Requirement Specification for 22N Dual Valve Bipropellant...

BC.ASU.SP.00018 Issue 01

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Document Autogenerated from DOORS Module : /BepiColombo Implementation Phase/Level 3 Equipment Specifications/MPB/22N Bipropellant Thruster Specification Final BC_ASU_SP_00018_22NBiPropThruster_Spec_Issue_01.05.02.08.doc

Requirement Specification for 22N Dual Valve Bipropellant (MON/MMH) Thruster

CI CODE: B3124 DRL Refs : EN-U16

UK EXPORT CONTROL RATING : Not Listed

Rated By : J. Bolter

Prepared by: Date:

Checked by: Date:

Approved by: Date:

Authorised by: Date:

This document is produced under ESA contract, ESA export exemptions may therefore apply. These Technologies may require an export licence if exported from the EU

© Astrium Limited 2008

Astrium Ltd owns the copyright of this document which is supplied in confidence and which shall not be used for any purpose other than that for which it is supplied and shall not in whole or in part be reproduced, copied, or communicated

to any person without written permission from the owner.

Astrium Limited, Registered in England and Wales No. 2449259 Registered Office: Gunnels Wood Road, Stevenage, Hertfordshire, SG1 2AS, England


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Astrium Ltd owns the copyright of this document which is supplied in confidence and which shall not be used for any purpose other than that for which it is supplied and shall not in whole or in part be reproduced, copied, or communicated to any person without written permission from the owner.

BC_ASU_SP_00018_22NBiPropThruster_Spec_Issue_01.05.02.08.doc

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CONTENTS

1 SCOPE.......................................................................................................................................................7 2 DOCUMENTATION....................................................................................................................................8

2.1 Applicable Documents ........................................................................................................................8 2.2 Standards............................................................................................................................................8

3 REQUIREMENTS ......................................................................................................................................9 3.1 Component Description.......................................................................................................................9 3.2 Performance........................................................................................................................................9

3.2.1 Functional Performance...............................................................................................................9 3.2.2 Electrical Characteristics............................................................................................................17 3.2.3 Operating Requirements............................................................................................................21

3.3 Design Criteria ..................................................................................................................................23 3.3.1 General Design Criteria .............................................................................................................23 3.3.2 Proof Pressure ...........................................................................................................................23 3.3.3 Burst Pressure ...........................................................................................................................24 3.3.4 Reverse Differential Pressure....................................................................................................24 3.3.5 Back-Pressure Relief .................................................................................................................24 3.3.6 Fracture Control Plan.................................................................................................................24 3.3.7 Thermal Design Requirements ..................................................................................................25

3.4 Environmental Conditions .................................................................................................................29 3.4.1 Pre-Launch Storage and Transportation ...................................................................................29 3.4.2 Pre-Launch System Assembly Integration and Test .................................................................30 3.4.3 Launch .......................................................................................................................................30 3.4.4 Post-Launch...............................................................................................................................32

3.5 Physical Characteristics ....................................................................................................................32 3.5.1 Configuration and Dimensions...................................................................................................32 3.5.2 Mass...........................................................................................................................................32 3.5.3 Stiffness .....................................................................................................................................32 3.5.4 Interfaces ...................................................................................................................................33 3.5.5 Alignment ...................................................................................................................................33 3.5.6 Filter ...........................................................................................................................................33 3.5.7 Calibration Orifices.....................................................................................................................34

3.6 Reliability ...........................................................................................................................................34 3.6.1 Failure Rates..............................................................................................................................34 3.6.2 Items Subject to Wear-Out/Degradation....................................................................................34

3.7 Maintainability ...................................................................................................................................34 3.8 Storage..............................................................................................................................................34

3.8.1 Storage Life................................................................................................................................34 3.8.2 Equipment Storage ....................................................................................................................34

3.9 Transportability..................................................................................................................................34 3.10 Design and Construction ...............................................................................................................35

3.10.1 Selection of Specifications and Standards ................................................................................35 3.10.2 Materials, Parts and Processing ................................................................................................35

3.11 Identification and Marking .............................................................................................................39 3.12 Safety.............................................................................................................................................39

3.12.1 General ......................................................................................................................................39 3.12.2 Toxic or Hazardous Materials ....................................................................................................39 3.12.3 Locking.......................................................................................................................................39 3.12.4 Explosive Atmospheres .............................................................................................................40 3.12.5 Decontamination ........................................................................................................................40


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4 QUALITY ASSURANCE PROVISIONS ...................................................................................................41

4.1 General Requirements ......................................................................................................................41 4.1.1 Responsibility for Inspection and test ........................................................................................41 4.1.2 Quality Assurance Programme..................................................................................................41 4.1.3 Surveillance, and Witness of Inspection and Test.....................................................................41 4.1.4 Preproduction Sample ...............................................................................................................41 4.1.5 Classification of Inspection and Test .........................................................................................41

4.2 Verification of Compliance ................................................................................................................42 4.2.1 General ......................................................................................................................................42 4.2.2 Acceptance, Inspection and Test...............................................................................................42 4.2.3 Qualification Inspection and Test...............................................................................................44

4.3 Test Conditions and Test Equipment ................................................................................................46 4.3.1 Ambient Conditions....................................................................................................................46 4.3.2 Test Equipment..........................................................................................................................46 4.3.3 Tolerance of Test Conditions (Excluding Ambient) ...................................................................47 4.3.4 Accuracy of Measurement .........................................................................................................47 4.3.5 Test Media .................................................................................................................................48 4.3.6 Product Test Controls ................................................................................................................48

4.4 Test Methods ....................................................................................................................................48 4.4.1 Inspection/Examination..............................................................................................................48 4.4.2 Proof Pressure Test ...................................................................................................................49 4.4.3 Vibration Tests ...........................................................................................................................50 4.4.4 Constant Acceleration................................................................................................................51 4.4.5 Shock Testing ............................................................................................................................51 4.4.6 Leakage Tests ...........................................................................................................................52 4.4.7 Gas Flow Tests (Qualification only) ...........................................................................................52 4.4.8 Thermal Vacuum Test................................................................................................................53 4.4.9 Life Cycle Tests .........................................................................................................................54 4.4.10 Firing Tests ................................................................................................................................55 4.4.11 Environmental Temperature (Non-Operating) ...........................................................................55 4.4.12 Electrical Functional Tests.........................................................................................................56 4.4.13 Attitude Sensitivity......................................................................................................................57 4.4.14 Pressure Margin.........................................................................................................................58 4.4.15 Back Pressure Relief Pressure..................................................................................................58 4.4.16 Contamination Test....................................................................................................................58 4.4.17 Cleanliness Verification..............................................................................................................58 4.4.18 Burst Pressure Test ...................................................................................................................59 4.4.19 Final Inspection..........................................................................................................................59

4.5 Preparation for Delivery, Inspection and Test...................................................................................59 5 PREPARATION FOR DELIVERY ............................................................................................................60

5.1 Methods of Preservation and Packaging ..........................................................................................60 5.1.1 Retention of Cleanliness ............................................................................................................60 5.1.2 Storage ......................................................................................................................................60 5.1.3 Protective Coverings..................................................................................................................60

5.2 Equipment Packaging .......................................................................................................................60 5.3 Equipment Container Design ............................................................................................................61 5.4 Packing..............................................................................................................................................61 5.5 Identification Marking for Shipment and Storage..............................................................................61

6 GDIR Applicability Matrix..........................................................................................................................62


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TABLES Table 3-1: Pressure Box Co-ordinates ............................................................................................................11 Table 3-2: Pulse Mode Duty Cycles ................................................................................................................16 Table 3-3: TICD Content .................................................................................................................................26 Table 3-4: Unit Thermal Data Sheet................................................................................................................27 Table 3-5: Random Spectrum .........................................................................................................................31 Table 3-6: Sinusoidal Vibration........................................................................................................................31 Table 3-7: Shock Levels ..................................................................................................................................32 Table 3-8: Cleanliness Requirements .............................................................................................................37 Table 4-1: Acceptance Tests...........................................................................................................................43 Table 4-2: Qualification Tests..........................................................................................................................45 Table 4-3: Test Tolerances..............................................................................................................................47

FIGURES Figure 1-1: Thruster Co-ordinate System..........................................................................................................7 Figure 3-1: Thruster Operating Pressure Box .................................................................................................11 Figure 4-1: Thermal Vacuum Testing at Thruster Level..................................................................................53 Figure 4-2: Thermal Vacuum Functional Performance Tests .........................................................................54


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1 SCOPE

This document specifies the performance, design and test requirements for the Dual Valve Bipropellant thruster of nominal thrust 22 Newtons for use on the BepiColombo Mercury Transfer Module, MTM.

Requirements within this document are shown in an italic font. Each requirement is preceded by a summary line that contains the following fields, delimited by '/'.

• Doors Requirement Number

• Created From

• Verification Method

The Doors Requirement Number has the form BPT-xxx where xxx is a unique number assigned consecutively.

The Created From field shows the parent requirement or 'Created' if the requirement is created at this level.

The Verification Method codes are as follows:

• R - Review

• A - Analysis

• I - Inspection

• T - Test

If Tables are considered as part of the requirement they are referenced clearly in the text and inserted after and separated from the requirement Table and are managed as free text attached to the identifier requirement.

The trace to the upper level requirements (Upper Links), shall be managed using the following format:

• AAA-NNN where AAA is a label associated to the upper document and NNN the requirement identifier of this upper level,

• or CREATED keyword if the requirement has no link with upper level.

All document elements not presented in the format explained above are not requirements and will not be verified or tracked.

Co-ordinate System

The following Figure 1-1 shows the co-ordinate system used in this document with respect to the thruster.

Axial

LateralLateral

22N Thruster

Figure 1-1: Thruster Co-ordinate System


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2 DOCUMENTATION

The following documents form a part of this specification to the extent specified herein. In the event of conflict between this specification and any of the applicable documents referenced below, this conflict shall be notified to the Customer.

2.1 Applicable Documents

Throughout this Specification, Applicable Documents are referred to in the text as AD(x).

a. Product Assurance Requirements For Subcontractors BC.ASD.SP.00018

b. General Design and Interface Requirements BC-ASD-SP-00001

c. Environmental and Test Requirements BC-ASD-SP-00002

d. Mechanical Propulsion Bus Specification BC-ASD-SP-00008

e. Interface Control Drawing, 22N Bipropellant Dual Valve Thruster

See Note 1.

Note 1:

Interface Control Drawing shall be provided by the Contractor at start of Contract and shall be subject to Customer Approval.

2.2 Standards

Throughout this Specification, Standards are referred to in the text as SD(x).

a. Monomethyl Hydrazine Propellant MIL-P-27404B, or equivalent

b. Nitrogen Tetroxide (MON-1 and 3) MIL-P-27401, or equivalent

c. Helium MIL-PRF-27407B, or equivalent

d. Nitrogen MIL-PRF-27401D, or equivalent

e. Argon Gas MIL-A-18455C, or equivalent

f. Contamination and Cleanliness ECSS-Q-70-01-A

g. Isopropyl Alcohol (Propan-2-ol) TT-I-735A, or equivalent

h. Deionised/Demineralised Water JSC-SPEC-C-20C, or equivalent

i. Dissimilar Metals MIL-STD-889B

j. Soldered Electrical Connections NASA-STD-8739.3

k. Structural Design of Pressurised Hardware ECSS-E-32-02


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3 REQUIREMENTS

3.1 Component Description

The normal function of the flight thruster is to provide the Delta V capability, forces, attitude and orbit correction torque(s) required to maintain the spacecraft on its planned mission trajectories.

The thruster shall be a pressure fed, hypergolic bipropellant device capable of operation with Monomethyl Hydrazine and Nitrogen Tetroxide MON 1 to 3 although the basis of the Qualification and flight Acceptance testing shall be MON 3. The thrusters shall be capable of operation in steady state and pulse modes in regulated and unregulated (blow-down) modes.

Each thruster shall contain a series redundant bipropellant valve. The valve shall conform to either of the two configurations below:

Configuration

The upstream and downstream valves shall be normally closed monostable valves. For operation, the upstream valves of the fuel and oxidiser valves shall be opened and held open, whilst the downstream valve pair shall be actuated in accordance with the AOCS commands. In this specification, when reference is made to thruster pulse performance, this relates to the operation of the downstream valve pair.

For the purpose of this requirements specification, the valves of either configuration shall be referred to as Upstream Valve or Downstream Valve, unless a configuration is referenced specifically.

BPT-2557/MPB-3659,Derived/I,R

Each thruster shall contain a series redundant dual mode valve. The thruster shall conform to the configuration below:

Configuration

The upstream and downstream valves shall be normally closed dual seat monostable valves. For operation, the upstream valves of the fuel and oxidiser valves shall be opened and held open, whilst the downstream valve pair shall be actuated in accordance with the AOCS commands. In this specification, when reference is made to thruster pulse performance, this relates to the operation of the downstream valve pair.

For the purpose of this requirements specification, the valves of either configuration shall be referred to as Upstream Valve or Downstream Valve, unless a configuration is referenced specifically.

BPT-104/Created/I,R

Each flight thruster shall include thermistors to monitor thruster flange temperature and Downstream Valve/Upstream Valve cap temperature.

There shall be one prime and one redundant thermistor supplied for each measurement position.

3.2 Performance

3.2.1 Functional Performance

3.2.1.1 Operating Pressures

Note:

All pressures specified in this document are pressures above local ambient gauge, unless explicitly stated.

3.2.1.1.1 Maximum Expected Operating Pressures

MEOP1

The Maximum Expected Operating Pressure is 20.0 bar.

This pressure is defined as MEOP1.


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MEOP2

Due to the back-pressure relief capability of the Upstream Valve, the normally closed Downstream Valve inlet will be exposed to internal pressures higher than those at which it will be required to fire. It is these higher pressures which have been used to define proof and burst pressure values for the interstage between the Upstream Valve and the Downstream Valve.


MEOP2 is MEOP1 + BPR bar (back pressure relief).

The value of BPR is to be determined by the Contractor under the operational conditions given in this Specification.

MEOP3

During firing, the thruster downstream of the Downstream Valve seat up to the inlet to the injector is pressurised due to the flow and combustion of propellant.


MEOP3 is MEOP1 - ∆P across Downstream Valve seat.

MEOP4

The nominal combustion chamber pressure during firing is to be determined by the Contractor.


