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BARREL System-Level Integration and Test Plan BARREL ITP-101 of 11

PRIOR TO USE, PLEASE CHECK THE BARREL MASTER DOCUMENT LIST AT http://www.dartmouth.edu/~barrel/documents.html TO VERIFY THIS IS THE CORRECT VERSION

SUBORBITAL AND SPECIAL ORBITAL PROJECTS DIRECTORATE

BARREL System-Level Integration and Test Plan

Revision: Initial Release

Effective date: March 25, 2011

National Aeronautics and Goddard Space Flight Center

Space Administration Wallops Flight Facility Wallops Island, Virginia



BARREL System-Level Integration and Test Plan Prepared By: ______________________________________________ March 22, 2011 Robyn Millan, Dartmouth College, Principal Investigator Date Concurrence: ___________________________________________ March 23, 2011 Linda Thompson, BARREL Project Manager Date ___________________________________________ March 23, 2011 David Smith, U. C. Santa Cruz, Co-Investigator Date ___________________________________________ March 23, 2011 Michael McCarthy, University of Washington, Co-Investigator Date ___________________________________________ March 23, 2011 John Sample, U. C. Berkeley, Co-Investigator Date ___________________________________________ March 25, 2011 David McGaw , Dartmouth College, System Engineer Date



CHANGE HISTORY LOG

REVISION CHANGE DESCRIPTION/PAGES EFFECTED DATE APPROVAL

BARREL System-Level Integration and Test Plan BARREL ITP-101

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TABLE OF CONTENTS TABLE OF CONTENTS ................................................................................................................................... 4 1. PURPOSE ...................................................................................................................................................... 5 2. ACRONYMS ............................................................................................................................................... 5 3. APPLICABLE DOCUMENTS .................................................................................................................. 5 4. REQUIREMENTS ..................................................................................................................................... 5 5. INTEGRATION FLOW ............................................................................................................................ 6 6. FACILITIES ............................................................................................................................................... 8 6.1 DARTMOUTH COLLEGE ............................................................................................................................. 8 6.2 COLUMBIA SCIENTIFIC BALLOON FACILITY ......................................................................................... 8 7. GROUND STATION EQUIPMENT ........................................................................................................ 9 7.1 LOCAL GROUND STATION ......................................................................................................................... 9 7.2 BARREL MISSION OPERATIONS CENTER ................................................................................................. 9 8. SUBSYSTEM TESTING PRIOR TO INTEGRATION ......................................................................... 9 8.1 PRIOR TO DELIVERY TO DARTMOUTH .................................................................................................... 9 8.2 ACCEPTANCE TESTING .............................................................................................................................. 9 9. SYSTEM LEVEL TESTS ........................................................................................................................ 10 9.1 FUNCTIONAL TESTING ............................................................................................................................. 10 9.2 COMPREHENSIVE PERFORMANCE TEST .............................................................................................. 10 9.3 SYSTEM LEVEL ENVIRONMENTAL TESTING ......................................................................................... 10 9.4 INTEGRATION AND TESTING IN ANTARCTICA ...................................................................................... 10 10. DOCUMENTATION AND REPORTING ........................................................................................... 10 10.1 PAYLOAD CONFIGURATION CONTROL ............................................................................................... 10 10.2 TRACKING AND LOGGING NOMINAL TEST OPERATIONS ................................................................ 11 10.3 ANOMALIES .............................................................................................................................................. 11


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1. Purpose The Integration and Test (I&T) plan for the Balloon Array for RBSP Relativistic Electron Losses (BARREL) outlines the sequence of integration tasks and testing necessary for verifying and validating the BARREL subsystems and system performance. The I&T tasks begin when the BARREL subsystem components arrive at Dartmouth College for integration. Testing continues through the final test prior to declaring flight readiness at the launch site.

