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Minutes for the AMS-02 Critical Design Review - The AMS-02

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Minutes for the AMS-02 Critical Design Review - The AMS-02

    AMS CDR Minutes Summary

The AMS-02 Critical Design Review (CDR) was conducted 13-16 May, 2003 at the

    Lunar and Planetary Sciences Institute, Houston, Texas. Attendees were given access to

    a very extensive data package prior to the CDR, and at the CDR AMS-02 technical and

    management personnel presented detailed summaries of each AMS-02 subsystem with

    emphasis on design, testing, safety, manufacturing and operations. During the review

    a total of 121 Review Item Dispositions (RID’s) were submitted by the reviewing

    personnel. The chart below is a summary of the RID’s submitted and the management

    disposition of them. Attachment #3 lists each RID and the resulting disposition.

Total Rids received 121

    Accepted with Actions 61

    Rolled up to “parent” Rid 13

    Closed w/Satisfactory Explanation 22

    Disapproved 22

    Withdrawn 3

The CDR was attended by personnel from DOE, NASA HQ, GSFC, KSC, representative

    AMS experimenters from the AMS collaboration, JSC personnel from STS, ISS, JSC

    Engineering Directorate personnel, and various NASA contractors. A typical list of the

    attendees for the four-day CDR is attached as attachment #4.

No major design deficiencies were identified and the AMS-02 Project, as a result, is

    now proceeding toward manufacturing and certification.

I appreciate your participation in this very important milestone.

Jim Bates

Attachments:

CDR Agenda

    CDR Technical Notes

    List of Attendees

    RID Summary (Separate Excel File)

    June 13, 2003 1

    Alpha Magnetic Spectrometer 02 (AMS02) Critical Design Review Agenda

    All presentations and splinter meetings are at the Lunar and Planetary Institute in the Center for Advanced Space Studies

    at 3600 Bay Area Boulevard (enter from Middlebrook Drive). Meeting rooms will be posted at the CDR.

    Tuesday, May 13, 2003 Wednesday, May 14, 2003 Thursday, May 15, 2003 Friday, May 16, 2003 Time

    Welcome, Introductions & Integration GSE/GHE / Ground 8:00 Ground Rules Operations (Europe & KSC) MPIO/LMSO RID Pre-Board J. Bates R. Harold Screening (continued) & Cryomagnet Structure, Avionics, Preparation of Board Briefing Flight & Ground Safety Status Cryosystems, Cryocoolers, GSE RID Review Teams T. Tinsler 9:00 S. Harrison, S Milward, Introduction to AMS J. Ross, A. Gretcho, S.C.C. Ting Materials S. Breon R. Dasgupta 10:00

    Certification Testing NASA/LMSO RID Review AMS Payload Overview & Structural P. Mott Board Experiment Components Magnet Non-linear Suspension Avionics/Data/Software 11:00 Summary C. Tutt P. Nemeth & P. Dennett K. Bollweg

    Adjourn 12:00 Lunch Lunch

    Lunch

    TRD Gas System 1:00 Reyco Henning

    MPIO/LMSO RID Pre-Board

    Screening & Flight Integration Splinter Meetings* Hardware Design 2:00 USS-02 R. Harold RID Review Teams/ Structural Analysis T. Martin Vacuum Case P. Mott Splinter Groups Loads & Dynamics C. Lauritzen PAS J. Kastelic Stress C. Balasubramanian 3:00 Avionics/Cables P. Nemeth Fracture C. Balasubramanian DDRS P. Dennett See Page 2 & 3 for Review Welding D. Rybicki

    Teams and Splinter Meetings 4:00

    ACOP P. Dennett MM/OD D. Lear

    Thermal Syst., Analysis & Test 5:00 Mission Operations C. Clark & B. Verlaat R. Sanchez & P. Nemeth

    RID Cut-Off is 4:00 PM Thursday, May 15, 2003

    June 13, 2003 2

RID REVIEW TEAMS

Team 1: Structural Design

    Flight & Ground Structural Design, Fabrication, Assembly, and Fluid Systems

    Team Leads: Ross Harold, Phil Mott, Stephanie Hicks, Ken Bollweg

Team 2: Structural Analyses, Magnetic Field Analyses, Tests, & Certification

    Stress, Fracture, and Dynamics Analyses, Welding, Certification Testing, MM/OD, Test Plans, & Test Reports