3.2.1.1.2 Operating Pressure Spectrum

BPT-1067/Created/T,A,R

The Thruster shall be compatible with the following pressure requirements:

System Level Post Integration Proof Pressure Tests

• Vacuum to 2 x MEOP1 (Upstream Valve open or closed, Downstream Valve closed)

• Vacuum to 1.25 x MEOP2 (Upstream Valve open, Downstream Valve closed)

Launch

• Vacuum to 4 bar (Upstream Valve open or closed, Downstream Valve closed)

Post Launch - Subsystem Priming

• Venting of Helium through thruster from 9 bar to vacuum (Upstream and Downstream valves open)

Post Launch - Operations

• Vacuum to MEOP1 to Upstream Valve inlet (Upstream and Downstream valves closed)

• Vacuum to MEOP1 to Downstream Valve inlet (Upstream Valve open, Downstream Valve closed)

• Vacuum to MEOP2 in Downstream Valve-Upstream Valve interstage (Upstream and Downstream valves closed)

Differential Propellant Line Pressure

• Differential propellant line pressure of MEOP1 (fuel to oxidant or oxidant to fuel)


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3.2.1.1.2.1 Operating Pressure Box

BPT-1173/MPB-5169,Derived/T

The thruster shall be able to operate within the following pressure box in Figure 3-1.

22N Bipropellant Thruster Pressure Box

8

10

12

14

16

18

20

22

24

26

8 10 12 14 16 18 20 22 24 26

Oxidiser Pressure, bar

Fuel

Pre

ssur

e, b

ar

1Q

2Q

3Q

6Q

7Q

8Q

9Q

11Q

13Q

A

B

C

D

E

F

Note:

The Unit shall be capable of operating at pressures up to 10% greater than the maximum operating pressure and down to 20% below the minimum operating pressure.

Figure 3-1: Thruster Operating Pressure Box

The co-ordinates of points are detailed in Table 3-1, below.

Point PLO PLF Point PLO PLF

A 17.26 19.08 1Q 13.80 10.20

B 20.44 16.91 2Q 9.12 8.65

C 13.97 11.36 3Q 10.27 13.47

D 12.50 13.59 6Q 18.32 21.19

E 12.62 11.70 7Q 21.50 16.30

F 14.75 13.70 8Q 16.90 16.76

9Q* 21.54 20.09 11Q 23.94 22.35

13Q* 17.2 16.00 T 16.2 16.0

Notes:

Points marked Q are Qualification Test Points. Points marked * are also Acceptance Test Points.

Table 3-1: Pressure Box Co-ordinates


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3.2.1.2 Leakage Rates

3.2.1.2.1 External Leakage (Upstream of Upstream Valve Seat)

BPT-142/Created/T

Leakage from the valve assembly and wetted volumes upstream of the Upstream Valve seats shall not exceed 1 x 10-6 scc/sec Helium, SD(c), when pressurised at any pressure up to MEOP1 and any temperature in the ranges defined in Section 3.2.3.2.

There shall be no leakage of liquid or propellant vapour.

3.2.1.2.2 External Leakage (Upstream Valve-Downstream Valve interstage)

BPT-145/Created/T

Due to thermal induced pressure effects, the pressure in the valve interstage (i.e. Upstream Valve outlet, valve interstage passages, and Downstream Valve inlet) can reach MEOP2. The external leakage from this section of the equipment shall not exceed 1.0 x 10-6 scc/sec of Helium, SD(c), at any pressure up to MEOP2 and at any temperature in the ranges defined in Section 3.2.3.2.


3.2.1.2.3 External Leakage (Downstream of Downstream Valve Seat, Verification of Valve/Thruster Interface)

BPT-148/Created/T

The leakage from the equipment when pressurised downstream of the Downstream Valve, including the interface flanges, should not exceed 1.0 x 10-4 scc/sec when pressurised with Helium, SD(c), at any pressure up to the relevant MEOP (i.e. MEOP3 or MEOP4) of that part of the thruster and at any temperature in the ranges defined in Section 3.2.3.2.


3.2.1.2.4 Internal (Valve Seat) Leakage

BPT-151/Created/T

The leakage across each seat shall not exceed 2.8 x 10-4 scc/sec of Helium, SD(c), at any inlet pressure up to MEOP1 for the upstream (Upstream Valve) valve, and MEOP2 for the downstream (Downstream Valve) valve with any downstream pressure in the range zero to 1.0 bar and at any temperature in the ranges defined in Section 3.2.3.2.


3.2.1.2.5 Internal Interfaces

BPT-154/Created/T

The leakage across any internal oxidiser/fuel interface or across the fluid/electrical compartment interfaces shall not exceed 1 x 10-6 scc/sec of helium at any relevant operating pressure (defined in Section 3.2.1.1.1) and at any temperature in the ranges defined in Section 3.2.3.2.


3.2.1.3 Mixture Ratio

The thruster is trimmed to operate at the mixture ratio and nominal inlet pressures defined in Section 3.2.1.7.1.

BPT-158/MPB-4746,Derived/R

The thruster shall operate over the inlet pressure Qualification range and meet the performance specified in Section 3.2.1.7.3 at any point within the Acceptance range.

The resulting mixture ratio is derived from this for information.


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3.2.1.4 Overpressure

BPT-161/Created/T,R

The equipment shall operate within specification after having been subjected to the proof pressure specified in Section 3.2.3.2.

3.2.1.5 Attitude Sensitivity

BPT-163/Created/R

The equipment shall comply with the requirements of the specification when oriented along any axis under 1 g conditions (on ground).

3.2.1.6 Pressurisation and Depressurisation Performance Requirements

3.2.1.6.1 Rapid Depressurisation

BPT-1779/Created/T

The equipment shall perform to the requirements of this specification after being subjected to a rapid pressure drop of Helium, Nitrogen, or Argon from Proof to ambient bar through both the upstream and the downstream open valves.

3.2.1.6.2 Priming of Lines Up to Closed Upstream Valve

BPT-166/Created/T

The equipment shall perform to the requirements of this specification after being subjected to a rapid pressure rise from 0 bar to MEOP1 inlet pressure within 200 milliseconds with both the Downstream Valve and the Upstream Valve in the closed position.

The Upstream Valve shall not open or leak as a result of this pressure rise.

3.2.1.6.3 Priming of Lines Up to Downstream Valve (Upstream Valve open)

BPT-169/Created/T

The equipment shall perform to the requirements of this specification after being subjected to a rapid pressure rise from 0 bar to MEOP1 inlet pressure within 200 milliseconds with the Downstream Valve in the closed position and the Upstream Valve open.

The Downstream Valve shall not open or leak as a result of this pressure rise nor should the Upstream Valve close.

3.2.1.6.4 Rapid Through Flow

BPT-172/Created/T

The equipment shall perform to the requirements of this specification after being subjected to a rapid through flow of propellant vapour/fluid as a results of opening the Upstream Valve with initially MEOP1 at its inlet and the Downstream Valve closed with 0 bar at its inlet.

The Downstream Valve shall not open or leak as a result of this pressure rise nor should the Upstream Valve close.

3.2.1.6.5 Hydraulic Shock

BPT-175/Created/T,R

The equipment shall perform to the requirements of this specification after being subjected to a hydraulic shock transient internal pressure spike of 150 bar within 20 milliseconds.

This hydraulic shock transient can take place with the Upstream Valve in either the open or closed position.

The Contractor shall inform the Customer of the maximum allowable pressure applied within 20 ms without causing plastic deformation.


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3.2.1.7 Thruster Firing Performance Requirements

BPT-179/Created/T,R

There shall be no thermal restrictions resulting from the number of pulses in any pulse train as defined in Section 3.2.1.7.3 and on the length of any continuous burn.

The thruster assembly shall be capable of successful pulsed or continued operation within specification requirements at all valve and thrust chamber temperatures, which might result from thermal soak-back after any operation during the mission.

It shall be possible to restart and operate any thruster within appropriate specifications regardless of when or for how long the thruster was last fired.

Thruster restart shall not be constrained by environmental conditions.

3.2.1.7.1 Standard Conditions

BPT-184/MPB-5158,Derived/T,R

Nominal performance data shall be based upon the standard conditions and exclude measurement errors unless otherwise noted or specified. The standard conditions shall be as follows:

Trim Point:

The thruster shall be trimmed such that for a fuel inlet pressure of 16.0 bar and an oxidiser inlet pressure of 16.2 bar a mixture ratio of 1.64 ± 0.05 is achieved and a nominal thrust 22 N ± 2%.

Ambient Pressure: 0 bars (Absolute)

Propellant Inlet Temperature: 21°C

All performance requirements shall be met regardless of the Helium saturation state of the propellants.

3.2.1.7.2 Steady State Performance

BPT-1071/Created/T

These requirements apply for:

• the operating pressure ranges in Section 3.2.1.1.2.1,

• the operating temperature ranges in Section 3.2.3.2,

• ON times > 500 ms,

unless otherwise stated.

3.2.1.7.2.1 Thrust

BPT-199/MPB-5158,Derived/T

The Qualification and flight thruster shall produce its nominal thrust of 22 N ± 2% at the trim point and standard conditions defined in Section 3.2.1.7.1.

The steady state vacuum thrust shall meet the maximum and minimum requirements stated in this Section.

The firing to firing variation in steady state thrust for the same thruster operating under identical conditions shall not exceed ± 1.0% 3σ.

The thrust shall be measured at all the test points of the operating pressure box in Section 3.2.1.1.2.1.


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3.2.1.7.2.2 Specific Impulse

BPT-205/Created/T

At the thruster trim point and the standard conditions defined in Section 3.2.1.7.1, the thruster shall deliver a specific impulse of not less than 295 seconds throughout its flight life.

The firing to firing variation in specific impulse for the same thruster operating under identical conditions shall not exceed ± 1.5% 3σ.

The firing to firing variation in specific impulse for different thrusters operating under identical conditions shall not exceed ± 1.5% 3σ.

The Contractor shall provide values of specific impulse at all the test points of the operating pressure box Section 3.2.1.1.2.1.

The steady state specific impulse performance shall meet the minimum requirements stated in this Section.

3.2.1.7.2.3 Roughness

BPT-211/Created/T

The Contractor shall, where practical, characterise the roughness during pulse and steady state operations and shall ensure that the impulse requirements defined in the specification, Section 3.2.1.7.3, and the steady state firing requirements defined in the specification, Section 3.2.1.7.1 and Section 3.2.1.7.2.1, are met.

3.2.1.7.2.4 Maximum Accumulated Steady State Firing Time

BPT-213/Created/T,R

Each thruster shall be capable of achieving an accumulated on-time of 6 hours.

For Qualification, the accumulated on-time shall be demonstrated with an additional margin of 50% above the nominal requirement.

3.2.1.7.2.5 Longest Single Burn

BPT-217/Created/T,R

Each thruster shall be capable of achieving a longest continuous steady state burn of at least 2700 seconds.

For Qualification, the longest single burn shall be demonstrated with an additional margin of 50% above the nominal requirement.

3.2.1.7.2.6 Impulse Predictability

BPT-220/Created/T

For firings lasting 1 seconds or longer the total impulse predictability of each thruster shall be at least ± 1% from an equivalent Qualification point.

3.2.1.7.2.7 Steady State Performance

BPT-222/Created/T

The steady state performance (thrust, specific impulse, and propellant temperature extremes) shall be provided for all of the Qualification Tests Points of Table 3-1.

3.2.1.7.3 Pulse Mode Performance

These requirements apply for the operating pressure ranges in Section 3.2.1.1.2.1 and the operating temperature ranges in Section 3.2.3.2 and a flight type valve driver.


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3.2.1.7.3.1 Impulse Bit

BPT-228/Created/T

Each thruster shall be able to deliver a minimum impulse bit of less than 50 mN.s.

For duty cycles with on times greater than 30 ms the impulse bit shall be repeatable with ± 2% at equivalent operating conditions.

The repeatability for on times lower than 30 ms shall be established.

For duty cycles with on times equal to or less than 30 ms, the impulse bit repeatability and pulse centroid delay shall be characterised down to the minimum on time capability of the thruster.

The total impulse predictability for each thruster shall be at least ± 4% (to 3σ) where an allowance is made for operating conditions.

The impulse bit performance shall be characterised during the testing defined in Section 3.2.1.7.3.5.

3.2.1.7.3.2 Centroid Delay

The pulse centroid delay is defined as the delay between the centre of the 'valve open' signal and the centre of the area under the thrust v time curve.

BPT-237/Created/T

For duty cycles with on times greater than, or equal to, 30 ms, the pulse centroid delay shall be in the range 19 ± 11 ms.

For duty cycles with on times less than 30 ms, or where the electrical off-time is less than 30 ms, the delay shall be characterised by the tests defined in Section 3.2.1.7.3.5.

3.2.1.7.3.3 Specific Impulse

BPT-240/Created/T,R

The Contractor shall supply a graph of Specific Impulse against 'On Time' over the range from 5 ms to 1000 ms over the range of pressures and temperatures defined in Section 3.2.3.2.

The Specific Impulse of each flight unit shall not differ from the Qualification unit be more than ±2.0% at the nominal point for TON > 50 ms at the standard conditions referred to in Section 3.2.1.7.1.

3.2.1.7.3.4 Minimum On Time

BPT-243/Created/T

The thruster minimum on time shall be as defined in Section 3.2.1.7.3.5, below.

3.2.1.7.3.5 Pulse Mode Duty Cycles

BPT-247/Created/T,R

The thruster shall be capable of the pulse mode duty cycles for pulse train lengths defined in Table 3-2.

On Time, s Command Time, s

0.005 0.2, 1, 4

0.007 0.2, 1, 4

0.01 to 0.02* 0.2, 1, 4

0.03 to 0.07* 0.2, 1, 4, 100, 600

0.12 to 0.25* 1, 4, 100, 600

0.4 to 1.0* 1, 4, 100, 600

* A single value for on time, between the two specified values, shall be demonstrated.

Table 3-2: Pulse Mode Duty Cycles


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BPT-1824/Created/T

The thruster shall be capable of 'Off Modulation'. There shall be no restriction on Minimum Off time.

3.2.1.7.4 Cycle Requirements

BPT-257/Created/T,A,R

The Upstream Valve shall not be degraded by up to 10,000 wet cycles and 100 dry cycles.

The Downstream Valve shall not be degraded by up to 500,000 wet cycles and 100 dry cycles.

The Downstream Valve performance shall not be degraded after exposure to a maximum of 100 dry actuations (no fluid flow) of length not exceeding 1 minute at 28 VDC (following initial valve opening at 28 VDC).

The thruster performance shall not be degraded after exposure to a minimum of 50 BPR cycles (as defined in Section 3.3.5) of the Upstream Valve.

BPR cycle capability shall be verified during Qualification or by Similarity.

Each thruster shall be capable of achieving the number of cycles specified above and shall demonstrate a factor of 1.5 for Qualification.

3.2.1.7.5 Helium Gas Ingestion

BPT-264/Created/T,A

The thruster shall meet the requirements of this document after the ingestion of helium prior to or during firing, in one or both propellant feed lines, this can be simulated during testing by using over saturated propellants.

Specifically the thruster shall survive the effects of helium gas bubble ingestion under the following operating conditions:

• Oxidant bubble ingestion at steady state condition, gas volume 82 cc at operating pressure,

• Fuel bubble ingestion at steady state condition, gas volume 82 cc at operating pressure,

• Oxidant and Fuel bubble ingestion at start up and during firing, gas volume 82 scc at operating pressure.

