04 IRR IFCT 20041117

Slide1: 

GLAST Large Area Telescope: Integration and Test Two Tower Integration Readiness Review Integration, Facilities, Configuration and Test (IFCT) Department Ken Fouts / Brian Grist

IFCT Outline: 

IFCT Outline Operations Readiness EGSE Integration Facility

IFCT Part I. Operations Readiness: 

IFCT Part I. Operations Readiness Summary of 2 tower I&T Operations and AIDS Mapping of AIDS to schedule / PMCS AIDS and Time Estimates Overview Grid Installation and Survey Calorimeter Receiving and Post-Ship Test TEM/TPS Receiving Tracker Receiving and Post-Ship Test Calorimeter and TEM/TPS I&T Test Bay I&T Grid Bay I&T Bays 8 + 9 I&T

Two Tower I&T Operations: 

Two Tower I&T Operations Receive Tracker Flight Unit A Install in Metrology Bay for Shimming & Assembly Install tower in Test Bay Receive Calorimeter, TEM/TEM PS Flight Units A Test Single Bay Tower Test CAL A & TEM/TEM PS A Integrate Tracker A into Grid De-Install Tower from test bay Receive and assemble Grid Integrate Grid onto Rotation Stand Grid Optical Survey Integrate CAL/TEM/TPS A into Grid Single Tower Test in Grid Integrate Tracker B into Grid Integrate Cal/TEM/TEM-PS B into Grid Single Tower Test in Grid Two Tower I&T Install in Metrology Bay for Shimming & Assembly Install tower in Test Bay Receive Calorimeter, TEM/TEM PS Flight Units B Receive Tracker Flight Unit B Test Single Bay Tower Test CAL B & TEM/TEM PS B De-Install Tower from test bay Optical Survey

Assembly and Inspection Data Sheet: 

Assembly and Inspection Data Sheet

Assembly and Inspection Data Sheet: 

Assembly and Inspection Data Sheet

Assembly and Inspection Data Sheet: 

Assembly and Inspection Data Sheet

Mapping of AIDS to schedule / PMCS: 

Mapping of AIDS to schedule / PMCS Strategy AIDS line items tracked in MS Project Line items are groups of work which take >1hr Status AIDS drafts delivered to scheduler; data input in process; ECD Dec. 18

AIDS and Time Estimates Overview: 

AIDS and Time Estimates Overview

Grid Installation and Survey: 

Grid Installation and Survey Notes Mechanical Systems (Martin Nordby) is working with SLAC metrology to define the Grid survey requirements. Risk Mitigation Plan for completing a Grid to Grid Perimeter Ring fit check in work ECD 12/1.

Calorimeter Receiving and Post-Ship Test: 

Calorimeter Receiving and Post-Ship Test Notes Calorimeter post-ship test performed by Calorimeter Subsystem using subsystem GSE and staff. Calorimeter TEM/TPS safe-to-mate performed by I&T for TEM-GASU and TPS-PDU connectors only Calorimeter I&T receiving test performed by I&T Risk Mitigation ELX will complete acceptance testing on EGSE Test Stand

TEM/TPS Receiving: 

TEM/TPS Receiving Notes TEM/TPS manufacturing is completed in Room 103 Safe-to-mate is performed on all TEM/TPS connectors (14)

Tracker Receiving and Post-Ship Test: 

Tracker Receiving and Post-Ship Test Notes Tracker receiving inspection yet to be defined Tracker post-ship test performed by tracker subsystem Risk Mitigation I&T working closely with TKR subsystem to develop processes. Plan is to use the TKR Mock Up with Flight-like Cables delivered in December to dry run receiving procedures. ELX will complete acceptance testing on EGSE Test Stand

Calorimeter and TEM/TPS I&T: 

Calorimeter and TEM/TPS I&T Notes I&T is considering requirements for relocating this process from room 104 (current baseline) to room 103 to relieve floor space usage in room 104 Risk Mitigation ELX will complete acceptance testing on EGSE Test Stand

Test Bay I&T: 

Test Bay I&T Notes Tracker installation procedures not finalized at this time Tower survey is managed by Martin Nordby and staffed from SLAC Metrology Tower trigger test procedures and software not finalized at this time E2E test software not finalized at this time SVAC test software not finalized at this time Risk Mitigation Plan is to use the TKR Mock Up with Flight-like Cables delivered in December to dry run receiving procedures ELX will complete acceptance testing on EGSE Test Stand

Tracker Installation: 

