Integration Process for Payloads in the Fluids and Combustion Facility

12 Pages·2001·1.6 MB·English

by  Free, James M.

This isapreprint orreprintofa paper intended for presentation at a
conference. Because changes maybe made before formal AIAA 2001-5040
publication, thisismade available withthe understanding thatitwill
notbe cited orreproduced without thepermission oftheauthor.
Conference & Exhibit on International Space
Station Utilization
Overview
Kennedy Space Center, Florida
15- 18 Oct 2001
The ISS FCF is amultidiscipline research
INTEGRATION PROCESS FOR PAYLOADS facility that provides accommodations to
IN THE FLUIDS AND COMBUSTION investigate combustion and fluids phenomenon
FACILITY in a sustained microgravity environment.
Investigations performed in a microgravity
James M. Free/NASA Glenn Research Center, environment provide unique insight into the
behavior of fluids and combustion science. The
Marsha M. Nail/NASA Glenn Research Center
combustion portion of the FCF supports
Abstract investigation and observation of laminar flames,
turbulent combustion, droplet and spray
The Fluids and Combustion Facility (FCF) is an combustion, and other types of combustion
ISS research facility located in the United States research. The fluids portion of the FCF supports
Laboratory (US Lab), Destiny. The FCF is a investigation and observation of multiphase
flows, boiling, condensation, colloid physics,
multi-discipline facility that performs
surface tension controlled flows, and other types
microgravity research primarily in fluids physics
science and combustion science. This facility of fluid physics research.
remains on-orbit and provides accommodations
Both the crew and ground operations personnel
to multi-user and Principal investigator (PI)
operate the FCF. The crew sets up and prepares
unique hardware. The FCF is designed to
the FCF payloads for semi-automated operations.
accommodate 15 PI's per year. In order to allow
Experiment setup involves installation of multi-
for this number of payloads per year, the FCF
user hardware, PI-unique hardware and samples
has developed an end-to-end analytical and
as well as reconfiguration of the diagnostics.
physical integration process. The process The crew also performs maintenance and
includes provision of integration tools, products
upgrades to the facility.
and interface management throughout the life of
the payload. The payload isprovided with a Data collected over the course of PI experiment
single point of contact from the facility and runs isprocessed and stored within the FCF. A
works with that interface from PI selection portion of this data may be downlinked in near
through post flight processing. The process real-time for decision making and/or engineering
utilizes electronic tools for creation of interface analysis. The crew removes PI-unique hardware
documents/agreements, storage of payload data and restores and/or reconfigures the facility for
and rollup for facility submittals to ISS. continuing PI experiments.
Additionally, the process provides integration to
and testing with flight-like simulators prior to The facility is comprised of three powered,
payload delivery to KSC. These simulators Active Rack Isolation System (ARIS)-equipped
allow the payload to test in the flight International Standard Payload Racks (ISPRs).
configuration and perform f'mal facility interface The FCF is incrementally launched with the
and science verifications. The process also Combustion Integrated Rack (CIR) as the initial
provides for support to the payload from the FCF deployment. The intermediate deployment
through the Payload Safety Review Panel consists of the Fluids Integrated Rack (FIR) in
(PSRP). Finally, the process includes support in conjunction with the CIR. The CIR and the FIR
the development of operational products and the operate independently until the Shared
operation of the payload on-orbit. Accommodations Rack (SAR) is added. At this
Copyright © 2001 by the American Institute of
Aeronautics and Astronautics, Inc. No copyright is asserted in the
United States under Title 17, U.S. Code. The U.S. Government has
_myalty-free license to exercise all rights under the copyright
_qned herein for Governmental Purposes. All other rights are
.".._.edby the copyright owner."
?
Figure 1 -Fluids and Combustion Facility
point the FCF is fully deployed as_shown in FCF team to understand the operational
Figure 1,Fluids and Combustion Facility. resources, design interfaces and verification
The FCF is designed to operate with amaximum requirements. Additionally, the payload will
of 15 PI's per year. This includes NASA
require a FCF ground system to which their
sponsored experiments, commercial
hardware can be tested prior to launch.
investigations and international experiments.
In order to meet the needs identified in the
Need for Integration Process
previous paragraph, the ISS requirements for
data delivery, and the need for repeatability; it
In order to accommodate ahigh volume of
was determined that a structured payload
payload flow through the on-orbit facility and integration process was required.
the associated ground system, a well-def'med
process isnecessary. Establishment of such a Process Overview
process will allow aconsistent, cost-effective,
and concise approach to ensure both FCF and
In def'ming and developing the integration
ISS requirements are satisfied.
process the first step taken was to understand the
end-to-end system required that would allow for
As apayload carder, FCF is responsible for groundbreaking research in the areas of fluid
systematically ensuring that each flight to the physics and combustion science. The system
ISS and FCF presents the highest quality and that is currently being developed consists of
amount of science return in the safest and most
three layers: Principal Investigator (PI), FCF and
efficient manner.