     Team Leads: Trent Martin, Chittur Balasubramanian, Phil Mott, Dan Rybicki

Team 3: Thermal Design, Analysis, and Testing

    Team Lead: Craig Clark

Team 4: Power, Avionics, Command, Data, Software

    Team Leads: Paul Nemeth, Peter Dennett

Team 5: Flight and Ground Operations

    Team Leads: Paul Nemeth, Ken Bollweg

Team 6: SR&QA

    Team Leads: Tom Tinsler, Trent Martin, Mike Fohey

Team 7: Program Management and Documentation

    Team Leads: Ken Bollweg, Trent Martin, Mike Fohey

Team 8: AMS Crew Operations Post (ACOP)

    Team Leads: Peter Dennett, Andrea Bertoli/CGS

June 13, 2003 3

    TEAM LEADS CONTACT INFO:

    Chittur Balasubramanian chittur.balas@lmco.com 281-333-7518 Ken Bollweg ken.Bollweg@lmco.com 281-335-2714 Craig Clark craig.clark@lmco.com 281-333-6779 Peter Dennett pdennett@padsoft.com 281-334-3800 Mike Fohey michael.f.fohey@lmco.com 281-335-2783 Ross Harold ross.harold@lmco.com 281-333-6134 Stephanie Hicks stephanie.hicks@lmco.com 281-335-2805 Trent Martin trent.martin@lmco.com 281-335-2139 Phil Mott phil.mott@lmco.com 281-333-6451 Paul Nemeth paul.nemeth@lmco.com 281-335-6706 Dan Rybicki daniel.rybicki1@jsc.nasa.gov 281-244-5181 Tom Tinsler tom.tinsler@lmco.com 281-333-6946

    SPLINTER MEETINGS:

    ? ACOP May 14, 2003, 2:00 4:00 PM CDT

    o Express Integration Agreement (EIA) M. Koenig

    o H/W ISS/STS ICD M. Koenig

    o International Space Station Payload Labeling Assessment Team (IPLAT) R. Ellenberger

    o Human Factors Implementation Team (HFIT) S. Harper

? AMS Experiment Hardware & Integration Hardware Welding

     May 15, 2003, 1:00 2:00 PM CDT D. Rybicki

    ? Robotics (SRMS to SSRMS Hand-Off)

     May 15, 2003, 1:00 2:00 PM CDT S. Piggot (CSA) ? AMS PIA May 15, 2003, 2:00 3:00 PM CDT R. Miley (J. Bates, J.J.

    Conwell, M. Fohey)

    ? AMS Payload to ISS ICD May 15, 2003, 3:00 4:00 PM CDT R. Miley (G. Cook, M.

    Fohey, Boeing PE&I)

    ? AMS Payload to STS ICD May 15, 2003, 4:00 5:00 PM CDT J. J. Conwell (M. Fohey) June 13, 2003 4

    CDR Technical Notes

    The AMS-02 Critical Design Review was conducted May 13, 14, 15 and 16, 2003 at the Lunar and Planetary Sciences Institute, Houston, Texas. Those participating in the CDR included AMS experiment Collaboration personnel representing Italy, France, Germany, Russia, England, Portugal, Spain, and the USA. Other participating US Government institutions included representatives from Department of Energy, NASA/HQ, GSFC, and KSC. JSC representation included personnel from STS, ISS, Crew, and technical representatives from Engineering Development Directorate. The purpose of the CDR was to review the AMS Integration hardware design, development certification plans, documentation, all interfaces, manufacturing processes, fabrication, assembly, and test of both flight hardware and GSE, software, and data acquisition hardware and plans, ground processing and pre launch plans. Any issues relating to the mission success of the collaboration/ DOE experiment were defined as non-RIDable items (this is consistent with the NASA/DOE Memorandum of agreement, dated 1995). Any issues involving the NASA/LMSO integration hardware, Safety, or Interfaces were defined as rid able.

    Mr. Jim Bates, NASA AMS Mission Manager, opened the CDR with an introduction. Mr. Bates presented the ground rules by which the CDR would be organized, and conducted. Mr. Bates also recognized and thanked all participants for their support to the AMS Project.

    Following Mr. Bates introduction, Professor Sam Ting, the AMS collaboration leader, presented a very extensive overview of the scientific objectives of AMS, the scientific value of each subsystem of the AMS experiment, an overview of the entire collaboration and the functions of each international participant, a brief description of the hardware, and the scientific principles and objectives for each experiment sub-system.

