8-Conf Material No License-0088 Orbital Proprietary Presented at the 19 th Conference on Quality in...

8-Conf Material No License-0088

Orbital Proprietary

Presented at the 19th Conference on Quality in the Space and Defense IndustriesCarl Walz, Vice President, Human Spaceflight Operations

Commercial Resupply

Services for the ISS


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International Space Station Overview

• The International Space Station is the largest and most complex international scientific project in history. Led by the United States, the International Space Station draws upon the scientific and technological resources of 16 nations: Canada, Japan, Russia, 11 nations of the European Space Agency, and Brazil

• More than four times as large as the Russian Mir space station, the completed International Space Station will have a mass of about 472,000 kg. It will measure 356 feet across and 290 feet long, with almost an acre of solar panels to provide electrical power to six state-of-the-art laboratories.

• The station is in an orbit with an altitude of approximately 400 km with an inclination of 51.6 degrees. The orbit provides excellent Earth observations with coverage of 85 percent of the globe and over flight of 95 percent of the population.

• The ISS houses an international crew of 6.


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International Space Station Overview

• Initial resupply of the ISS was primarily accomplished by the Space Shuttle and the Russian Progress autonomous resupply vehicle.

• With the retirement of the Space Shuttle, additional international partner resupply capabilities have

been developed and demonstrated. These vehicles include the Japanese HTV and the ESA ATV.

• Resupply items include water, air, food, clothing, general operational supplies, spare parts, and scientific payload items

• Service also includes carrying away trash and other non-serviceable items for disposal during Cygnus destructive reentry

• Missions purchased on a per-mission basis, regardless of amount of cargo up and down


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Low Earth Orbit Transfer Operations

Drawing Upon Its 29 Years Of Satellite And Major Space Systems Development And Operations Experience, Orbital Sciences Corporation

Has Embarked On A New Venture To Provide Low Earth Orbit Cargo Transfer Services To NASA’s ISS Program

• Under the joint NASA / Orbital Commercial Orbital Transportation Services (COTS) program, Orbital is Developing the “Cygnus” Advanced Maneuvering Space Vehicle, Which is Designed to Meet the Stringent Safety Requirements for International Space Station (ISS) Operations.

• The Cygnus Spacecraft Will Provide Cargo Resupply to the ISS Program under the Cargo Resupply Services Contract


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• Commercial Orbital Transportation Services (COTS)

– Orbital Selected In February 2008 For a Single 2011 Demonstration Mission

– Safety Review Panel Phase 1 & II completed March/Nov 2009. Phase III in progress

– CDR completed March 2010– 20 of 24 Milestones

completed to date– Taurus Test Launch now

planned for summer 2011– COTS Demo Launch to ISS

Planned for 2011

• Commercial Resupply Services (CRS)

– Operational Service-Phase Follow-on to COTS Demonstration

– Orbital Selection December 2008

– 8 Flights Over Period From 2012-2015

– Have received Authority to Proceed for 3 missions

– First mission (Orb 1) planned for March 2012

COTS/CRS Summary


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Orbital COTS Systems Architecture

Taurus II

Cargo OperationsIntegrated Launch Site OperationsMission Operations

Orbital COTS System

Cygnus Visiting Vehicle

The Orbital COTS System is comprised of 5 Major Elements


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Cygnus Overview

• The Cygnus vehicle is comprised of two major modules

•Service Module

•Provides all utility services to the cargo modules

•Manages the autonomous rendezvous to the ISS

•Provides required resources to allow the mission to be successfully completed

•Structural interface to the launch vehicle and cargo modules

•Integrated at Orbital’s Dulles facility

•Pressurized Cargo Module

•Supports NASA Cargo Requiring a Pressurized Environment

•Built by Thales Alenia

Heritage: LEO Star/Star Bus

Power Generation : 3.5 kW DC Power

Propellant: Dual Mode N2H4/NTO or N2H4


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Cygnus General Cargo Capabilities

• Cygnus Pressurized Cargo Module (PCM) provides pressurized volume for internal cargo delivery to ISS

– Cygnus is berthed to ISS Node 2 Nadir Port utilizing the SSRMS

– Up to 2000Kg Cargo can be accommodated by the Standard PCM

– Up to 2700 kg Cargo can be accommodated by the Enhanced PCM

• Standardized Active and Passive cargo accommodations available within PCM

– Passive Cargo: Cargo Transfer Bags (CTB), M-bags, Mid-Deck Lockers (MDL)

– Active Cargo: Two single MDL or one Double MDL sized payloads

– Disposal Cargo reloaded into Cygnus prior to Unberthing


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Trash on ISS


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Flight PCM Development

•Alenia on Track for PCM Delivery in 2011•PCM Cargo Integration Demo Complete!