ISS. It became clear that an understanding of
each layer and how they fit into the overall
The increment and planning period structure
system was necessary. In understanding the PI
defined by ISS and the aggressive payload layer, GRC drew on its history of flying
throughput of the facility have resulted in a experiments aboard the Shuttle and Mir. To
significant overlap of work. During each phase understand the ISS level, GRC drew upon its
the payload will require information and
interaction with the ISS Payloads Office,
assistance from the facility in order to complete particularly in the development of the ISS
planning, to design required analyses and to payload requirements and integration process.
perform testing to ensure compatibility with the
Understanding of the FCF layer was provided by
on-orbit hardware. To complete this work the the direct interaction with the FCF development
payload will require regular interaction with the
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team. The system was then def'med at a top level The FCF Payload Planning Process is the set of
as shown in Figure 2. activities developed to address the above
responsibilities. The process includes resource
I....1
NRA .
l_lSS ions
guideline development, collection and
Although it represents ahigh degree of roll-up, management of payload resource requirements
the figure allowed the FCF integration team the data, and resource analysis that results in a
ability to clearly see the how the system works payload being manifested on the FCF for a
with FCF as the carrier of the PI hardware tothe particular ISS increment or increments.
ISS.
Resource Development
P_y!o_d_ P!_n_njng
The allocation of resources down to the facility
In order to properly establish an early interface level has been problematic and unclear in the
to the FCF payload projects to convey resource early stages of increment development for ISS.
availability, a payload planning function was The primary document for conveying the
developed. The payload planning function has available utilization resources for future
four primary responsibilities: increments is the ISS Operations Summary
Document. In order to provide an FCF payload
1) Provide a rolled-up set of the FCF with a resource "envelope" or guideline, the
required resources to ISS GRC payload planning group worked with the
2) Perform an integrated FCF resource Microgravity Research Program Office (MRPO)
analysis to develop arepresentative percentage of the
3) Develop an FCF traffic model resources to apply to the Microgravity Science
4) Provide the initial integration Division (MSD). This percentage was
process interface to payload project determined to be 9.5% of the total utilization
teams resources presented in the Operations Summary
Document. The appropriate percentage of the
MSD allocation is then determined for the FCF
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J •
and can be used for planning purposes. launch and return flights for all payloads
Nominally, resource allocation to MSD would managed or sponsored by GRC/MSD. It isthe
not be received until after payloads are primary strategic and tactical planning tool to
manifested at the L-24 milestone. This early forecast and track the long-term usage of the
resource analysis performed by the planning FCF. The FCF portion of the traffic model is
group allows a payload project and the FCF developed as a system including both fluids and
project to obtain an early picture of what combustion payloads. An example of the traffic
resources will be available for the increment or
model is shown in Figure 3. This traffic model
increments on which they will be flying. will be continually validated against projected
ISS resource allocations and each update is
Resource Analysis
published and reviewed with the GRC MSD
management.
Once the planning group has developed the
available resources, they are then able to analyze Initial Process Interface
the feasibility of flying a specific payload
complement during a given increment. The
In order to meet the early need for planning data,
analysis consists of totaling up resource
the payload project interfaces with the planning
requirements data submitted to the planning group as early as L-54. This early interface
group from the payload project, performing a allows an introduction to the entire integration
roll-up with facility requirements, and then process. Therefore, the payload planning
comparing the required resources to the representative serves as the early integration
theoretical available resources. The categories interface or integration manager. With the
compared are: upmass, launch stowage, on-orbit assistance of other integration personnel, the
stowage, crew time, energy and downmass. This planningrepresentative provides an integration
analysis is then used in the development of the process overview to the payload project team at a
GRC/MSD ISS Utilization Traffic Model.
