and remaining spacecraft, a nominal axial deployment may not be desirable. As part of this procurement, GSFC is interested in a system that is capable of an angled deployment. The is encouraged to propose a design (conceptual or flight proven) to achieve this objective and specify the expected maximum angular capability, and any expected limitations, for use in further design activities.

1.6 Verb Application

Statements containing the verb “shall” are binding requirements regardless of location within this

Statement of Work. The verbs “should” and “may” are used for stating non-mandatory goals or denoting a statement of best practice. The verb “will” is used in a statement of fact, expected occurrence, or declaration of purpose.

1.7 Changes

All revisions, deletions and other changes to the Statement of Work and any referenced documents must be authorized in writing by the Buyer’s Contracting Officer.

1.8 Applicable Documentation

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 B for applicable documents.

There are many applicable documents (standards, procedures, etc.) referenced throughout this

SOW. The expectation is The Seller and its suppliers will be compliant with the requirements within those documents. However, comparable documents may be used in lieu of those listed herein. The alternative documents will be evaluated by the CCRS project for compliance and approval from the Buyer is required prior to usage.

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2 MANAGEMENT, REPORTING, DOCUMENTATION, AND

REVIEWS

2.1 Program Management

The Seller 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 and cost constraints.

The Seller shall designate and identify by name a single individual who shall serve as a point of contact with the Buyer for all technical aspects of the Separation System contract.

The Seller 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, documentation control, and distribution.

2.2 Reporting

The Seller shall prepare and present to the NASA/GSFC COR technical status reports via telecon every two (2) weeks and a written report every month. The reprt shall be a summary presentation of the period's progress to include topics such as schedule overview, accomplishments, technical performance measures (e.g. mass), status of key milestones, risks, problem areas, challenges/issues and activities on-going and planned. The Seller shall generate a list of significant milestones that will enable the NASA/GSFC COR to ascertain program progress.

2.3 Advanced Notifications

The Seller shall notify the Buyer at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, TIM’s, and deliveries at either the Seller’s or a sub-seller’s facility to allow timely participation by the Buyer’s or NASA/GSFC 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 Kickoff Meeting

The Seller shall provide to the Buyer a Kick-off Presentation Package and all other required deliverables. 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 Separation System Specification (MSRCCRS-SD-SPEC-0022) in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

• Program Management

• Requirements

• Design description

• Quality Assurance Plan

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• Detailed architectural block diagrams for the different deliverable units

• Manufacturing flow with inspection points

• Verification Test Plan, Including Performance Test Description (if available)

• Materials and Processes

• Flight Heritage

• Verification Matrix (per Section Error! Reference source not found.)

2.4.2 Design Conformance Review (DCR)

The Seller shall organize and present a Design Conformance Review to a GSFC Review Team prior to the manufacturing program. The review may be held at the Seller’s facility or via telecon with video. The Seller shall provide to the Buyer a Design Conformance Review

Presentation Package and all other required deliverable data prior to the review. The Design

Conformance Review shall address all program management, design, drawings, analysis, manufacturing, test, and quality assurance activities outlined in this SOW and the CCRS Project

Separation System Specification (MSRCCRS-SD-SPEC-0022) 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

• Requested waivers

• Design description, including drawings

• Supporting analysis

• Quality Assurance

• Electrical, Mechanical, and Environmental specifications

• Detailed architectural block diagrams for the different deliverable units

• Manufacturing flow with inspection points

• Facilities

• Verification Test Plan (Including Performance Test Description)

• Materials and Processes

• Mechanical/Structural analyses including force margin analyses

• Failure Modes Effects Analysis

• Flight Heritage

• Verification Matrix (per Section Error! Reference source not found.), including verification description statements

• A demonstration, utilizing mockups, that the separation system can be installed, tensioned, and removed in the envelope shown in MSRCCRS-SD-SPEC-0022.

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.

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2.4.3 Pre-Test Review (PTR)

The Seller shall organize and conduct a Pre-Test Review before the test program begins. The review may be held at the Seller’s facility or via telecon with video. This presentation shall demonstrate overall conformance of the requirements specified in the CCRS Separation System

Specification (MSRCCRS-SD-SPEC-0022) and this Statement of Work for this phase of the procurement. This presentation shall cover programmatic, technical, test and verification, and quality assurance topics, and address any changes made to the Verification Matrix since DCR.

This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the testing of the hardware.