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Program Summary• Develop Delta II/Atlas III Class Launch Vehicle and Ground

System• Initial Contract for COTS-Demo Launch in 2011• Launch Vehicle for Commercial Resupply System

Program Goals• Minimize Development NRE • Minimize Recurring Costs -- Eliminated Strap-on Boosters• Minimize Launch Site Infrastructure – Use Horizontal

Integration/Clean Pad Concept• Design for High Reliability -- Use Heritage Components

Vehicle Parameters• Gross Liftoff Mass: 290,000 kg• Vehicle Length: 40 m• Vehicle Diameter: 3.9 m• Payload Fairing Diameter: 3.9 m• Options 3rd Stage Bipropellant Kit – Unavailable on First

Flights

3.9 m Fairing (Orbital)

CASTOR® 30Stage 2 Motor

(ATK)

3.9 m Propellant Tanks/ Stage 1 Core(Yuzhnoye)

Dual LO2/RP AJ26 Engines(Aerojet)

Taurus II Overview

Avionics (Orbital)


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Cygnus Mission Operations

Cygnus will be boosted into orbit by Orbital's Taurus II

medium-class space launch vehicle

• Cygnus mission operations will be managed from Orbital's state-of-the-art Mission Control Complex in Dulles, Virginia, in concert with NASA’s Johnson Space Center in Houston, Texas.

After being launched into low-Earth orbit by Taurus II, the Cygnus spacecraft has substantial maneuvering capability to transport it’s payload from a low parking orbit to the ISS or other LEO destination.

After the payload mission is complete, Cygnus is steered to a safe destructive reentry over the Pacific Ocean.


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Orbital Flight Control Team

• New MOC 4 has been designed with larger COTS/CRS team in mind

• Cygnus flight control team– Includes front (real-

time ops) and back room (engineering) functions

– New MOC will provide those rooms and connectivity between them

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COTS/CRS model consistent with Industry Standards


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Taurus II Wallops Footprint

H-100

Cargo

Processing

V-55

Payload

Fueling

HIF

Pad 0A

8.53 Miles

1.1 Miles

2.46 Miles


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COTS/CRS Top Level Launch Site Concept of Operations

Launch Pad

• Cygnus Fueling

• Cygnus Mate to Payload Adapter/ Sep System• Cargo Late Load Demonstration• Cygnus to LV Integration & Encapsulation

NASA

Cargo

TAS-I

Pressurized Cargo Module

Orbital

Taurus II

Launch Vehicle

V-55 Payload

Fueling Facility

Horizontal Integration Facility (HIF)

• P/L EGSE Vault • Roll-out and Erection• Launch Preparation and Launch

• SM Integrated System Test• PCM Checkout• Cargo Storage, Process and Load• SM-PCM Mate• Cygnus Integrated Test• Cygnus Mass Properties

H-100 Payload Processing FacilityOrbital

Service Module

Horizontal Integration Facility (HIF) Launch Pad


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Taurus II First Stage in HIF


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Taurus II Launch Pad at Wallops


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Cygnus Design Process “Bakes” In Success

• Strong recipe for success– Orbital’s strong systems engineering– Along with ISO and AS9100 Processes– Along with vigilant and independent Safety and Mission

Assurance

• Coupled with a highly involved customer – NASA– Expert insight through COTS and CRS programs– Independent Safety Review Panel required additional design

requirements above those required for non-human space missions

– Extensive verification activity to prove design works and is safe to complete mission successfully, and safely


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NASA Insight and Oversight for Cygnus and Taurus II

• Insight– Commercial Crew and Cargo Program Office

– International Space Station Program Office

– JSC Mission Operations Directorate

– NASA Launch Services Program

• Oversight– JSC Safety Review Panel


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Safety and Mission Assurance Approach on COTS/CRS

• Partnership with selected team members having strong experience in NASA human space missions

• Disciplined process for system requirements flowdown and verifications – supported by Cradle requirements management database

• Clear understanding of fault tolerant system designs and their implementation – supported by top-down system analyses and probabilistic risk assessment

• Strong interaction between S&MA, system engineering, and other engineering disciplines

• Firm baseline of proven design and process standards for flight hardware and software - refined during 29 years of successful NASA, DOD and commercial space programs

