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Mary.faller

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  • 1. John F. Kennedy Space Center LAUNCH SERVICES PROGRAM Help Us Help You - Spacecraft Lessons Learned From a Launch Vehicle Technical Integration Perspective Mary Faller VA-G2 Mission Integration Branch Fleet and System Management Division Launch Services Program 321-867-8943 mary.k.faller@nasa.gov 1
  • 2. AgendaJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Purpose • Who we are • Why you need this information • Spacecraft system design considerations – lessons from integration • Summary • Contacts 2
  • 3. PurposeJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Heighten awareness of the impact launch vehicle integration and launch has on your spacecraft – Sustaining mission operations may not be the harshest environment you need to design to • Transmit recurring lessons learned to those who actually design, build, or procure spacecraft – YOU! • Ensure our expertise is transmitted early enough to make a difference – Wonderful – Pre-AO response – Ideal – prior to awarding any instrument or SC bus contract – Great – SRR – Good – PDR – Ok – CDR 3
  • 4. John F. Kennedy Space Center LAUNCH SERVICES PROGRAM Who we are: Launch Services Program (LSP) 4
  • 5. ExperienceJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Why are we telling you (aka “the experts”) about spacecraft design considerations? – Over 50 SC launched – Experience on all commercial fleets » Atlas II, Atlas III, Atlas V, Delta II, Delta III, Taurus, Pegasus, Delta IV – Experience with Risk Category Class A to Class D payloads – Multiple launch sites » KSC, VAFB, Kodiak LC, Kwajalein Been there, done that 5
  • 6. Launch Services LocationsJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM Dulles Denver WFF VAFB VAFB Pueblo Huntington Beach Chandler Decatur/MSFC KSC ELV Resident Offices CCAFS Launch Sites Kodiak, Alaska Kwajalein 6
  • 7. Launch Services Program CharterJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Launch Services Program (LSP) resides at Kennedy Space Center (KSC) • Charter: Provide the commercially available Expendable Launch Vehicle (ELV) launch services acquisition and management functions for NASA and its customers • Objectives: to ensure ELV mission success, provide the lowest cost services on-time, and maximize customer satisfaction • Established in 1998 (consolidation of functions across the agency to KSC) 7
  • 8. NPD’s for ELV Launch ServicesJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • NPD 8610.23, Technical Oversight of Expendable Launch Vehicle (ELV) Launch Services – This Directive establishes the NASA policy for Government technical oversight (insight and approval) of ELV launch services provided by commercial launch service providers • NPD 8610.24, Expendable Launch Vehicle (ELV) Launch Services Pre- Launch Readiness Reviews – This directive standardizes the Launch Services Program (LSP) pre-launch review process for all NASA acquired/managed launch services missions deemed necessary to fulfill Space Operations responsibilities for assuring launch readiness certification for NASA payloads/missions • NPD 8610.7, Launch Services Risk Mitigation Policy for NASA-owned or NASA-sponsored Payloads – This directive addresses the process that enables NASA to take advantage of the full range of available launch capability while ensuring that the risks associated with access to space are consistent with the risk classification approved for individual payloads and missions 8
  • 9. LSP Primary FunctionsJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM – ELV Launch Services Contract acquisition/management – Launch Services Budget development/execution – Mission Integration Management (AO Process through launch) – Core vehicle engineering, production, test, and operations insight – Mission Analysis – Engineering services, studies and technical services – Communications/Telemetry (Hangar AE) – Program and business management support – Launch Site Integration Management – Safety and Mission Assurance – Advanced Missions Planning 9
  • 10. LSP Engineering Mission ObjectivesJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • To aid the Spacecraft customer in achieving total mission success by – Ensuring that all interface requirements are identified and met through production, assembly, analysis and test (verification) – Developing and implementing technical risk mitigation for the Expendable Launch Vehicle – Certifying the launch vehicle – Actively participating in the launch operations campaign We are launch vehicle environments, operations, test experts 10