3.2.2 Electrical Characteristics

BPT-270/Created/I,R

The Upstream Valve coils shall be wired independently with separate negative return lines.

The thruster shall have electrical connections and electrical interface characteristics in accordance with Section 3.2.2.1 to Section 3.2.2.17 inclusive.


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3.2.2.1 Supply Voltage

BPT-1085/Created/T

Normal Operation

• The thrusters shall meet the requirements of this specification when its Upstream Valve and Downstream Valve are supplied with voltage in the normal operating range 28 ± 4 VDC.

• Each Downstream Valve shall be capable of being opened at the Pull In voltage defined in Section 3.2.2.16.

Abnormal Operation

• Each Upstream Valve and Downstream Valve shall be capable of withstanding an over voltage at 40 VDC for one minute and shall operate within the requirements of this specification after the over voltage condition has been removed.

Spurious Voltage

• Both the Upstream Valve (open or close) and Downstream Valve (open) shall not operate when subjected to a spurious voltage of 32 VDC for ≤ 0.5 ms.

3.2.2.2 Power Consumption/Input Current

BPT-281/Created/T

The electrical power consumption of the Upstream Valve when operating shall be < 9 Watts at < 32 VDC and at 21°C.

The electrical power consumption of the Downstream Valve when operating shall be < 14 Watts at < 32 VDC and at 21°C.

3.2.2.3 Insulation Resistance

BPT-284/Created/T

The insulation resistance between each lead in turn and the valve housing shall be no less than 100 Mohms at 21°C, when subjected to a difference in potential of 500 VDC, for a minimum duration of 60 seconds.

3.2.2.4 Corona Discharge

BPT-286/Created/T

No thruster shall exhibit corona discharge while operating in an environmental pressure range from atmospheric pressure to a vacuum of 1 x 10-7 torr.

3.2.2.5 Electrical Bonding

BPT-288/Created/T,I,R

The equipment mounting surfaces shall be unpainted and any protective coating shall produce a conductive finish suitable for electrical bonding.

The DC resistance, measured in either direction, between any metallic part of the equipment housing and the grounding point shall be less than 25 milliohms.

The equipment shall be capable of being mounted such that the DC resistance measured in either direction, between any metallic point of the equipment housing and the structure shall be less than 20 milliohms.

A bonding point shall be provided on the thruster.


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3.2.2.6 Electrical Connections

BPT-293/Created/I,R

The propellant valves shall have flying leads, with a length of 1500 ± 51 mm.

All leads shall be insulated flying wires and be clearly and unambiguously identified.

3.2.2.7 Electromagnetic Compatibility

BPT-296/Created/I,R

The equipment shall comply with the electromagnetic compatibility requirements defined in AD(b).

3.2.2.8 Valve Coil Resistance

BPT-298/Created/T

The resistance of each Upstream Valve (open and close coils) shall be stated by the Contractor.

The resistance of each Downstream Valve shall be stated by the Contractor.

3.2.2.9 Valve Coil Inductance

BPT-301/Created/T

The inductance of each Upstream Valve (open and close coils) shall not exceed that stated by the Contractor.

The inductance of each Downstream Valve shall not exceed that stated by the Contractor.

3.2.2.10 Explosion Proofing

BPT-304/Created/R

The electrically operated valves shall be designed to be non-hazardous when operated in an explosive atmosphere.

Electrical components shall not provide an ignition source for any explosive mixture surrounding the thruster valves.

3.2.2.11 Dielectric Strength

BPT-307/Created/T

There will be no evidence of damage, arcing, electrical breakdown or leakage current exceeding 0.5 mA when a potential of 500 Vac 60 Hz, is applied between any electrical lead and the housing for a duration of 60 seconds.

3.2.2.12 Grounding

BPT-309/Created/R

All the wired interfaces shall use wired returns and not structure, and shall be electrically isolated from the valve casing.

3.2.2.13 Soldering

BPT-311/Created/I,R

Soldering of electrical connections shall conform to SD(j).

A hot wire stripper shall be used to remove insulation from wire in preparation for soldering.

3.2.2.14 Potting

BPT-314/Created/R

The coils shall be protected from shorting to the case by potting the coil cavity.


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3.2.2.15 Valve Response

BPT-316/Created/T,R

The Upstream Valve shall open and close within 15 msec when a voltage within that specified in Section 3.2.2.1 is applied across the opening or closing coil leads respectively, with an inlet pressure of MEOP1 at any temperature in the range specified in Section 3.2.3.2.

The Upstream Valve shall actuate with a pulse duration in the range 20 to 1000 ms (to be confirmed by the Contractor).

The Downstream Valve shall open within 5 msec when a voltage within that specified in Section 3.2.2.1 is applied across the opening coil leads, with an inlet pressure of MEOP1 at any temperature in the range specified in Section 3.2.3.2.

The Downstream Valve shall open when a voltage within that specified in Section 3.2.2.1 is applied across the opening coil leads, with an inlet pressure of MEOP2 at any temperature in the range specified in Section 3.2.3.2.

Note: The test at MEOP2 is a capability demonstration only and not subjected to any response time requirement, however, the Downstream Valve shall continue to comply to all requirements for all subsequent nominal operations.

The Downstream Valve shall close within 2 msec when the voltage is removed with an inlet pressure of MEOP1 ± 0.4 bar at any temperature in the range specified in Section 3.2.3.2.

The Upstream Valve and Downstream Valve shall not actuate with a pulse of 0.5 ms or less.

The Upstream Valve and Downstream Valve shall operate with response profiles that are repeatable and consistent with expected qualified operation.

Qualification data shall be made available from valve or thruster level to demonstrate compliance with the specification with regard to temperature, supply voltage and pressurisation state.

The specific effect of the flight valve driver shall be identified during thrusters level testing.

3.2.2.16 Pull In Voltage/Operating Margin

BPT-327/GDI-2185,Derived/T

The Downstream Valve shall open at a voltage not exceeding 20 VDC at MEOP1 and at any temperature in the range specified in Section 3.2.3.2 with a minimum margin of 0.25.

The Downstream Valve shall be designed to be capable of opening under the above conditions but with inlet pressure at MEOP2 with a minimum margin of 0.25.

Note:

The test at MEOP2 is a capability demonstration only, however, the Downstream Valve shall continue to comply to all requirements for all subsequent nominal operations.

BPT-330/GDI-2185,Derived/T,A

The Upstream Valve shall open at a voltage not exceeding 20 VDC under all inlet (up to MEOP1)/outlet pressure (up to MEOP2) and at any temperature in the range specified in Section 3.2.3.2 with a minimum margin of 0.25.

Note:

1 - R I

V Margin Operating ��

��

�=

where: V is the minimum specified voltage, Volts,

I is the minimum current to actuate, Amps,

R is coil resistance, Ohms.

BPT-2533/Created/T

The Upstream Valve shall not operate when voltages of up to 3V are applied.


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3.2.2.17 Drop Out Voltage

BPT-340/Created/T

The Upstream and Downstream Valves shall close at a voltage not less than 3.0 VDC with the inlet pressurised to a maximum of 4 bar and at any temperature in the range specified in Section 3.2.3.2.

3.2.3 Operating Requirements

3.2.3.1 Operating/Test Fluids

BPT-349/Created/R

The equipment shall be designed to operate and perform to this specification with the following media:

Working Media

• Nitrogen Tetroxide MON1 to MON3 (liquid and vapour) to SD(a),

• MonoMethyl Hydrazine (liquid and vapour) to SD(b),

• Gaseous Helium to SD(c) *.

The equipment shall be compatible (non-operating) with the following media:

Test Media

• Gaseous Nitrogen to SD(d) *,

• Argon Gas to SD(e) *,

• Isopropyl Alcohol (IPA) to SD(g) **,

• Deionised/Demineralised Water to SD(h).

BPT-1092/Created/R

Notes:

* During ground testing when gas is flowing through the thruster, its inlet pressure will be limited to 3 bar when on the spacecraft.

** If the Contractor wishes to pressurise IPA in contact with Titanium or Titanium Alloys, prior consent shall be obtained from the Customer. The pressurisation of IPA in contact with Titanium or Titanium Alloys to greater than 4 bar gauge is prohibited.

3.2.3.2 Fluid/Equipment Temperature

BPT-1093/Created/R

The equipment shall meet the requirements of this specification when operating within the following ranges of equipment temperatures:

• Operating 0°C to +94°C *,

• Acceptance -4°C to +99°C *,

• Qualification -9°C to +104°C *.

The non-operating Qualification temperature range (relevant to dry thermal vacuum testing) shall be -10°C to 90°C *.

Note:

* The actual upper test temperature shall be further increased such that any heat soak back effects are incorporated.

The above temperatures are for the valve/valve block assembly only. The temperature of the nozzle will be much higher.


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BPT-1095/Created/T,R

The thrusters shall meet the above requirements when supplied with propellant temperatures in the range:

• Operating: 0°C to +30°C,

• Acceptance: 0°C to +35°C,

• Qualification: 0°C to +40°C.

• The maximum difference between propellant temperatures is 5°C.

The temperature of each propellant shall be measured at positions to be identified in the relevant Hot Fire Test Plan.

3.2.3.3 Design Life

BPT-378/MPB-5176,Derived/R

The equipment shall be designed with positive margins of safety, to operate and meet the requirements of this specification, for a design life after storage of 10 years in the space environment and the cycle life defined in Section 3.2.1.7.3.5.


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3.3 Design Criteria

3.3.1 General Design Criteria

BPT-381/Created/R

The equipment shall be as designed with positive margins of safety (factor of at least 1.5) to meet the requirements of this specification prior to exposure, during exposure and after exposure to the environments specified herein, as applicable.

Environments experienced during fabrication (see note), transportation and storage shall be controlled so as to be significantly less severe than the environments specified herein.

Components using sliding surfaces for their actuation and operation as well as components with bellows inside the fluid containing part shall not be allowed without the consent of the Customer.

Note:

Exceptions where the process is an integral part of fabrication are to be approved by the Customer.

3.3.2 Proof Pressure

BPT-386/Created/T,A

The closed Upstream Valve seat shall be subjected to a differential proof pressure of 2.0 x MEOP1 with pressure applied at the Upstream Valve inlet.

The closed Downstream Valve seat shall be subjected to a differential proof pressure of 1.5 x MEOP2.

This proof pressure shall be applied to the complete valve interstage (i.e. Upstream Valve outlet, valve interstage passages, and Downstream Valve inlet).

The thrust chamber/injector assembly, its interface to the valve assembly and the valve manifold downstream of the Downstream Valve seat shall be subjected to a proof pressure of 1.5 x the relevant MEOP (i.e. MEOP3 or MEOP4) of that part of the thruster.

The electrical compartment enclosures of the valves shall be designed to withstand an external to internal differential proof pressure of 2 bar minimum.

The Upstream Valve inlet shall be subjected to a differential propellant line (fuel to oxidiser or oxidiser to fuel) proof pressure of 2.0 x MEOP1.

The Upstream Valve shall be closed whilst this pressure is applied so that a differential proof pressure of 2.0 x MEOP1 is created across the relevant seat.

This shall not cause the Upstream Valve to open/close.

The valve interstage (i.e. Upstream Valve outlet, valve interstage passages, and Downstream Valve inlet) shall be subjected to a differential propellant line (fuel to oxidiser or oxidiser to fuel) proof pressure of 1.5 x MEOP2.

The Downstream Valve shall be closed whilst this pressure is applied so that a differential proof pressure of 1.5 x MEOP2 is created across the relevant seat.

This shall not cause the Upstream Valve to open/close.

The propellant lines downstream of the Downstream Valve seat up to the injector assembly, including the thruster/valve interface, shall be subjected to a differential propellant line (fuel to oxidiser or oxidiser to fuel) proof pressure of 1.5 x MEOP3.

If it is shown that the thruster material properties are degraded at operational temperatures the proof pressure shall be factored up accordingly, or the test shall be performed at maximum operating temperature including soak-back.

The equipment shall be subject to 'post integration system level' proof testing at a pressure not exceeding that specified above.


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3.3.3 Burst Pressure

BPT-1096/Created/T,A

The equipment shall withstand, without rupture, burst pressures of:

2.5 x MEOP1 differential pressure across the closed Upstream Valve seat and applied at the Upstream Valve inlet.

2.5 x MEOP2 differential pressure across the closed Downstream Valve seat and applied to the valve interstage (i.e. Upstream Valve outlet, valve interstage passages, and Downstream Valve inlet).

2.5 x MEOP3 applied to the wetted volume in the valve manifold downstream of the Downstream Valve seat up to the injector assembly, including the thruster/valve interface.

Each thrust chamber shall be capable of withstanding, without rupture, a burst pressure of 2.5 x thruster MEOP4.

The propellant lines up to the closed Downstream Valve shall be capable of withstanding, without rupture, a differential propellant line (fuel to oxidiser or oxidiser to fuel) burst pressure of 2.5 x MEOP1.

Up to the burst pressure, any rupture of internal elements shall not result in external leakage higher than that specified in Section 3.2.1.2.1.

3.3.4 Reverse Differential Pressure

BPT-409/Created/T,A

Each Downstream Valve shall withstand without opening or degradation a 1.0 bar reverse differential pressure (internal vacuum to external ambient).

3.3.5 Back-Pressure Relief

BPT-411/Created/R

The Upstream Valve shall incorporate a Back Pressure Relief (BPR) capability to minimise excessive thermal induced pressure effects in the valve interstage (Upstream Valve to Downstream Valve) under all specified conditions.

BPT-412/Created/T,I

This BPR is defined as the reverse pressure differential at which a minimum leakage rate of 50 scc/hr is achieved

This BPR shall be determined by the Contractor for each valve and recorded in the equipment's End Item Data Pack.

The Upstream Valve-Upstream Valve interstage shall be capable of withstanding this BPR added to the MEOP1 pressure, i.e. MEOP2 as defined in Section 3.2.1.1.1.

The equipment's performance shall not be degraded by BPR cycles.

3.3.6 Fracture Control Plan

BPT-418/Created/R

If the equipment has a burst factor of ≥ 4, it does not require analysis to be performed in support of fracture control.


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3.3.7 Thermal Design Requirements

BPT-420/Created/A,R

The Thruster shall be compatible with a mounting that thermally decouples it from the MTM to the maximum extent possible.

For the purposes of design and analysis, it shall be assumed that conductive heat flow across the interface during firing and soak back is zero.

The Thruster shall be designed to ensure that its temperatures are maintained within those acceptable for the equipment when exposed to the specified operating and non-operating thermal environments.

Thermal analysis shall be performed by the Thruster Contractor to demonstrate that the thermal performance of the Thruster provides acceptable temperature gradients and component temperatures when exposed to the specified operating and non-operating environments with respect to the thruster temperature and material limits.

