GLAST LAT Project November 18 2004 GLAST Large

GLAST LAT Project November 18, 2004 GLAST Large Area Telescope: Gamma-ray Large Area Space Telescope Integration and Test Two Tower Integration Readiness Review I&T Plan Ken Fouts / Brian Grist I&T Two Tower IRR 1

GLAST LAT Project November 18, 2004 Two Tower Schedule I&T Two Tower IRR 2

GLAST LAT Project November 18, 2004 Integration Sequence • Integration Sequence is defined in LAT-MD-00676 -02 LAT Assembly Sequence • Two tower starts with the integration of Bay 9 and then Bay 8 • Optical surveys will be completed after each installation to determine installation accuracy I&T Two Tower IRR 3

GLAST LAT Project November 18, 2004 On Bench Single Bay Integration and Test Flow TKR Module Post Ship Test CAL Module Post Ship Test TEM/TPS Module Post Ship Test TKR Module CPT CAL Module CPT TEM/TPS Module CPT LAT-PS-03290 LAT-PS-03287 LAT-TD-3415 LAT-PS-03287 LAT-PS-03062 In Flight like Single bay LAT-PS-03058 TKR Module LPT LAT-PS-03290 Cal Module Install LAT-PS-03027 CAL Module LPT LAT-PS-03287 TEM/TPS EICIT/IVT LAT-PS-03875, 04097, 04098, 04099 CAL Module CPT LAT-PS-03287 LAT-PS-03062 In Metrology Bay TRK Module Install Cal Module LPT LAT-PS-03287 TEM-TKR EICIT/IVT LAT-PS-03875, 04097 Single Bay CPT LAT-PS-03276 I&T Two Tower IRR 4

GLAST LAT Project November 18, 2004 CALORIMITER INSTALLATION SEQUENCE Remove CAL, TEM/TEMPS from Metrology Bay Install CAL, TEM/TEMPS into Single Bay (TKR Previously installed) Install CAL, TEM/TEMPS into Grid (TKR Previously installed) Mate TKR Connectors to TEM Invert Cal Tower usingle Bay Test Mate TKR Connectors to TEM Remove CAL, TEM/TEMPS from Single Bay Invert Grid Install Cal into Metrology Bay Mate Connectors from TEM/TEMPS to CAL Invert Single Bay Demate TKR Flex Cables Final Test Receive CAL Tower Legend Remove EM TEM/TEMPS (Demate Cal Connectors) Install and shim Flight TEM/TEMPS Test Invert Single Bay Turnover Op Lift Operation Manual Op Connector Mate/Demate I&T Two Tower IRR 5

GLAST LAT Project November 18, 2004 Tracker Installation Sequence Receive TKR Tower Invert Single bay Demate TKR Flex Cables from TEM Install CAL, TEM/TEMPS Mate TKR Flex Cables Install TKR Tower into Single Bay Test Remove CAL, TEM-PS, & TKR Tower from Single Bay Invert Grid Invert Single bay Remove TKR Tower from Single Bay Install TKR Tower into Grid Final Test Install Cal Tower into Single Bay Mate TKR Flex cables to TEM Install TKR into alignment fixture Legend Verify TKR Alignment Turnover Op Lift Operation Manual Op Connector Mate/Demate I&T Two Tower IRR 6

GLAST LAT Project November 18, 2004 Workaround for Late TEM Delivery • Late TEM delivery – Complete Single Bay test with EM TEM/TPS – Install TKR in Grid • Tracker installation into the grid and cable work may take additional development. – EM TEM may be installed into the Grid with CAL and replaced with a flight unit when available. – Removal of the EM TEM and Installation of the Flight TEM/TPS will require detailed height measurements in the metrology bay to make custom shims. – An optical survey or mechanical measurements will be used to verify location after installation. I&T Two Tower IRR 7

