april 19, 2012 acme monthly status april 2012 mark hickman, project manager dennis stocker, project...
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April 19, 20121
ACME Monthly StatusApril 2012
Mark Hickman, Project Manager
Dennis Stocker, Project Scientist
Brian Borowski, Project Contractor Lead
April 19, 2012
Advanced Combustion via Microgravity Experiments (ACME)GRC Project Manager: MSI/J. Mark HickmanProject Chief Engineer: DT0/Alan LinneSafety Mission Assurance Lead: QE0/Bipin PatelDPMI: Brian Quigley/MB0; Scheduler: Paul McMasters/QinetiQContractor Lead: Brian Borowski, ZIN Technologies, Inc.NASA Customer: HEOMD
Project Mission Statement:• Investigate gaseous fuel combustion by studying:
– combustion structure and stability near flammability limits – soot inception, surface growth, and oxidation processes– emission reduction through nitrogen exchange– combustion stability enhancements via an electric field– ignition and flammability of solid spacecraft materials in
realistic atmospheric conditions using a gas analog
GRC Scope:• Requirements, Design, Development, Test, Evaluation, and Operations for Project
Project Life Cycle ScheduleMilestones SCR RDR PDR IDR CDR Safety (PH-3) SAR
(PSR)FHA Launch Ops End Ops Final
Report
Actual/ Baseline 2/2008 5/2010 01/2011 6/2012 9/2013 12/2015 8/2015 8/2015 12/2015 1/2016 11/2017 11/2018
The Combustion Integrated Rack. ACME Chamber Insert Assembly Concept.
2
Structure and Response of Spherical Diffusion Flames (s-Flame), PI: Prof. C. K. Law, Princeton U.; Co-Is: Prof. Stephen Tse, Rutgers U.; Dr. Kurt Sacksteder, NASA GRC
Flame Design, PI: Prof. Richard Axelbaum, Washington U., St. Louis; Co-Is: Prof. Beei-Huan Chao, U. Hawaii; Prof. Peter Sunderland, U. Maryland; Dr. David Urban, NASA GRC
Coflow Laminar Diffusion Flame (CLD Flame), PI: Prof. Marshall Long, Yale U.; Co-I: Prof. Mitchell Smooke, Yale U.
Electric-Field Effects on Laminar Diffusion Flames (E-FIELD Flames), PI: Prof. Derek Dunn-Rankin, UC Irvine; Co-Is: Prof. Felix Weinberg, Imperial College, London; Dr. Zeng-Guang Yuan, NCSER/GRC
Burning Rate Emulator (BRE), PI: Prof. James Quintiere, University of Maryland; Co-Is: Peter Sunderland, U. of Maryland
Project Scientists: Dennis Stocker, NASA GRC; Dr. Fumiaki Takahashi, NCSER/GRC; Paul Ferkul, NCSER/GRC
s-Flame(drop test)
E-FIELD Flames
(1g schlieren)
Flame Design
(drop test)
CLD Flame(aircraft test)
BRE(1g test)
April 19, 2012
ACME within the CIR Utilization Plan
3
April 19, 2012
ACME Status
Project Manager: Mark Hickman Status
Variances• ZIN costing is a bit low; however purchases ordered in March should be costed in the next weeks for Avionics
Package hardware, as well as the Igniter and E-Field Subsystems• Procurement of the Data Cube Subsystem, Mass Flow Controller/Flow System, and the Color Camera Enclosure
Assembly will be ordered in the next months• ZIN ACME team now fully staffed
Cost Schedule Technical Mgmt.
Apr 2012 Y G G GMar 2012 Y G G G
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Key Issue/Concern Potential Impact Action Plan Resolution Date
Data transfer rates from IPSU to IOP too slow for data files
May reduce obtainable science or extend on-orbit time to years
Request FCF Sustaining Engineering to investigate methods of improving data transfer rates
Request made to FCF Mgr. for inclusion in DO-101 Sustaining Engineering SOW; full resolution likely in FY11. Ops changes by FCF have improved average transfer rates a bit, to1.15 MB/s, a 28% improvement. Improvement to 1.80 MB/sec not realized as IOP-HP upgrade implementation results in rack lock-up.