The specified environment ranges defined in Section 3.2.3.2 are to be used for the prediction of the design temperature range (which shall include an appropriate thermal design margin).

Margins for Acceptance and Qualification shall be added to the design temperature range in order to establish the test temperature ranges, in accordance with this specification.

The design of the equipment shall ensure that heat soak back following thruster firings is minimised.

Thruster operation during soak back shall not result in a degraded performance.


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3.3.7.1 Thermal Interface Requirements

BPT-430/Created/T,A,I,R

The Thruster thermal interfaces shall be described within a unit Thermal Interface Control Document, clearly indicating information of Table 3-3.

The thermo-environment shall be defined, i.e. 10 solar constants. Degradation properties of surface finishes shall be quantified.

Thermal Control Type (Conduction/Radiation/Mixed) Temperature Reference Point (TRP) Location

Temperature Distribution for non-isothermal Unit (one TRP per Node) Internal Temperature Measurement Points (if any)

Thermal Capacity and Tolerance Power dissipation and tolerance for each operating mode, including significant transient and failure cases when necessary

Operating and non-operating temperature ranges, including minimum start-up temperature Temperature increment or correction relating to local measured temperatures to average case or baseplate

Finish (material and treatment) including percentage of unit total area for each finish type Absorbance (for external unit), BOL and EOL

Hemispherical emittance, BOL and EOL MLI

Absorbance (for external unit), BOL and EOL Hemispherical emittance, BOL and EOL

Paint free areas (tywrap, heaters...) Special thermal provisions

Alternate finishes (local emittance tape, insulation blanket...) Alternative finishes properties

Thermal interface filler or gaskets Low conductance stand off mounts

Thermistors Heaters

Table 3-3: TICD Content


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BPT-433/Created/R

The unit Contractor shall provide a summary of unit thermal characteristics as per Table 3-4.

Unit: Date:

Subsystem: Issue:

Functioning Temperature (°C) Dissipation per working unit

Operating: TFO Min:

Mission Phase No. of working units

Min (W) Max (W)

TFO Max:

Acceptance: TFO Min: Launch:

TFO Max:

Qualification: TFO Min: Sun:

TFO Max:

In Orbit

Eclipse:

Non Functioning Temperature (°C) Safe Mode:

Non Functioning TNF Min:

TNF Max:

Unit Individual Cold/Hot Failure:

Start up Temperature (°C) Min:

Ground Storage Temperature (°C) Min:

Max:

Unit wall sizing L(mm)*W(mm)*H(mm):

Unit baseplate sizing L(mm)*W(mm):

Unit contact area (cm2):

Unit radiative area (cm2):

Unit emittance:

Unit solar absorbivity:

Unit thermal capacitance (J/°C):

Remarks: (to clarify dissipations in all the existing modes and measured values)

Comments: Mission Phase description:

Unit individual hot failure dissipation shall be computed for maximum figure. Launch: From lift-off to separation from Launcher

Duration shall be given if applicable.

When applicable, heat dissipation profile shall be provided on a separate sheet.

Unit dissipation values of different modes to be provided in addition to Min and Max figures.

Table 3-4: Unit Thermal Data Sheet


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BPT-436/Created/R

The equipment Contractor shall prepare and supply Thermal Interface Control Drawings, which shall define the complete thermal interfaces. These drawings and their issue shall be included in the ICD.

The interface requirements given below may be defined either in the ICD or in this Thermal Interface Control Drawing. It shall, at least, contain the following data:

• Overall layout,

• Dimensions - overall size including thickness and their attachment,

• Nominal base contact area,

• Temperature Reference Point (TRP),

• Internal temperature measurement points (if applicable),

• Thermal capacity and tolerance,

• Power dissipation and tolerance for each operating mode, including significant transient cases,

• Operating and non-operating temperature ranges including minimum start-up temperatures,

• Radiator areas,

• External surface optical properties,

• Apertures (position and size),

• Blankets (if applicable),

• Blanket performance (if applicable),

• Optical properties of box in/outside and protruding parts, apertures, lenses... (BOL, EOL if applicable), and compliance to ESD requirements,

• Non operational heater location,

• Grounding of MLI (if applicable),

• Temperature increment or correction relating locally measured temperatures to average case or baseplate temperature.

3.3.7.2 Thermal Mathematical Model Requirements

3.3.7.2.1 Thermal Interface Modelling

BPT-457/Created/A,R

The use of the ESARAD and ESATAN software packages is recommended for all thermal analyses and shall be required for all deliverable thermal mathematical models.

A reduced thermal mathematical model (both geometric and mathematical) model shall be supplied. This thermal model shall:

• be both geometrically and mathematically representative of the Thruster Assembly,

• contain sufficient information to represent the heat flows across the radiative and conductive interfaces of the Thruster Assembly,

• represent the temperature gradients in the Thruster Assembly,

• include nodes representing the combustion chamber, nozzle, mounting flanges and Upstream Valve/Downstream Valve,

• include thermal capacitance relevant to each node of the Thruster Assembly,

• model the assembly thermal heat dissipation as a function of the operation mode (non-firing, firing and soak back).


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The model shall include at least 6 nodes representing as a minimum the combustion chamber, nozzle, mounting flanges and Upstream Valve/Downstream Valve.

Units:

All units used in thermal models (geometrical and thermal mathematical models) will conform to the International System units (SI units).

In particular for,

• Radiative coupling: square metres,

• Temperature: Kelvin (or Celsius),

• Power: Watts,

• Energy: Joules,

• Dimensions: metres,

• Mass: kg.

For all other parameters, measurement units shall be declared by the Contractor.

3.3.7.2.2 Thermal Model Correlation

BPT-476/Created/R

The detailed thermal model of a unit shall be verified and correlated with a thermal test. The correlation criteria shall be:

• ± 3°C on the temperatures,

• ± 10% on the generated combustion heat flux.

3.3.7.2.3 Reduced Thermal Model

BPT-480/Created/R

The consistency between reduced and detailed thermal model shall be demonstrated by:

• The temperature difference less than ± 2 degrees,

• The generated combustion heat flux less than ± 10%.

The convergence of the thermal models shall be demonstrated.

3.4 Environmental Conditions

3.4.1 Pre-Launch Storage and Transportation

BPT-1100/Created/R

The equipment shall meet the requirements of this specification after being exposed to the following storage and transportation environmental conditions:

• The surrounding medium will be Air, Nitrogen or Helium,

• Relative humidity not in excess of 100%,

• Ambient pressure between sea-level and 15000 metres,

• Ambient temperature range from -40°C to 65°C.


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3.4.2 Pre-Launch System Assembly Integration and Test

BPT-1101/Created/R

The equipment shall meet the requirements of this specification during exposure to the following AIT conditions:

• The surrounding medium will be Air, Nitrogen, Helium, or Argon,

• Relative humidity not in excess of 100%,

• Ambient pressure between sea level and vacuum.

3.4.3 Launch

BPT-497/Created/R

The equipment shall meet the requirements of this specification during and after exposure to the following launch environmental conditions.

Furthermore the equipment shall meet the requirements of Section 3.2.1.2 during exposure to this launch environment:

a. The surrounding medium will be Air, Nitrogen, or Helium.

b. Ambient Pressure

Sea Level to 1 x 10-10 torr. Pressure gradients of -0.03 bar per second from sea level ambient pressure to vacuum and 0.02 bar per second from vacuum to sea level shall not result in any degradation of the equipment or its performance.

c. Temperature (As per Section 3.2.3.2.)


d. Constant Acceleration [derived from AD (b)]

± 96 g in axial direction and ± 72 g in lateral direction applied separately.

For a duration of 60 secs each.

BPT-2013/ET-14391,Derived/T,A

e. Random Vibration (As per Table 3-5.)

Note:

If mechanical couplings are used then flight standard adaptor, seal and nut should be included in the test set-up.

BPT-2014/ET-14312,Derived/T,A

f. Sinusoidal Vibration (As per Table 3-6.)

Note:


BPT-2016/ET-14590,Derived/T,A,R

g. Shock (As per Table 3-7)

Note:



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BPT-516/Created/T

h. Relative Humidity

Relative Humidity up to 100%.

The following Table 3-5 describes the random levels.

Axis Frequency, Hz Qualification, dB/oct

or g²/Hz Acceptance, dB/oct

or g²/Hz

Axial

20 to 100 100 to 300

300 to 2000

+ 3 dB/oct 2.0 g²/Hz - 6 dB/oct


Composite 31.82 grms 22.5 grms

Lateral

20 to 100 100 to 300

300 to 2000



Composite 21.35 grms 15.09 grms

Duration 120 sec/axis 60 sec/axis

Notes:

The equipment shall be pressurised to 4 bar for test.

Table 3-5: Random Spectrum [derived from AD (c)]

The following Table 3-6 describes the sinusoidal levels.

Axis Frequency, Hz Qualification, g or

mm 0 to Peak Acceptance, g or

mm 0 to Peak

Axial 5 to 20 20 to 100

15 mm 0 to Peak 24 g

9.9 mm 0 to Peak 16 g

Lateral 5 to 20 20 to 100

9.9 mm 0 to Peak 16 g

6.6 mm 0 to Peak 10.7 g

Sweep Rate 2 oct/min 4 oct/min

Duration 1 Sweep Up 1 Sweep Up

Notes:


Table 3-6: Sinusoidal Vibration [derived from AD (c)]


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The following Table 3-7 describes the shock levels.

Axis Frequency, Hz Shock Level, g

All Axes

100 300

1000 2000

10000

20 300 820

1500 1500

Notes:

The associated amplification factor is Q = 10, in all cases.


Table 3-7: Shock Levels [derived from AD (c)]

3.4.4 Post-Launch

BPT-1102/ET-227,ET-439,Derived/R

The equipment shall operate within the requirements of this specification when exposed to the following environments:

• Ambient Pressure is 1 x 10-4 torr to 1 x 10-10 torr,

• Temperature is as per Section 3.2.3.2,

• Acceleration of 0 g to 1g in all axes,

• Radiation of 1.5 x 106 rads ionising dose of protons and electrons absorbed in silicon per year of mission.

3.5 Physical Characteristics

3.5.1 Configuration and Dimensions

BPT-532/Created/I,R

The equipment shall comply with the dimensions plus their tolerances and the configuration as defined in Section 3.5.4.

All drawings, specifications and engineering data shall only use the International System of Units (SI units), with the exception of accelerations which may be expressed in terms of multiples of g (gravity).

The maximum overall length shall be 276 mm

The mounting flange to nozzle exit maximum length shall be 142 mm..

The maximum nozzle exit diameter shall be 74.5 mm.

3.5.2 Mass

BPT-535/Created/T

The mass of the equipment shall be the minimum necessary to meet the requirements of this specification, and shall not exceed 850 grams without thermal equipment.

3.5.3 Stiffness


The equipment shall have a natural frequency greater than or equal to 140 Hz when supported rigidly.


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3.5.4 Interfaces

3.5.4.1 Interface with Propulsion Subsystem

BPT-540/Created/I

Fuel and oxidiser inlets shall be clearly identified on the hardware.

The equipment shall be designed for connection to 6.35 mm (0.25 in) O.D., 0.71 mm wall thickness, titanium alloy pipework.

3.5.4.2 Interface with Structure Subsystem

BPT-544/Created/R

Details of the interface requirements of the proposed thruster design shall be supplied by the Contractor.

3.5.4.3 Interface with Thermal Control Subsystem (TCS)

BPT-1103/Created/I,R

The equipment design shall permit the attachment of the following TCS hardware:

• Heaters,

• Temperature Sensors,

• Low emissivity tape or multilayer insulation blanket,

• Thermistors (on both the flange and Upstream Valve/Downstream Valve).

3.5.4.4 Interface with Harness

BPT-552/Created/R

The equipment shall comply with the electrical interface requirements of Section 3.2.2.6.

3.5.4.5 Interface with Ground Support Equipment (GSE)

BPT-554/Created/R

The equipment design shall reflect the requirement to conduct continuity and resistance checks and to operate the equipment at subsystem and equipment level.

In the case of special handling, operating, precautions or instructions being necessary these shall be included in the Contractors Handling and Transportation Procedures, and/or Operating Procedures.

3.5.5 Alignment

BPT-559/Created/R

The nozzle axis shall be at 90° ± 30' to the mounting flange.

The nozzle exit plane shall be parallel to the thruster-mounting plane to within 18 minutes of arc (0.3°).

Geometric thrust vector alignment shall not be affected by the launch environment and total mission operations.

It shall be possible to measure the nozzle alignment to an accuracy of 0.03°.

The thrust vector shall be parallel to the nozzle central axis within an accuracy of 0.03°.

3.5.6 Filter

BPT-563/Created/R

A filter of rating 25 microns nominal, 40 microns absolute shall be incorporated in both the fuel and oxidiser inlet ports of each thruster to protect the thruster from valve blockage, valve seat damage or injector clogging.


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3.5.7 Calibration Orifices

BPT-565/Created/R

The thruster shall be capable of being trimmed to the mixture ratio specified in Section 3.2.1.7.1 at the inlet conditions specified in Section 3.2.1.7.1.

In addition, the calibrated orifices shall be installed and adjusted to meet the requirements of Section 3.2.1.7.1.

3.6 Reliability

3.6.1 Failure Rates

BPT-569/Created/A,R

The equipment shall meet the requirements of AD(a) and this specification with a reliability figure of 12 x 10-9 failures per cycle at an upper 60% confidence level.

3.6.2 Items Subject to Wear-Out/Degradation

BPT-571/Created/R

Equipment parts, materials and processes, subject to wear-out or deterioration due to environment, including radiation, application stresses, or inherent physical processes, shall be designed, fabricated, selected and used to attain performance life requirements.

The design life of such items (except those meant for one-time operation in the initial period) shall be at least 10 years operation in orbit.

3.7 Maintainability

BPT-574/Created/R

No field maintenance servicing, or adjustment shall be required within the specified lifetime.

3.8 Storage

3.8.1 Storage Life

BPT-577/Created/R

All equipments shall meet the requirements of this specification after being stored for a minimum of 8 years total post delivery ground storage at equipment, subsystem or spacecraft level.

The equipment shall be capable of storage under the conditions specified in Section 3.4.1 and Section 3.4.2.

3.8.2 Equipment Storage

BPT-580/Created/R

The equipment will be stored, post-delivery, packaged as per Section 5.1 and stored at subsystem and spacecraft level under clean conditions, Class 100,000 or better, with temperature, relative humidity and barometric pressure as in Section 3.4.1.

3.9 Transportability

BPT-582/Created/R

Special packing shall be used as necessary to ensure that transportation methods do not incur design penalties.

The equipment shall be transportable by air, ship or road.

Shipment by train is prohibited.


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3.10 Design and Construction

3.10.1 Selection of Specifications and Standards

BPT-587/Created/R

All specifications and standards intended for use in the design and construction of the equipment shall be in accordance with the requirements defined in AD(a).