    Mr. Ken Bollweg, LMSO Project Manager for AMS-02, followed Professor Ting. Mr. Bollweg’s presentation included an overview of the entire AMS, including experiment components, such as the cryo magnet, TRD, TOF, ACC, Tracker, RICH, ECAL, electronics crates, star tracker, thermal control system, and integration hardware. Mr. Bollweg’s

    presentation included hardware description, materials, testing, analyses, dynamic frequencies, safety margins, load factors, certification testing, magnetic field test and analysis, interface testing thermal vacuum tests, life testing of some items, and the KSC pre flight flow plan. Mr. Bollweg presented all safety related information for each item covered in his presentation. He also presented an overall AMS weight summary. Some questions were asked by reviewers, however most of the questions were requests for additional details. Several members of the LMSO Technical Team followed Mr. Bollweg’s presentation. Their presentations were detailed descriptions and design test, and analysis summaries of the NASA/LMSO AMS integration hardware.

    Mr. Ross Harold presented the USS-02 design, interfaces with the experiment hardware, and interfaces with the STS, and ISS, structural requirements, materials, etc. Mr. Phil Mott presented the details of the Vacuum Case design, structural requirements, welding, interfaces, assembly details, materials, testing, etc. Mr. J. Kastelic presented the details of the PAS, which included the mechanical design requirements, static testing, ISS/AMS IVT testing at KSC, and future thermal tests planned.

    June 13, 2003 5

    Mr. Paul Nemeth presented a design overview of the AMS avionics, flight wire harnesses, and KSC electronics verification tests. These included the power distribution box and PDB interfaces, cryo avionics box, UPS, Launch Pad and STS interface connections and tests, resource requirements, an overview of the data system, data compatibility testing, power compatibility testing, and EMI/EMC testing.

    Mr. Peter Dennett presented the AMS-02 Digital Data Retrieval Systems purpose, design overview, operations profile, and communications specifications. Mr. Dennett also presented an detailed overview of the ACOP which included the express integration agreement, purpose of ACOP, interface requirements, operations scenario, mechanical design, cooling requirements, power and weight budgets. Command and data handling design, software design and architecture, and a planned low fidelity model which can be used in ground testing and possibly crew training. Mr. Paul Nemeth concluded day one of the AMS-02 CDR with a presentation of AMS Mission Operations. This included Pre-Launch ops, ascent, mission abort, on-orbit STS, on orbit handover to ISS, ISS on orbit ops, end of mission operations, EVA interfaces, and a summary of NBL testing at JSC.

    Day two of the CDR began with Mr. Steve Harrison presenting details of the cryo magnet design. Mr. Harrison included cryo magnet structure, avionics, cryo systems, cryo coolers and GSE. Details were presented for cryo cooling, cryo safety, coil design, non-linear straps, cryo valves, avionics, self-protection systems, magnet charging, and quenching. One specific question was asked concerning burst disc installation problem if the burst discs were installed incorrectly during assembly. This item was referred to a magnet splinter group to address the issue, and provide adequate installation, test, and quality control procedures to preclude backwards installation of the discs.

    Mr. A. Gretchko presented an overview of the cryo system GSE, which included top off of the system at KSC, system charging, GSE systems components list, and vacuum pumps. Mr. C. Tutt next presented an overview of the non-linear straps (an integral part of the cryo magnet structural safety design). This included design and certification testing and analysis. Results of and on going data analysis of the static and dynamic testing performed at Lockheed, Denver, strap verification plan, test to failure, warm and cold tests planned, modal testing of the full-up system, analysis plans for loads, stress, fracture control, test results/analysis correlation, documentation/test plans/reports, and future work. Mr. Reyko Henning then presented an overview of the TRD Gas System which included a schematic arrangement, vibration test results for boxes and manifold, assessment of magnetic field results on components, description of electrical and mechanical components, description of pressure vessels and valves, circulation pumps, etc., functional testing and schedule, assembly schedule and thermal vacuum test plans.

    Mr. C. Lauritzen then presented the AMS structural certification analysis plans for primary and secondary structure, including load factors for lift off, on orbit ISS, and landing, description of math models, definition of interface loads, dynamic clearance assessments, coupled loads, quasi-static loads, static loads, etc. Mr. Laurentzen included an overview of June 13, 2003 6

    how all the analyses would flow together to provide structural certification of the AMS payload.

    Mr. C. Balasubramanian then presented the AMS stress analysis plans. He stated that the governing requirements were spelled out in the AMS-02 structural verification Plan that includes the vacuum case and components, USS-02 and components, and PAS. Mr. Balasubramanian then pointed out that components with low margins of safety would be tested to destruction. Mr. Balasubramanian also presented the AMS-02 Fracture control program. He identified the critical components, identified NASA controlling documents, listed PIH fracture critical and non-fracture critical parts, presented fracture control plans for fasteners and shear pins. Results of vacuum case and components fracture control results and plans were also presented.