2.4.4 Pre-Ship Review (PSR)

The Seller shall hold a Pre-Ship Review at the Seller's facility at the completion of verification tests and prior to the shipment of each hardware item to NASA/GSFC. 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 Seller shall present the completed verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses) where applicable. Any requirements that are not met shall be identified in the Deviations/Waivers etc. list and discussed with the Buyer 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. 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:

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

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

• Problem/anomaly reporting (complete copies of report)

• Deviations/Waivers/open items/non-conformances and their dispositions

• Status of all action items from previous reviews

• Class I Material Review Board (MRB) (complete copies of reports)

• List of Materials and Processes used

• Log of mate /demate and tension cycles

• List and status of all identified Life-Limited Items

• Trended Critical Parameters Data (when applicable)

• Verification matrix, test data and reports

• Photograph Documentation (Pre-Closure and Closed)

• Certificate of Conformance

• End Item Inspection Report

• As-Built Configuration List

• Storage and Transportation Plans and Requirements

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2.4.5 Technical Interchange Meetings (TIM)

The seller shall plan for and facilitate up to four (4) informal, face-to-face technical interchange meetings to be held at the seller facilities. 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.

2.4.6 Training

The seller shall train a team of up to six people from CCRS to install / remove the separation systems. The training can be held at the vendor facility or at GSFC and it can coincide with another meeting already scheduled.

Training shall include:

• band tensioning / de-tensioning

• pyro safety / handling

• electrical connector mate

• refurbishment

• safety device installation / removal

• review of the user manual (see section 3.11)

2.5 Documentation

The Seller shall ensure the generation and delivery of all documentation as called for in the contract and listed in the DILS document, MSRCCRS-SD-LIST-0011.

In addition to that documentation specifically called for in the contract, upon request by the

Buyer, the Seller shall make available a copy of any document or data generated during this contract performance for review by the Buyer at either the Seller'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

NASA/GSFC shall furnish the following list of data, equipment, and facilities to the seller for completion of this SOW.

• Updated CE and AE/Spacecraft mass properties (SC will included Solar Arrays, propellant modal mass and slosh coefficients) to verify separation properties.

• All loads and environments in MSRCCRS-SD-SPEC-0022 are preliminary and will be updated as the CCRS/spacecraft is defined.

• The CCRS Project will supply the CCRS and spacecraft NASTRAN CONM2 and RBE3 model, as well as CCRS/spacecraft stiffness model to support the Fundamental Launch

Frequency analysis.

• Connectors, per MSRCCRS-SD-SPEC-0022, Section TBD

• Geometry model of CCRS and SC primary load path, including material properties

• Slosh model

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• GIDEP alerts as they arise

2.7 Existing Components

2.7.1 Existing Documentation and Analysis

If analysis or documentation exists already for the flight unit that satisfies the requirements within the Separation System Specification, MSRCCRS-SD-SPEC-0022, then the analysis or documentation may not need to be redone, and the requirement can be satisfied by similarity with the delivery of the previous analysis/documentation to the Buyer.

2.7.2 Use of Inherited Products

For inherited products that will not be re-qualified, defined as those that were previously developed and exist (e.g., spares), will be build-to-print (BTP), or are available as commercial-off-the-shelf

(COTS), the Seller may follow an inherited items review process. With this process the

Government establishes a risk for using the product that is based on established prior history, changes in design, environment or operations, and information regarding the processes used to develop the product. The Government will determine if the risks are acceptable or if mitigations are required. The developer shall assume ownership and responsibility for risks mitigation.

To follow this process, the Seller shall provide the data specified in Table 3-1 to substantiate the product’s baseline and risk of use. The Seller may provide additional available information from

Table 3-2 to reduce the risk.

The Seller shall participate in Technical Interchange Meetings (TIMs) to substantiate the baseline risk and potential risk mitigation strategies for inherited products.

Use of this process does not relieve the Seller from meeting contractual performance and functional requirements.

All heritage flight hardware shall be fully qualified and verified for use in its new application. This qualification shall take into consideration necessary design modifications, changes to expected environments, and differences in operational use.