Getting BRE up to speed quickly enough that the design is not negatively impacted
May have to do some redesign to ACME
Working with BRE PS to get requirements in as early as possible.
SCR, Aug 28, 2012 (tentative)
Contractor staffing levels may be difficult to maintain
The pace of the contracted work could slow
Continue to monitor progress and staffing levels
September 2012
4
April 19, 2012
ACME Key Project Metrics WBS 904211.04.02.30.14
5
• Accomplishments• Staffing
• ZIN staffing now complete for design• Avionics Package (AVP)
• 43 drawings completed as of January and under configuration management• Hard Drive Assembly drawings 100% complete• Card Cage Assembly drawings to be completed May 2012• AVP Housing Assembly drawings to be completed May 2012
• Framework drawings through review and are ready for release• Final tolerance stack-up for Hard Drive design in process• Power Board Heatsink complete and undergoing final updates before
engineering review • Chamber Insert Assembly (CIA)
• 85 drawings completed as of January and under configuration management• Cube drawings 100% complete
• EM Igniter Assembly build complete• EM Igniter Test Plan in review cycle• E-Field Power Supply assembly completed and drawings into CM• E-Field Mesh brazing fixture designed• Radiometer boards received
• Color Camera Package (CCP)• Camera Enclosure Drawings 90% complete; scheduled to be completed May
2012• Redesigning the motor mounts on the Zoom Lens• Determining if the camera assembly can be made an ORU
• Other• Completed Phase 0/1 Flight Safety Review, February 2012• Holding BRE requirements meetings in preparation for SCR, Aug 28, 2012
April 19, 2012
ACME FY12 Milestone Summary
Next Milestone Risk• Next major milestone is Interim Design Review, June 2012. This will be prior to major Engineering Model hardware
build efforts and an independent check on technical progress to date.
Milestones (FY12) Baseline Projected Actual Comments/Schedule Variance
Phase 0/1 Safety Review Nov 2011 Feb 2012
Ignition subsystem build complete Dec 2011 Jan 2012
Stereo-Lith of 3 main subsystem packages (CIA, Camera, Avionics)
Jan 2012 Feb 2012 Vendor quote process taking longer than expected for all purchases
Complete Assembly of E-Field subsystem Feb 2012 May 2012 Awaiting epoxy arrival and some fixtures required to complete mesh assembly. Completion 5/21/12.
BRE Interface Requirements Document Feb 2012 Jan 2012 Draft document completed
Procurement of EM Mass Flow Controllers Mar 2012 Mar 2012
Preliminary EMI testing of E-Field subsystem
Apr 2012 Jun 2012 EMI Test scheduled for June 1, 2012.
Ignition subsystem test complete Apr 2012 Apr 2012
Card Cage Assembly Drawings complete May 2012 May 2012
Interim Design Review Jun 2012 Jun 2012 Scheduled for June 15, 2012
Avionics package structure design complete
Aug 2012 Aug 2012
BRE SCR Aug 2012 Aug 2012 Tentatively scheduled for Aug 28, 2012
Flow subsystem build complete Sep 2012 Sep 2012
Project is less than 1 month behind plan Project is less than 2 months behind plan Project is greater than 2 months behind plan
Schedule Color Key
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6
April 19, 2012
ACME Monthly Schedule Progress (ZIN)
7
April 19, 2012
Project Manager’s Top Challenges
1. Integration of BRE into ACME may be difficult and the timing may be problematic (BRE SCR tentatively scheduled for August 28)
2. 63% of materials budget obligated through 20% of contract period of performance (Feb 2013• ZIN directed to slow down purchases of flight hardware and focus on EM hardware
• Will likely slow progress
• Alternative would be to find $100-150K for additional purchases
• Does not impact workforce funding
3. Technical, cost, and schedule integration of BRE into ACME; funding liens created for next 2-3 years (mitigated by infusion of funds; reflected as Over Guideline in PPBE-14)
4. Insufficient on-orbit transfer rates to quickly telemeter data to ground (performed telemetry analysis to determine data volume and rates; however rates still determined to be insufficient)
5. Large number of Test Points to accomplish over mission life—approximately 250 test points for 5 experiments
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8
Prosilica Camera, Color Camera Package
(outside Chamber)Hitachi Analog Camera, Operations Imaging
(inside Chamber)
April 19, 2012
ACME Risk Assessment (Top 5 Risks)
LIKELIHOOD
5 014
4 021
3 010
2 008
1 003 017
1 2 3 4 5
CONSEQUENCES
Criticality L x C Trend
High Increasing (Worsening)
Decreasing (Improving)
Unchanged
(★) New since last month
Med
Low
Approaches: Mitigate, Watch, Accept, Research
Last update 04/02/12
WBS 904211.04.02.30.14
Risk ID Risk Title Risk Statement L C Approach
ACME014
O’Toole12/2010
IPSU to IOP image transfer rate
Given that the current data transfer rates from the IPSU to the IOP is severely limited, transfer of ACME data may take an unacceptable amount of time and may reduce obtainable science for the allotted operational time on-board ISS.