  • 11. LSP Engineering ResponsibilitiesJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Implement KSC Documented Procedures (KDPs) for requirements development, engineering reviews, requirements verification, etc. • Assist spacecraft (SC) with inputs to integrated analyses, tests and procedures • Actively participate in working groups, design reviews, test planning, and tests/operations to ensure requirements are defined and met • Launch Services Contractor (LSC) factory insight for production – hardware built to meet requirements • Core vehicle configuration insight – fleet issue resolution • Engineering verifications for launch campaign and readiness reviews 11
  • 12. NASA Launch Services Technical OversightJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • NASA Policy: NPD 8610.23, “Technical Oversight of Expendable Launch Vehicle (ELV) Launch Services” • NASA’s technical oversight approach seeks to ensure the highest practicable probability of launch success by involvement in, and control of, the launch through technical oversight – Technical Oversight – Combination of focused approvals and technical insight of contractor launch activities – Insight – Acquiring knowledge and understanding of contractor’s actions by monitoring of selected metrics and/or milestones through watchful observation, documentation review, meeting attendance, reviews, tests, and compliance evaluations – Approval – Providing the contractor authority to proceed and/or formal acceptance of requirements, plans, tests, or success criteria in specified areas • NASA retains the right to non-concur with the contractor’s proposed actions based on knowledge obtained through insight • Policy applies to all NASA managed launches 12
  • 13. NASA Launch Services Technical Oversight (cont’d)John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Specific areas requiring government approval are focused on the interface with the spacecraft – S/C to LV Interface Control Documents (ICD’s) and drawings – Resolution/closeout of Mission Integration Working Group (MIWG), Mission Readiness Review (MRR) and Flight Readiness Review (FRR) action items – Mission unique hardware/software design, analyses, manufacture and test – Top level test plans, requirements and success criteria for integrated vehicle systems and for tests that verify the integrated vehicle interfaces – Integrated spacecraft handling procedures and deviations – Integrated spacecraft to launch vehicle mate, test and closeout procedures, as-run procedures and deviations – Anomaly resolutions that affect the integrated spacecraft to launch vehicle assembly – Launch commit criteria and launch GO/NO-GO SC to LV Integration Expertise 13
  • 14. NASA Launch Services Technical Oversight (cont’d)John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Specific areas open to government insight are widespread – Baseline vehicle design, analyses and configuration management – Production: Including reviews, plans, schedules, tests, post-test data, MRB’s and critical flight hardware pedigree – Major system and integrated systems tests – Post-test data, anomaly resolution/closeout, failure analysis – Launch Site schedules, plans, vehicle preparation, closeout data, walkdowns, operations and procedure discipline – Post-launch data and anomaly investigations/closeouts Vehicle Expertise 14
  • 15. SC to LSP InterfacesJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Programmatic • Technical 15
  • 16. Mission Flow - ExampleJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM Spacecraft Services SC/LSP Launch Gates Pre SC MCR MDR PDR/NAR CDR/SIR Mate FRR L+5 Mon Preship Review •GEC •Midex •GOES-P** •GOES O** •AIM •THEMIS •STEREO •JWST** •Geo ITM •MMS •WISE •SDO •CALIPSO* •GOES R •Geo RBM •AQUARIUS* •NOAA-N’ •CLOUDSAT •LISA •TDRS •MSL •NPP •ConX •AMS •ST-8 •GLAST •LDCM •New Millennium •LCROSS •GLORY •RBSP •New Frontiers •IBEX •LRO GSFC •JUNO JPL •SIM •STSS DOD •STSSB201 Other •ST-9 ARC •ESSP 0 •DAWN *International •GPMC** **Potential Advisory •Discovery •PHOENIX Underline is Competed •LPRP •OCO Update as of 10-30-06 •Mars Scout •OSTM* 16 •SMEX •KEPLER
  • 17. Launch Services Communication PathsJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM Spacecraft Customer Launch Services Policy Manifesting Program Status Mission Directorate & Funding SOMD AAA or Designee Program Exec Mgr Launch Service Contractors (LSC) LSP Program Mgmt SC Progr Mgr PM/Dep PM SC Progr Mission Manager Information Mission Mgmt, Eng, Etc. Information Mission Integration SC Project Manager Requirements Launch date Manager SC Business Mgmt Funding Program Integration nt s (Prgr/Proj) me uir e Manager Req LV and LSC-provided Systems Eng &/or Launch Integration Engineer launch site requirements Vehicle Integrator &/or ATLO Mgr LSP-provided launch site Launch Site requirements Integration Mgr Safety/Quality/Mission Safety requirements Safety and Mission Assurance Assurance 17
  • 18. Technical IntegrationJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC Technical Interface is via Mission Integration Team – Mission Manager (Project functions) – Integration Engineer (engineering and integration) – Launch Site Integration Manager (facilities and operations support) – Program Integration Manager (funding) – Safety and Mission Assurance 18