Table 3-1 Inherited Product Data Requirements

No. Data Needed for Inherited Products

List of inherited products and statement of approach to use – rebuild, modification of previous build, or use of existing product

Summary results of qualification, acceptance, and/or prototype/proto-flight testing completed, or comparison of current qualification/proto-qualification requirements and what was performed/realized on the inherited design, including environments, required design margins, and life

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No. Data Needed for Inherited Products

Flight history of the products and specific attributes for each flight, including environments (compare previous environment to current, including duty cycle and general concept of operations)

Ground and on-orbit anomaly and failure history including the determination of root causes or information that root cause was not determined. Ground anomalies may be restricted to major anomalies, where component performance requirements were violated

5 Reliability analyses performed for the most recent version of the product

Identification of significant changes in manufacturing from qualified product to current product (facility, process, sub-tier supplier, testing changes, company change of ownership, etc.), and any changes in design or materials, including electronic parts, printed circuit boards, and standards used (changing from an older revision of a standard to the latest revision need not be discussed).

Table 3-2 Inherited Product Supplementary Information

No. Supplement Information for Inherited Product

Deviations of each product from original design (white wires, cut traces, splices, etc., if not objectively clear to be part of the design) and reasons for each deviation. If the design has been qualified on a previous GSFC project in the same environment and same risk posture, then the deviations may be declared relative to the previously qualified design.

Specifications and/or standards used to develop the products (e.g., IPC, J-STD, NASA, or GSFC requirements, including fastener integrity approach, or company standards). For products with minimal prior flight history, company standards or detailed synopses of such should be provided, if such are used to develop the product

Previous as-built parts list, including lot date codes, and the differences for new inherited item. This should include evidence that Government Industry Data

Exchange Program (GIDEP) alerts and advisories have been properly dispositioned, if the parts have already been procured. Note that GIDEP should always be used as an aid in procuring new parts or pulling parts from inventory. Reference to prior project deliveries to GSFC is acceptable, in which case, an amendment may be delivered to indicate any changes

2-7

No. Supplement Information for Inherited Product

Known obsolete parts that will be supplied from existing inventory, including the quantity required and the quantity available. If available, include the sparing plan

(quantity required, quantity available, and sparing philosophy)

Materials list and approved Material Usage Agreements (MUAs). Materials list includes lot date codes and evidence that GIDEP alerts and advisories have been properly dispositioned, if the materials have already been procured. Such evidence should be encompassed in GIDEP closure records for each of the items that have impacts. Reference to prior project deliveries to GSFC is acceptable, in which case, an amendment may be delivered to indicate any changes

6 List of major mechanical analyses completed and summary of results

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3 DESIGN AND ANALYSIS

The seller shall perform analyses of the technical and environmental requirements specified in the CCRS Separation System Specification (MSRCCRS-SD-SPEC-0022) to ensure compliance of the hardware fabrication and to assemble the documentation necessary to ensure its usability by NASA/GSFC users.

3.1 Design Documentation

3.1.1 Interface Control Documentation

The seller shall provide document(s) and/or drawing(s) that define, in detail, all electrical, thermal, and mechanical interfaces, subject to review and approval by the NASA / GSFC COTR.

Thermal interface information shall include thermal coatings on surfaces since they form a radiative interface with other items or the environment. The separation system Mechanical ICD shall clearly identify areas where the CCRS may elect to add thermal control hardware to the separation system where this hardware does not interfere with operation of the separation system.

The mechanical ICD shall also include the installation envelope and the operational envelope

(protrusion of extended kickoff springs, etc). The electrical ICD shall, at a minimum, identify all connector interfaces and grounding locations. Interface drawings will be included in the

Drawing package below, while interface documents shall be delivered on their own. The CCRS will work with the seller to develop the ICD.

3.1.2 Heritage Documentation

The seller shall provide data from previous tests to determine if any material or process changes in the CCRS Separation System design justify re-tests of CCRS design.

3.2 Drawing Package

The seller shall provide a drawing package that includes, but is not limited to:

ELECTRICAL: assembly and interface drawings (detailed schematics available on request)

MECHANICAL: assembly and interface drawings

3.3 Computer Models

The seller shall deliver the following models used in the performance of the below analyses or used for CAD/CAM/CAE:

3.3.1 NASTRAN Model

The seller shall supply a NASTRAN model of the Separation System Assembly which meets the following list of requirements:

3.3.2 Finite Element Model Requirements

1. Model shall be submitted as an MSC/NASTRAN data deck.

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2. At a minimum, all official CCRS global and subsystem finite element models shall include the date (YYMMDD) that they were made at the beginning of their name.

