ISRO-PAS-203 - ISRO Satellite Centre (ISAC), … ISRO Indian Space Research Organisation Department...

ISRO-PAS-203 Issue 3, November 2012

Procedures and ReviewRequirements for Major Ground Tests

and Ground Test Facilities

ISRO Reliability Standards

Directorate of Systems Reliability and Quality, ISRO Headquarters, Bangalore

MESSAGE

ISRO Reliability Standards, addressing the various disciplines of Engineering, have been in vogue for almost three decades now. These standards are followed across ISRO centres as well as external work centers for design, fabrication, testing, analysis and other processes involved in the realization of Launch Vehicles, Spacecraft, Space Applications, Ground support systems and other launch infrastructure. The need for standardization of processes towards achieving high reliability systems can never be over emphasized, and ISRO Reliability Standards are just an attempt towards explicitly stating this.

With the advent of newer techniques and with the evolution of technology itself, over the last 30 years, it has become essential to revisit the existing ISRO Reliability Standards and revise and update the standards wherever essential. Towards this, the Directorate of Systems Reliability and Quality (DSRQ) at ISRO Headquarters has taken an initiative to re-invigorate the reach and visibility of ISRO Reliability standards across all the Centres of ISRO. Specific Inter-centre teams were formed to revise each of these documents and I would like to place on record their commendable efforts in bringing out these documents.

There is a pressing need for ensuring uniformity of practices, across various functions of design, fabrication, testing, review mechanisms etc., across the centres and units of ISRO. Towards this goal, the mandatory adoption of ISRO Reliability Standards will ensure standardization in quality processes and products. I am certain that this will go a long way towards ensuring overall system level Quality and Reliability and in achieving the goal of zero defects in the delivery of space systems of ISRO.

K Radhakrishnan Chairman, ISRO

Indian Space Research OrganisationDepartment of Space

Government of India

Antariksh Bhavan

New BEL Road, Bangalore - 560 231, India

Telephone : +91-80-2341 5241/2217 2333

Fax : +91-80-23415328

e-mail : [email protected]

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Dr. K. Radhakrishnan

Chairman

PREFACE

ISRO Reliability standards are a result of the need for standardization of processes towards achieving high reliability systems. The transfer of knowledge and techniques from the seniors to their successors is best done with proper documentation and checklists translating the entire know-how into black and white.

This particular document, ‘Procedures and Review Requirements for Major Ground Tests and Ground Test Facilities’ addresses the aspects of ground tests from the point of view of test facility requirements, test plan/procedure, reviews and conduct of the test. The details regarding the formation of test team, choice of test director, calibration and involvement of Quality professionals is also specifically addressed. This document also lays thrust on the test abort conditions, review of test facility, article, test readiness and post test reviews and finally the countdown manual and documentation of test results. Aspects of safety have also been imbibed into the test plan/procedure.

It is deemed essential that these standards be strictly adhered to, in order to ensure uniformity of practices across ISRO centers and achieve zero defects in the delivery of space systems.

I am grateful to Chairman ISRO, for being the source of inspiration in the release of these documents. Thanks are also due to the centre Directors for their encouragement. I am also thankful to the Heads of SR Entities/Groups of various ISRO centres for their relentless support and guidance. I am also indebted to the members of the Integrated Product Assurance Board (IPAB) for the meticulous review of these documents. I also owe gratitude to the task team members and other experts for putting efforts in the realization of these documents. I am glad to carry forward this rich lineage of ISRO reliability standards, championed by Shri R Aravamudan, a revered pioneer in the area of Quality & Reliability in ISRO.

S Selvaraju Sr. Advisor (SRQ)

Directorate of Systems Reliability & QualityISRO HeadquartersAntariksh BhavanNew BEL Road, Bangalore -560231Ph :080 - 2341 5414 Fax :080 – 2341 2826Cell:09448397704Email: [email protected]

S Selvaraju Senior Advisor, Systems Reliability and Quality

CONTENTS

1. SCOPE 9

2. APPLICABILITY 9 2.1 Applicable Documents 9

3. ORGANISATION OF THE TEST 9 3.1 Test Director 9 3.2 Test Team 10

4. TEST FACILITY REQUIREMENTS 10 4.1 Facility Organization 10 4.2 Test Facility Operations requirements 10 4.3 Quality assurance / Quality Control 11 4.4 Calibration 11 4.5 Documentation 11

5. TEST PLAN AND TEST PROCEDURE 12 5.1 Test Plan 12 5.2 Test Procedure 12 5.3 Safety Plan 13

6. TEST REVIEW BOARDS 13 6.1 Test Facility Review 14 6.2 Test Article Review 15 6.3 Test Readiness Review 15 6.4 Post Test Review 16

7. CONDUCT OF THE TEST 16 7.1 Test Countdown Manual 16 7.2 Test Abort 17 7.3 Post Test Observations and Quick Look Data 17

ISRO-PAS-203

1. SCOPEThe purpose of this document is to ensure that all major tests on Flight/ Space hardware are performed in accordance

with established procedures with regard to the validity and conduct of the tests, integrity of the test articles, facility

and overall safety.