  • 19. LSP Mission Integration TeamJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM NASA HQ KSC LSP S/C LSC Customer PM / MM NASA / KSC PM & LVI MM NASA / KSC NASA / KSC NASA / KSC NASA / KSC IE LSIM SMA PIM SHIA LSC Engrg KSC Resident Engrg Office KSC PPF Range LSC NASA NASA & Safety SMA Contracts Budget KSC KSC Services Mission Vehicle Analysis Systems S/C S/C Comm. LSC Launch Business S/C LSC & Contracts Site Manager Syst. Eng. Launch Telemetry LSC Team LVI Site Launch Site 19
  • 20. Requirements DocumentsJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Interface Requirements Document (IRD) (aka SC Questionnaire) – IRD is the document to provide your requirements to the launch vehicle (LV) – SC-owned document – Usually used as the requirements in a LSC competition (launch service task order (LSTO)) – Write your requirements, not LV design solutions • Interface Control Document (ICD) – The ICD will be agreed to and signed by LSP, LSC, and SC » LSP must follow LSP-P-330.07, Interface Control Document (ICD) Development, Change and Approval Process for LSP Missions » Requires Engineering Review Board (ERB) prior to LSP signature – If LSC provides it, it must be in the ICD – KSC will process a Waiver request following LSP Interface Control Document (ICD) Waiver Process (LSP-P-333.11) – Waivers are usually only granted in extraordinary circumstances, LSP usually requires SC or LV perform the necessary action meet the original ICD requirement IRD and ICD are critical documents for SC and LV design, LSP has rigorous review process 20
  • 21. Interface Verification Flowdown (con’t)John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • This independent verification task is a LSP responsibility (LSP ICD Verification Process, LSP-P-333.08) – Typically utilizes the same documentation for verification closure as the LSP process, but may require additional / different supporting documentation – Documentation supporting compliance with the requirements must be official documentation (i.e. Plan, Procedure, Analysis Memo, Test Data Summary). Nominally, a memo stating “we comply with…” is inadequate. LSP requires data, analysis, test, inspection to show compliance • Every requirement in the ICD is identified for verification – Both launch service contractor and SC are required to provide supporting documentation to LSP showing compliance with the requirements • Incremental verifications are performed for many items – e.g. Drawing, released procedure, fitcheck, flight mate, as-run procedures – e.g. Test Plan, Test Results, Test Summary • LSP verification matrix is coordinated with SC customer and LSC LSP has a Vigorous Interface Verification Process 21
  • 22. LSP ICD Verification ProcessJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM Participants in the LSP engineering I/F Control process: Document (ICD) -Mission Analysis - Electrical Reviews: - Mechanical PDR, CDR, DCR, MPDR, - Systems Verification MUDR, MM/MAR Engineering Matrix & Integration - Ground Processing Resident Office ERBs Verification Analysis*: Documentation Lower Level Reqs: Analyses & PRD, LSSP, Comm Matrix, Reports DMR Annex Test*: Verification Plans, Reports & Procedures Review Demonstration*: Inspection*: Verification Procedures & Walkdowns, Drawings Fitchecks & Build Paper Complete * LSP performs ICD verification of SC/LV interfaces using both SC and LSC data and documentation 22
  • 23. Integrated OperationsJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • LSP has approval for integrated operations - final step in ICD verification process • At the SC factory – Fitcheck – Test adapters for testing – Harnesses – Pathfinders • At the launch site – Touch and go – SC mate to adapter – Fairing installation (occurs at processing facility or Pad depending upon vehicle) – SC transport to pad (ground or flight) – Integrated electrical tests – SC closeouts 23
  • 24. Who We Are: SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • We know the vehicle from tip to tail • We are involved through SC separation – from the beginning of vehicle production – from the beginning of your SC project • We are continuously involved with vehicle evolution and anomaly resolution • We have proven expertise to integrate your payload successfully 24
  • 25. John F. Kennedy Space Center LAUNCH SERVICES PROGRAM Why do you need this information? 25
  • 26. SC Design ConsiderationsJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Cost • Schedule • Does it do what we said it would do? • Cost • Schedule • Cost The launch vehicle portion of your costs are significant. Delays for redesigns cost everyone money. 26
  • 27. We want to talk to you hereCourtesy of Small Satellite Home Page http://centaur.sstl.co.uk/SSHP/