5 3 Mitigate: FCF Sustaining Engineering will investigate methods of improving data transfer rates.Close: Dec 2012
ACME010
Beltram06/2010
CIA electronics and fuel mixture compatibility
Given that the CIA electronics are exposed to chamber atmosphere; then there may be incompatibility with elements of the chamber atmosphere including fuels, oxygen and diluent mixtures causing the cube to fail.
3 5 Research: Develop a test plan to determine what components and what surface treatments would mitigate this risk.Close: Dec 2012
ACME021
Beltram04/2012
Inability to disassemble Mass Flow Controllers for Conformal Coat / Ruggedizing
The assembly of the Mass Flow Controllers makes it such that they cannot be fully taken apart in order to access the boards and perform conformal coat / staking. Additionally, the boards use "no clean" flux, which means they cannot be properly cleaned to allow for conformal coating to occur.
4 2 Pending
ACME008
Gobeli12/2009
E-field emission exceedences
Given that there might be e-field exceedence emissions; then there is the possibility that the EMI requirement will not be met and ACME hardware would be adversely effected causing diminished science to occur.
2 3 Mitigate: Test integrated system bread board for EMI interference.Close: April 2012June 2012, delayed to accommodate EMI testing
ACME017
Rogers8/2011
Lack of adequate ISS supplied Nitrogen
Given that it is not known how much ISS Nitrogen can be supplied and re-supplied for use by the CIR for ACME; then there is the possibility that Nitrogen will not be available for ACME and a loss of science will occur.
1 3 Watch: Awaiting the test point matrix to be developed to get a better estimate of required nitrogen.Close: Dec 2012
9
★
April 19, 201210
ACME Key Project Metrics — FY11
Released Drawings Measure of Performance
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• Drawings come in batches. Additional CIA drawings should be entered into Configuration Management by the end of the Month.• AVP drawings ahead of schedule due to additional designer.• With addition of third mechanical designer, work on Color Camera Package will begin early and in parallel to other work instead of in series.
Sep-07 Dec-07 Mar-08 Jun-08 Sep-08 Dec-08 Mar-09 Jun-09 Sep-09 Dec-09 Mar-100
50
100
150
200
250
300
350
CIA PlanCam Package PlanAVP PlanCIA ActualsAVP Actuals
April 19, 2012
Backup Charts
11
11
E-Field Power Supply
Cooling Plate
Thin Fiber Pyrometry (TFP) Motor
Motor Drivers
Burner
Far Field TCs
Mass Flow Controllers
Input ManifoldAnalog Camera
Cube
E-Field Mesh
PMTs
Igniter Motor
Igniter notes – The model shows the igniter armIn both deployed and stowed positions, and shows
the igniter tip in two different places
April 19, 2012
ACME Detectors WBS 904211.04.02.30.14
12
Hamamatsu Photomultiplier Tube
Dexter Thermopile Detector,Radiometer with Board
April 19, 2012
ACME Igniter Assembly WBS 904211.04.02.30.14
13
Breadboard Igniter Arm Assembly
April 19, 2012
ACME Camera Assembly WBS 904211.04.02.30.14
14
Digital Camera
Zoom Lens
Filter Barrel
Mirror
Camera Control Assembly
April 19, 201215
Advanced Combustion via Microgravity Experiments (ACME) WBS: 904211.04.02.30.14
Project Life Cycle Schedule
ISS Resource RequirementsObjective:• Modular apparatus designed for gaseous fuel investigations, studying:
– combustion structure and stability near flammability limits – soot inception, surface growth, and oxidation processes– emission reduction through nitrogen exchange– combustion stability enhancements via an electric field
Relevance/Impact:• 85% of delivered energy comes from combustion. ACME tests will enable improved carbon
sequestration and pollution control with “Important consequences for energy conversion, pollutant formation, fire safety, and green house gas emission”
• Verified computational models that will enable the design of high efficiency, low emission combustors operating at near-limit conditions
• Reduced design costs due to improved capabilities to numerically simulate combustion processes• “Great prospects of improving our understanding of nearly every practical combustion device.”