The major guidelines are:

a. Test is performed as per established procedure and monitored for the specified duration employing the

measurement accuracies necessary to ensure the validity and usefulness of the test results.

b. The test article and the test facility meet the test requirements and are protected against deterioration and

damage from all origins, other than those defined to be necessary by the specified test criteria.

c. The test is conducted by following all established safety and quality norms.

d. Test requirements for all sub-systems and components of Launch Control Centre for launch operations

shall be separately identified and conducted.

2. APPLICABILITY These procedures shall be strictly adhered to for major tests such as

• thermal vacuum, vibration and acoustic tests on spacecraft, engine & sub systems,

• Stage hot tests and static test of rocket motors for launch vehicles.

It is also mandatory to follow these procedures for tests using hazardous chemicals, high-pressure pneumatic

tests and high altitude tests where safety is of paramount concern.

2.1 Applicable Documents

The relevant portions of the following specifications generally form part of this document.

ISRO-PAS-100 Nonconformance Control Requirements for ISRO Projects

ISRO-PAS-201 Failure Reporting, Analysis and Corrective Action System.

Currently valid revision of the above documents only shall be considered.

3. ORGANISATION OF THE TESTThe project / designer shall stipulate the requirements for the conduct of the test. Documents highlighting all the

requirements, specifications and conditions shall be prepared by the project/ designer and approved by appropriate

committees.

3.1 Test Director

For each test, a Test Director shall be nominated. The Test Director shall have the complete responsibility for the

conduct of the particular test. He shall also be responsible for the interface between the user and the test facility

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and ensure that test procedures are in accordance with test objectives as well as facility specifications /

regulations. In addition, he shall ensure that the procedures cover all the user required operations, that

the test is performed in accordance with the test specifications, applicable safety norms while meeting the

schedule.

3.2 Test Team

Test Director shall be assisted by a team for carrying out the test with members drawn from relevant areas

like the project, centers representing the test article, facility. Test Director and the other members of the team

shall be appointed by the Project Director or the Centre Director.

Note: The designations such as Test Director, Facility Manager etc., and reference to Sections/Divisions and

the like, which are used in this document are in a generic sense in order to identify specific responsibilities.

Actual titles may be in accordance with current practices prevailing in the Centres/Projects.

4. TEST FACILITY REQUIREMENTSIt is necessary that the test facilities, where these tests are to be conducted, should satisfy certain organizational/

operational requirements.

4.1 Facility Organization

There shall be one identified person (Test Facility Manager) responsible for all operations of the test facility.

He shall have the overall responsibility for augmentation, modifications, upkeep and maintenance of the test

facility, safety of the personnel, the facility and also the test article.

The test facility shall comprise of various systems with identified personnel for the supervision and maintenance

of each of them, ensuring that the operational procedures are followed, checklists/ operational documents are

updated, instruments are duly calibrated and periodical validation tests of vessels and components are carried

out. Checklists/ operational documents shall contain stage-wise clearances by QC for all critical activities.

4.2 Test Facility Operations Requirements

The test facility should have the necessary operational infrastructure for the conduct of the test. It shall

be ensured that necessary documentation is available for the conduct of the test and all the required test

personnel are fully trained with the operations for the test.

If there are any deficiencies in the facility for the conduct of the test, it shall be brought out in the test plan

itself. Any modification carried out in the facility shall be reviewed by appropriate committee.

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4.3 Quality Assurance/Quality Control

There shall be an identified agency (Quality Control section) having full responsibility for carrying out

on-line quality control activities of the test facility, test article and test operations. It shall ensure that necessary

document is available for the conduct of the test and all the required test personnel are fully familiar with the

operations for the test.

The QC / QA plan shall be worked out by the concerned QC / QA divisions in consultation with the test

facility managers. The QC / QA plan shall cover all specific checks / inspection requirements prior to and after

the test.

Any Non Conformance Review Board (NC) will have to be raised by quality agencies. This agency will ensure

that all NCs and any related anomalies are closed satisfactorily before the test. The team also will prepare an

independent quality audit report of the test article and facility and submit it to the test review board/ Standing

Review Committee.