  • 28. If We Succeed Today….John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Use our experience for “elegant” design – simple, yet robust – Meets your needs AND – Meets standard interfaces or “easy” changes • Use our experience for timely design – Reduce potential for redesign post-CDR – Reduce surprises during launch campaign – Increased focus on integration instead of firefighting • Use our experience for least “cost” design – best value – If it seems too good to be true…. – Easiest (to you, right now) is not necessarily easiest for you in the long term – Increase the best value for government – Increased focus on spacecraft build and test instead of team’s focus on external issues / coordination 28
  • 29. John F. Kennedy Space Center LAUNCH SERVICES PROGRAM Spacecraft System Design Considerations – Lessons from Integration “Top ~10 List” “Top 11 Areas of Concern” 29
  • 30. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us In no particular order: – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes » Mass to orbit performance – Vehicle controllability – Loads / Verified Loads Cycle timing – EMI/EMC/RF/Electrical – Access at the launch site – Operations at the launch site 30
  • 31. Lesson #1John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Call us (see contacts at end of presentation) Launch vehicles continually evolve Always coordinate with LSP prior to implementing PPG, previous missions, historical environments and knowledge – your team’s assumptions may not always be correct 31
  • 32. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides 32
  • 33. Using Planner’s GuidesJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Not always accurate or up to date – Living document, updated infrequently – Examples of errors/out of date info/omissions » Acoustic » SC static envelope » Shock levels (clampband tension) » Sine vibe levels » EMI/EMC levels 33
  • 34. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis 34
  • 35. Thermal AnalysisJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Need for Reduced Thermal Model for Integrated Thermal Analysis (ITA) – SC must provide a reduced thermal model to launch service contractor (500 nodes maximum) – Models have to be converted to launch service contractor format – takes time and money (e.g. TRAYSYS) – SC must provide nodes of interest & max/min allowable thermal design limits (critical thermal items) – Pre-launch (including AC requirements)/launch/ascent – If done only at final trajectory delivery timeframe (results at L-6 m), then it is too late to modify hardware/mitigate problem. ITA during preliminary trajectory (results at L-12 m) timeframe is an option 35
  • 36. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning 36
  • 37. Air ConditioningJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • At the launch complex – SC prop vs. Batteries vs. LV prop – August is hottest month - contingencies or alternate operations if lowest AC setting does not provide adequate cooling » But if you are launching in December, you may slip to August! So, design to worst case hot/cold – If low end of cold capability required, need requirement early on (LV prop, performance), actual AC (as run) must be within analytical limits – Conflicting requirements between SC and LV (e.g. LV Prop load temps) – Outages happen – contingency planning 37
  • 38. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination 38
  • 39. ContaminationJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Cleanliness is difficult to achieve and maintain – Provide protection (through launch) for your instruments – e.g. deployable doors/ covers, etc. – Plan cleaning into your I&T schedule and for contingencies – Charred paint from fairing nose – may be an issue depending upon trajectory (worst case 0.17% obscuration ) – Keep sensitive instruments away from the clampband installation zone and away from bolt cutters (small debris) – Avoid having sensitive instruments pointing forward of SC (or have deployable covers if you do so) – Out-gassing materials are present in the fairing and on adapter – Contamination requirements are sometimes violated • T-0 purge, design for outages, and recovery options • Ensure requirements are written as a specification (e.g. MIL-STD) NOT a cleaning process (e.g. VC-6) to ensure a proper cleanliness level that is verified by sampling and maintained • EELV pads were not designed to be clean – no whiteroom 39
  • 40. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes 40
  • 41. SC EnvelopeJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Do not design to max volume • SC stay out zones change over time – Ensure you understand static and dynamic envelopes – Stay clear of the stay out zone below the sep plane » Clamp band installation is difficult, keep sensitive instruments away from the clampband installation zone – potential human damage – Fairing envelopes – these can change over time » Coupled loads analysis » Clearance analysis 41