GLAST LAT Project November 18, 2004 I&T Operations I&T Two Tower IRR 8

GLAST LAT Project November 18, 2004 I&T Organization I&T Two Tower IRR 9

GLAST LAT Project November 18, 2004 I&T Roles and Responsibilities • I&T Management – Ensure that all aspects of LAT integration and test planning are in place and these plans are executed – Define I&T priorities and resolve resource conflicts – Provide program scheduling, cost accounting, performance tracking and reporting for entire subsystem. – Ensure the implementation of the LAT Integration and Test plan and the LAT Performance and Operations test plan are achieved. – Ensure that scientific performance and requirements are met per applicable requirements. – Support development of subsystem specifications, verification plans, and interfaces with neighboring subsystems. – Control subsystem environmental requirements and performance metrics. – Support team meetings and project reviews. Travel to meetings and site visits for test support. – Help develop and focus Collaboration support for beam test, data analysis, calibration, environmental test, spacecraft and observatory. I&T Two Tower IRR 10

GLAST LAT Project November 18, 2004 I&T Roles and Responsibilities • Integration Facilities, Configuration, and Test (IFCT) Department – Develop I&T plans for the EM units and LAT. – Develop operations and test procedures. – Layout, spec, and procure equipment and facilities needed for LAT integration at SLAC, specifically the LAT integration facility at SLAC (Building 33). – Train and certify technicians for LAT flight hardware handling. – Provide on-going operational support of integration facilities and staff. – Supervise I&T work in Integration Facility (Building 33). – Record and maintain records of installation and logs of activities to provide configuration control of the LAT during assembly and test. I&T Two Tower IRR 11

GLAST LAT Project November 18, 2004 I&T Roles and Responsibilities • Mechanical Ground Support Equipment (MGSE) Department – Design MGSE to support instrument integration and test. – Support procurement/fabrication of all MGSE. – Plan and coordinate the assembly and proof test of LAT MGSE. – Provide support during integration. I&T Two Tower IRR 12

GLAST LAT Project November 18, 2004 I&T Roles and Responsibilities • Online Software Department – Develop, test, and support software used to collect data from the EM units, CU and LAT test stands, saves them to persistent storage, and to monitor and control the test stand data acquisition system. – Responsible for the online software, workstations on which the online software operates, and network connections. – The online software includes a test executive that communicates with the embedded system to control the test stand, collects data from the hardware under test, a scripting language, Graphical User Interface (GUI) tools, a database, analysis and monitoring tools, and a mechanism to archive data. – Provide a code management and release control system. – Responsible for the design and implementation of a standard test suite (scripts) used to qualify the instrument and instrument components. – The Electronics Subsystem is responsible for substantial elements of the test stand. Thus, there will be close coordination between the Online Software department and Electronics Subsystem. – Online will provide a release control and code management system to configuration control the Online software, this includes the all test scripts used by I&T Two Tower IRR 13

GLAST LAT Project November 18, 2004 I&T Roles and Responsibilities • Particle Test Department – – – Develop, plan, and lead in the implementation of particle tests for the EM units and LAT. Particle tests will include ground cosmic rays and Van de Graaff photons for the EM, Calibration Unit (CU), LAT and observatory levels. These tasks require close coordination with all other departments in I&T. Design, construct, and maintain the Van de Graaff accelerator, its associated diagnostic and support equipment, and scintillator telescope for cosmic ray data acquisition. Particle test leads in the design and equipment manufacture for the CU beam test. Particle Test is supported by the I&T MGSE department and the SLAC Experimental Facilities Department (EFD). I&T Two Tower IRR 14

GLAST LAT Project November 18, 2004 I&T Roles and Responsibilities • Science Verification, Analysis, and Calibration (SVAC) Department – – The SVAC department is responsible to coordinate and help perform the data analysis for particle beam and cosmic ray tests. These tests are designed to ultimately calibrate the LAT, and to validate the Monte Carlo simulations that will be used to verify the LAT science performance requirements. The SVAC department plan builds gradually on the knowledge acquired from low-level calibration tests on hardware units by the subsystems, in the process of I&T, and from particle tests using EM units, and the LAT. The SVAC manager is responsible for developing and leading the collaboration support for offline data analysis of data taken during the LAT integration and testing phases. I&T Two Tower IRR 15

