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					Safety and QA




  Bruno HA YEN
 10 gennaio 2005




       Quality Assurance Center in CSIST
                 Contents

 Program Parts Selection List (PPSL);
 Parts, Materials and Processes (PMP)
 Design Report
 1. EMI/EMC
 2. Grounding, Bonding and Shielding
 3. Other Safety Concerned Topics
 CGS Requirements
 Quality Assurance Activities in CSIST for ACOP




                        Quality Assurance Center in CSIST
                   Inputs for Safety Data Package:
                      Payload description
   Slides at the same level of detail of the presentation of the last
    TIM, with images, block schemes, tables of following
    subsystems:
     Electrical architecture
     EMC/EMI assessment
     Summary of Thermal and of Structural analysis results
     Mechanical architecture with a description of interfaces
     Materials and process (machining, painting, anodizing, alodine, etc.) that are
        foreseen for the various parts (locker, fins, LCD display, etc…..)
     Preliminary power distribution schematic showing wire sizing and circuit
        protection
     Preliminary bonding and grounding diagram/plan for flight and ground
        hardware
     Description of Ground Support Equipment (Electrical and Mechanical) and
        ground operations to be performed in the launch site.




                                            Quality Assurance Center in CSIST
               Inputs for Safety Data Package:
                                Lists
   Lists for flight hardware and for ground support
    equipment of:
     materials (aluminum type, glues, fillers, gaskets, PCB,
       etc.)
     processes (machining, painting, any type of surface
       finishing like paint, alodine, anodize, etc.)
     electrical components
     mechanical part components (fans, handles, screws,
       bolts, heli-coils, card locks, etc.)




                                   Quality Assurance Center in CSIST
                                    Safety
   The safety assurance program shall
     consider all pertinent aspects applicable to safety assurance during all project
       phases and
     provide a disciplined approach to methodically controlling safety aspects,
       evaluating the project design, identifying hazards and imposing corrective
       actions in a timely manner.


   Possible safety hazards will be identified by CGS
    according to the design description and suggestions will
    be provided for improvement.

   CGS is responsible for the preparation of Flight and
    Ground Safety Data Packages and attend safety reviews
    with NASA



                                           Quality Assurance Center in CSIST
      Applicable Safety Documents
   NSTS/ISS 13830C "Implementation Procedure for NSTS/ISS
    Payload System Safety Requirements for Payloads using the
    STS",

   NSTS 1700.7B "Safety Policy and Requirements for Payloads
    using the STS" with ISS Addendum

   NSTS/ISS 18798B "Interpretations of NSTS/ISS Payload Safety
    Requirements",

   KHB 1700.7C "Space Shuttle Payload Ground Safety
    Handbook".

These documents are available on the NASA website http://psrp-
  pub.jsc.nasa.gov/


                                 Quality Assurance Center in CSIST
                             Reviews
   FSDP and GSDP will be developed and submitted to the
    ISS Safety Authorities for review and approval in the
    three phases of the safety review process:
     Phase 0/I Flight Safety Review / Phase 0/I Ground Safety Review (near
       the Preliminary Design Review)
     Phase II Flight Safety Review / Phase II Ground Safety Review
     Phase III Flight Safety review / Phase III Ground Safety Review
   As a consequence of the Safety reviews with NASA,
    ACOP shall implement the corrective measures or action
    items identified as necessary by NASA, in terms of the
    implementation of both hardware and documentation
    corrections.
   Safety Data Packages for safety review 0-I will be
    delivered at PDR



                                     Quality Assurance Center in CSIST
    Specific points of interest: Materials

   Materials shall be accepted by NASA data base (called
    MAPTIS: http://maptis.nasa.gov/) checking the following
    CGS shall certify that the materials and processes used
    are be compliant to NASA requirements.
   characteristics (reference : NASA-STD-6001) :
     off-gassing,
     toxicity,
     flammability,
     stress corrosion


 CSG needs a detailed list of the materials and processes
 that are used for ACOP



                              Quality Assurance Center in CSIST
             Specific points of interest :
                    Sharp edges
   Sharp edges of any accessible item (handles, corners,
    protrusions, boards and hard drives mechanical parts,
    front panel, etc.) shall be compliant to the Safety &
    Human Factor requirements :
     NASA-STD-3000 (for Space Shuttle, http://www.edj.net/cgi-bin/phi.exe?C'0.0*'|msis) and
     SSP 50005 (for ISS)




                                              Quality Assurance Center in CSIST
             Safety Data Packages by CGS
   Safety Data Packages              shall    be    be    self-standing
    documents including:
     Structural Verification Plan + Fasteners Integrity Plan (by CGS)
     Fracture control Plan (by CGS)
     Description of on-orbit maintenance operations (by CGS)
     Software general description (by CGS)
     Identification of possible hazards (by CGS)
     Methods for hazards control (by CGS)

     Payload description and mission scenario at PDR level
      (by CGS/Dennett with inputs CSIST)

