GLAST Large Area Telescope: Integration and Test Two Tower Integration Readiness Review I&T Plan Ken Fouts / Brian G

1. Gamma-ray Large Area Space Telescope GLAST Large Area Telescope: Integration and Test Two Tower Integration Readiness Review I&T Plan Ken Fouts / Brian Grist

2. Two Tower Schedule

3. 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

4. Single Bay Integration and Test Flow TKR Module Post Ship Test CAL Module Post Ship Test TEM/TPS Module Post Ship Test LAT-PS-03287 LAT-PS-03290 On Bench TKR Module CPT CAL Module CPT TEM/TPS Module CPT LAT-TD-3415 LAT-PS-03290 LAT-PS-03287 LAT-PS-03062 CAL Module LPT TRK Module Install LAT-PS-03287 LAT-PS-03058 LAT-PS-03062 TKR Module LPT TEM/TPS EICIT/IVT LAT-PS-03290 In Metrology Bay LAT-PS-03875, 04097, 04098, 04099 Cal Module Install CAL Module CPT In Flight like Single bay LAT-PS-03287 LAT-PS-03027 Cal Module LPT LAT-PS-03287 TEM-TKR EICIT/IVT LAT-PS-03875, 04097 Single Bay CPT LAT-PS-03276

5. CALORIMITER INSTALLATION SEQUENCE Install CAL, TEM/TEMPS into Single Bay (TKR Previously installed) Receive CAL Tower Install CAL, TEM/TEMPS into Grid (TKR Previously installed) Remove CAL, TEM/TEMPS from Metrology Bay Mate TKR Connectors to TEM Invert Cal Tower using single Bay Remove CAL, TEM/TEMPS from Single Bay Mate TKR Connectors to TEM Invert Grid Test Demate TKR Flex Cables Final Test Install Cal into Metrology Bay Mate Connectors from TEM/TEMPS to CAL Invert Single Bay Legend Turnover Op Remove EM TEM/TEMPS (Demate Cal Connectors) Install and shim Flight TEM/TEMPS Invert Single Bay Test Lift Operation Manual Op Connector Mate/Demate

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

7. 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.

8. I&T Operations

9. I&T Organization

10. 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.

11. 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.

12. 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.

13. 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 and 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.

14. 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).

15. 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.

16. 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 7:00am-3:30pm and 3:00pm-11:30pm • Daily morning meeting at 7:00am • Half hour overlap will facilitate a daily “hand-off” meeting at 3:00pm. • Swing shift Test Conductor will hold an informal meeting at the end of the shift and complete the Shift Log. • Shift hand-off between 2nd shift and the following day will be accomplished via shift log. • Baseline plan is 2-8hr shifts/5 days a week. • Extended shifts and/or Saturdays will be used to maintain schedule as required.

17. 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 0700 Meeting Swing shift Day shift Day shift 1500 Meeting 1500 Meeting Swing shift Swing shift

18. I&T Test Roles and Responsibilities

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

20. 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.

21. Procedure Plan • Key Requirements • I&T Documentation Flow • I&T Procedure Development Process • I&T Standard Processes • Status • Configuration Management

22. Key I&T Requirement Documents Requirements Definition Key to Successful I&T

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

24. 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.

25. I&T Process Procedures Document Standard Processes for use in I&T

26. Configuration Management • I&T follows the project CM plan, LAT-MD-00068. • The figure on the right shows document flow through CM • The figure below from LAT-MD-00068 defines who is required to sign

27. Procedure Status • 61 documents total • 34 have been submitted for sign-off • 20 have been released

28. Procedure Status (1 of 6) - Management Green is complete

29. Procedure Status (2 of 6) - MGSE Green is complete

30. Procedure Status (3 of 6) – IFCT Electrical Green is complete

31. Procedure Status (4 of 6) – IFCT Mechanical Green is complete

32. Procedure Status (5 of 6) - Particle Green is complete

33. Procedure Status (5 of 6) - SVAC Green is complete

34. Procedure Status – Burndown Chart

35. Backup Charts

36. 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.

37. 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.

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