3.10.2 Materials, Parts and Processing

BPT-589/Created/R

Each material, part and process shall be controlled by a detailed specification and shall satisfy the applicable requirements of AD(a).

3.10.2.1 Dissimilar Metals

BPT-591/Created/R

Contact of dissimilar metals with each other, as defined in SD(i) shall be avoided wherever possible.

Where necessary, protection against electrolytic corrosion which can result from such contact shall be provided by surface treatment of the metals.

3.10.2.2 Moisture and Fungus Resistance

BPT-594/Created/R

Materials that are nutrients to fungi shall be avoided.

Where used, and not hermetically sealed, they shall be treated with a suitable fungicidal agent.

3.10.2.3 Corrosion of Materials

3.10.2.3.1 Stress Corrosion Sensitivity

BPT-598/Created/R

Metals and alloys which are susceptible to stress corrosion cracking shall not be used.

Heat treating of alloys to obtain non-stress--corrosion sensitive conditions is allowed.

3.10.2.3.2 Corrosion Resistance

BPT-601/Created/R

Materials shall be corrosion resistant type or suitably treated to resist corrosive effects likely to result from exposure to the environmental conditions specified.

Protective coating shall not crack, chip, peel or scale with age when subjected to the environmental extremes specified.

3.10.2.4 Magnetic Materials

BPT-604/Created/R

Magnetic materials shall only be used where necessary for equipment operation.

Materials used shall minimise the permanent, induced, and transient magnetic fields.

Magnetic materials shall be avoided as far as is practicable.

Any magnetic material used within the equipment shall be reported to, and approved by the Customer.

3.10.2.5 Ceramic Materials

BPT-609/Created/R

Ceramic materials or coatings that may crack or break under any combination of operating conditions or environments specified shall not be used.


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3.10.2.6 Seals

BPT-611/Created/R

Any seals used shall comply with all the applicable requirements of this specification, particularly Section 3.10.2.11 and Section 3.10.2.12.

3.10.2.7 Lubricants and Sealants

BPT-613/Created/R

Lubricants and sealants shall be used only if essential for equipment assembly.

Their use shall be minimised and subject to the Customer approval.

3.10.2.8 Standard and Commercial Parts

BPT-616/Created/R

Standard and commercial parts may be used if they do not degrade the reliability of the equipment and are in accordance with the requirements for approved materials and parts.

3.10.2.9 Finish

BPT-618/Created/R

The surface of the equipment shall be adequately finished to prevent deterioration from exposure to the specified environments that might jeopardise fulfilment of the specified performance.

No cadmium, tin, or zinc plating shall be used on any components.

3.10.2.10 Contamination and Cleanliness

3.10.2.10.1 Contamination

BPT-622/Created/R

Operation of the equipment shall not result in the release or generation of particles entering the fluid passage. The interior of the equipment shall be designed and fabricated to facilitate cleaning and prevent the entrapment of contaminants.

Equipment shall contain no chips, slag, particulate matter, oil, grease, liquid or other foreign material.


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3.10.2.10.2 Equipment Cleanliness

BPT-625/Created/T,I

The equipment shall be assembled under Cleanroom conditions, Class 100,000 or better.

All equipments shall be measurably clean to equal or better that the levels shown in Table 3-8.

The first sample (as described below) taken after passage through the equipment shall not exceed the listed particle count or distribution.

The flushing media shall be Filtered (3 microns absolute) Isopropyl Alcohol to SD(g), Deionised Water to SD(h).

BPT-629/Created/T,I

The Cleanliness Verification Fluid Sample shall consist of 100 ml of fluid, or 100 ml of fluid per 929 cm² (1 ft²) of internal surface area, whichever is the greater.

Particle Count, microns Maximum Allowable Count per 100 ml

> 100* 51 to 100* 26 to 50 11 to 25 6 to 10 0 to 5

Non-Volatile Residue (NVR)

0 1 5

20 140

No Silting Less than 1 mg/100 ml

Notes:

* No metallic particles greater than 50 microns.

The equivalent particle size of any particle at its maximum dimension (i.e. fibre length in the case of a fibre).

Table 3-8: Cleanliness Requirements


Flight equipment shall not be subjected to propellant liquids or vapours prior to flight use except for hot fired equipment.

Any other liquids shall be removed by flushing with Isopropyl Alcohol per SD(g) and then purge with Nitrogen SD(d) and then vacuum dried such that all traces of the liquids are removed (e.g. < 10 ppm for IPA, dew point < - 40 degrees C).

After all cleaning procedures have been completed, the level of chemical contaminants retained in the equipment shall be such that correct functioning shall not be impaired or compromised throughout the operational lifetime.


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3.10.2.11 Fluid Compatibility

BPT-636/Created/R

All equipment shall be compatible with the working media of Section 3.2.3.1 for the lifetimes quoted in this specification, without performance degradation or external leakage.

Propellant compatibility shall be demonstrated by exposure of representative equipment models to propellants.

The equipment shall also be compatible with the test media of Section 3.2.3.1 and any fluids used by the equipment Contractors and subcontractors to test, clean or dry the equipment for periods of exposure of at least 2 months.

The equipment shall be compatible with Cleanroom air as specified by Section 3.4.1 and Section 3.4.2.

The use of halogenated solvents in contact with titanium alloys is expressly prohibited.

The use of FREON is expressly prohibited.

All fluids used shall be agreed by the Customer.

3.10.2.12 Outgassing

BPT-644/Created/R

Outgassing shall comply with the requirements of AD(a).

3.10.2.13 Interchangeability

BPT-646/Created/I,R

All like parts shall have the same part number.

Each equipment item shall be directly interchangeable in form, fit, and function with other equipment of the same part number.

The performance characteristics shall permit interchange with a minimum of adjustments and recalibrations.

The equipment must be of the same Qualification status and reliability to meet interchangeability requirements.

3.10.2.14 Workmanship

BPT-651/Created/R

Workmanship shall be executed such that the design standard is not degraded or changed.

At all points in the manufacture, production, integration, test, handling, storage, and transportation, special steps shall be taken to maintain the design standard.

The skill level of personnel is to be such that all aspects of workmanship will ensure retention of the high reliability standards, with particular attention to the following:

• Free from blemishes, burrs, and sharp edge,

• Required tolerances on dimension,

• Compliance with designed radii of fillet,

• Adequate and correct marking of parts and assemblies,

• Thoroughness of cleaning, soldering, welding, brazing and finishing,

• Freedom from oxidation, cracks, undercuts, lack of fusion, incomplete penetration and sharp edge,

• Freedom from paints, dyes and grease,

• Alignment of parts and assemblies, in accordance with specified requirement,

• Interlocking of components and assemblies.


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3.11 Identification and Marking

BPT-1105/Created/I

Each equipment shall be permanently labelled. This to include, but not be limited to, the following:

a. Equipment Title.

b. Serial Number.

c. Direction of Flow.

d. Manufacturers Part Number.

e. Fuel and oxidiser inlet identification.

Note:

To aid identification upon delivery, the CI number and issue number are to be marked on the Certificate of Conformance, and included within the inner packaging of the flight hardware.

The identification shall be visible when marked on the equipment and its location shall be noted on the top assembly drawings for the equipment.

Assemblies and higher level equipment shall be assigned a unique serial number.

Serial numbers once assigned shall not be transferred or used again on other items of the same part number.

Where equipment contains levels of serialised hardware items, the lower level items shall be traceable through the tiers of serialisation to the end items.

3.12 Safety

3.12.1 General

BPT-678/Created/A,R

All equipments shall be designed and fabricated with compatible materials in such a manner that all hazards associated with the equipment are eliminated or minimised and controlled.

A hazard analysis report is required [reference AD(a)].

The equipment shall be designed to comply with the requirements of Section 3.3.

3.12.2 Toxic or Hazardous Materials

BPT-682/Created/I

Where toxic or hazardous materials are used in equipment, that equipment shall bear a label that identifies the hazard source i.e. 'Warning: This unit contains…………'.

In addition the following hazard reduction criteria shall be implemented:

•The provision of warning notes in manufacturing document,

•Special handling constraints and procedures,

•Scrap disposal controls.

3.12.3 Locking

BPT-688/Created/I,R

Positive locking of screw type hardware used on the equipment shall be achieved by safety wire where possible.

Alternative methods of locking and internal locking shall be approved by the Customer.


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3.12.4 Explosive Atmospheres

BPT-691/Created/R

The electrical valve assembly shall be non-hazardous when operating in an explosive atmosphere.

3.12.5 Decontamination

BPT-693/Created/I

Each thruster shall be delivered free of propellant with a decontamination certificate.


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4 QUALITY ASSURANCE PROVISIONS

4.1 General Requirements

These requirements apply to BepiColombo spacecraft.

4.1.1 Responsibility for Inspection and test

Unless otherwise specified in the contract or purchase order, the Contractor is responsible for the performance of all inspection and test requirements as specified herein.

4.1.2 Quality Assurance Programme

BPT-700/Created/R

The Contractor shall have or shall establish and implement a Quality Programme that complies with the requirements of AD(a).

The Contractor's Quality Programme/Plan shall be approved by the Customer.

4.1.3 Surveillance, and Witness of Inspection and Test

BPT-703/Created/I

The Customer shall be given access to the Contractor's facilities at all times, given reasonable notice, in order to inspect the Contractor's quality control system and the records specified to be maintained therein.

The Contractor shall ensure that appropriate arrangements are made for access to lower tier Contractor's facilities/test houses where critical operations are to be performed.

The Customer and the Customer's Customer (or their nominated representatives) reserve the right to witness or review the tests or documentation of any of the inspections set forth in the specification where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

The Contractor shall notify the Customer at least 2 weeks and subsequently 48 hours (fax/email) prior to the commencement of the Qualification or Acceptance Test phases to enable representation by the Customer and witnessing of any or all Tests as considered necessary by the Customer.

4.1.4 Preproduction Sample

BPT-708/Created/R

Prior to manufacturing of a new equipment batch, the manufacturer shall verify the use of the same materials, techniques and processes as are applicable to the unit referred to in Section 4.2.3.1.

4.1.5 Classification of Inspection and Test

BPT-710/Created/R

The examination and testing of the equipment shall be classified as follows:

a. Qualification Inspection and test (Section 4.2.3.2).

b. Acceptance Inspection and test (Section 4.2.2).

c. Preparation for delivery Inspection and test (Section 4.5).


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4.2 Verification of Compliance

BPT-715/Created/R

Compliance with the requirements of Section 3 shall be verified by Acceptance inspections and tests, Qualification, or analysis as stated in Section 4.

The method of verification of Section 3 and Section 4 shall be presented in a Design Verification Matrix Report to a format to be agreed between the Contractor and the Customer.

The equipment Contractor shall provide positive verification from trials or in service experience (and supported by reference data), of the compatibility of the equipment with the operating and test fluids to the requirements of Section 3.10.2.11.

At the discretion of the Customer, if the verification of compliance with Section 3.10.2.11 is not conclusive, further testing prior to and as part of Qualification to Section 4.2.3.2 will be required.

4.2.1 General

4.2.1.1 Acceptance

BPT-721//

The applicable paragraphs of Section 3 shall be verified by performing Acceptance inspections and tests in accordance with Section 4.2.2 on each deliverable equipment.

4.2.1.2 Qualification

BPT-1106/Created/T,A,I,R,S

Qualification of the equipment to meet the requirements of Section 3 may be demonstrated as specified below:

a. Qualification Inspection and Tests

Design Verification of the equipment shall be established by performing the Qualification inspections and tests detailed in Section 4.2.3.2 on a minimum of one unit. This unit shall not subsequently be used on a flight spacecraft.

b. Qualification by Similarity

If the Contractor can demonstrate by analysis that the proposed equipment is similar in design, construction and performance to existing space qualified equipment and that previous Qualification covers all or part of the performance and environmental requirements of Section 3, then the Contractor may offer 'Qualification by Similarity' against the relevant requirement(s). Qualification testing may be then omitted subject to the Customer approval

c. Qualification by Analysis

Where analysis is proposed to demonstrate compliance with any of the requirements of this specification, it is subject to the Customer approval.

d. Protoflight Qualifications

Subject to the Customer agreement, delta Qualifications can be performed using a protoflight Qualification philosophy. The testing shall occur at Qualification levels as detailed in this specification, but at Acceptance Level times and sweep rates. Protoflight units are subsequently acceptable for flight use.

4.2.2 Acceptance, Inspection and Test

4.2.2.1 Test Sample

BPT-734/Created/T,I

Each deliverable unit produced in accordance with this specification, shall be subjected to the Acceptance Tests specified in Section 4.2.2.2.

Each unit shall be clean prior to entering Acceptance testing in accordance with Section 3.10.2.10.2.


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4.2.2.2 Acceptance Tests Required (Minimum)

BPT-737/Created/T

The series of tests shown in Table 4-1 are to be conducted on the complete thruster i.e. Thrust Chamber Assembly (TCA), Upstream Valve and Flow Control Valve (Downstream Valve).

Test Sequence Test Description Section

1 Inspection Section 4.4.1

2 Proof Pressure Test Section 4.4.2

3 Internal and External Leakage Section 4.4.6.2 and Section 4.4.6.1

4 Sine Resonance Search Section 4.4.3.1

5 Sine Vibration Section 4.4.3.3


7 Random Vibration Section 4.4.3.2 (b)


9 Acceptance Firing Tests Section 4.4.10.2

10 Proof Pressure Test Section 4.4.2

11 Electrical Functional Tests Section 4.4.12


13 Cleanliness Verification Section 4.4.17

14 Final Inspection Section 4.4.1

Table 4-1: Acceptance Tests

BPT-740/Created/I,R

A summary of test results, to be agreed with the Customer, from valve level Acceptance tests shall be presented in the thruster's End Item Data Pack.

4.2.2.3 Failure Criteria

BPT-742/Created/R

The unit shall exhibit no failure, malfunction or out-of-tolerance performance degradation as a result of Acceptance inspections and tests specified in Section 4.2.2.2.

Any such occurrence shall be cause for rejection.

4.2.2.4 Acceptance Test Report

BPT-745/Created/R

Following completion of Acceptance tests on each unit, a test report shall be prepared evaluating results of tests in accordance with AD(a).

4.2.2.5 Test Limitations

BPT-747/Created/R

The Acceptance Inspection and test shall not degrade the unit performance or expose the Assembly to test levels or conditions which could induce a subsequent failure.


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4.2.2.6 Rejection and Resubmittal

BPT-749/Created/R

Any failure, malfunction, or out-of-specification conditions which occur during the test programmes shall result in immediate stoppage of the test to avoid the possibility of further hazard to equipment or personnel.

Further testing shall not be recommended unless the condition shall be properly investigated and the proposed recovery and corrective action shall be reviewed and approved by the Customer.

In the case of a failure requiring replacement or rework, the test programme will be repeated in its entirety except as mutually agreed between the Contractor and the Customer.