3. The node numbering system shall adhere to the numbering range provided by GSFC.

4. Property and material cards shall have descriptive names.

5. Models shall be “full” models with no symmetry assumptions made to reduce model size. “Super elements” shall not be used.

3.3.3 Model Documentations

Each formal finite element model submission shall have a document to go with it that describes the following:

1. The version of the model.

2. A list of element, node, property, and material ID numbers.

3. A description of the nonstructural mass represented on each property card.

4. A description of units

5. A description of the local reference coordinate system.

6. The results of validity checks.

7. Mass properties (CG location, inertias, and total model mass).

8. Eight rigid-base mode frequencies.

3.3.4 Model Checks

Before a finite element model can be used for analysis, it shall pass the following validity checks: unit enforced displacement and rotation, free-free dynamics with equilibrium check, and unit gravity loading. Finite element models used for thermal analysis should also pass a unit increased temperature check. DMAPs for performing these checks can found on the FEMCI website (http://femci.gsfc.nasa.gov/) or other sources. Craig-Bampton models shall also pass strain energy checks.

3.3.5 Solid Model

The Seller shall deliver the following Computer-Aided Design (CAD) solid model for the

Separation System in CREO, STEP, IGES or other neutral format.

3.4 Structural Analysis Report

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. The analysis shall also address loads on the GSE interface points as well. For http://femci.gsfc.nasa.gov/

3-3 metallic elements whose strengths are to be qualified by analysis (rather than by test, subject to

Buyer approval), margins of safety will be 2.0 on yield and 2.6 on ultimate. Beryllium and composite materials shall not be qualified by analysis alone. 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 twice those induced by the maximum pressure differential during launch. The results of these analyses shall be summarized in a Seller format Structural Analyses Report that will be provided to the Buyer for review.

3.5 Mass Properties Analysis Report

The seller shall calculate the mass properties (mass, cg, and inertias) of the passive and active rings, in stowed and deployed configurations, using measured properties as much as possible.

The results of these analyses shall be summarized in a seller format Mass Properties Report that will be provided to the NASA / GSFC COTR for review.

3.6 Separation Analysis Report

The seller shall perform a separation analysis to show that under the worst case conditions the

CE will separate without re-contact, and will meet the post separation requirements. This analysis shall using Monte Carlo simulations that include the following parameters at a minimum, with their associated uncertainty values:

• Spin rates – N/A

• Mass properties (mass, cg, inertias)

• Slosh effects

• Separation Spring rates, lengths, and friction

• Clampband stiffness and friction

• Separation Ring deflection and friction coefficient

• Connector force and friction coefficient(s)

The results of these analyses shall be summarized in a seller format Separation Analyses Report that will be provided to the NASA /GSFC COTR for review.

3.7 Thermal Analysis Report

The seller shall provide qualification by similarity data or a thermal analysis that illustrates that the Separation System operates under the temperatures provided in MSRCCRS-SD-SPEC-0022 in a vacuum environment. By analysis or by similarity to other flight qualified systems, seller shall also prove that the minimum survival temperature is not an issue. All thermal analysis results shall be summarized in a Seller format for the Thermal Analyses Report, to be provided for review as per the contract schedule.

3.8 Reliability Analysis Report

The seller shall provide a numerical reliability assessment of the component, using reliability data from historical on-orbit performance, life-testing, or data books. The results of this analysis

3-4 shall be summarized in a Seller format Reliability Analysis Report that will be provided to the

NASA/GSFC COTR for review.

3.9 Failure Modes And Effects Analysis Report

The Seller shall perform a Failure Modes and Effects Analysis (FMEA) in accordance with

GSFC Guideline P-302-720, "Performing A Failure Mode and Effects Analysis". The FMEA shall identify failures at the functional level and address attendant consequences. The results of these analyses shall be summarized in a Seller format FMEA Report that will be provided to the

NASA / GSFC COTR for review.

3.10 Safety Analysis Report

The seller shall perform any safety related analyses necessary to support the safety requirements of Section Error! Reference source not found.. The results of these analyses shall be summarized in a Seller format Safety Analysis Report that will be provided to the NASA / GSFC

COTR for review.

3.11 User/Instruction Manuals

The seller shall deliver procedures to install the clamp band and establish the system pre-load.

The seller shall establish the upper and lower limits of the clamp band pre-load.