GLAST LAT Project November 18, 2004 I&T Operating Plan • The detailed LAT I&T schedule is maintained in MS Project by the I&T Scheduler. – Schedules will be updated daily via the morning meeting with progress from previous day. – Once every other week I&T will hold a planning meeting with the scheduler and interested or affected subsystems to agree on the plan for the next two weeks. • Plan 2 shift operation – Minimum staff will be 1 S&E Associate, 2 Technicians and a Test Conductor or Test Director on shift (4 people per shift). • Shifts will run 7: 00 am-3: 30 pm and 3: 00 pm-11: 30 pm – Daily morning meeting at 7: 00 am – Half hour overlap will facilitate a daily “hand-off” meeting at 3: 00 pm. – Swing shift Test Conductor will hold an informal meeting at the end of the shift and complete the Shift Log. – Shift hand-off between 2 nd shift and the following day will be accomplished via shift log. • Baseline plan is 2 -8 hr shifts/5 days a week. – Extended shifts and/or Saturdays will be used to maintain schedule as required. I&T Two Tower IRR 16

GLAST LAT Project November 18, 2004 Two Shift Operation Flow • Status of day shift test flow (Shift log review) • Generate/Assign Swing Tasks from schedule. • Items for Test Prep 1500 Daily Meeting Integration Test Director I&T Staff • Shift log Review • Status test flow from previous swing shift • Assign days tasks from schedule. 0700 Daily Meeting Integration Test Director IFCT Staff Thursday Friday Saturday Sunday Monday 1500 Meeting 0700 Meeting Swing shift Day shift 1500 Meeting Swing shift I&T Two Tower IRR 17

GLAST LAT Project November 18, 2004 I&T Test Roles and Responsibilities Test Director Larry Wai Brian Grist Brian Horwitz (Backup) Test Conductors Brian Horwitz (EE Lead) John Canfield (S&E Assoc) Toan Le (Backup) Electrical Technicians Toan Le Phuc Hoang Mechanical Engineers Tom Borden (IFCT Engr) Eliazar Ortiz (Lead) Mechanical S&E Associates Mark Molini Leo Manger Reggie Rogers (MGSE) Mechanical Technicians Dave Kiehl Tom Nieland I&T Two Tower IRR 18

GLAST LAT Project November 18, 2004 Problem Resolution in I&T Problem Observed Inspection, Testing, Data Analysis (HW, SW, Data) Issue Closed False Alarm! Corrective Actions Test Conductor Error No Preliminary NCR (FLAG) Test Procedure/Set Up Error Flight HW Risk? Test Equipment Problem Categorize by Test Conductor and/or Test Director Yes Possible Flight HW Failure NCR Issued Troubleshoot HW MRB Root Cause Identified Corrective Actions Possible Flight SW, DB Failure NCR Issued Troubleshoot SW, DB MRB Root Cause Identified Corrective Actions I&T Two Tower IRR 19

GLAST LAT Project November 18, 2004 Troubleshooting in I&T • No troubleshooting will be done without appropriate disposition on an NCR. • When an anomaly occurs: – The test set-up is frozen – The instrument and test equipment is safed. – The test set-up and instrument configuration is reviewed and documented by the Test Conductor. – Test conductor notifies the TD, Subsystem Engineer and QA. • QA initiates an NCR with information from TC and convenes MRB. – At a minimum, MRB consists of the Test Director, Test Conductor, Subsystem Engineer and QA. • MRB will provide detailed disposition for troubleshooting. • The test procedure will be redlined or a separate procedure will be written (as defined by MRB) to document the troubleshooting activity defined in the disposition. I&T Two Tower IRR 20

GLAST LAT Project November 18, 2004 Procedure Plan • • • Key Requirements I&T Documentation Flow I&T Procedure Development Process I&T Standard Processes Status Configuration Management I&T Two Tower IRR 21

