GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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LAT Planning MeetingLAT Planning Meeting

Mechanical/Thermal Systems

November 2004

Marc Campell

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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THE GRID IS HERE!THE GRID IS HERE!

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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MECH MilestonesMECH Milestones

Dates T

BR

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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LM ETCLM ETC

• Formal ETC from LM is in progress. This data has not been submitted by LM.

LM Lien Calculation

Step 1) Identify LM Budget

Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Total

Total PMCS Budget 113.8 118.3 100.6 118.3 112.4 136.1 124.2 124.2 130.1 53.4 0.0 0.0 1131.5

Est FTEs 4.2 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 2.1 0.0 0.0 43.3

Step 2) Calculate Cost of ETC Manpower

Est. ETC FTEs 18.0 18.0 18.0 12.0 12.0 8.0 6.0 6.0 4.0 1.0 1.0 1.0 105.0

Hours/Month 168 160 136 160 152 184 168 168 176 160 184 168 1984.0

Cost/Hour 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 1.9

Cost/Man-month 26.88 25.6 21.76 25.6 24.32 29.44 26.88 26.88 28.16 25.6 29.44 26.88 317.4

Cost of ETC FTEs 483.8 460.8 391.7 307.2 291.8 235.5 161.3 161.3 112.6 25.6 29.4 26.9 2688.0

Step 3) Calculate Delta

Cost of ETC FTEs 483.8 460.8 391.7 307.2 291.8 235.5 161.3 161.3 112.6 25.6 29.4 26.9 2688.0

Total PMCS Budget 113.8 118.3 100.6 118.3 112.4 136.1 124.2 124.2 130.1 53.4 0.0 0.0 1131.5

Delta 370.0 342.5 291.1 188.9 179.4 99.5 37.1 37.1 -17.5 -27.8 29.4 26.9 1556.5

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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LM RisksLM Risks

• Radiator– Timely headcount roll-off– First time use of bonding/assembly tool & procedures (No

full sized Dev hardware). MFG marching army costs– Radiator Assembly design doesn’t accommodate repairs– Handling risks – large, fragile hardware– Cost over runs in testing

• Fixture design (Acoustic)• Facility scheduling – competing with other LM priority

programs• Resolution of TCS anomalies during Thermal Balance

testing. Test marching army costs– Satisfactory replacement of key personnel

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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LM De-scope OptionsLM De-scope Options

• Radiator Vibe testing– Current plan

• 5-150 Hz low level sine sweep in 3 axes• 5-50 Hz sine sweep in 2 axes• 5-150 Hz low level sine sweep in 3 axes• Acoustic test• 5-150 Hz low level sine sweep in 3 axes (plan to

substitute - 6 dB acoustic run for this)

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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LM De-scope Options (cont)LM De-scope Options (cont)

• Radiator Vibe testing - De-scope options– Defer 5-150 Hz sine sweep until LAT level

• Perform twang and/or tap test of Radiator for model validation (first modes only)

– Delete 5-150 Hz sine sweep for post test signatures• Perform -6 dB Acoustic runs before & after P/Qual level

Acoustic test for pass/fail evaluation – Delete 5-50 Hz sine sweep

• Qual by analysis (LM is defining where there are inadequate margins for this)

• Interface potted inserts are tested by witness coupons that are bonded simultaneously on the sides of the Radiator panel during layup

– These actions carry low to moderate risk per J. Ku– Cost savings ~$160,000 (8 LM EM x .75 month)?

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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LM De-scope Options (cont)LM De-scope Options (cont)

• X-LAT Thermal Testing– Perform Thermal Cycle test in air instead of thermal

vacuum– This is primarily a workmanship test and there is low risk.– Violates MAR requirement for 4 Thermal Vacuum cycles.– Tom McCarthy indicated that 8 thermal cycles in air would

be acceptable to him.– Need to implement now to maximize savings (test

preparations are underway).– LM will investigate the feasibility of this change.– Cost Savings ~$50,000 (~1/2 of quoted cost)

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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Grid #2 Static Load Test To GoGrid #2 Static Load Test To Go

• SLT budget– Grid Box #2 Assy Operations $34,170– Design & Fab MGSE/fixtures $78,650– Test $180,000– Total $292,820

– Note: This test does not drive LAT schedule• Risks

– Test house not selected– If FE model doesn’t correlate then additional test cases will

be required– There is sufficient budget for these contingencies

• De-scope options– None. This test allows deletion of LAT Sine Vibe (LAT de-

scope).– The number of load cases required has been reduced.