  • 42. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes » Mass to orbit performance 42
  • 43. Flight DesignJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Do not design to max performance – All trajectory analyses provide a max mass (current best estimate) capability for performance – LV models can change reducing performance – Tested and guaranteed values and reserves required can change - reducing performance – Know the contract performance number - LSP contract (mission success) values is usually LESS than the planners guide number! » The only guarantee of performance is listed in contract or reference mission » Deviations of original target request are responsibility of SC to not exceed contract mass (launch service task order) 43
  • 44. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes » Mass to orbit performance – Vehicle controllability 44
  • 45. Vehicle ControllabilityJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Slosh models required by launch service contractor • Ensures vehicle controllability • 3-stage missions – If spinner, get professional help in designing tank layout – Nutation time constant (NTC) sensitivity, prop tank design and need for testing » NTC also caused by items that are in motion during flight (gyros, heat pipes, fluids) – Spinning, non-spinning, de-spun (each option has different mass, design impacts) 45
  • 46. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes » Mass to orbit performance – Vehicle controllability – Loads / Verified Loads Cycle timing 46
  • 47. LoadsJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Loads – Coupled loads issues may drive design changes. Recommend Preliminary Design Loads Cycle prior to PDR – Test as early as possible to gain confidence in your coupled loads modeling • Verified Loads Cycle (VLC) timing – VLC is required to be performed 12 months prior to launch (results feed into other analyses). Verified model can only be provided after environmental testing (usually later than L-12) – Schedule disconnect requires additional mitigation for SC » modal testing, earlier environmental testing 47
  • 48. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes » Mass to orbit performance – Vehicle controllability – Loads / Verified Loads Cycle timing – EMI/EMC/RF/Electrical 48
  • 49. EMI/EMC/RF/ElectricalJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • E-field levels from LV antennas have been found to be greater than the advertised • Provide adequate EMI protection • Ensure you understand if margins are included in advertised levels • Goddard Environmental Verification Specification (GEVS) does not encompass launch site environment – use NASA-STD-7002A, refers to MIL-STD-461 – hand held devices – uncontrollable sources • Provide damage and interference levels as a deliverable to LSP for your SC receivers – Ensures proper protections are in place for sensitive frequencies • Critical circuits (EEDs, deployables) – must show 6dB margins to LV environment 49
  • 50. EMI/EMC/RF/Electrical (cont’d)John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Dont expect high data rates connecting to your spacecraft with the LV umbilicals – Not broadband Ethernet, only what is required during the launch process should be used – Lab environment and launch complex / pad environment are very different » Distance » Wiring • LV umbilical and LV complex do not provide lightening protection – Design lightening protection into your SC bus – Induced currents – provide for circuit protection on umbilical wiring on SC side – Recommend use Section 22 out of RTCA/DO-160E as a guideline for lightening hardening of cable interfaces LC level 3 • Limited access / space at launch complex / pad – Drag on cables (for pad processing) should be worked early – Special EGSE – Operational limitations (pad clears, RF environment/ordinance installation) • There is a max, per pin, liftoff current – no communications at liftoff • Think twice before using timers prior to separation 50
  • 51. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes » Mass to orbit performance – Vehicle controllability – Loads / Verified Loads Cycle timing – EMI/EMC/RF/Electrical – Access at the launch site 51
  • 52. Access at the Launch ComplexJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Minimize access needs – Its dirty out there - See contamination section – Post SC encapsulation –Interleaved SC and LV operations – a dance and compromise » Platforms, workstands, clean tents are expensive » Self contained atmospheric pressure ensemble (SCAPE) • SCAPE access isn’t easy! • Fill and drain valve access through the fairing – Increased access, increases chances for damage 52
  • 53. Lessons Learned SummaryJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • SC customers need to implement or be aware of the following to ensure mission success and smooth integration effort: – Lesson #1 – call us – Using planner’s guides – Thermal Analysis – Air Conditioning – Contamination – Designing to the max » Allowable envelopes » Mass to orbit performance – Vehicle controllability – Loads / Verified Loads Cycle timing – EMI/EMC/RF/Electrical – Access at the launch site – Operations at the launch site 53