     Lists of materials, processes, components and
       mechanical parts (by CSIST)



                                     Quality Assurance Center in CSIST
Quality Assurance Center in CSIST
Quality Assurance Center in CSIST
     Quality Assurance Actions for AMS
Item     Quality Plan           Working Items

1.       Parts Level          .Parts Control
                              .Incoming Inspection
                              .Reliability Screening

2.       PCB(Board)Level       .Visual Inspection
                               .Temperature Cycling

3.       Crate(Module)Level    .ESS
                               .Temperature Cycling
                               .Random Vibration
                               .EMI
                               .TVT (TBD)



                        Quality Assurance Center in CSIST
                            AMS                                         CSIST                    ESS     Test     Cond.
                 Electronics     Environment                  Current     ESS    Spec.                   for AMS

1.    Limit      load   factor                 40g           None                 None                   None

                                                          Boards (PCB)     Modules (Crate)      Boards            Crates

2.    Random Vibration                     6.8g(rms)         None               6.0g(rms)       None             6.8g(rms)

           20 Hz           .01g^2/Hz
        20-80 Hz        +3 dB/Octave
       80-500 Hz         .040 g^2/Hz                                        20-2000 Hz                           Same as
                                                                                                                 Left Table
     500-2000 Hz         -3dB/Octave
         2000 Hz           .01 g^2/Hz

3.    Pressure                            0.0~18.0psi        None                 None          None               TBD

         Pressurization Rate              1.7 psi/min.                                                 (Vacuum)

         Depressurization Rate            11.0 psi/min.


4.    Temperature
         Storage                         -40 to +70 ℃      -40 to +95 ℃     -40 to +70℃      -40 to +95 ℃ -40 to +90℃

         Operation                        0 to +60 ℃          ---           -10 to +65℃          ---            -15 to +65℃


5.    EMI                                        ---                MIL- STD-461                   MIL- STD-461



                                                            Quality Assurance Center in CSIST
      PCB & Assembly               Environmental Test Flow Chart
                                           for Hardware
                     100%
          ESS
    Temperature Cycling


           Module
                     100%
           ESS
     Temperature Cycling
    and Random Vibration


     Units or Subsystems



Environmental Acceptance Test


          Delivery



                            Quality Assurance Center in CSIST
                             1st cycle       2nd, 19th cycle             20th cycle
              95℃
Temperature




              23℃

                                                               …
                                                                                    Time

              -40℃

                     ‧Temperature Change Rate >= 15 ℃/min.
                     ‧One Hour Dwell Time For Each Step

                                                                           Dat e: Jul y 9 1997
                      Temperature Cycling Test Profile for PCB of AMS      No: AM S-ESS-TC01




                                                  Quality Assurance Center in CSIST
                                1st, 2nd cycle   3rd, 8th cycle               9th, 10th cycle
                 90℃
                                          *                                               *
                 60℃
   Temperature




                 23℃

                                                                          …                         Time


                 -15℃
                                *                                             *
                 -40℃
Function Test




                  On
  Power &




                  Off                                                     …
                        .This Test Prior To The Vibration Test
                        .Temperature Change Rate ≧ 15 ℃/min.
                        .One Hour Dwell Time for Each Step
                                                                                  Dat e: Sep. 12 1997
                        * Function Test at 1st, 2nd, 9th and 10th Cycle           No: AM S-ESS-TH03
                        .Last Two Cycles Shall be Failure Free
                        Pre-Temperature Cycling Test Profile for Tracker and DAQ Crates


                                                            Quality Assurance Center in CSIST
                         G2/Hz                                              Dat e: Apri l 28 1997
                                                                            No: AM S-ESS-RV01


                                                        0.04
Power Spectral Density

                                  +3 dB/Oct                              -3 dB/Oct

                                 0.01
                                                      6.8                              0.007
                                                      Grms




                                        20       80              500            2000
                                                                           Frequency(Hz)
                            .X, Y and Z Directions are 10 Minutes
                            .Function Test at Each Direction and Without Failure

                           The ESS Random Vibration Spectrum for AMS


                                                      Quality Assurance Center in CSIST
                                    1st cycle   2nd, 3rd cycle             4th, 5th cycle
                 90℃
                                            *                                         *
                 60℃
   Temperature




                 23℃

                                                                       …                        Time


                 -15℃
                                *                                          *
                 -40℃
Function Test




                  On
  Power &




                  Off                                                  …
                        .This Test is Performed After Vibration Test
                        .Temperature Change Rate ≧ 15 ℃/min.
                        .One Hour Dwell Time for Each Step
                                                                               Dat e: Sep. 12 1997
                        * Function Test at 1st, 4th and 5th Cycle              No: AM S-ESS-TH03B
                        .Last Two Cycles Shall be Failure Free
                        Post-Temperature Cycling Test Profile for Tracker and DAQ Crates


                                                          Quality Assurance Center in CSIST
Quality Assurance Center in CSIST
Quality Assurance Center in CSIST

				
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