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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BACK-UPBACK-UP

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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MECH ETCMECH ETCBCWS SLAC: Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 CumSLAC Labor 88.9 81.5 49.8 49.0 43.8 50.7 49.0 50.3 52.7 42.1 13.0 0.8 571.5SLAC Materials 37.3 221.5 9.8 155.3 94.6 113.3 12.1 12.1 12.7 5.2 0.0 0.0 530.0SLAC Travel 1.5 0.8 0.5 0.0 0.0 0.0 0.0 0.0 6.8 0.0 0.0 0.0 9.6SLAC Total BCWS 127.7 303.8 60.1 204.3 138.4 164.0 61.1 62.4 72.2 47.3 13.0 0.8 1,111.1

Adds:SLAC Labor (incl 40K MLI design) 10.0 10.0 10.0 10.0 10.0 39.0 51.5 140.5SLAC Materials (includes 40K MLI fab) 40.0 40.0SLAC Travel -6.8 6.8 0.0SLAC Total Adds 10.0 10.0 10.0 10.0 0.0 40.0 0.0 0.0 -6.8 10.0 39.0 58.3 180.5

Total with AddsSLAC Labor 98.9 91.5 59.8 59.0 43.8 50.7 49.0 50.3 52.7 52.1 52.0 52.3 712.1SLAC Materials 37.3 221.5 9.8 155.3 94.6 153.3 12.1 12.1 12.7 5.2 0.0 0.0 713.9SLAC Travel 1.5 0.8 0.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 6.8 9.6SLAC Total with Adds 137.7 313.8 70.1 214.3 138.4 204.0 61.1 62.4 65.4 57.3 52.0 59.1 1,435.6

BCWS LM:LM Materials 97.2 102.5 87.2 102.5 97.4 117.9 107.6 107.6 112.8 46.3 0.0 0.0 979.1

Adds (Materials):LM Phase II increase (FY05 portion) 0.0LM rate increase 24.0 24.0LM delay 370.0 342.5 291.1 188.9 179.4 99.5 37.1 37.1 -17.5 -27.8 29.4 26.9 1,556.5LM Total Adds 394.0 342.5 291.1 188.9 179.4 99.5 37.1 37.1 -17.5 -27.8 29.4 26.9 1,580.5

LM Total with Adds 491.2 445.0 378.3 291.4 276.8 217.4 144.7 144.7 95.3 18.5 29.4 26.9 2,559.5Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Cum

Total BCWS 224.9 406.3 147.3 306.8 235.8 281.9 168.7 170.0 185.0 93.6 13.0 0.8 2,090.2Total Adds (SLAC + LM) 404.0 352.5 301.1 198.9 179.4 139.5 37.1 37.1 -24.3 -17.8 68.4 85.2 1,761.0Total with Adds 628.9 758.8 448.4 505.7 415.2 421.4 205.8 207.1 160.7 75.8 81.4 86.0 3,995.1

Breakdown of increaseTotal Adds Labor 10.0 10.0 10.0 10.0 0.0 0.0 0.0 0.0 0.0 10.0 39.0 51.5 140.5Total Adds Material 394.0 342.5 291.1 188.9 179.4 139.5 37.1 37.1 -17.5 -27.8 29.4 26.9 1,620.5Total Adds Travel 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 -6.8 0.0 0.0 6.8 0.0

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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MECH BOEMECH BOE

Mechanical Systems Labor Increases $140.5K

• This increase consists of $40K for the Multi- Layer Insulation (MLI) blanket design. Very early on in the program, the ACD subsystem was responsible for the LAT MLI design and fabrication. Because of the complexity of the MLI interfaces with the Spacecraft, Radiators and LAT external features, it was decided to pull this work back to SLAC. Additionally, Thermal Engineering support is now available at SLAC to support this task.

• $100.5K has been added for Mechanical Systems support of the LAT I & T efforts at the end of FY05. These tasks include X-LAT Plate installation and Radiator fit check and shimming operations on the LAT prior to LAT shipment.

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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MECH BOE (con’t)MECH BOE (con’t)

Mechanical Systems Material Increases $1,620.5K

This increase consists of $1,580.5K (TBR) additional funding to complete the Lockheed Martin contract. There are two main cost drivers: 1) Lockheed schedule delays and 2) SLAC imposed changes.

• 1) LM overran the following tasks:

– Radiator design,

– Radiator analysis (structural development),

– Radiator tooling design & fab,

– Radiator Thermal Controls design and

– X-LAT Plate analysis.

• These overruns have left insufficient budget for the remaining tasks to be completed.

GLAST LAT Project LAT Mgr’s Meeting November 17, 2004

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MECH BOE (con’t)MECH BOE (con’t)

• 2) The following changes were made after Lockheed submitted their February 2004 cost proposal and resulted in extra costs (WAG $150K).

– Additional thermal analyses for the X-LAT plate to electronics box interface, for the thermal combs (heat shunt for the GASU box) and for the U-shaped heat pipes that were added then removed from the X-LAT plate,

– MLI blanket design consultant,

– Radiator EMI coupon testing,

– Added keying features to the Radiator

There is also an additional $40K for the Multi- Layer Insulation (MLI) blanket fabrication. Very early on in the program, the ACD subsystem was responsible for the LAT MLI fabrication. Because of the complexity of the MLI interfaces with the Spacecraft, Radiators and LAT external features, it was decided to pull this work back to SLAC.