  • 54. Operations at the Launch SiteJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Don’t forget processing, pad operations and countdown in your design trades. These are usually afterthoughts and sometimes drive launch delays and very expensive changes after the fact – Mechanical » Fill and drain valves accessible by a reach of a standard person in SCAPE through a standard fairing door » Remove / install before flight items accessibility during/after fairing installation (special hardware i.e. diving boards) » COPV’s require lower manloading in procedures – Electrical/EMI/RF » RF needs two *independent* inhibits on pad or analysis showing personnel exposure level meets Range Safety requirements » LV EMC levels may drive to more inhibits » SC Transmitter may be too powerful to allow testing in fairing - RF hat access – EWR 127-1 no longer governing document. New Range Safety Document is AFSPCMAN 91-710 – New and onerous Li Ion Battery monitoring requirement from Range 54
  • 55. ConclusionJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • This is not a comprehensive list of lessons learned – call us – see Lesson Learned #1! • Robust SC design – Must consider launch site integrated processing – Must consider “the ride” – Goal is to minimize SC testing / access once integrated 55
  • 56. Were We Successful Today?John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Heighten awareness of the impact launch vehicle integration and launch has on your spacecraft – Sustaining mission operations may not be the harshest environment you need to design to • Transmit recurring lessons learned to those who actually design, build, or procure spacecraft – YOU! • Ensure our expertise is transmitted early enough to make a difference – Wonderful – Pre-AO response – Ideal – prior to awarding any instrument or SC bus contract – Great – SRR – Good – PDR – Ok – CDR PM Challenge 2008 – Excellent! 56
  • 57. Contacts and InformationJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM If you need help during early spacecraft design, the following Launch Services Program mission management will put you in contact with the right technical personnel: Program(s): Mars, TDRS; Center(s): JPL; External Agencies: None Tammy Harrington, Mission Manager, Flight Projects Office (321) 867-4984 Tammy.L.Harrington@nasa.gov Program(s): Explorers; Center(s): GSFC; External Agencies: NOAA Cheryl Malloy, Mission Manager, Flight Projects Office (321) 867-3778 Cheryl.A.Malloy@nasa.gov Program(s): Discovery, Lunar; Center(s): MSFC, JSC; External Agencies: None Ron Mueller, Mission Manager, Flight Projects Office (321) 867-2599 Ronald.G.Mueller@nasa.gov More info: LSP Home page: http://www.nasa.gov/centers/kennedy/launchingrockets/index.html 57
  • 58. John F. Kennedy Space Center LAUNCH SERVICES PROGRAM Questions? 58
  • 59. John F. Kennedy Space Center LAUNCH SERVICES PROGRAM Back Up Slides 59
  • 60. Resident Office SupportJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Resident Offices provide localized support to the Program – Vandenberg Air Force Base (VAFB) – Chandler (Orbital Sciences Corporation (OSC)) – Decatur (United Launch Alliance (ULA)) – Huntington Beach (Delta - ULA) – Denver (Atlas/Delta – ULA) – Dulles (Pegasus/Taurus - OSC) 60
  • 61. Mission AnalysisJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Overall objective is to decrease mission risk through review and verification of mission unique requirements/analyses and relevant fleet issues • Baseline approach is to review Launch Service Contractor analyses and documentation • Intend to obtain and/or develop launch vehicle models as practicable in all mission analyses areas – Philosophy is to get the models, learn to run the models, so we don’t always have to run the models – Detailed knowledge of models enables effective review of analyses – Models and enhanced systems knowledge will help solve technical issues in conjunction with the LSC – Use models for verification of critical mission unique requirements – Current status of model capability is a result of vehicle maturity and GSFC/GRC heritage 61
  • 62. Interface Requirements Document (IRD) (aka SC Questionnaire)John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • IRD is the document to provide your requirements to the launch vehicle (LV) • SC-owned document • Usually used as the requirements in a LSC competition • Write your requirements, not LV design solutions • LSP will help you with your IRD inputs • LSP requires an ERB be held for your IRD to ensure technical feasibility and assess risk • Used as input to the Interface Control Document • Once ICD is created, IRD is no longer used 62