4-1

4 HARDWARE PROCUREMENT/MANUFACTURING

4.1 General Requirements

The Seller shall either procure or manufacture all components required to assemble, integrate, and test the Separation Systemto support the delivery dates as called for in the contract and listed in the DILS document, MSRCCRS-SD-LIST-0011.

The Seller shall assemble the quantities of hardware described below. The Seller shall provide a

Fabrication, Assembly, and Inspection Flow plan at the DCR that shall include a step-by-step procedure that describes the method of fabrication, assembly, and inspection from piece parts to the completely assembled Separation System.

4.2 Deliverable Milestones

The seller shall provide the following hardware to meet the requirements of the CCRS

Separation System Specification (MSRCCRS-SD-SPEC-0022).

• Two (2) active 818 mm nominal diameter separation rings, including restraining bands, separation springs, and separation connector towers with harness tie-down points.

• Two (2) passive 818 mm nominal diameter separation rings including separation connector towers with harness tie-down points, which mate to the two (2) active rings above

• Sixteen (16) Pin pullers, each with two (2) initiators. [thirty two (32) initiators total]

• Eight (8) spare clamps

4.3 Support Hardware

The Seller shall provide the following supporting hardware:

• Non-outgassing contamination covers for all initiator ports

• RF and non-outgassing static control covers for all initiators.

4.4 Ground Support Equipment Description

The Seller shall provide Ground Support Equipment to support Integration and Test activities at the CCRS level. Required Ground Support Equipment includes:

• One (1) tensioning device to generate the preload in the Separation System

• One (1) device to measure and display preload tension in the Separation System

• Two (2) safety devices to secure the Separation System in case of loss of preload during ground operations

• One (1) set of Separation System installation aids / tools , including any unique initiator installation tools

• Two (2) identical drill templates to drill :

o Active Ring, o AE interface for the Active Ring, 4-2 o Passive Ring, o CE interface for the Passive Ring, 5-1

5 PERFORMANCE AND VERIFICATION

5.1 Verification Plan

A Verification Plan shall be generated by the Seller to describe the details of how the analyses, inspections, and verification tests identified in the CCRS Separation System (MSRCCRS-SD-

SPEC-0022 will be performed. Verification tests shall demonstrate the item meets all of the specified performance requirements over the specified range of environments, measure performance parameters and reveal inadequacies in manufacturing and assembly such as workmanship or material problems. Any requirement that exceeds previous qualification test data shall be presented to the Buyer as part of the planning process for evaluation and a possible delta qualification test.

The plan shall state the purpose of each test, state acceptance criteria, describe in detail the test method, set up, instrumentation, data analysis methods (if applicable), and give the sequence of the tests. The plan shall include a verification matrix summarizing how all requirements are verified (analysis, inspection, test, per the definitions in the Spec.), and listing all tests that will be performed on the Separation System.

This plan shall be a Seller controlled document and shall indicate all changes made after the initial approval by the Buyer. After Verification Plan approval, no changes shall be made without written Buyer approval.

If any individual test plans are created in addition to the master Verification Plan, those plans shall also be provided.

5.2 Verification Test Procedure

The Seller shall generate Verification Test Procedures and provide them to the Buyer. 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 Seller controlled documents and shall indicate all changes made after the initial release for review to the Buyer.

5.3 Verification Test Reports

The seller shall generate Verification Test Reports. These reports shall document the results of each test that was performed, what test levels were achieved, what performance requirements were verified, what anomalies were seen, and how they were resolved.

6-2

6 QUALITY ASSURANCE

6.1 General Requirements

6.1.1 Quality Assurance Plan/Manual

The seller shall implement a Quality Management System that meets the intent of the requirements of American National Standards Institute (ANSI)/ISO, American Society for

Quality (ASQ) Q9001 (1994 or 2000 version) or equivalent, as documented in a Quality

Assurance Plan. The Plan shall be delivered to the GSFC COTR, and GSFC shall be notified of any changes to the QA program.

6.1.2 Surveillance of Seller

The work activities and operations of the Seller, subcontractors, and suppliers are subject to evaluation, review, survey, audit, and inspection by the Buyer and Government QA representative.

The Seller shall provide the Buyer and Government QA representative with documents, records, equipment, and a suitable work area within their facilities that are required by the representative to perform their overview activities.

Government Source Inspection

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

The Government quality representative who has been delegated NASA quality assurance functions on this procurement shall be notified immediately upon Seller 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.

Sell Source of Inspection

The Seller 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 Seller 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…