Thermal Vacuum Test: Plans and Procedures
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1 GLAST Large Area Telescope Gamma-ray Large Area Space Telescope Pre-Shipment Review Thermal Vacuum Test: Plans and Procedures Jesse Armiger Thermal Vacuum Test Director Thermal Vacuum Test Stanford Linear Accelerator Center 1
2 Agenda Compliance to requirements System level analysis Subsystem tests Thermal vacuum test overview Environmental test flow Thermal vacuum test timeline Thermal vacuum test analysis Thermal vacuum test readiness Thermal vacuum test test plans and procedures Pre-test analysis Facilities readiness and certification Test staffing Conclusions Thermal Vacuum Test 2
3 Thermal Vacuum Test 3 Compliance to Requirements All flight system thermal design analyses have been successfully completed and demonstrate adequate margin All subsystems have been successfully thermally tested in compliance with governing documents Governing Documents: Level IIA (NASA) Mission System Specification: 433-SPEC-0001 Thermal design requirements Mission Assurance Requirements: 433-MAR-0001 Thermal test and verification requirements -SC Interface Requirements Specification: 433-IRD-0001 Interface requirements Level IIB (SLAC) Environmental Requirements Specification: -SS Design and test requirements Performance Verification Plan: -MD Verification test definition
4 Compliance to Requirements System level thermal analysis show compliance to requirements Cold Survival Limits Cold Operating Limits Hot Operating Limits +X SUN PT Margins- +X SUN PT Sky Survey Rock EOL Margins- Sky Survey Rock EOL Margins- Cold Margins- Survival Component Cold Survival TKR(SSD) CAL BP EPU* GASU* PDU* SIU* TPS* TEM* ACD BEA ACD TDA All temperatures are in degrees C Temperatures shown are for the hottest/coldest extremity of the subsytem, except as indicated Hot case temperature predicts include 5 C analysis uncertainty margin For cold and survival cases, 5 C uncertainty not used because of heater control (*) Temperatures shown are for the box interface to its heat sink Based upon the Latest Power Summary of 536 Watts Disipation, not including the thermal subsystem All cases use the Spacecraft Solar Array Thermal Vacuum Test 4
5 Compliance to Requirements All lower level flight system verification activities have been satisfactorily completed per -SS Qual AT Oper. Oper. AT Qual Low High Tracker Module Calorimeter Module TEM, TPS Box (1) EPU Box (1) SIU Box (1, +) PDU Box (1, +) GASU Box (1, +) ACD, BEA Sub-Ass'y (2, +) TSA Sub-Ass'y (+) -40* Grid Box Sub-Ass'y (+) -40* Heater Control Box (+) CCHP Components -40* VCHP Components -40* Radiator Sub-Ass'y (+) Notes: All temperatures are in degrees C; see acronym list for an explanation of acronyms used Temperatures shown are for the hottest/coldest extremity of the subsytem, except as indicated (+) Protoflight units only. Qual temps shown are for proto-flight qual testing (*) Not all performance requirements will be met at EOL for this test. See Appendix A for a full explanation (1) Temperatures shown are for the box interface to its heat sink (2) BEA temperature limits apply to the full ACD assembly a Thermal Vacuum Test 5
6 Compliance to Requirements All lower level flight system verification activities have been satisfactorily completed per -MD Hot Surv Hot QT Bake Out On/Off/On CPT OFF/On LPT OFF/On LPT OFF/On CPT Off 12 Hour Soak Hot T- Bal Pump-Down Repress Cold T-Bal Cold QT Cold Surv T-Bal Off On 12 Hour Soak CPT OFF/On LPT LPT CPT OFF/On OFF/On Test Procedures, Reports, and ATDPs are posted on the GLAST homepage ( under Subsystems Thermal Vacuum Test 6 T-Bal T-Vac Cycles Ambient Pressure, Temp Pressure < 1x 10-5 Torr
7 Compliance to Requirements Radiator/TCS Subsystem thermal vacuum testing: Testing of the Radiator subassembly was successfully completed on 9/2/05 Survival mode testing demonstrated that the VCHPs were successfully closed by the reservoir heaters but reservoir temperatures were significantly below predictions Documentation GLS , GLAST Radiator Thermal Vac Test Procedure, 8/22/05 GLS , GLAST Radiator Assemblies Thermal Vacuum Test Report, 09/12/05 GLS , GLAST Radiator Assembly Thermal Vacuum Test Correlation Report NCRs VCHP reservoir heater operation during Survival Mode + Y Radiator antifreeze heater primary and redundant circuits crosswired Suspect flight telemetry (+Y Radiator VCHP reservoirs) Thermal Vacuum Test 7