GLAST LAT Project November 18, 2004 Key I&T Requirement Documents Released Revision LAT-MD-00408 -03 LAT Instrument Performance Verification Plan 11/8/04 Document LAT-MD-02730 LAT Performance and Operations Test Plan Draft LAT-MD-00676 -02 LAT Assembly Sequence 3/12/04 LAT-MD-00895 LAT Instrument Survey Plan Draft LAT-MD-00446 -06 SVAC Plan 10/5/04 LAT-MD-03489 -02 Ad Hoc Committee on End-to-End Testing 6/25/04 LAT-DS-02561 LAT Tower and Electronics Assembly Draft LAT-DS-02560 LAT Tower Assembly Draft LAT-DS-02559 -01 CAL-TEM-TPS Module Assembly 11/1/04 LAT-DS-00851 -03 TRACKER-LAT IDD 10/11/04 LAT-DS-00233 -06 CAL-LAT IDD 5/2/03 Requirements Definition Key to Successful I&T Two Tower IRR 22

GLAST LAT Project November 18, 2004 I&T Documentation Flow Test Performance and Operation Plan LAT-MD-02730 Drawings (Mechanical Assembly, Cabling, EGSE/MGSE interface, etc. ) Test Sequence LAT-MD-00676 Assembly Instruction Data Sheet (AIDS) I&T Operating Processes and Procedures QA and Archive Task Specific Procedures (Assembly, Test, Process, Etc. ) Procedure Data Sheet Electronic Logbooks (Component installation, Mate/Demate, Etc. ) FLAG Non-Conformance Report (NCR) I&T Two Tower IRR 23

GLAST LAT Project November 18, 2004 I&T Procedure Process • I&T Procedures are developed by the appropriate Electrical or Mechanical Team members. • Procedures are reviewed internally by I&T and then the draft is put in LAT Docs for external review. Subsystems are notified by e-mail of the document status. • Whenever possible draft procedures are used to dry run assembly, integration and testing of EM hardware. • Document signature cycle is determined by Systems Engineering. • I&T Procedures (including AIDS) are reviewed and signed off (at a minimum) by: – The document author – Quality Engineer – Subsystem Engineer (TKR, CAL, ELX, Mech. , I&T) – I&T Manager and/or I&T Engineering Manager. • Daily “huddles” will be used prior to first use of procedures with flight hardware to review the steps and “mistakeproof” the process. • I&T Procedures will be executed by the appropriate Mechanical or Electrical Technicians and/or Science & Engineering (S&E) Associates. I&T Two Tower IRR 24

GLAST LAT Project November 18, 2004 I&T Process Procedures Document LAT-PS-03481 -02 GLAST LAT Integration Facility Emergency Response Plan LAT-PS-03263 -01 Fastener Installation and Torqueing Procedure LAT-PS-04727 -01 Connector Mate and Demate Released Revision 11/4/04 In Signoff 9/3/04 LAT-MD-04601 -01 LAT I&T e. Log Book Implementation Plan In Signoff LAT-MD-01386 -01 LAT Facilities Plan In Signoff LAT-PS-03291 -01 Flight Hardware Bag and Purge Procedure In Signoff LAT-PS-04436 -01 Aero. Go Bearing Reference Guide 11/4/04 LAT-PS-04511 -01 LAT Data Collection Procedure Draft LAT-MD-01533 -01 LAT EGSE Plan Draft LAT-MD 01462 -02 LAT MGSE Plan Draft Document Standard Processes for use in I&T Two Tower IRR 25

GLAST LAT Project November 18, 2004 Configuration Management • I&T follows the project CM plan, LATMD-00068. • The figure on the right shows document flow through CM • The figure below from LAT-MD-00068 defines who is required to sign I&T Two Tower IRR 26

GLAST LAT Project November 18, 2004 Procedure Status • • • 61 documents total 34 have been submitted for sign-off 20 have been released I&T Two Tower IRR 27