2. Acronyms ADP Acceptance Data Package BARREL Balloon Array for RBSP Relativistic Electron Losses BPO Balloon Program Office CSBF Columbia Scientific Balloon Facility CPT Comprehensive Performance Test CVP Component Verification Plan FPRD Functional/Performance Requirements Document GSE Ground Support Equipment GSFC Goddard Space Flight Center I&T Integration and Test MOC Mission Operations Center NASA National Aeronautics and Space Administration PDL Product Design Lead PI Principal Investigator PFR Problem Failure Report

3. Applicable documents BARREL PP-101 BARREL Project Plan BARREL CVP-101 BARREL Component Verification Plan BARREL FPRD-101 BARREL Functional/Performance

Requirements Document BARREL VTM-101 BARREL Verification Test Matrix BARREL VPT-102 BARREL Comprehensive Performance Test BARREL SSD-110 BARREL Control Center Specification

Document

4. Requirements I&T requirements as derived from BARREL FPRD-101 are shown below. SYS-58 Thermal testing in the flight environment shall be carried out to verify the

payload design. 58.1 Thermal testing shall be carried out at the subsystem level for all applicable components as described in the CVP. 58.2 Thermal-vacuum testing shall be carried out on a subset of payloads


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to verify the functionality of the system in the flight environment. SYS-61 The function of each payload shall be verified and validated as described in V&V matrix prior to shipment for launch. SYS-62 Subsystem testing shall be performed prior to integration of each payload.

62.1 Subsystem functional testing shall be carried out by each subsystem PDL prior to delivery to Dartmouth.

62.2 Subsystem test results shall be documented and delivered with the hardware in an ADP.

62.3 An acceptance test shall be carried out on each subsystem at Dartmouth prior to integration.

SYS-63 An end-to-end comprehensive performance test shall be performed. SYS-64 At the conclusion of the verification program, the payloads shall have demonstrated minimum reliability by trouble-free performance testing for at least 48 hours. SYS-65 A burn-in test shall be carried out on one payload for a minimum duration of 10

days.

5. Integration Flow The integration flow for a single BARREL payload is shown in Figure 1. Upon receipt at Dartmouth, each subsystem undergoes an acceptance test to verify functionality after transport. Components are then placed in ESD-safe bags and shelved for later use. Prior to integration, subsystem components will be selected and the serial numbers recorded. An identifying tag (e.g., a colored sticker that is payload-specific) will be attached to each component to facilitate easy identification. A pre-integration checklist will be completed to verify that subsystem level testing is completed, and documentation is in place. The DPU, DC/DC converter box, modem, charge controller, magnetometer electronics, and X-ray detector are then assembled onto the payload central mechanical structure. After testing of the central structure (payload without solar panels), cables are routed and temperature sensors attached. The solar panels and magnetometer boom are then mounted, the payload is moved outside, and the flight train is attached. A Comprehensive Performance Test (CPT) is conducted in full sun. Finally, the payload is balanced, solar panels removed, and an indoor burn-in test conducted on the payload (without solar panels). After successful completion, the payload is packed and moved to storage. One payload will be integrated first as a “pathfinder”. After successful integration of the pathfinder payload, payloads will generally be integrated in pairs. During burn-in (while payloads are running autonomously on the bench), the integration of two more payloads can begin. See Figure 2.


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Figure 1: I&T Flow for Single Payload

Figure 2: I&T Flow for Group of Five Payloads


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6. Facilities

6.1 Dartmouth College The bulk of I&T activities will be carried out in Room 337 of Wilder Laboratory at Dartmouth College. Semi-permanent test stations will be set-up to allow for an assembly-line approach (Figure 3). These include stations for each acceptance test, payload central structure I&T area, GSE, assembly/packing area, burn-in bench.

Figure 3: BARREL Integration and Test Lab Storage will include a shed behind Wilder Lab which is not environmentally controlled (for empty payload boxes and materials) and an off-site Dartmouth-owned location (for payloads) that is environmentally controlled and is located at Centerra Plaza in Lebanon, NH approximately five miles from campus

6.2 Columbia Scientific Balloon Facility Thermal-vacuum testing will be carried out in the BEMCO chamber at CSBF. Up to four payloads may undergo thermal-vac simultaneously in this chamber.


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7. Ground Station Equipment

7.1 Local Ground Station A local ground station capable of supporting at least two payloads shall be set up at Dartmouth for initial I&T. Ground station equipment consists of a laptop computer running Windows XP with the current version of the GSE software installed, two Iridium modems configured for ground use, and antennas mounted to the roof with sufficiently clear view of the sky. The GSE software is also capable of communicating directly with the flight DPU via RS-232 serial link.