• Effective selection and control of critical suppliers

• High Technology Readiness Level Components

Safety and Mission Assurance approach to Orbital‘s Human Space missions emphasizes effective integration of system engineering disciplines, and mature and disciplined processes for design, procurement, production,

verification


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QMS and Continuous Improvement

• Orbital’s Quality Management System (QMS) is registered to ISO 9001:2000 and AS 9100

– Third party registration by the British Standards Institution– Implemented as a series of standard business practices– Mandatory employee training includes: business ethics; safety; risk

management; design and workmanship standards; etc.– Includes an internal audit system to monitor ISO and AS compliance– Overseen by a Continuous Improvement management team to improve and refine

our business procedures

• ISO 9001:2000 and AS9100 assessment was recently performed (November 2010) with no major findings

• Dulles and Chandler S&MA management are active NASA team members:

– Quality Leadership Forum– Joint Audit Planning Committee– Aerospace Space Quality Improvement Council


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Reliability Analysis Lab

Reliability Analysis Lab Capabilities

Part and material qualification/ acceptance

• Particle impact nose detection (PIND)

• Prohibited material screen

• Destructive Physical analysis (DPA)

• Material properties

• PCB coupon exam

• Part functional verification

• Life test

Failure investigation

• Dynamic and static X-ray

• Destructive examinations

• Failure simulations

IR&D / process qualifications

• Coupon preparation and testing

• Material properties and stress tests


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S&MA Institutional Practices

• Electrical, Electronic, Electromagnetic (EEE) parts– Selection from NASA EEE-INST-0002 and Orbital Preferred Parts List (PPL)– Compatibility with mission Total Dose and Single Event radiation requirements verified by

test data – Traceability maintained to lot date code and/or serial number

• Materials selected from heritage programs and for verified compatibility with space environment

– Vacuum stability, flammability, toxicity– Resistance to stress corrosion cracking– Cadmium, zinc and pure tin plating strictly prohibited – verified by lot sample inspection

• Process and workmanship standards based on high reliability NASA, MIL and industry standards

– NASA-STD-8739 series for soldering, wiring, bonding– PWB design and fabrication to IPC standards– Strict ESD and FOD controls, with 100% training by engineering, assembly, test and quality

personnel


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Supplier Assurance & Control

• Strong supplier achieved through:– Capability and Quality Surveys performed by a Cross-Functional Team– Benchmarking our Supplier requirements with other top Aerospace

Contractors– Use of a Suppler Rating System, providing monthly reporting of quality and

delivery performance, as well as responsiveness to any Supplier Corrective Action Requests

– Managing, monitoring, and reporting to Orbital management the impact of supplier changes affecting facilities, management or processes

– Reducing the Supplier Database for reduced risk and improved efficiencies

• Certified Supplier Program – Identifies top rated suppliers through past performance– Designates supplier’s Quality Representative with authority to accept Orbital

product– Orbital oversight maintained through mandatory inspection points (MIP) and

metric reporting

Strong performance from our team members and suppliers is absolutely critical to success of our

Space programs


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Manufacturing, Integration, Test

• All flight hardware builds are to approved and CM released documentation– Assembly drawings and parts lists, with approved ECNs– Detailed work instructions

• Hardware identification, traceability, history– End Item Data Package (EIDP) provides configuration, traceability,

nonconformance and accptance results at all levels of assembly

• Receiving, in-process and final inspection/test points are clearly identified at all levels, and performed to documented and approved procedures

• Material Review Board (MRB) implemented for manufacturing anomalies, with participation of flight assurance, engineering and program management

• Failure Review Board (FRB)– Conducted for all failure after start of function testing – Chaired by program Flight Assurance Manager, with engineering, systems, I&T

and program participation


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COTS/CRS Safety Implementation Process

• Cygnus safety requirements defined in the COTS Interface Requirements Document (IRD), with specific requirements for control of Catastrophic and Critical hazards

– Has been overriding consideration in Cygnus design trades, from inception of the program– Redundancy in critical hardware functions

• Follows “phased” safety review process with JSC/ISS Safety Review Panel (SRP)

• First Review (Phase I) conducted in February 2009, with 80% of the SRP’s attention directed to the Cygnus “Collision” hazard report

• Cygnus Phase II safety review (for detailed design phase) was successfully

completed in November 2009

• Follow-on reviews have been held to brief the SRP on design updates and testing issues

• Next SRP milestone is the submittal of the Phase III data package summer 2011


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Thank You!

8-Conf Material No License-0088 Orbital Proprietary Presented at the 19 th Conference on Quality in...

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