kickoff meeting. This early interaction between
the project team and the FCF integration team
Traffic Model
allows the payload project to have a single point
of contact throughout the payload's entire
The GRC/MSD ISS Utilization Traffic Model is
lifecycle. Additionally this early interface allows
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Flight TBD TBD TBD I-BD _ TBD leo Itsl._ TBD TBD TBD TBD TBD " TBD TBD TBD
TBD TBD _UD T-BD TBD TBD .... -1-uu TBD TBD TBD TBD TBD TBD TBD TBD
Faciliete
Comlmsfi Dn
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Payload OOC • O0,, O0 o0 C • o¢_o() 9c O() oc OC
_ r:m,MCe_-A Z":"
Non-GR
Payload
Payload • t[:]@ > [3 0
.-...-.__,_,
Accelerati,
Mea_urem, tt
Payloada
Ml!O_ V V V V •o Vo
Discipline Mini-Facility
Combustion Science
Fluid Physic. Figure 3 - Sample Traffic Model
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communicatioofndesignrequirementotsthe
4. Provide payload projects with a single
payloapdrojectT.hecompletceontenotfthe
point of contact for resolution of all FCF and
kickoffmeetinwgillbediscusseindalatter ISS matters
section.
Integration Process Ground Rules To match the ground rule of minimum
documentation and a comprehensive set of
The development of the integration process was requirements, it was determined that a single
conducted at GRC by a diverse team. The point of contact would simplify the integration
purpose of the diversity was to ensure that all process. This allows the payload to consistently
know where to look for inputs and know where
entities responsible for designing, utilizing and
to submit required information. This interfaces
operating the FCF would be represented. The
is discussed in a latter section.
participants in the integration process
development team included Payload Project
5. Provide the payload project with
Managers, Science Discipline Interface
autonomy in the ISS safety process as
Managers, FCF Rack Managers, Operation
applicable
Personnel and Integration Process Developers.
A strong sentiment among the process
The initial product of this team was the
development team from the payload side was the
development of integration process ground rules.
need for freedom of operation in the safety
The purpose of the ground rules was to establish
submittal and approval process. The PSRP also
a set of guidelines or criteria against which each
agrees with this method. Details of this
to the processes, documents and/or requirements
implementation are in a latter section.
could be compared against for validity and
acceptability. The ground rules developed were:
Payload Interfaces
1. Minimize the amount of documentation
In def'ming the methods by which the FCF
required to integrate an FCF payload
integration team would interface with the
payload, itwas determined that a lead for each
2. Provide the payload with
payload would be necessary. This individual,
comprehensive source for all requirements
known as the Integration Manager, would then
(FCF,MRPO,ISS, STS)
be solely responsible for the successful
integration and operation of the payload in the
The primary concern of payload projects as
FCF. The Integration Manager would transition
discussed in the development team was the
from the payload planning representative, as
amount of documentation in place with ISS and mentioned earlier, around the L-42 timeframe.
the impact that would have on the payload's The primary responsibilities of the Integration
integration into the FCF. In order to allay this Manager are to act as the single point of contact
fear, it was determined that the best effort would with the payload project for integration issues;
be made to combine documents/requirements as provide detailed technical guidance in the area of
possible.
FCF interface and integration including access to
the FCF engineering discipline team; preparation
3. Keep consistency with ISS and and submittal of integration, training and
EXPRESS Rack documentation structure
operations documentation; design review support
where possible and execution in the area of FCF interface and
integration; and liaison to the FCF Increment
Because of FCF functions as a carrier for Manager on the payloads behalf.
payloads and as well as a payload itself to ISS, it
was determined that maintaining consistency Because of the number of payloads flying within
with ISS documents and data structures was
the FCF during any one increment as evidenced
important for requirements and data traceability in earlier figures, a single point of representation
during roll-ups.
for FCF on a specific increment isrequired. The
FCF Increment Manger acts as the individual
responsible for the overall increment
programmatic interface and reporting. In this
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rolet,heFCFIncremeMntanagearctsasthe
interfacteotheISSforFCFincludinagll
payloadwsithintheincremenTt.hisindividual Interaction between the FCF Ground Processing
isappointeadtapproximate1l-y30i,ntimeto Team and the FCF Operations Team will be
solidifytheeffortsforthegivenincremenint coordinated through the Increment Engineer.
supporotfthemanifesretquesatndduringthe
manifestinpgrocessT.heindividuaallso A figure showing the general integration
representhtseFCFtotheISSPayloaMdission interface structure is shown in Figure 4.
Integration
Team (PMIT) forum.