4.2.3 Qualification Inspection and Test

4.2.3.1 Test Sample

BPT-754/Created/T,I

Qualification Testing shall be carried out on a unit which shall be manufactured in accordance with the requirements of this specification.

The unit shall be identical to the units that will be supplied for flight spacecraft.


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4.2.3.2 Qualification Tests Required

BPT-757/Created/T

Qualification shall verify compliance of the equipment to all the requirements in Section 3 and as a minimum, the Qualification Inspection and Tests listed below shall be conducted in the following sequence:

Test Step Test Description Section

1 Acceptance Tests (excluding Vibration) Section 4.2.2.2

2 Environmental Test (Climatic non-operating) Section 4.4.11


4 Sine Vibration Section 4.4.3.3


6 Constant Acceleration Section 4.4.4


8 Random Vibration Section 4.4.3.2(a)


10 Shock Test Section 4.4.5


12 Gas Flow Tests Section 4.4.7

13 Operating Margin Section 4.4.14


15 Thermal Vacuum Test (see Note 1) Section 4.4.8

16 Life Cycle Tests Section 4.4.9

17 Firing Tests (including bubble ingestion) Section 4.4.10.1

18 Internal and External Leakage (see Note 2) Section 4.4.6.2 and Section 4.4.6.1

19 Electrical Functional Tests Section 4.4.12

20 Cleanliness Section 4.4.17

21 Proof Test (Valve only) Section 4.4.2


23 Burst Pressure Test Section 4.4.18

24 Final Examination Section 4.4.19

Note 1: Subject to Customer approval, individual tests above may be omitted if Qualification can be verified by similarity and/or analysis as stated in Section 4.2.1.2 (b) and (c). For special notes on thermal vacuum test requirements see Section 4.4.8.

Note 2: For external leakage, a nitrogen gas pressure decay test post hot-firing may be acceptable to the Customer in cases where a fully enclosed mass spectrometer test is not possible due to safety reasons (thruster still contaminated prior to strip down). The actual test procedure shall be reviewed and agreed by the Customer prior to such a substitution.

Table 4-2: Qualification Tests


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4.2.3.3 Failure Criteria

BPT-761/Created/T,R

The unit shall exhibit no failure, malfunction or out of tolerance performance degradation as a result of Qualification inspections and tests specified in Section 4.2.3.2.

Any such occurrence shall be cause for rejection and refusal to grant Qualification.

4.2.3.4 Qualification Test Report

BPT-764/Created/R

Following the completion of Qualification Tests, a Test Report containing the Test Results, together with an evaluation and comparison with the requirements, shall be delivered.

4.2.3.5 Rejection and Resubmittal

BPT-766/Created/T,R

Any failure, malfunction, or out of specification conditions which occur during the test programme shall result in immediate stoppage of the test to avoid the possibility of further hazard to equipment or personnel.

Further testing shall not be recommenced unless the condition shall be correctly investigated and the proposed recovery and corrective action shall be reviewed and approved by the Customer.

In the case of a failure requiring a replacement, or rework, the test programme will be repeated in its entirety except as mutually agreed between the Contractor and the Customer.

4.3 Test Conditions and Test Equipment

4.3.1 Ambient Conditions

BPT-771/Created/R

Unless otherwise stated, all measurements and tests shall be made within the following ambient conditions:

• Temperature: 23°C ± 5°C

• Relative Humidity: 60% maximum

• Pressure: 760 ± 25 mm Mercury

All pressures and temperatures shall be recorded unless specified otherwise.

Whenever these conditions must be closely controlled in order to obtain reproducible results, a reference temperature of 23°C, a relative humidity of 50% and an atmospheric pressure of 760 mm of Mercury respectively shall be used, together with whatever tolerances are required to obtain the desired precision of measurement.

4.3.2 Test Equipment

BPT-778/Created/R

The apparatus used in conducting tests shall be capable of producing and maintaining the required test conditions as defined in the applicable test procedures.


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4.3.3 Tolerance of Test Conditions (Excluding Ambient)


All testing shall observe the tolerances stated in Table 4-3.

Parameter Tolerance

Temperature, Maximum -0°C, +3°C

Temperature, Minimum +0°C, -3°C

Pressure For proof and leak tests a tolerance of -0/+0.5 bar applies. For all other pressures not specified directly, a tolerance of ±2% applies.

Relative Humidity ±5%

Acceleration +10%, -0%

Sinusoidal Vibration +10%, 0 'g' peak

At low frequencies, the electrodynamic exciter may have an amplitude limitation which prevents achievement of 12.5 mm, zero to peak, and the subsequent 'g' level. Such limitations are acceptable down to a minimum amplitude of 5 mm zero to peak for equipment having resonant frequencies greater than 30 Hz.

Random Power Spectral Density ±3 dB

Random Overall Acceleration (RMS) Frequencies:

+10%, -0% ± 2%, ± 0.5 Hz below 20 Hz

Time +5%, -0

Acoustic Pressure Force

+ 3, -0 dB in each octave + 5%, -0

Dry Mass ± 1 g (see Section 4.4.1.4)

Shock: 100 Hz to 1 kHz Shock: 1 kHz to 10 kHz

+ 0, + 3 dB + 0, + 6 dB

Table 4-3: Test Tolerances

4.3.4 Accuracy of Measurement

BPT-784/Created/I

The accuracy of all instruments and test equipments used to control or monitor the test parameters, whether located at the Contractor's testing laboratory or at a subcontractor's plant shall be verified periodically by calibration.

Such calibration shall be traceable to National Standards.


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4.3.5 Test Media


The test media to be used shall be in accordance with Section 3.2.3.1.

• Helium gas to SD(c)

• Nitrogen gas to SD(d)

• Isopropyl Alcohol (IPA)* to SD(g)

• Deionised/Demineralised Water to SD(h)

Notes:

* Pressurisation of equipment with Isopropyl Alcohol (IPA) in excess of 4 bar gauge is prohibited.

Pure MMH and MON-3 in accordance with Section 3.2.3.1 are to be used for test firings.

Propellant samples shall be taken from the thruster inlet interface and analysed to verify compliance with SD(a) and SD(b).

4.3.6 Product Test Controls

BPT-796/Created/R

Controls for item configuration, testing item documentation, non-conformance and failure reporting, the Customer and the Customer's Customer inspection and test surveillance shall be as specified in AD(a).

4.4 Test Methods

BPT-798/Created/T

The following tests shall be carried out in the sequence specified in Section 4.2.3.2.

4.4.1 Inspection/Examination

BPT-800/Created/R

The unit shall be inspected by Subcontractor Quality Assurance for the applicable requirements listed below in accordance with this specification and approved subcontractor standards.

Mechanical inspection criteria shall be as specified on the applicable drawings.

4.4.1.1 Dimensions

Dimensional requirements are to be provided to the Customer for assessment.

4.4.1.2 Identification and Marking

BPT-805/Created/I

The unit shall be inspected for compliance with the marking requirements of Section 3.11.


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4.4.1.3 Materials and Processes

BPT-807/Created/I

The unit shall be visually inspected and manufacturing records and drawings shall be reviewed to verify that materials and processes used conform to specified requirements.

Inspection shall verify the following as a minimum:

a. Completeness of product.

b. Conformance to drawings or other manufacturing document.

c. Completion of all steps in the manufacturing process and proper certification.

d. Workmanship, assembly and fit.

e. Materials, parts and finish.

f. All welds subject to pressure shall be inspected by a Customer approved method. Inspection methods shall comply with the requirements of AD(a). Subsequent tests will subject the welds to proof and leak test.

g. There shall be no evidence of nicks, cracks, scratches, burrs or any defect (or physical imperfection) which would adversely affect the performance of the unit, compromise cleanliness or interface requirements (e.g. stub tube).

4.4.1.4 Physical Measurements

BPT-1109/Created/T,A,I

The following physical measurement shall be performed:

a. The weight of each unit shall be measured to an accuracy of ± 1.0g.

b. The centre of gravity and the moment of inertia of the unit shall be calculated.

c. The thrust vector alignment error with respect to the requirements of Section 3.5.5 shall be determined.

d. The alignment angle shall be measured and recorded in the manufacturing cards.

4.4.2 Proof Pressure Test

BPT-1110/Created/T,I

With the Upstream Valve closed, the inlet ports shall be pressurised with helium or nitrogen at ambient temperature to the proof pressure specified in Section 3.3.2.

The pressure shall be maintained for 5 minutes minimum.

With the Upstream Valve open and Downstream Valve closed, the inlet ports shall be pressurised with helium or nitrogen at ambient temperature to the proof pressure specified in Section 3.3.2.

The pressure shall be maintained for 5 minute minimum.

Subsequent to this test, helium or nitrogen shall be applied at the pressure defined in Section 3.3.2 from the downstream end of the thruster as far as the closed Downstream Valve to test the thrust chamber, injector assembly, and interface to the valve assembly.

The pressure shall be maintained for 5 minutes minimum.

The propellant line differential proof pressures defined in Section 3.3.2 shall be verified during Qualification.

Following the above tests, the unit shall meet all the specified requirements and show no evidence of damage or distortion.

For Qualification, a representative unit (valve level) shall be proof tested to the pressure specified in Section 3.3.2.


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4.4.3 Vibration Tests

4.4.3.1 General Requirements

BPT-834/ET-140,Derived/T,R

A sine vibration survey of 0.2 g, 10 to 2000 Hz shall be conducted in each of the three mutually perpendicular axes prior to and after performing the Qualification and Acceptance Tests specified. Survey results shall indicate no shift in eigenfrequency greater than ± 10% between pre and post vibration surveys attributable to a change in Test Item or Test Fixture characteristics. It shall be mandatory that the procuring authority is notified in the event of any non-conformance to this requirement and notified in due time to allow delta-test if necessary prior to completion of tests.

The unit shall meet the stiffness requirement of Section 3.5.3.

The transmissibility and crosstalk of the test fixture shall be determined by a swept sine vibration (as above) or a low level random vibration applied in each of three mutually perpendicular axes. The test fixture shall be sufficiently stiff to be considered rigid for the frequency range up to 2000 Hz (random case) and 100 Hz (sine case).

4.4.3.2 Random Vibration

BPT-1111/ET-14319,Derived/T

Observing the general requirements of Section 4.4.3.1, the unit shall be subjected to random vibration inputs separately along the three orthogonal axes at the following levels, where applicable:

a. Qualification

120 seconds per axis at Qualification Levels defined in Table 3-5.

b. Acceptance

60 seconds per axis at Acceptance Levels defined in Table 3-5.

c. Protoflight Qualifications

60 seconds per axis at Qualification Levels defined in Table 3-5.

Following testing, the unit shall be inspected to confirm no physical damage.

During Qualification and protoflight vibration, the unit shall be pressurised to 4 bar using helium.

For Qualification vibration, this test should be performed twice, once with the Upstream Valve open and the Downstream Valve closed, and secondly with the Downstream Valve open and the Upstream Valve closed, thus verifying that the Upstream and Downstream Valves do not open during the testing.

The pressure shall be monitored to verify no leakage of Upstream Valve or Downstream Valve during vibration.

The unit shall not normally be pressurised during Acceptance vibration.

The pressure shall be monitored to verify no leakage of the Upstream Valve or Downstream Valve during vibration.


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4.4.3.3 Sinusoidal Vibration

BPT-856/ET-14312,Derived/T,I

Observing the general requirements of Section 4.4.3.1 the unit shall be vibrated at the levels specified in Table 3-6.

The levels shall be applied along each of three orthogonal axes at a sweep rate of 2 octaves/minute.

If protoflight level vibration is required the sweep rate shall be 4 octaves/minutes.

During vibration the unit shall be pressurised to 4 bar helium.

For Qualification vibration, this test should be performed twice, once with the Upstream Valve open and the Downstream Valve closed, and secondly with the Downstream Valve open and the Upstream Valve closed, thus verifying that the Upstream and Downstream Valves do not open during the testing.

The pressure shall be monitored to verify no leakage of Upstream Valve or Downstream Valve during vibration.

Following testing the unit shall be inspected to confirm no physical damage.

4.4.4 Constant Acceleration

BPT-900/GDI-3673,Derived/T

The unit shall be subject to the constant acceleration levels specified in Section 3.4.3, applied separately along each of three orthogonal axes in both directions.

Test duration shall be 1 minute in each direction (6 minutes total).

As an alternative, sustained acceleration Qualification may be achieved by sinusoidal vibration testing (sine dwell) at a frequency which is demonstrated by a low level sine sweep to be well separated from any equipment resonances.

In this case, a constant frequency sine input shall be held for 1 minute after a steady state sine level has been established, along each of the 3 orthogonal axes.

For Qualification, this test should be performed twice, once with the Upstream Valve open and the Downstream Valve closed, and secondly with the Downstream Valve open and the Upstream Valve closed, thus verifying that the Upstream and Downstream Valves do not open during the testing.

The pressure shall be monitored to verify no leakage of Upstream Valve or Downstream Valve during the testing.

4.4.5 Shock Testing

BPT-1751/ET-14590,Derived/T

The units shall be subject to levels specified in Table 3-7 applied separately along each of the three orthogonal axes.

The unit shall be pressurised to 4 bar with flight representative connections and suitable capillary tubing (to prevent significant effects on pressure), and the pressure shall be monitored.

For Qualification, this test should be performed twice, once with the Upstream Valve open and the Downstream Valve closed, and secondly with the Downstream Valve open and the Upstream Valve closed, thus verifying that the Upstream and Downstream Valves do not open during the testing.

The pressure shall be monitored to verify no leakage of Upstream Valve or Downstream Valve during the testing.


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4.4.6 Leakage Tests

4.4.6.1 External Leakage


For the purpose of this test the thruster shall be pressurised with Helium at ambient temperature:

• with FCV closed and inlet pressurised to MEIP,

• with FCV open, nozzle capped and inlet pressurised to MEOP (This assumes that the nozzle/chamber is rated for this pressure).

The total external leakage shall be measured by a mass spectrometer, and shall not exceed the level stated in Section 3.2.1.2.

4.4.6.2 Internal Leakage


For the purpose of this test the thruster shall be set to the closed position, and pressurised with Helium at ambient temperature to a pressure of MEIP, MEOP, and 3.5 bar.

The internal leakage past the individual and combined valve seats shall be measured, and shall not exceed the levels stated in Section 3.2.1.2.

4.4.7 Gas Flow Tests (Qualification only)

4.4.7.1 Rapid Depressurisation

BPT-1715/Created/T

The unit shall be subjected to external depressurisation to the levels and rates specified in Section 3.2.1.6.1.

The configuration shall be that applicable to the launch phase with the unit internally pressurised with helium to 4 bar.

4.4.7.2 Priming of Lines up to Upstream Valve

BPT-1727/Created/T

With the unit's valves in the closed position, the unit shall be subjected to two pressure spikes in accordance with Section 3.2.1.6.2.