GLAST LAT Project November 18, 2004 Procedure Status (1 of 6) - Management Green is complete I&T Two Tower IRR 28

GLAST LAT Project November 18, 2004 Procedure Status (2 of 6) - MGSE Green is complete I&T Two Tower IRR 29

GLAST LAT Project November 18, 2004 Procedure Status (3 of 6) – IFCT Electrical Green is complete I&T Two Tower IRR 30

GLAST LAT Project November 18, 2004 Procedure Status (4 of 6) – IFCT Mechanical Green is complete I&T Two Tower IRR 31

GLAST LAT Project November 18, 2004 Procedure Status (5 of 6) - Particle Green is complete I&T Two Tower IRR 32

GLAST LAT Project November 18, 2004 Procedure Status (5 of 6) - SVAC Green is complete I&T Two Tower IRR 33

GLAST LAT Project November 18, 2004 Procedure Status – Burndown Chart I&T Two Tower IRR 34

GLAST LAT Project November 18, 2004 Backup Charts I&T Two Tower IRR 35

GLAST LAT Project November 18, 2004 Integration Facilities, Configuration, and Test (IFCT) Department (1 of 2) – IFCT Manager and IFCT Engineer: • Managers for the department. • Coordinated activities between IFCT staff. • Oversees the coordination with other subsystem liaison test groups. • Building manager and assistant building manager for the Integration Facility (SLAC building 33). – Mechanical Floor Engineer: • Oversee and work on the mechanical and thermal aspects of the instrument assembly, integration, and test operations. • Supervise mechanical technicians. Develop flight hardware handling procedures and training. Play a key role in developing the LAT assembly and integration procedures. Lead the mechanical assembly, integration and testing of the LAT. • Responsible engineer to the test and assembly procedures. Responsible for the Assembly Instruction Data Sheets (AIDS). • Supervises the mechanical technicians. • Prepares and coordinates the daily tasks. This person is the test conductor for the mechanical operations. – Electrical Floor Engineer: • Responsible engineer for the electrical test procedures. • Supervises the electrical technicians. • Prepares and coordinated the daily tasks. • This person is the test conductor for the electrical testing. I&T Two Tower IRR 36

GLAST LAT Project November 18, 2004 Integration Facilities, Configuration, and Test (IFCT) Department (2 of 2) – – Mechanical Technicians: • Responsible for hands on mechanical assembly of the LAT under the supervision of the Mechanical Floor Engineer. • Follow written procedures and Assembly Instruction Data Sheets (AIDS). • Review and implement procedures for integration and test of the LAT. • Support fabrication and assembly of integration support equipment. Support calibration of Instrumentation and the LAT instrument. • Conduct test under controlled conditions and report results. • Conduct daily integration operations assigned by lead technician/floor engineer. Conduct crane operation. • Identify, maintain and inventory tools and support equipment related to LAT mechanical integration. • The mechanical technicians are responsible for the physical mate demate of flight connectors. Electrical Technicians: • Responsible to execute written electrical test procedures under the direction of the Electrical Floor Engineer. • Follow written procedures and Assembly Instruction Data Sheets (AIDS). • Will perform tests using automated test and diagnostic equipment, troubleshooting digital and analog interfaces using oscilloscopes, logic and protocol analyzers, multi-meters, and signal generators, and perform interface verifications. I&T Two Tower IRR 37

GLAST LAT Project November 18, 2004 I&T Flow For Tower Installation Receive CAL Tower Receive TKR Tower Install TKR into alignment fixture Measure TKR and Align Cones Install Cal Tower into Metrology Bay Inspect, Metrology & El Test Remove CAL, TEM-PS, & TKR Tower from Single Bay Install TKR Tower into Grid Bay Shim Flight TEM/TEMPS Install TKR Tower into Single Bay Test Install CAL, TEM, & TEM-PS Test Install CAL With Flt TEM/TEMPS Prepare Grid Bay Final Test I&T Two Tower IRR 38