4.4 Calibration

The test facility shall draw up a quality plan incorporating the calibration of the instruments specifying calibration

intervals and making reference to calibration procedures for all instruments used in the data management for the

tests. The instruments shall be periodically calibrated and they shall carry current calibration status tags.

In addition, there shall be a maintenance and control plan for the environment and the like. The environment in the

facilities shall be monitored periodically, controlled and recorded.

4.5 Documentation

The test facility shall maintain an up-to-date, comprehensive documentation on the facility. This document should

cover the following:

• Organizational set-up of the facility

• A technical description of the facility and its components including maximum and minimum ratings.

A drawing of the facility identifying the location of all major test equipments

• A functional block diagram for the test system including redundancy and fault tolerant features

• The environmental conditions required to be maintained in the area

• A description of system failure modes and their possible effects on test articles

• Safety procedures including emergency shutdown operation

• Requirements on users for utilizing the facilities

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• Facility operations sequence procedures and special care, if any

• Area for test preparations and storage of test article

• Checklist/ quality plan containing information on facility utilization, facility maintenance

and calibration of equipment

5. TEST PLAN AND TEST PROCEDURE5.1 Test Plan

For each test, the project/ designer shall provide a detailed test plan. This plan shall specify the following

mandatory requirements:

• Scope and objective of the test

• Description of test article and test requirements

• Identification of the test article with description, its mechanical and electrical interfaces

• Success / Failure criteria

• Description of the test conditions, test profile and sequence

• Specification of Propellants and other fluids to be used (if applicable)

• Measurement plan and accuracies

• Check out requirements

• Measurement processing and test data requirements

• Expected performance parameters

• Abort conditions/criteria.

The Test Plan shall conform to the test requirements laid down by the project and shall be approved by

appropriate committees.

5.2 Test Procedure

Based on the Test plan, the Facility Manager shall work out the detailed test procedure for the conduct of the

test in consultation with the user agency. It shall include the following mandatory aspects.

• Mechanical configuration and interface details

• Electrical configuration and interface details

• Handling and transportation of the test article and its installation for test.

• Handling system qualification details.

• List of hazardous elements / systems

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• Precautions to handle potential hazards to equipments, facilities and personnel

• Cleanliness and Contamination control

• Requirements of power, communication and other utilities for conducting the tests

• Normal shutdown procedures

• Emergency shutdown procedures

• Calibration requirements before and after the test

• Safety and medical stand-by requirements

• Data recording and Data reduction details

• Data certification and distribution requirements

• Assembly and Post-Test disassembly procedure of the test-article

• Name of key personnel conducting the test

• Countdown details / sequence of tests.

• Hold and recovery procedure

5.3 Safety Plan

It is also necessary to prepare a general safety plan for each type of test by the Safety section of the facility / centre.

These plans are to be cleared by the Centre Safety Committee, as required by the ISRO safety norms. Specific safety

procedures relating to the particular test shall be included in the test procedure document. HAZOP/ FMECA

analysis for test facility, test article and contingency/ emergency preparedness plans shall be prepared. Safety plan

shall address the environmental and meteorological issues also.

6. TEST REVIEW BOARDSComprehensive reviews shall be conducted before and after each test to ensure safety and validity of the test. There

shall be four types of reviews as follows:

a. Test Facility Review (TFR)

b. Test Article Review (TAR)

c. Test Readiness Review (TRR)

d. Post Test Review (PTR)

The reviews shall be conducted either separately or together by separate Boards formed for this purpose or by

Standing Review Committees (SRC). Depending upon the size/criticality of the test, inter- centre members shall also

be inducted into the review boards. These Boards shall be constituted by the Centre Director and shall comprise

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minimum of the following members:

• Test Director

• Test Facility

• Test Facility Instrumentation

• System Development Agency

• User Project

• Safety representative

• Other specialists as necessary.

• Appropriate Quality Personnel

6.1 Test Facility Review

Prior to the formal test, the readiness of the facility to perform the test shall be assessed by a Test Facility

Review Board (TFRB)/ SRC. This includes new facility established and all major facilities which are critical.

The TFRB/SRC shall

• Review test plans and procedures and assess their adequacy

• Verify that approved test and inspection documentation are available and are agreed to,

by the Test Director

• Ensure that requirements for facility preparations have been met

• Verify that the facility is in the correct configuration and ready for test

• Ensure that the environmental and other controls are adequate

• Verify that all test / support equipments are calibrated, checked for endurance and ready for test

• Review, in particular, equipment meant for handling hazardous material

• Review, in particular, the QA & safety plans for their adequacy

• Review QC / QA issues

• Certify whether the facility is ready for test or not, and in the latter case, identify the actions to be

taken

• Review facility performance / maintenance requirements

• Review the adequacy of instrumentation support

• Review results of dry runs / functional tests/ confirmatory tests

The Test Facility team shall have the responsibility to provide all the details of the facility, test plans and

procedures, inspection documents etc., to this Review Board.