  • 63. Interface Control Document (ICD) & WaiversJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • The ICD will be agreed to and signed by LSP, LSC, and SC – LSP must follow LSP-P-330.07, Interface Control Document (ICD) Development, Change and Approval Process for LSP Missions – Requires Engineering Review Board (ERB) prior to LSP signature – If LSC provides it, it must be in the ICD. » Some items were previously documented in the Launch Site Support Plan • KSC will process a Waiver request following LSP Interface Control Document (ICD) Waiver Process (LSP-P-333.11 – draft) – A written authorization to accept an item in the event that a discrepancy or violation of an ICD requirement is identified in as-built hardware, an analysis, an as-run procedure, or in the event of a special test or emergency procedure but nevertheless is considered suitable for use "as is" or after repair by an approved method. – Differs from a requirements change (SCN) usually due to timing of the non- conformance, but not always. – Waivers are usually only granted in extraordinary circumstances, LSP usually requires SC or LV perform the necessary action meet the original ICD requirement. 63
  • 64. IRD Article (LSP Newsletter, Dec 2004)John F. Kennedy Space Center LAUNCH SERVICES PROGRAM 64
  • 65. ICD Article (LSP Newsletter, Jan 2006)John F. Kennedy Space Center LAUNCH SERVICES PROGRAM 65
  • 66. Engineering Review (ER) Process - K-ELV-02.6John F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Establishes criteria for documenting and evaluating certain technical issues that require engineering disposition • Process results in technical recommendations to the Launch Service Program • Rationale exclusively considers technical adequacy – Does not consider cost or schedule – Process goal is to establish a “technically adequate” solution, not the “best” solution – May consider multiple courses of action as required due to cost and schedule considerations and evaluate each independently on technical merit • Documented process released in Dec 2000 characterizes results of evolution since program consolidation in 1998, and adds near term improvements: – Engineering Review Sheet and database to facilitate issue documentation and information management – Additional attention to mission unique requirements – Tie between launch service provider design reviews and the Engineering Review Board • ER items are tracked in a NASA-managed database called ERBIS (Engineering Review Board Information System) 66
  • 67. Engineering Review BoardJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Engineering Review Board (ERB) is a NASA GRC/LMA-heritage tool adapted by KSC ELV following consolidation – Expanded by Launch Service Program into a more-global process for engineering review – Used to disposition and provide technical recommendations and rationale for a subset of engineering issues • ERB Membership – Chaired by LSP Chief Engineer » May designate alternate chair from permanent board membership – Permanent board membership consists of Engineering Division Chief and Branch Chiefs » Systems Engineering skills and a particular area of expertise required » Each permanent board member may designate an alternate as required 67
  • 68. ERB ParticipationJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • NASA Vehicle Systems Engineer, Integration Engineer and cognizant engineers are typically responsible for presentation of material • ERB is a completely open process – Launch Service Contractor attendance always invited, either in person or by telecon » Visibility encourages higher quality » Purely engineering discussion needs no “government caucus” – Launch Service Contractor representatives are free to ask questions and recommend actions • Launch Service Contractor participation in an ERB is never interpreted to indicate contractor agreement with ERB recommendations – Preserves freedom of the team to achieve maximum benefit from technical interchange 68
  • 69. Engineering Review vs. ERB Trigger CriteriaJohn F. Kennedy Space Center LAUNCH SERVICES PROGRAM • Engineering Review Trigger Criteria • ERB Trigger Criteria – Any flight observation or anomaly occurring – Any flight anomaly occurring on any ELV on any ELV providing NASA providing launch services to NASA launch services – Qual status change for any component – Qual status change for any component – New or upgraded component expected to be – First Flight Item if expected to be used on a used on a NASA mission within the first NASA mission within the first 6 flights 6 flights – Major non-conformance of any component – Significant non-conformances, test to a degree that may threaten anomalies or process deviations that mission success warrant investigation – Mission “Turn On” and ICD release – Mission-Specific technical requirements – Mission-Specific PDRs, CDRs and DCRs – Class I change, deviation or waiver to a mission-specific requirement 69