4.4.7.3 Priming of Lines up to Downstream Valve:

BPT-1730/Created/T

With the Upstream Valve open and Downstream Valve closed, the unit shall be subjected to 2 pressure spikes in accordance with Section 3.2.1.6.3.

4.4.7.4 Rapid Through Flow

BPT-1733/Created/T

With both thruster valves initially closed and unit pressurised Section 3.2.1.6.4, the Upstream Valve shall opened to generate a rapid through flow.

4.4.7.5 Hydraulic Shock

BPT-1736/Created/T

The unit shall be subjected to a hydraulic shock as specified in Section 3.2.1.6.5.

This shall first be performed with the Upstream Valve closed and then repeated with the Upstream Valve open.

The closed valve(s) shall not open undemanded nor leak as a result of this test and the unit shall continue to meet all specified requirements after the test.


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4.4.7.6 Constant Pressure Gas Flow Test

BPT-1756/Created/T

To verify there is no gross blockage of the injector, this test shall be conducted by flushing the thruster with GN2 and recording the flow rate (fuel and oxidiser side) through the unit at a feed pressure of 2 +0/-0.2 bar.

Note:

This test is used to provide a reference measurement against which post-subsystem integration tests are compared.

4.4.8 Thermal Vacuum Test

BPT-911/Created/T

The thruster/valve assembly shall be subjected to the level of vacuum and the thermal cycle defined in Figure 4-1.

BPT-912/Created/T

Ambient Temp

Minimum Temperature

Maximum Temperature *

Cycle 1 Final Cycle

Q

Q

Q

Q

Q

Q

Q

A

A

A

Total No. Cycles:

FM: 5 cycles PFM: 5 cycles QM: 30 cycles

Stabilisation Period prior to functional testing. 2 hr Acc, 4 hrs Qual.

Temp Rate ≤ 3°C/min Pressure ≤ 10-5 torr

Stabilisation Period 1 hr

A

* plus any soak back effects

Q = Qualification Functional Testing defined below.

A = Acceptance Functional Testing defined below.

Maximum and Minimum Temperatures are defined in Section 3.2.3.2.

Note:

The thermal cycle profile may be reversed, i.e. cold followed by hot, subject to Customer approval.

Figure 4-1: Thermal Vacuum Testing at Thruster Level


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BPT-914/Created/T,A

During all non-operating phases, the requirements of Section 4.4.11 shall be met.

The Upstream Valve shall be open during thermal cycling and MEOP2 pressure applied to the valve inlet for Acceptance and Protoflight testing. For Qualification thermal vacuum cycling, 1.25 x MEOP2 pressure shall be applied to the valve inlet.

The pressure downstream of the Downstream Valve shall be monitored to verify no leakage during the cycling.

Leakage tests - The internal and external leakage shall be measured at ambient and at the temperature extremes. Measured leakage shall be in accordance with Section 3.2.1.2.3.

Additionally, it shall be demonstrated during hot firing Qualification testing and Acceptance testing that no external or internal leakage is induced by thermal vacuum/hot fire cycles.

Functional performance checks shall be performed at the points indicated in Figure 4-1.

Test Description Section

Pull In Voltage Section 4.4.12.1

Drop Out Voltage Section 4.4.12.2

Coil Inductance Section 4.4.12.5

Electrical Resistance Section 4.4.12.6

Valve Response Section 4.4.12.8

Figure 4-2: Thermal Vacuum Functional Performance Tests

Note for Qualification:

Subject to Customer approval the Qualification thermal test may be performed at valve level if the Contractor can provide validation of the valve/nozzle interface by similarity. Furthermore, if it can be shown that vacuum does not contribute to the test, the test may be performed at ambient pressure.

Note for Flight Acceptance:

Subject to the Customer approval, the electrical performance, the valve external leakage and internal leakage parts of the thermal test may be performed at valve level. If it can be shown that vacuum does not contribute to the test, the test may be performed at ambient pressure. For the external leakage test on the manifold to flange interface, subject to the Customer approval, the high and low temperature test may be deleted if the Contractor can provide justification that the Qualification temperature extremes do not contribute to the test. Should the Contractor wish to perform an external and/or internal leakage test at thruster level at high and low temperatures then an alternative method of leak measurement may be used subject to prior review and agreement of the specific test procedure by the Customer.

4.4.9 Life Cycle Tests

BPT-924/Created/T

Each thruster shall meet the cycle performance requirements of Section 3.2.1.7.4 allowing for a Qualification factor of 1.5 over the spacecraft mission requirements.


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4.4.10 Firing Tests

Details of the equipment driver are as specified in AD (f).

BPT-1626/Created/T

During testing the thruster shall be mounted in a manner representative of that on the spacecraft. If this is not possible the thruster shall be thermally isolated from the test cell mounting structure.

Parameters to be measured and recorded during firings shall include, but not necessarily be limited to, thrust, propellant flow rates, chamber temperature, propellant valve temperatures, test cell pressure, propellant supply pressure and temperature.

Maximum soak back temperatures after engine shut down shall be determined and reported.

All recorded firing data shall be deliverable and submitted to the Customer request.

4.4.10.1 Qualification Firing Tests

BPT-1631/Created/T,R

The thruster shall be subjected to a comprehensive firing test programme in order to verify performance compliance with all the requirements of Section 3.2.1.7.

This includes performance mapping to define the in-flight performance with respect to all the variable extremes specified in Section 3.2.1.7.

The thruster shall demonstrate compliance to all the requirements of Section 3.2.1.7.

The Qualification firing programme shall be agreed with the Customer and be based on AD (f).

4.4.10.2 Acceptance Firing Tests

BPT-1636/Created/T

A series of performance mapping test firings in pulse mode and continuous mode shall be conducted in accordance with AD (f).

These mapping firings shall cover all the ranges of mass flow rates and mixture ratios implied by the temperature and pressure variations in this specification.

The Acceptance firing programme shall be agreed with the Customer and be based on AD (f).

Output data from these tests shall include, but not be limited to, thrust and specific impulse measurements.

4.4.11 Environmental Temperature (Non-Operating)

BPT-926/Created/T

The empty and dry unit shall be mounted in a climatic chamber, and helium at ambient pressure and temperature applied to the spacecraft side of the valve.

With the chamber at ambient pressure, the chamber temperature shall be raised to 338 K and the relative humidity adjusted to between 70% and 80% RH.

This condition shall be maintained for 8 hours*.

Immediately following this, the temperature shall be reduced to 233 K and maintained at this condition for 16 hours*.

The unit shall be examined for evidence of deterioration following the completion.

* where the Contractor can show that the equipment is not sensitive to the extended test duration specified, subject to the Customer approval, the test duration may be reduced.


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4.4.12 Electrical Functional Tests

4.4.12.1 Pull In Voltage

BPT-947/Created/T

The pull in voltage of the Downstream Valve shall be measured and shall comply with the requirements of Section 3.2.2.16.

The opening force margin for the Upstream Valve shall be measured and shall comply with the requirement of Section 3.2.2.16.

(This test may be performed at valve level only subject to Customer approval).

4.4.12.2 Drop Out Voltage

BPT-951/Created/T

The drop out voltage of the Downstream Valve shall be measured and shall comply with the requirements of Section 3.2.2.17.

4.4.12.3 Overvoltage Test

BPT-1740/Created/T

An overvoltage as specified in Section 3.2.2.1 shall be applied to the unit's Downstream Valve for a minimum of 60 seconds.

The unit shall not be damaged by the testing and shall continue to meet the requirements of this specification.

The overvoltage as specified in Section 3.2.2.1 shall be applied to the unit's Upstream Valve for a minimum of 60 seconds.

This shall be then be followed by a closing pulse at the same voltage and duration.

This cycle shall be repeated a minimum of 3 times at 5 minute intervals.

The unit shall not be damaged by the testing and shall continue to meet the requirements of this specification.

4.4.12.4 Insulation Resistance Test

BPT-953/Created/T

A potential of 500 VDC shall be applied between each lead in turn and the valve element case and maintained for 1 minute or until a stable reading is obtained.

The insulation resistance shall comply with the requirements of Section 3.2.2.3.

4.4.12.5 Coil Inductance

BPT-956/Created/T

The electrical inductance of each valve shall be measured and shall comply with the requirements of Section 3.2.2.9.

The requirements of Section 3.2.2.11 shall be met following this test.

4.4.12.6 Electrical Resistance

BPT-959/Created/T

The electrical resistance of each valve coil shall be measured, and shall comply with the requirements of Section 3.2.2.8.


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4.4.12.7 Electrical Bonding Test

BPT-961/Created/T

Using a suitable electronic bonding test meter, the DC resistance shall be measured between the metallic external parts of the unit. The resistance shall not exceed that specified in Section 3.2.2.5.

4.4.12.8 Valve Response

4.4.12.8.1 Upstream Valve Response

BPT-964/Created/T

The opening and closed response of the Upstream Valve shall be measured and verified against the requirements of Section 3.2.2.15.

The Maximum Operating Time of the Upstream Valve shall be established for the following conditions:

a. An initially closed valve with an inlet pressure of MEOP1, being opened using a voltage set to the minimum value specified in Section 3.2.2.1.

b. An initially open valve with an inlet pressure at ambient, being closed using a voltage set to the minimum value specified in Section 3.2.2.1.

The Minimum Operating Time of the Upstream Valve shall be established for the following conditions:

a. An initially closed valve with an inlet pressure at ambient, being opened using a voltage set to the maximum value specified in Section 3.2.2.1.

b. An initially open valve with an inlet pressure at MEOP1, being closed using a voltage set to the maximum value specified in Section 3.2.2.1.

In all tests, the electrical signal duration shall be < 50 ms.

Response traces shall be included in the equipment's End Item Data Pack and shall show no abnormal profiles or adverse trends.

4.4.12.8.2 Downstream Valve Response

BPT-974/Created/T

The opening and closing responses of the Downstream Valve shall be measured and verified against the requirements of Section 3.2.2.15.

Response traces shall be included in the equipment's End Item Data Pack and shall show no abnormal profiles or adverse trends.

4.4.12.9 Dielectric Strength

BPT-979/Created/T

At valve level, a voltage of 500 Vac shall be separately applied between each propellant valve electrical lead and the valve body for a minimum of 60 seconds.

The requirements of Section 3.2.2.11 shall be met.

4.4.13 Attitude Sensitivity

BPT-982/Created/T

The unit shall meet the requirements of Section 3.2.1.5 in any of the attitudes tested.


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4.4.14 Pressure Margin

With an internal proof pressure of 1.5 x MEOP1 applied at the inlet ports of the Upstream Valve and ambient pressure downstream of the Upstream Valve, the valve shall be electrically operated to the open position with minimum voltage (Section 3.2.2.1) and signal duration (Section 3.2.2.15).

The valve shall operate and indicate open without damage or performance degradation.

The test shall be repeated operating to the closed position.

4.4.15 Back Pressure Relief Pressure

BPT-1009/Created/T

At valve level, the Upstream Valve shall be set to the closed position and a supply of nitrogen connected to the output port.

The reverse pressure differential shall then slowly be increased and the pressure recorded at which leakage first occurs.

The pressure shall continue to be increased to determine the Back Pressure Relief at which the leakage specified in Section 3.3.5 is met.

4.4.16 Contamination Test

BPT-1020/Created/T

The Contractor shall propose methods of quantifying the amount of thruster exhaust backscatter produced by the thruster during Acceptance Tests. Test methods should include physical means such as optical devices or witness plates.

The validity of these tests shall also be assessed, with respect to the limitations of the test cell in comparison with spaceflight environment.

4.4.17 Cleanliness Verification


The purpose of this test is to verify that the unit still meets the cleanliness requirements of Section 3.10.2.10 in readiness for delivery. The units should be clean prior to entering Acceptance or Qualification testing. It should not be subjected to any cleaning procedure immediately prior to this Cleanliness Verification or after any preceding tests (unless otherwise stated).

The unit shall be flushed with the specified quantity of Isopropyl Alcohol to SD(g) or Deionised/Demineralised Water to SD(h) filtered to 3 microns absolute or better.

The flushing fluid shall be verified to meet the NVR requirements of Section 3.10.2.10.

The first 100 ml fluid sample shall be used. The effluent shall be withdrawn from the unit for particle count. The particulate count of the total effluent sample when tested using a procedure approved by the Customer, shall meet the requirements of Section 3.10.2.10.

In the event that the unit fails to meet the specified requirement on the first cleanliness verification test the Contractor shall inform the Customer of the failure and particulate count, and await Customer approval before subjecting the unit to additional cleaning, cleaning verification tests, or any other tests.

Following the cleanliness verification test, the unit shall be gas purged and thoroughly dried in vacuum to a the Customer approved procedure to remove all traces of residual liquid.

The unit shall then be protected against contamination in accordance with Section 5.1 prior to removal from the contamination controlled area.


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4.4.18 Burst Pressure Test

BPT-1617/Created/T

The unit shall be pressurised at ambient temperature to the burst pressures specified in Section 3.3.3 above test ambient.

The pressure shall be increased at a uniform rate to be agreed with the Customer and the burst pressure shall be maintained for a minimum of 1 minute.

Rupture of the unit at or below the specified level shall be cause for rejection.

Rupture of internal elements shall not result in external leakage higher than that specified in Section 3.2.1.2.

Tests shall be performed in such a way as to fully Test the assembly in accordance with Section 3.3.3 including burst differential across valve seats.

The Contractor may propose a 'Qualification by Similarity' approach if required in order to preserve hardware for possible future testing.

4.4.19 Final Inspection

BPT-1746/Created/T

Prior to the burst test of the equipment inspect for any damage or deformation including non-destructive endoscopic inspection downstream of the injector, etc.

Following the burst test, should rupture have occurred, then the equipment shall be stripped and inspected for any damage or deformation.

Record which equipment parts are showing evidence of damage and take photographs of all piece parts if and where applicable.

4.5 Preparation for Delivery, Inspection and Test

BPT-1023/Created/R

Examination of preservation, packaging, and marking shall be conducted to assure compliance with the requirements of Section 5 of this specification.


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5 PREPARATION FOR DELIVERY

5.1 Methods of Preservation and Packaging

BPT-1026/Created/R

Unless otherwise specified in the contract or purchasing order, equipment procured to this specification shall be packaged, packed and marked for shipment as specified herein.

A copy of the Contractors handling/transportation and safety procedures and decontamination certificate shall be included with the equipment in an obvious and readily accessible position to facilitate reference before final stages of unpacking.

5.1.1 Retention of Cleanliness

BPT-1029/Created/R

After cleaning, and while the unit is still in a controlled clean room area, tube ends are to be capped off or enclosed using antistatic Nylon material conforming to SD(f) cleaned to Level I.

Material should then be secured in place with clean-room tape to a specification approved by the Customer.

Tape shall not touch the tube outer diameter surface closer than 50 mm from tube end.