Requirements Flow and Documentation
Additional personnel with whom the payload
project will have occasional interaction include
The primary integration process ground rule was
the Increment Engineer, Science Discipline
Interface Managers and the Utilization Scientist. to develop a comprehensive source of all
requirements for the payload and to minimize the
llae Increment Engineer has the responsibili,_,
for ensuring technical compliance with all FCF amount of documentation required of the
and ISS requirements via verifications prior to payload project. Figures 5and 6represent the
flow/distillation of requirements from levels
submittal to ISS. The FCF Increment Engineer
acts as the competent technical authority for the above the payload into a unique set of payload
required documents.
integration engineers. The Science Discipline
Interface Managers continue as payload
advocates during the development of FCF As the figures show, the integration process has
upgrades and in general FCF been developed such that the payload project is
integration/interface forums. The Utilization required to refer to only one document to obtain
all payload technical and interface requirements
Scientist works directly with the Principal
fi'om the FCF. This document is the Interface
Investigators for each payload during the
Definition Document (IDD). The IDD contains
development of science priorities internal to the
FCF and with the ISS Increment Scientist for all interfaces and requirements for integrating to
development of science priorities on ISS.
Figure 4 - Payload Project Interfaces
INTERNATIONAL SPACE STATION (ISS)
Facility, Payload Engineering and Integration (OZ2)
Payload Integration Manager (PIM)
,",F,l _,_,sT 1
FCF Increment
Engineer
PD SpeeifieSAMS Payload
Project Teams
PD Specific Phase 'B' Managers
(Fluids/Combustion Interface klana_ers
I:Ct" trlcrement En_ineerit_ Team (Example Functions1
,. .. , , , •
Sal'el_ Lead I Tllerlnai I c"ld / I P_,_.er 1e:ld I ' .
" [ "' ][ ..... [X,l ,,_v_tc1.n..,..I.
....
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I
ISSDocumentation
PDDocumentation
FCF IPDocumentation
OtherDocumentation
FCFDocumentation
Figure 5 - Requirements Flow (Part 1)
aspecific FCF rack. The payload project team, plan in a similar process as the ICD is from the
with the guidance of the Integration Manager, IDD based on the interfaces and requirements
selects from the IDD those interfaces and
selected in the applicability matrix. These
requirements that are applicable to their specific verifications, where required by ISS, are then
payload via an applicability matrix. The
rolled up into a single submittal for the specific
Integration Manager then develops apayload rack and total FCF.
specific Interface Control Document (ICD)
which isjointly signed by the Integration A payload, in conjunction with the Integration
Manager and the payload Project Manager. The Manager, also develops an Integration
payload project isthen required to show payload Agreement (IA). The IA consists of the main
compliance to the interfaces and requirements in volume and the data sets. This structure is
the ICD by the Payload specific Verification identical to the previous ISS structure with the
Plan (PVP). The PVP is derived from ageneric exception of tailoring for FCF and payload
project unique roles, responsibilities, resources
:;!:-ii2_i!iiiiii;ii::ii!i!!:,!i_i:
I
[_ ISSDocumentation
__.'_'.-_1
PDDocumentation
• I I I _ _ii
FCF IPDocumentation
OtherDocumentation
FCF Documentation
*Onetimesubmittal forallFCF racks,payloadsandupgrades
Figure 6 - Requirements Flow (Part 2)
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andprovisionsA.swiththeverifications,
dates of FCF products to ISS. The
detailepdayloaidncremenretquiremenatrse
rolledupandsubmittetodISSasaspecifircack interdependence of the schedules requires close
ortotalFCFsubmittaTl.hepayloaddatasets scrutiny and discussion between the payload
willalsoberolledupwiththeFCFdatasetsbut, project team and the FCF integration team to
ensure that shortfalls in payload deliveries do not
itiscurrentleynvisionethdatthepayloadswill
impact the FCF deliveries to ISS.
havethecapabilittyosubmittherequired
informatiodnirectlytoPDL;theFCFintegration
teamwillbeabletoviewandrollupthedata An important event noted on the template is the
withinPDL;andthedatacanthenbesubmitted Integration Kickoff meeting. As referenced
asaspecifircackorFCFcombineddataset. earlier in the paper, the kickoff meeting occurs
early in the payload development phase typically
after the payload has completed the Science
Integration Template
Concept Review (SCR). At this meeting the
In order to provide a payload project with a payload will receive a comprehensive
schedule of deliverables to the FCF integration presentation of the end-to-end integration
team and to track upcoming design and flight process. Additionally, the payload will receive a
set of applicable documents including the FCF
L-48 L-42 1.,-36 L-30 L-24 L-18 L-12 I,-6 L-0
iw Kicko!,!ff !!I lI ll II ]l Ii lI !I A
MeR_tI:ibIngR 1[I --, PIeIR!,...................... II_!_.'............. CI__!R ....... :, II1II1 PSRIAR[l!tI1| III!........
'! !' i;............. i"
,!,, IPAreMliVm PIG,D¢im BIAa_MVlir_,B_aIGsDi_liIAnBeA_d4lle1ndia n,_ IllI1
II,:1 1I11 PPre!l/iPm I_ IAPArte_ldimenda !III !I1I
!: I1 i i Crew BaPsVePline ,,_ II I!