    Mr. D Rycicki presented an overview of the welding and brazing of AMS components. He listed the items which will be welded and/or brazed, the driving requirements documentation, the processes to be used, requirements/certification and training, inspections and NDE testing considered in the hardware design for the helium tank plumbing, tubing, trunnion and bridge beams. He showed videos of some of the welding techniques to be used in the AMS manufacturing and Assembly. Mr. D. Lear then presented the MM/OD risk assessment, including a list of items assessed, identification of risk items, and a summary of the odds/probability of micrometeoroid impacts on the vacuum case and TRD over an on orbit stay from 1 to 5 years. The final presentation on day 2 of the CDR was by Mr. C. Clark who presented an overview of the AMS thermal systems design and analysis. Included was a thermal overview, definition of defining documentation, requirements, and environments for analysis. Assessment of operations thermal scenarios, AMS thermal responsibilities, and results of component analyses were presented along with final thermal certification plans.

No notes taken on morning of Day #3.

    On the afternoon of day three, RID’s were submitted to RID control, where they were logged in, given a number, and then submitted to technical team leaders for review with RID originators, and for written comments. After each team leader reviewed and provided a comment or recommendation, the RID’s were collected and prepared for review by the pre-

    board chairmen Mr. Ken Bollweg.

    On the morning of day four, Mr. Bollweg reviewed and dispositioned each RID. Mr. Bollweg presented to the board, chaired by Mr. Bates a summary of each RID, it’s purpose, and his disposition of each one. A summary of the AMS-02 RID’s and their

    disposition is as follows:

Total Rids received 121

    Accepted with Actions 61

    Rolled up to “parent” Rid 13

    Closed w/Satisfactory Explanation 22

    Disapproved 22

    Withdrawn 3

June 13, 2003 7

There were no RIDS which were required to be submitted for specific board action. All

    RID’S were dispositioned by Mr. Bollweg and the board approved of Mr. Bollweg’s

    disposition of the RID’s with some small changes.

Mr. Bates thanked all participants for their cooperation and stated that theAMS-02 project

    has been aided by the detailed CDR review process.

    June 13, 2003 8

    NAME ORGANIZATION

    CDR BOARD

    Bates, Jim NASA/JSC Rogers, Joseph NASA/JSC/ES2 Scheib, James NASA/JSC/OZ3 Miley, Bob ISS/Boeing Conwell, J.J. JSC/STS Standford, John NASA/JSC/NT3

    AMS TEAM Alia, Sergio CGS

    Balasubramanian, Chittur LMSO Battiston, Roberto INFN

    Becker, Robert MIT

    Berdugo, Javier CIEMAT Bertoli, Andrea CGS

    Bindi, Veronica INFN

    Blackmer, Stan LMSO Blanchard, Doug NASA/JSC Bollweg, Ken LMSO Braccia-a-Ferri Fabio ASI

    Breon, Susan R. NASA/GSFC Brown, Tony LMSO Burger, Joe MIT

    Cadoux, Franck Annecy Capell, Mike MIT

    Carter, Howard LMSO Clark, Craig LMSO Contin, Andrea University of Bologna Dennett, Peter Padsoft Dunker, Chris NASA/GSFC Fisher, Peter MIT

    June 13, 2003 9

    Fohey, Mike LMSO Garciulo, Corrado CGS Grechko, Alexander CERN Gutierrez, Manuel LMSO Harold, Ross LMSO Harrison, Stephen SCL Henning, Reyco MIT Hoang, Peter LMSO Hofer, Hans ETH Hungerford, Bill LMSO Jones, Vernon NASA/HQ Ju, Hsing LMSO Kastelic, Joe LMSO Kenney, Gerry LMSO Kounine, Andrei MIT Koutsenko, Valdimir MIT Laurenti, Giuliano INFN Lauritzen, Carl LMSO Lebedev, Alexei MIT Li, Louis LMSO LiPoma, Phil LMSO Lopez, Lollie LMSO Luebelsmeyer, Klaus RWTH Aachen

    Martin, Trent LMSO Mason, Peter Cal Tech/JPL

    Milward, Steven SCL Mohler, Robert LMSO Molina, Marco Carlo Gavazzi Space

    Mott, Phillip LMSO Nemeth, Paul LMSO Nguyen, Ken LMSO Posada, Adolfo CRISA-Spain

    Prince, Gary D LMSO Read, Dean LMSO June 13, 2003 10

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