Tracker Installation Basic Procedure complete New inputs from Tracker Group to be incorporated Cone assembly process (done) Cable bonding process (still in work) Some Project decisions pending Adjustment of Tower lean Measurement of Tower location Procedures and documentation for Lifting need approval after procedure release

I&T Test Definitions: 

I&T Test Definitions Single Bay Test (in EM single bay) 54 hrs total (40 hrs w/o E2E/SVAC/VDG) Aliveness Test (15 min) Calorimeter: CPT (2 hrs) Tracker: Pass/fail tests (2hrs) Trigger: Module internal timing, GEM timing alignment, subsystem TACK delays (36 hours) End-to-end Test, 6 hrs SVAC Data Collection (Bay 9 only, includes VDG) 8 hrs Single Bay Test (in flight grid) 44 hrs total (4 hrs w/o SVAC) Aliveness Test (15 min) Calorimeter: CPT (2 hrs) Tracker: Pass/fail tests (2hrs) SVAC Data Collection (Bay 9 only, no VDG) Day 1=16 hrs, Day 2 = 24 hrs Two Bay Test (in flight grid) 104 hrs total Aliveness Test (15 min) Calorimeter: CPT (4 hours) Tracker: Pass/fail tests (4hrs) End-to-end Test, 40 hrs SVAC Data Collection (includes VDG) Day 1=16 hrs, Day 2 = 24 hrs, VDG=16 hrs

Grid Bay I&T: 

Grid Bay I&T Notes Same as for test bay I&T, except no trigger nor E2E tests Risk Mitigation Plan is to use the TKR Mock Up with Flight-like Cables delivered in December to dry run receiving procedures ELX will complete acceptance testing on EGSE Test Stand

Bays 8+9 I&T: 

Bays 8+9 I&T Notes Flight mates are performed on DAQ cables to bays 8 & 9 Subsystem tests are executed module by module E2E test software not finalized at this time SVAC test software not finalized at this time Risk Mitigation ELX will complete acceptance testing on EGSE Test Stand Test definition in process with Systems Engineering

IFCT Part II. EGSE Preparation: 

IFCT Part II. EGSE Preparation Acceptance and validation process COTS BOBs Connector savers PDU GASU TEM/TPS BPU Test Stands Test Procedures

EGSE Process; Design to Use: 

EGSE Process; Design to Use Integration and Test (I&T) Subsystem Electrical Ground Support Equipment (EGSE) Plan LAT-MD-01533 Just released for review.

Break Out Boxes are Ready: 

Break Out Boxes are Ready Breakout boxes facilitate interface verification without significant risk to flight hardware. Note that the LAT electronics design does not easily permit measurements of LVDS signaling characteristics at data rate. Four boxes are required: 26 pin interface 44 pin interface 78 pin interface 104 pin interface Adapter cables adapt between different pin outs, connector styles and sizes. Examples of breakout boxes are shown in the following picture:

Configuration Block Diagram, Tracker Test: 

Configuration Block Diagram, Tracker Test EGSE TKR

Equipment List, Tracker Test : 

Equipment List, Tracker Test

Configuration Block Diagram, Two Tower Test: 

Configuration Block Diagram, Two Tower Test

Equipment List, Two Tower Test: 

Equipment List, Two Tower Test

EGSE IN SINGLE TOWER ASSY FLOW: 

EGSE IN SINGLE TOWER ASSY FLOW

EGSE IN TWO TOWER ASSY : 

EGSE IN TWO TOWER ASSY

EGSE TEST REQUIREMENTS: MD-00408: 

EGSE TEST REQUIREMENTS: MD-00408 Configuration of EGSE shall be controlled via released documentation EGSE shall be acceptance tested EGSE shall be validated before use if it has been moved, reconfigured, or repaired Validation shows that equipment is both ready for use and safe to use High degree of confidence that equipment in that configuration has full operating capabilities NASA guidance Perform an EICIT and an SVT to ensure electrical safety Trip points on circuit breakers, current limits in power supplies, shall be verified While everything is validated, the scope of validation is tailored for each piece equipment type

STATUS OF EGSE– COTS: 

STATUS OF EGSE– COTS Digital Multimeters (I&T responsible for these) Calibrated Instrument Validation Tests Embedded within test procedure that calls them STATUS: Meter purchased exceed maximum voltage for parts in some equipment, so we are re-procuring Borrowing “Safe” DMM’s in the meantime Hand Tools Procured, cleaned, and placed in toolbox within cleanroom Automated Test Equipment for Safe to Mate All parts received - calibrated Interconnection harness designed –in assembly Rack tray’s sent out for machining – affected by safety stand down at SLAC

SCOPE OF EGSE TESTS – BOB’s ETC.: 