7.2 BARREL Mission Operations Center The BARREL MOC is located in Santa Cruz, CA and described in BARREL SSD-110. The MOC will be used for Comprehensive Performance Testing of each integrated payload.

8. Subsystem Testing Prior to Integration

8.1 Prior to Delivery to Dartmouth An overview of testing at the subsystem level is described in the Component Verification Plan BARREL CVP-101. Test procedures conducted at the subsystem level are

Document Number Document Title BARREL FTP-101 BARREL X-ray Detector and DPU Test Procedure BARREL FTP-102 BARREL DC Mag Calibration and Thermal Test Procedure BARREL FTP-103 BARREL Iridium Flight modem Functional and Thermal Test BARREL FTP-104 BARREL Power System Functional and Thermal Test Proc. BARREL FTP-105 BARREL Engineering Data Interface Functional Test Proc. BARREL FTP-106 BARREL Terminate System Functional and Thermal Test BARREL FTP-107 BARREL Harness Test Procedure BARREL FTP-108 BARREL Control Center Functional Test Procedure

8.2 Acceptance Testing Once the subsystems have arrived at Dartmouth College and they have been accepted with their ADP by the project, limited functional tests will be performed:

Document Number Document Title BARREL FTP-109 BARREL X-ray Detector Acceptance Test Procedure BARREL FTP-110 BARREL Data Processing Unit Acceptance Test Procedure BARREL FTP-111 BARREL DC Magnetometer Acceptance Test Procedure BARREL FTP-112 BARREL Iridium Flight Modem Acceptance Test Procedure BARREL FTP-113 BARREL Charge Controller Acceptance Test Procedure BARREL FTP-114 BARREL DC/DC Converter Box Acceptance Test Procedure


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9. System Level Tests

9.1 Functional Testing The Payload Integration Procedure (BARREL VTP-101) will include steps necessary to verify functionality of each subsystem while active and interfacing with the BARREL payload. The MOC and its supporting software shall also be verified in conjunction with all phases of the BARREL testing.

9.2 Comprehensive Performance Test Comprehensive performance testing will verify and validate the interaction of subsystems, and the overall performance of the BARREL payload. The Comprehensive Performance Test (BARREL VTP-102) will be carried out at the completion of subsystem testing at Dartmouth and again prior to declaring flight-ready in the field.

9.3 System Level Environmental Testing Thermal-vacuum testing will be carried out on a subset of BARREL payloads as described in the following documents. BARREL TTP-101 BARREL Thermal Vacuum Test Plan BARREL VTP-103 BARREL Thermal/Vacuum Test Procedure

9.4 Integration and Testing in Antarctica BARREL payloads will be shipped fully integrated with the exception of the scintillator and solar panels which must be attached in the field. The BARREL Launch Operations Procedures (BARREL OPS-102) includes procedures for final payload checkout and assembly to be carried out prior to conducting the CPT (hang test), and a pre-launch payload checklist.

10. Documentation and Reporting

10.1 Payload Configuration Control Each payload will have a designated traveler binder that travels with the payload at all times. The binder should be easily identified, for example with labels for Payload ID and color-coding. The traveler will also include a list of subsystems, identified by serial number, that are currently integrated onto the payload. A revision page shall be included to track any change of subsystem components used. Colored stickers will be used on all subsystems and the payload structure for quick identification of subsystems belonging to a particular payload.


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10.2 Tracking and Logging Nominal Test Operations Test results will be recorded electronically and a hardcopy will also be placed in the traveler for each payload. A logbook will also be included with each traveler to document test events, with a time notation for each entry. Run-time and payload configuration should be recorded any time the payload is operating.

10.3 Anomalies An anomaly is any non-nominal or unexpected result that occurs. All anomalies that occur during I&T shall be initially noted in the payload logbook. The symptoms, time of event, and description of the test setup should be included. A problem/failure report (PFR) shall be filled out for all anomalies that are not immediately resolved (e.g. because of operator error or incorrect test set-up). The PFR will be stored electronically and a hardcopy placed in the payload traveler binder.

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