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GLAST Proposal Review

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On-site inspection and Pioneer's responsiveness has allowed quick resolution of ... Support electronics assembly at Aeroflex. Support flex cable production at Pioneer ... – PowerPoint PPT presentation

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Title: GLAST Proposal Review


1
GLAST Large Area Telescope Performance Safety
Assurance Joseph Cullinan SLAC Perform
ance Safety Assurance Manager cullinan_at_slac.sta
nford.edu (650) 926-5034
2
4.1.A PSA Status August 2005
  • DAQ/Electronics
  • TEM/TPS
  • Have now completed handoff of 14 TEM/TPS
    assemblies to IT
  • MRB held to review replacement of TPS units
    currently installed in Bays 0 and 4.
  • TPS units in the first two TEM/TPS assemblies
    installed in the Grid did not have CCA rework
    performed to eliminate voltage oscillation
    problem (NCR 397).
  • MRB concluded to remove TPS units only from Bays
    0 and 4. Plan is to keep existing TEMs in Bays 0
    and 4. Pros and cons of five different options
    hardware removal (including use-as-is) were
    considered
  • This option will allow for subsequent removal of
    TEM or TEM/CAL if replacement TPS fails to meet
    electrical or mechanical fit requirements
  • Replacement TPS units with HV calibration
    constants similar to those of the TPS units to be
    removed have been selected from fully tested
    TEM/TPS assemblies
  • TPS removal and replacement procedure being
    finalized and documented by IT
  • Recalibration of new TEM/TPS telemetry and TKR
    and CAL detectors will be required following TPS
    replacement
  • PDU
  • T/V test started on 1st box, 2nd box delivered to
    SLAC for initial testing
  • GASU
  • GASU Power Supply boards and CCAs for 1st GASU
    completed rework at SLAC following initial
    testing
  • Updating drawings and BOM to reflect changes
  • Boards and CCAs for 2nd GASU still in assembly at
    Aeroflex

3
4.1.A PSA Status August 2005
  • DAQ/Electronics
  • LCB/SIB/CPS boards
  • Last month LAT QA observed workmanship issues
    with first SIB, LCB and CPS boards delivered and
    reviewed these issues with Aeroflex and SLAC
    source inspector
  • Discrepancies were result of carelessness rather
    than unclear drawings or lack of technical
    expertise at Aeroflex
  • Corrective action Aeroflex project management
    reviewed procedures with technicians to increase
    awareness of drawing requirements, hardware
    handling and workmanship requirements
  • SLAC source inspector now documents all
    in-process and final inspections and forwards
    reports to LAT QA and DAQ for review.
  • Discrepancies now are more clearly documented for
    evaluation. Any discrepancies that require
    rework is more quickly addressed by LAT/GSFC QA
    and DAQ, and if necessary additional corrective
    action can be implemented
  • Cables
  • Performing final inspection of remaining flight
    cables (including spares) at vendor facility
    (Cicon) this week.

4
4.1.A PSA Status August 2005
  • Integration and Test
  • Supported completion of 6-tower and 8-tower
    testing
  • Supported receipt and acceptance of ACD
  • ACD final acceptance data package forthcoming
  • Elevated 4 open ACD nonconformances to LAT level
    NCRs

5
4.1.A PSA Status August 2005
  • TKR
  • Supported MRB presented by INFN on Tower 8 tray
    anomaly observed during T/V testing (INFN NCR
    551)
  • Ladders in Tray M007 began to show excessive
    noise or dead channels when temperatures rose
    above 25 deg. C
  • Similar failure was observed on Tray M010 on
    Tower 7. This tray was eventually removed and
    replaced, and Tower 7 retested
  • Both trays were fabricated for Tower 0 and
    subsequently requalified and placed into Towers 7
    and 8
  • MRB concurred to remove and replace tray M007
    from Tower 8, and followed by repeat of
    environmental testing
  • Cause is unknown after considerable electrical
    testing on tray M010
  • Testing on tray M010 to troubleshoot this problem
    appears to be exhausted currently INFN does not
    have additional testing planned for tray M007
  • INFNs analysis indicates failure is typical of
    missing bias on Si detector and not wire bond
    intermittent failure
  • Additional Tower 0 requalified trays L023 and
    B002 are installed in flight Towers 4 and 5 no
    anomalies have been observed with these trays
  • INFN reported that insignificant performance
    degradation would result in Towers 4 and 5
    ifthese trays began to show similar problems with
    ladders
  • Last flight tray (L015) from Tower 0 is now on
    hold at INFN