I, I
!_TrainingDSiPlanningDS ,I ConfigDS :_ !I
I
1
II !I I, : 1l I, :I
Pha_ 0/I PMseII 1 t PhaseIII II
II:I1 "I1I! Safe_:!.R...vw Safet:l_Rvw [,l i!, SafetyRvw :!! +III--_
!:II [II :I ll, ll, : , !I
I1 I ' : Engineering _ 1I FIVT ! !II
I ,, [::Model Tests _,_: _,i O@n-D_ocskc i1
Figure 7 - Integration Template
milestones atop level integration template was
Payload Accommodations Handbook, IA blank
developed. The template, Figure 7, serves as the
book, IDD and the FCF GPVP.
starting point for development of a payload
unique integration schedule.
As the payload progresses through the design
phase, the FCF integration team, through the
Integration Manager, provides support to the
payload project at payload reviews to ensure
The integration schedule is the working
complete coverage of issues that affect the
agreement between the FCF integration team and
design or implementation of the carrier
the payload project team for delivery of
interfaces. This support includes the
products, hardware or data. The delivery dates
development of draft IAs, ICDs and PVPs.
on the schedule are closely tied to the delivery
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Finallyt,herearetwoFCFuniquereviewtshat
during the package development and during the
.:_. .... .
qP
"Simulators
"Component
•Ground Integration Unit
-Diagnostic •Engineering Design Unit •Final Verification •KSC Off-line Processing
•Trial Hardware •Engineering Model •Flight Unit •Final Flight Preparations
.Brassboard
"Breadboard
Figure 8 - FCF Ground Processing
are part of the integration template: Increment
presentation of the referenced phase. The FCF
Requirements Review and the increment
integration team collates all phase 3data
Acceptance Review. These reviews are in place packages into a single FCF submittal to the
to identify and assess compliance with all
PSRP. This package represents a picture of all
increment-unique requirements imposed on the FCF operational configurations and the
FCF by the payloads. The reviews are chaired
associated safety controls for those
•by the Increment Manager and require
configurations. The FCF integration team then
participation by the payload projects that have
presents this integrated assessment to the panel
payloads operating within the FCF for the given
with the payload projects' support.
increment.
Gro,___dn_Processi_n_g
Sofe_ Proce__:
The payload ground processing for FCF consists
The payload safety process closely follows the
of four phases as discussed in the following text
process in place by the Payload Safety Review
and shown graphically in Figure 8.
Panel (PSRP).
he first ground processing phases begins early on
in the payload development and may continue
The payload project has complete responsibility
through early flight hardware development
for compliance of their payload with all safety
depending on the payloads needs. In this phase a
requirements enforced by the ISS Program. The suite of FCF simulators ismade available to the
FCF imposes no additional requirements on the payload project team. The simulators include
payload. Development of the safety data science diagnostics or FCF rack simulators. The
packages and safety specific verifications are the payload project can use these simulators to test
responsibility of the payload project.
scientific phenomena measurement capabilities
Additionally, the payload project team is
or to test payload equipment operation with FCF
responsible for presentation to the PSRP ofthe
supplied resources such as power or cooling.
phase 0,1,and 2payload safety data packages.
The FCF integration team acts in a support role
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The second ground processing phase consists of as closure for many of the items in the PVP.
testing the payload engineering model or in some This isthe only ground processing phase which
cases the flight unit in an FCF rack Experiment all payloads must complete.
Development Unit (EDU). The EDU provides a
functional equivalent of the FCF rack but does The fourth and f'mal phase consists of the
not contain flight interfaces. The EDU ismade payload processing at the Kennedy Space Center
available to the payload during the payload (KSC). Because there will not be a FCF
engineering model test phase. This early system simulator at KSC, this is not anticipated to be an
test availability allows the payload project time extensive test phase to avoid nullifying
to make any corrections or modifications prior to verifications performed at GRC. It is understood
proceeding with flight unit fabrication. that some payloads may require abrief aliveness
test or maintenance of some consumables prior
The third phase of ground processing occurs to launch.
after the payload project has tumed over the
flight unit to the FCF integration team. This Oper_tio_n_s
phase is the payload final interface verification
testing and occurs in the FCF Ground Integration The operations process includes all
Unit (GIU) at GRC. The GIU is a flight documentation, hardware, and personnel support
equivalent unit and contains all interfaces that to assure that the FCF and its payloads operate as
are in the flight rack. These verifications serve planned. This process begins with flight and
!SS
Figure 9 - FCF Operations
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