8 Thermal Vacuum Test Overview Initial flight system comprehensive performance testing has established a valid performance baseline that complies with requirements Baseline C F S at SLAC Ship to NRL Receive, Unpack NRL Post-Ship C Sine Vibe L L L L Mount Radiators T EMI/EMC L E L Acoustic L L Pre Post-Axis Pre-TV C S T-Bal L S T-Cycle L C Final C F S Remove Radiators Weight CG Pack Ship to Spectrum TESTING IN THERMAL VAC CHAMBER L Limited Performance Test F Functional and FSW Test C Comprehensive Performance Test T TCS Functional Test S SVAC Test E EMI/EMC Emissions/Susceptibility Test Thermal Vacuum Test 8
9 Thermal Vacuum Test Overview 50.0 Hot-TB Thermal-Vacuum Test Timeline 45.0 Hot-Perf Final-Perf Test 40.0 Hot-Plateau 2 Hot-Plateau 3 Hot-Plateau TCS Hot-Cold Hot-Cold Hot-Cold Hot-Cold Pre-TV Perf Test 30.0 Temperature (deg. C) Open Door Prep Pumpdown Bake Out Peak Load Test Hot Thermal-Balance Hot TCS Testing Hot PFQ Perf Cold Survival Thermal- Balance Cold Operational Thermal-Balance Cold TCS Testing Cold PFQ Performance Testing Thermal-Vacuum Cycle Testing Vent Open Door Close-Out RIT Temp Extreme Temp 10 Mar 2006 Update Init Cold-TB Surv-TB Cold-Perf TCS Cold-Hot Cold-Plateau 1 Cold-Plateau 2 Cold-Plateau 3 Time (days) Cold-Hot Cold-Hot Cold-Plateau 4 Cold-Hot Thermal Vacuum Test 9
10 Timeline Analysis Thermal Vacuum Test Overview Total Duration Number of Duration Event (hours) Occurances (hours) Basis Notes Pumpdown Estimate (NRL) ition to Bakeout Analysis Ratio of Full Cold-to-Hot ition Bakeout Estimate (SLAC) TBR-Contamination Engineering ition to Hot Thermal Balance Analysis Ratio of Full Cold-to-Hot ition Hot Thermal Balance Estimate (SLAC) Hot/Cold Operational TCS Testing Estimate (SLAC) ition to Hot Perf. Testing Analysis Ratio of Full Cold-to-Hot ition Hot/Cold Perf. Testing Allocation CPT (TBR-Grist/Baun) ition to Cold Surv Analysis Cold Survival Thermal Balance Estimate (SLAC) Cold Survival Heater Testing Estimate (SLAC) Includes Margin Test ition to Cold Perf Analysis Ratio of Full Cold-to-Hot ition Cold Operational Thermal Balance Estimate (SLAC) Cold-to-Hot/Hot-to-Cold itions Analysis Hot/Cold Soak (Cycles 2&3) Allocation Min. Soak Time Hot/Cold Soak Cycle Allocation CPT+SVAC (TBR-Grist/Baun) Return to Ambient & Turn-off Analysis Ratio of Full Cold-to-Hot ition Consent to Break Vacuum/Recovery Estimate (SLAC/NRL) Total Thermal Vacuum Hours: 958 Total Thermal Vacuum Days: 40 Thermal Vacuum Test 10
11 Thermal Vacuum Test Readiness Thermal vacuum test test plans and procedures Test Plan Status Initial plan released 6/05: -MD Final version ready for release Updates reflect changes test sequence, test hardware configuration and other changes which have occurred since the initial release Test Procedure Status Initial procedure released 3/06: -MD Final version in progress (Expected Completion 6/2/06) Remaining TBDs:» Thermal predicts from the thermal vacuum test TMM» Final temperature sensor list and alarm limits» Figures showing temperature sensor locations Final walk-throughs with the NRL test team, the electrical test team, and SLAC systems engineering will take place prior to final release Thermal Vacuum Test 11
12 Thermal Vacuum Test Readiness Pre-test analysis Analysis used to develop test plan is complete Pre-test predicts are in progress Expected completion date: 5/17/06 Will be included in final revision of test procedure Thermal Vacuum Test 12
13 Thermal Vacuum Test Readiness Facilities readiness and certification TVAC Chamber Cleaning of TVAC chamber complete TVAC chamber certified and ready for testing by 5/1/06 Data Acquisition System Ready for STE Validation Test by 5/1/06 Ready for TVAC Test by 6/1/06 (waiting on equipment calibration) Specialized Test Equipment (STE) and Test Stand STE and Test Stand hardware complete for STE Validation Test by 5/1/06 Extra configuration needed for TVAC Test complete by 6/1/06 -DS & -DS show STE and Test Stand thermal build configurations Thermal Vacuum Test 13
14 Test Staffing Thermal Vacuum Test Readiness Shift Schedule in Progress Available resources Jesse Armiger Jack Goodman Brett Pugh Jeff Wang Eric Grob Carlton Peters Hume Peabody Bryan Matonak Thermal Vacuum Test 14
15 Conclusions Work still to be performed: Conduct Thermal STE validation test Add test software GUI to support upload of thermal parameters Complete pre-test analysis Complete final revision of test procedure Complete final test preparations at NRL Hold Test Readiness Review ready to ship all thermal requirements satisfied Pending completion of the above items, the will be ready for thermal vacuum test Thermal Vacuum Test 15
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