Development Approach:• Flight design leverages off the MDCA flight design• Multi-user, re-usable apparatus within CIR minimizing up-mass/volume, costs, and crew involvement• ACME fuels will be dilutions of ethylene/nitrogen, methane/nitrogen and methane/hydrogen
Structure and Response of Spherical Diffusion Flames (s-Flame), PI: Prof. C. K. Law, Princeton University; Co-Is: Prof. Stephen Tse, Rutgers U.; Dr. Kurt Sacksteder, NASA GRC
Flame Design, PI: Prof. Richard Axelbaum, Washington University, St. LouisCo-Is: Prof. Beei-Huan Chao, U. Hawaii; Prof. Peter Sunderland, U. Maryland; Dr. David Urban,
NASA GRCCoflow Laminar Diffusion Flame (CLD Flame), PI: Prof. Marshall Long, Yale University
Co-I: Prof. Mitchell Smooke, Yale UniversityElectric-Field Effects on Laminar Diffusion Flames (E-FIELD Flames), PI: Prof. Derek
Dunn-Rankin, UC IrvineCo-Is: Prof. Felix Weinberg, Imperial College, London; Dr. Zeng-Guang Yuan, NCSER/GRC
Burning Rate Emulator (BRE), PI: Prof. James Quintiere, University of Maryland; Co-Is: Peter Sunderland, U. of Maryland
PS’s: Dennis Stocker, NASA GRC; Dr. Fumiaki Takahashi, NCSER/GRCPM: Mark Hickman, NASA GRCEngineering Team: ZIN Technologies, Inc.
Accommodation (carrier) CIR
Upmass (kg)(w/o packing factor)
250 kg
Volume (m3)(w/o packing factor)
0.50 m3
Power (kw)(peak)
0.75 Kw
Crew Time (hrs)- Initial configuration of CIR Rack- Change-outs during experiment
8 hrs
8 hrs
Autonomous Ops (hrs) 200 hrs
Launch/Increment TBD/Inc. 49-54
s-Flame(drop test)
E-FIELD Flames
(1g schlieren)
Flame Design
(drop test)
CLD Flame(aircraft test)
Website: spaceflightsystems.grc.nasa.gov/Advanced/ISSResearch/Investigations/ACME
Milestones SCR RDR/SDR PDR CDR Safety (PH-3) SAR (PSR) FHA Launch Ops End Ops Final Report
Actual/ Baseline 2/2008 5/2010 01/2011 2/2014 12/2015 6/2016 6/2016 10/2016 1/2017 4/2018 4/2019
April 19, 2012
ACME Science Team Locations
16
1. C.K. Law, Princeton University
2. Stephen Tse, Rutgers University
3. Richard Axelbaum, Washington University, St. Louis
4. Beei-Huan Chao, University of Hawaii
5. James Quintiere, Peter Sunderland, University of Maryland
6. Marshall Long, Mitchell Smooke, Yale University
7. Derek Dunn-Rankin, UC Irvine
8. Felix Weinberg, Imperial College, London
9. Zeng-Guan Yuan, NCSER, Kurt Sacksteder, GRC, David Urban, GRC
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