SCOPE OF EGSE TESTS – BOB’s ETC. Cables and break out boxes (I&T is responsible for these) Design documentation complete and released Acceptance Tests include Configuration inspection to assembly drawing Interface integrity and cleanliness, inspection Electrical continuity & isolation tests per LAT-TD-04325 Labeling with test due date, operator, QA Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical continuity tests, manual Connector Savers Tests: Interface integrity and cleanliness, inspection

STATUS OF BOB’s ETC: 

STATUS OF BOB’s ETC All BOB’s designed, built, and tested Inspection remains to be completed Associated cables designed, built to shortage, and tested The backshells for the 100 pin cables were back ordered and just arrived. Estimate assembly complete 12/1 Inspection remains to be completed Long versions of the Two Tower test cables for EGSE interconnections are awaiting the floor layout to determine lengths. Design, build, and test complete 12/31. Acceptance and Validation Test Procedures in sign off cycle

STATUS OF CONNECTOR SAVERS: 

STATUS OF CONNECTOR SAVERS Determining connector saver needs Coordinating with subsystems All ELX boxes arrive with connector savers on each connector CAL delivers mated to an EM TEM, so they are not needed TKR towers arrive with connector savers that will be turned over to I&T Determining who buys connector savers for the flight cables – submitted lien to program office to fund procurement Complete determination by 11/24

SCOPE OF EGSE TESTS - PDU: 

SCOPE OF EGSE TESTS - PDU EM PDU Acceptance Tests include Configuration inspection to LAT-DS-01696 Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD-02544-01 Labeling with test due date, operator, QA Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Further validation tests performed within the test stand using load box

SCOPE OF EGSE TESTS – PDU LOAD: 

SCOPE OF EGSE TESTS – PDU LOAD EM PDU LOAD BOX Acceptance Tests include Configuration inspection to LAT-DS-03400 Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD-04095-01 Labeling with test due date, operator, QA Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Further validation tests performed within the test stand

STATUS OF PDU & LOAD BOX: 

STATUS OF PDU & LOAD BOX Documentation PDU Assy, LAT-DS-01696, released PDU Test Procedure, LAT-TD-02544-01, released PDU Load Box Assy, LAT-DS-03400, released PDU Load Test Procedure, LAT-TD-04095-01, released EICIT Procedure, PDU, LAT-TD-04332, released SVT Procedure, PDU, LAT-TD-04332, in work (12/1) Delivered to I&T Inspection, acceptance test, validation pending development of flight documentation

SCOPE OF EGSE TESTS - GASU: 

SCOPE OF EGSE TESTS - GASU EM GASU Acceptance Tests include Configuration inspection to LAT-DS-01611-09 Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD-04267-02 Labeling with test due date, operator, QA Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Further validation tests performed within the test stand

STATUS OF GASU: 

STATUS OF GASU Documentation GASU Assy, LAT-DS-01611-09, released GASU/Test Stand Test Procedure, LAT-TD-04267-02, released EICIT Procedure, GASU, LAT-TD-04260, released SVT Procedure, GASU, LAT-TD-04382, in work (12/1) Delivered to I&T Inspection, acceptance test, validation pending development of flight documentation

SCOPE OF EGSE TESTS – TEM/TPS: 

SCOPE OF EGSE TESTS – TEM/TPS EM TEM/TPS Acceptance Tests include Configuration inspection to LAT-DS-01643 Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD-4085-01 Labeling with test due date, operator, QA Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Further validation tests performed within the test stand

STATUS OF TEM/TPS: 

STATUS OF TEM/TPS Documentation TEM/TPS Assy, LAT-DS-01643, released TEM/TPS Test Procedure, LAT-TD-4085-01, released EICIT Procedure, TEM, LAT-TD-03875-02, released SVT Procedure, TEM, LAT-TD-04097-02, released EICIT Procedure, TPS, LAT-TD-03875-02, released SVT Procedure, TPS, LAT-TD-04098-01, released Two delivered to I&T Inspection, acceptance test, validation pending development of flight documentation

SCOPE OF EGSE TESTS – BUS PROTECTOR: 

SCOPE OF EGSE TESTS – BUS PROTECTOR Acceptance Tests include Configuration inspection to LAT-DS- Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD- Labeling with test due date, operator, QA Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Validation tests performed in accordance with LAT-TD-

STATUS OF BUS PROTECTOR: 

STATUS OF BUS PROTECTOR Requirements identified in EGSE Plan Design assigned within ELX Documentation needs be created Developing schedule with ELX to support Two Tower Test

TEM TEST STAND - CAL AND TKR TESTS: 