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6.2 Test Article Review

Prior to the formal test, the readiness of the test article which is to undergo the specified test shall be assessed by

Test Article Review Board (TARB)/ SRC. The TARB / SRC shall

• Assess the configuration and readiness of the test article and review all related documentation

• Review the status of NCs and verify that open NCs have no impact on the validity of the test

• Identify the potential hazards and controls needed to handle these NCs for the particular test

• Review failure modes of the test article and their effects

• Review measurements onboard the test article vis-à-vis the flight measurements

• Verify the inspection data and checklists

• Verify the results of the intermediate / previous test

• Verify the Test Plan and Procedure Document and assess adequacy of preparations

• Review Quality issues / Safety assessment as applicable

• Review differences between test conditions and flight conditions

• Review qualification status of instrumentation chain including transducers

• In the case of environmental stress test, ensure that basic reference performance data is available

and meets the system requirements

• Ensure all failures encountered are satisfactorily addressed and closed

• Certify that the item is ready for test

The System Development Agency shall be responsible to provide all the details of the test article configuration,

fabrication & inspection documents, QA/QC reports etc., for this review.

6.3 Test Readiness Review

After receipt of the test article at the test facility and prior to start of the test, the readiness of both the test article

and the test facility shall comprehensively be assessed by Test Readiness Review Board (TRRB) at the test site. The

TRRB shall

• Review physically the preparation for the tests at the test facility.

• Review the details regarding receipt, handling and assembly of test article in the facility.

• Assess adequacy of controls to handle potential hazards, availability of utilities such as

communication, power etc., and adequacy of general test preparations and access control

• Review the TFR and TAR deliberations, their recommendations and the follow-up action status

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• Verify the closure status of failures noticed during facility/test article preparation, if any

• Verify the approved test configurations and the test procedures and inspection documentation

• Verify the status of data recording facilities

• Review QC / QA concerns

• Give authorization for conducting the test.

6.4 Post Test Review

Post Test Review Board (PTRB)/ SRC shall meet immediately after the test, to review the test data and

provide preliminary approval of test results, The PTRB/SRC shall

• Review the test data after completion of the test

• Review the changes in test procedures, test deficiencies, defects and failures noticed and give

corrective actions for future tests

• Review the post test inspection data of the Test article / Test facility

• Determine the acceptance of the test results and further analysis required on the test results.

• Recommend the next phase of testing

In the event of failure of facility or major anomaly in the performance of test article, this shall be referred to

a Specialist Committee for review.

It will be the responsibility of the System Development Agency to consolidate all the test documentation

along with the PTRB/SRC report and forward to the projects concerned for further analysis and action.

7. CONDUCT OF THE TESTPre test meeting shall be conducted just prior to commencement of countdown to review the closure of all

action points identified by various committees and to get clearance from all concerned agencies.

All initial conditions required for the test facility shall be fulfilled. The test shall be conducted as per the

countdown procedure laid down in the countdown manual.

7.1 Test Countdown Manual

A detailed countdown manual document for the conduct of the test shall be prepared by the facility team in

consultation with the test article / system team (Section 5.2). It shall be reviewed and approved by appropriate

committee. All software used for the test shall be cleared by expert committee. The countdown manual

shall stipulate initial conditions for the test, limitations, detailed operations with specific time duration and

chronology of various operations during the test. The countdown manual/equivalent checklist shall also

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include abort conditions and roll back procedures from any holds/abort during countdown and post-test operations

to bring test article and facility to safe mode.

7.2 Test Abort

The testing should be aborted automatically by the checkout system based on agreed parameters going

out of bounds for a specified period during test. Manual over riding by the Test Director for abort based on

specific conditions should also be provided, wherever applicable. Test conditions for manual abort shall be

clearly defined.

7.3 Post Test Observations and Quick Look Data

Post test observations on the test article and the facility have to be recorded by a competent team formed by the

Test Director/ Facility Manager / Project Director, after the test.

Quick look data analysis highlighting major observations during tests, anomalies, if any, along with the data on

performance of the test article have to be prepared and presented to the review team.

Detailed analysis of the test conducted including observations, performance of the facilities and the test article and

test data recorded has to be carried out. A detailed report containing the analysis mentioning whether the test

objectives are fulfilled/not fulfilled has to be brought out. Specific recommendations needed for improving the facility

or the test article, measurement plan/checkout shall also be addressed.

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ISRO-PAS-203 - ISRO Satellite Centre (ISAC), … ISRO Indian Space Research Organisation Department...

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