6
4.1.A PSA Status August 2005
  • TKR
  • Pioneer Flex Cables
  • Supported in-process and final source inspection
    of cable assemblies at Pioneer
  • Pioneer has delivered qty 29 finished cable
    assemblies qty 22 have been hand carried to
    INFN
  • Minor workmanship issues have been observed
    during source inspections
  • Omnetics connectors with damaged and bent pins
    from handling and worn test connector savers were
    removed and replaced without problems
  • Missing conformal coating observed on some
    resistors
  • On-site inspection and Pioneers responsiveness
    has allowed quick resolution of these workmanship
    issues. Causes were identified and corrective
    actions were put in place
  • GSFC has not rejected any Pioneer test coupons to
    date
  • Parlex Flex Cables Qualification Test Plan
  • Reviewed relevant documentation on Qual plan with
    GSFC and TKR
  • Will use flight and non-flight cables and coupons
    to complete qual testing
  • Non-flight cables will be hand selected to ensure
    qual testing will not be impacted by
    nonconforming condition of cable. Non-flight
    cables with slight annular ring failures would be
    best candidates.
  • Minor changes to the Parlex qualification test
    plan would include using cables instead of
    coupons for some tests.

7
4.1.A PSA Status August 2005
  • Mechanical Systems
  • X-LAT Plate
  • Delivered to SLAC in July still awaiting
    acceptance data package from Lockheed Martin.
  • Lifting sling returned to LM for scheduled rework
  • Radiators
  • T/V testing initiated

8
LAT NCR Metrics 8/26/05
9
4.1.A PSA Status August 2005
  • Software QA
  • Supporting reviews of FSW test procedures
  • Supported the IT release of LATTE R4.10.0
    including VV and documention review for LAT
    Docs.
  • Met with GSFC Software QA (Randy Worden) to
    discuss LAT QA processes for FSW oversight
  • QA requirements for FSW were reviewed
  • Randy provided recommendations for the LAT QA
    process overseeing FSW documentation and approval
  • SLAC reviewing these recommendations for
    implementation

10
Issues and Concerns
  • Pioneer Flex Cables
  • Must ensure that coupon testing at GSFC keeps up
    with cable production and delivery to INFN, so we
    dont end up waiting for a test report before a
    cable can be installed on a tower.
  • GSFC has provided exceptional support in
    prioritizing coupon testing in response to a
    highly accelerated delivery schedule for Pioneer
    cables, so the process is working so far.
  • Tower testing
  • TKR, INFN and LAT QA need to closely follow the
    process for removing non-flight cables used to
    support tower environmental testing, and the
    subsequent replacement of flight cables
  • Towers 7, 8 tray anomalies observed in T/V
  • Cause is still unknown, and currently there are
    no known additional tests or analyses on removed
    trays to determine cause

11
4.1.A PSA Planned Accomplishments September
2005
  • Support PDU, GASU testing
  • Support electronics assembly at Aeroflex
  • Support flex cable production at Pioneer
  • Support flex cable qual testing at Parlex

12
Cost Report
13
Cost Variance Explanation
  • Why overrun/underrun?
  • Did not reduce headcount to follow planned FTE
    dropoff due to extended production runs through
    end of July at Teledyne and General Technology
    with full time source quality engineers. Also
    required same headcount as last month to support
    subsystem production and testing.
  • What will be done to correct?
  • Source quality engineers at Teledyne and General
    Technology have rolled off as of end of July (2
    FTE)
  • Look to consolidate QA headcount at SLAC in
    September as subsystem production (cables, flex
    cables, incoming inspection) ramps down

14
FTE Report (DOE/NASA-funded only)
15
FTE Variance Explanation
  • Why overrun/underrun?
  • Source QA support was needed longer than expected
    at Teledyne and General Technology to support
    production. Also needed to continue current
    level of QE support at SLAC
  • What is the impact?
  • 2 FTE required to support extended production
    cycles at these two vendors
  • What will be done to correct?
  • Roll off of 2 source QEs at end of July is
    reduction of 2 FTE for August. Will also see
    additional reduction of approximately 1 FTE in
    August due to vacations. Also look to consolidate
    FTE at SLAC in September as vendor production
    runs near completion.
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