TEM TEST STAND - CAL AND TKR TESTS Acceptance Tests include Configuration inspection LAT-DS-02861 CAL LAT-DS-03605 TKR Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD-4085-01 Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Perform tests described in LAT-TD-4085-01, Para. 5.5.4, Basic Test

STATUS OF TEM TEST STAND: 

STATUS OF TEM TEST STAND Documentation CAL Test Stand set up procedure, LAT-DS-02861, released TKR Test Stand set up procedure, LAT-DS-03605, released TEM/TPS Test Procedure, LAT-TD-4085-01, released EICIT Procedure, TEM, LAT-TD-03875-02, released SVT Procedure, TEM, LAT-TD-04097-02, released EICIT Procedure, TPS, LAT-TD-03875-02, released SVT Procedure, TPS, LAT-TD-04098-01, released Two Test Stands delivered to I&T Inspection, acceptance test, validation pending development of flight documentation

GASU TEST STAND – TESTS IN 1X1: 

GASU TEST STAND – TESTS IN 1X1 Acceptance Tests include Configuration inspection LAT-TD-04267-02 Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD-04267-02 Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Perform tests described in LAT-TD-4085-01, Para. 5.5.4, Basic Test

STATUS OF GASU TEST STAND: 

STATUS OF GASU TEST STAND Documentation Assembly and test procedure, LAT-TD-04267-02, released Validation test, run LAT-TD-4085-01, released EICIT Procedure, GASU, LAT-TD-04260, released SVT Procedure, GASU, LAT-TD-04382, in work (12/1) Delivered to I&T Inspection, acceptance test, validation pending development of flight documentation

GASU/PDU TEST STAND – TWO TOWER: 

GASU/PDU TEST STAND – TWO TOWER Acceptance Tests include Configuration inspection LAT-TD-04267-02 Interface integrity and cleanliness, inspection EICIT and SVT tests Functional Tests in accordance with LAT-TD-04267-02 Validation Tests include Verify Acceptance Testing has been performed and is not due for re-test Configuration inspection Interface integrity and cleanliness, inspection Electrical STM tests Perform tests described in LAT-TD-02544-01, Para. 5.3.6, PDU-GASU Interface and electrical load tests LAT-TD-4085-01, Para. 5.5.4, Basic Test

STATUS OF GASU/PDU TEST STAND : 

STATUS OF GASU/PDU TEST STAND Documentation Assembly and test procedure, LAT-TD-04267-02, released PDU Validation LAT-TD-02544, released Validation test, run LAT-TD-4085-01, released EICIT Procedure, PDU, LAT-TD-04332, released SVT Procedure, PDU, LAT-TD-04332, in work (12/1) EICIT Procedure, GASU, LAT-TD-04260, released SVT Procedure, GASU, LAT-TD-04382, in work (12/1) Delivered to I&T Inspection, acceptance test, validation pending development of flight documentation

TEST PROCEDURE STATUS: 

TEST PROCEDURE STATUS I&T Test procedures are being written prior to completion of test plan. CAL Test Procedure Draft complete and in review Draft must be updated with new input from CAL subsystem (received after procedure completed) Complete one week after CAL final update TKR Test Procedure Draft was complete and in review three weeks ago Draft was updated with new input from TKR subsystem (received after procedure completed) Complete one week after TKR final update

TEST PROCEDURE STATUS (cont): 

TEST PROCEDURE STATUS (cont) Single Tower Test Draft in review in I&T Affected by change to subordinate documents References to be updated and test descriptions re-written Complete 12/15 Two Tower Test Draft begun Complete 12/31 VG and CR Data Runs for LAT Integration

IFCT Part III. Integration Facility: 

IFCT Part III. Integration Facility Cleanroom Computing

Cleanroom: 

Cleanroom Building 33 Clean Rooms functional and occupied Monitoring system fully operational. Clean Rooms fully certified. All computers and oxygen sensors have battery back ups. Upgrades Grounding system for ESD and Multi-point ground to be installed. ECD 1/3/05 15 ton crane to get two speed option, after initial Grid handling. ECD 3/1/05 (TBR) Stand alone hot water boiler. ECD 3/1/05 (TBR) Upgrade environmental controls on clean room air handler. ECD 3/1/05 (TBR) Substation upgrade. ECD 3/31/05 Extend back up generator lease thru Jun 05. ECD 12/31/04

Computing: 

Computing Hardware and networking Online network / firewall fully operational SLAC centrally administered accounts (active directory) working Upgrades RAID5 servers in hand (3 units+spare) and migration is in progress; ECD Dec.18 Environmental test computing infrastructure design in progress