The unit shall then be bagged using a 2 mil minimum antistatic Nylon inner bag cleaned to Level 1, per SD(f) and outer bagged with 4 mil minimum Nylon or Polyethylene transparent antistatic material cleaned to Level 2 per SD(f).

Bag ends are to be heat sealed closed; the inner bag shall be evacuated prior to heat sealing.

An identification non-shedding tag shall be placed between the inner and outer bags, and shall display the following caution note as a minimum: 'Open in a Contamination Controlled Area only'.

A humidity indicator shall also be placed between the inner and outer bags.

5.1.2 Storage

BPT-1037/Created/R

The unit shall be capable of being stored for a minimum of that stated in Section 3.8.1 without requiring repair, maintenance or retesting at the end of storage.

5.1.3 Protective Coverings

BPT-1039/Created/R

The unit shall be provided with protective covering to prevent contamination during transportation outside clean areas and where necessary to protect against damage in handling, where applicable blanking caps shall be fitted at any venting or sensing ports.

Blanking caps shall be labelled and instructions included in the Handling and Transportation Procedures to 'Remove Before Flight or Test' as applicable.

5.2 Equipment Packaging

BPT-1042/Created/R

Each bagged unit shall be inserted into an equipment container.

Additional cushioning material shall be used to fill all voids and prevent movement of the unit during handling and shipping.


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5.3 Equipment Container Design

BPT-1045/Created/R

The equipment container shall be designed and constructed to provide sufficient strength and protection of the equipment during the handling and environmental hazards which may be encountered when transported by common carrier.

The inside dimensions of the container shall permit a minimum of 50 mm spacing between any surface of the equipment and inside surface of the container.

The equipment container shall be usable for storage of packaged equipment.

5.4 Packing

BPT-1049/Created/R

Any number of equipment containers shall be uniformly loaded into a shipping container.

The shipping container shall provide protection for each equipment and equipment container during shipment and handling and shall meet the minimum packaging requirements of the common carrier (if so shipped) for safe transportation at the lowest rate to the point of delivery.

5.5 Identification Marking for Shipment and Storage

BPT-1116/Created/I

Each unit's intermediate and shipping container shall be labelled, tagged, or marked to show at least the following:

• CCD Number

• Nomenclature

• Contractor's Part and Serial Number

• Contractor's Name or Trademark

• Quantity or Weight (kg)

• Contractor's Customer Contract Number/Name and line item

• WARNING: OPEN ONLY WITH QA/QC SUPERVISION and in clean room class 100,000

• Decontamination Safety Certificate.


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6 GDIR APPLICABILITY MATRIX

The following table lists the applicable requirements of the GDIR.

It contains, in the first column, the Local ID for each applicable GDIR requirement number.

The second column contains the GDIR Requirement number and the opening text of the requirement.

The third column defines the Applicability Y/N

The final column shows the intended verification method. If no method is shown it shall be assumed that verification is required and the method is TBD

Req No. Reference Applicability Verif.

Method 2.1 Applicable Documents BPT-2561 GDI-3994:

The following documents, of the latest issue, or o ... Y

2.2 Applicable Standards BPT-2563 GDI-3993:

The following documents, of the latest issue, or o ... Y

3.1 General Design Requirements BPT-2565 GDI-3287:

All BepiColombo documentation shall use the SI Int ... Y R

3.1.1 Lifetime BPT-2567 GDI-35:

The equipment/subsystem shall meet the requirement ... Y TBD

BPT-2568 GDI-38: Maintenance during storage shall be as limited as ...

Y A

BPT-2569 GDI-37: The MPO equipment/subsystems shall be designed wit ...

Y A

BPT-2570 GDI-51: The MPO equipment/subsystems shall be designed to ...

Y T,A

BPT-2571 GDI-53: The MTM equipment/subsystems shall be designed wit ...

Y T,A

BPT-2572 GDI-48: Where the design margin on nominal lifetime is not ...

Y R,TBC

BPT-2573 GDI-49: The lifetime of items which degrade shall be desig ...

Y R,TBC

3.1.2 Safety and Product Liability BPT-2575 GDI-55:

The subcontractor shall comply to the applicable s ... Y A

3.1.5 Interchangeability BPT-2577 GDI-70:

All spacecraft equipment/subsystems of the same pa ... Y R

3.1.6 Identification & Marking BPT-2579 GDI-72:

The equipment hardware shall be identified with a ... Y I

BPT-2580 GDI-73: The equipment/subsystem identification nameplate s ...

Y I

3.1.7 Accessibility/Maintainability & Ground Testing Requirements

BPT-2582 GDI-82: The design of the equipment/subsystem, the positio ...

Y R

BPT-2583 GDI-83: The equipment shall be designed to require a minim ...

Y R

BPT-2584 GDI-84: No field maintenance, servicing or adjustment shal ...

Y R


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Req No. Reference Applicability Verif. Method

3.1.8 Transportation, Handling and Storage 3.1.8.1 Transport BPT-2587 GDI-77:

The equipment/subsystems shall be transported usin ... Y R

BPT-2588 GDI-78: The equipment/subsystem containers, covers (for op ...

Y R

BPT-2589 GDI-79: The equipment/subsystem transport container shall ...

Y R

BPT-2590 GDI-80: The equipment/subsystem storage container shall be ...

Y R

3.1.8.2 Equipment/Subsystem Packing BPT-2592 GDI-90:

Where applicable blanking caps shall be fitted to ... Y I

BPT-2593 GDI-91: All equipment shall be packaged to ensure that it ...

Y I

BPT-2594 GDI-93: The specified item GSE shall follow as far as appr ...

Y I

3.1.8.3 Container Identification BPT-2596 GDI-95:

Each container shall be labelled, tagged or marked ... Y I

BPT-2597 GDI-96: In addition to the above, the container shall also ...

Y I

BPT-2598 GDI-2267: Size of company labels on containers shall be agre ...

Y R

3.1.8.4 Handling BPT-2600 GDI-98:

Equipment/subsystem weighing more than 10 kg shall ... Y R

3.1.9 Seals BPT-2602 GDI-100:

Any seals used shall comply with all the applicabl ... Y R

BPT-2603 GDI-101: Any seals requiring periodic replacement during gr ...

Y R

3.1.10 Lubricants and Sealants BPT-2605 GDI-103:

No lubricants or sealants shall be used without th ... Y R

3.1.11 Radiation Environment BPT-2607 GDI-3289:

The spacecraft equipments/subsystems shall be able ... Y A

BPT-2608 GDI-3292: The equipment/subsystem shall be able to safely wi ...

Y A

BPT-2609 GDI-3594: SEE in terms of transients are depending on applic ...

Y A

BPT-2610 GDI-3595: The subcontractor shall perform a displacement ana ...

Y A

BPT-2611 GDI-3596: With respect to radiation impact, the unit shall b ...

Y A

3.2 Mechanical Design and Interface Requirements BPT-2613 GDI-105:

All drawings, specifications and engineering data ... Y R

BPT-2614 GDI-106: Equipment/subsystem shall be compatible with mecha ...

Y R

BPT-2615 GDI-2137: Material selection shall be in accordance with ECS ...

Y R


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BPT-2616 GDI-2139: Mechanical parts selection shall be in accordance ...

Y R

BPT-2617 GDI-3980: All reference frames shall be right-handed orthogo ...

Y R

3.2.2 Structural Design 3.2.2.1 General Requirements BPT-2620 GDI-117:

The following failure modes, for equipment/subsyst ... Y A

BPT-2621 GDI-118: For all structural items the following analyses ar ...

Y A

BPT-2622 GDI-119: Dynamic Analysis: The dynamic analysis shall show ...

Y A

BPT-2623 GDI-121: Stress Analysis: For each item a complete stress/s ...

Y A

BPT-2624 GDI-122: No yielding is allowed at proof load/proof pressur ...

Y T

BPT-2625 GDI-2053: The structure shall be of adequate strength to wit ...

Y A

BPT-2626 GDI-2054: Local buckling shall be tolerated only if it is re ...

Y A

BPT-2627 GDI-2055: For composite materials, microbuckling of fibers s ...

Y A

BPT-2628 GDI-123: The equipment/subsystem shall be designed to withs ...

Y A

BPT-2629 GDI-124: For sine and random vibrations, the mechanical siz ...

Y A

BPT-2630 GDI-125: Wherever practical in the design of the primary st ...

Y A

BPT-2631 GDI-126: Redundancy concepts (fail-safe) shall be considere ...

Y A

BPT-2632 GDI-127: Fracture control principles shall be applied where ...

Y A

BPT-2633 GDI-128: In cases where a fail-safe design cannot be implem ...

Y A

BPT-2634 GDI-129: Pressure vessels shall be potential fracture criti ...

Y A

BPT-2635 GDI-130: A sealed container is a pressurized container, com ...

Y A

BPT-2636 GDI-131: Pressure lines, fittings and components shall subj ...

Y T

BPT-2637 GDI-133: All fusion joints shall be 100 %inspected accordin ...

Y I

BPT-2638 GDI-134: Fasteners used in safe life applications, items fa ...

Y A

BPT-2639 GDI-135: Fasteners a. Fasteners shall be classified and ana ...

Y A

BPT-2640 GDI-136: PFCIs shall comply with ECSS-E-30-01A in full. ...

Y A

BPT-2641 GDI-137: Non-metallic flight structural items (composite, g ...

Y T


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BPT-2642 GDI-138: For load cases involving thermal and/or moisture d ...

Y A

BPT-2643 GDI-139: Where pressure and/or temperature and/or moisture ...

Y A

BPT-2644 GDI-140: The Flight equipment shall be able to survive 4 ti ...

Y A

3.2.2.2 Mass Properies BPT-2646 GDI-143:

All equipment/subsystem suppliers shall provide eq ... Y R

BPT-2647 GDI-146: The mass of an item must be measured with the foll ...

Y T

3.2.2.3 Centre of Gravity and Moment of Inertia BPT-2649 GDI-148:

All COG and MOI estimates shall be accompanied by ... Y A

BPT-2650 GDI-149: The Center of Gravity (CoG) shall be given. w.r.t. ...

Y R

BPT-2651 GDI-150: The Moments of Inertia (MoI) shall be given about ...

Y R

3.2.2.4 Stiffness requirements BPT-2653 GDI-2140:

Minimum natural frequency requirements are imposed ... Y A

BPT-2654 GDI-154: Except otherwise specified, when equipment/subsyst ...

Y T,A

BPT-2655 GDI-155: Modal analysis shall be performed to verify the fr ...

Y T,A

3.2.2.5.1 Ground Operations Loads BPT-2657 GDI-2188:

The units and associated transport containers shal ... Y A

BPT-2658 GDI-2189: Vertical and horizontal loads shall be considered ...

Y A

BPT-2659 GDI-2199: The transportation containers shall be designed to ...

Y A

BPT-2660 GDI-2200: The MGSE design and analysis shall consider a desi ...

Y A

BPT-2661 GDI-3629: During ground transportation the units shall withs ...

Y A

BPT-2662 GDI-3664: All MGSE, containers, transportation and handling ...

Y A

BPT-2663 GDI-3665: Sine and random vibrations: the unit transport con ...

Y A

BPT-2664 GDI-3666: For containers, the shock requirement is a drop of ...

Y T,R

3.2.2.6 Strength requirements 3.2.2.6.1 Definitions and General Requirements 3.2.2.6.2 Margins of Safety and Factors of Safety BPT-2668 GDI-186:

An uncertainty factor Jf shall be defined to provi ... Y A

BPT-2669 GDI-187: A Qualification Factor of 1.5 shall be used for KQ ...

Y T

BPT-2670 GDI-188: An Acceptance Factor of 1.0 shall be used for KA t ...

Y A

BPT-2671 GDI-189: A Design Factor of 1.5 shall be used for DF to det ...

Y A


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BPT-2672 GDI-194: The unit shall be able to withstand, without failu ...

Y A

BPT-2673 GDI-195: Margin of safety (MOS) a. Margins of safety (MOS) ...

Y A

BPT-2674 GDI-197: Minimum Factors of Safety against ultimate for pre ...

Y A

BPT-2675 GDI-198: For combined loads where L(P) is the load due to m ...

Y A

BPT-2676 GDI-207: Conservative friction coefficients regarding minim ...

Y A

BPT-2677 GDI-208: Wherever applicable, for general design of bolts, ...

Y R

BPT-2678 GDI-209: In addition, in case of combined loads due to ther ...

Y A

3.2.3 Design Requirements 3.2.3.1 Mounting Requirements BPT-2681 GDI-219:

The attachment points of the equipment/subsystem s ... Y R

BPT-2682 GDI-3996: The mechanical mounting interface shall be consist ...

Y R

BPT-2683 GDI-220: The number of attachment bolts for an equipment sh ...

Y A

BPT-2684 GDI-221: The interface plane flatness of a equipment/subsys ...

Y I

BPT-2685 GDI-222: The equipment/subsystem bolts type and number shal ...

Y R

BPT-2686 GDI-223: Except otherwise specified, all equipment/subsyste ...

Y R

BPT-2687 GDI-228: Unless special conditions override, the thickness ...

Y R

BPT-2688 GDI-229: Minimum clearance between mechanical parts shall c ...

Y R

BPT-2689 GDI-230: All equipment/subsystems shall be designed allowin ...

Y A

BPT-2690 GDI-2550: The minimum load carrying capability of the insert ...

Y A,R

BPT-2691 GDI-2551: The following typical insert distances along the m ...

Y A,R

3.2.4 Mechanical / Optical Interface Control Documents BPT-2693 GDI-239:

The mechanical and optical configuration and its i ... Y A

BPT-2694 GDI-240: Interfaces will be subjected to a formal inspectio ...

Y T,I

BPT-2695 GDI-241: The issues of ICDs have to be released as defined ...

Y A

BPT-2696 GDI-242: One of the attachment holes on a equipment/subsyst ...

Y R

BPT-2697 GDI-243: The equipment/subsystem reference frame shall have ...

Y R

BPT-2698 GDI-246: The dimensioning of the attachment hole pattern sh ...

Y A

BPT-2699 GDI-247: Interface Control Drawings shall be provided to AS ...

Y R


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3.2.5 Mechanical Mathematical Model Requirements BPT-2701 GDI-253:

Detailed Finite Element Models (FEM) shall be prov ... Y A

BPT-2702 GDI-254: All FE model requirements, checks and formats are ...

Y T

3.4 Thermal Design and Interface Requirements 3.4.2 Definition of Temperatures and Terms BPT-2705 GDI-298:

In the frame of BepiColombo, all equipment/subsyst ... Y R

3.4.2.3 Isothermal Equipment/Subsystem BPT-2707 GDI-302:

As far as possible thermal gradients across the ba ... Y R

BPT-2708 GDI-303: For radiative equipment/subsystems the temperature ...

Y T,A

BPT-2709 GDI-304: For conductive equipment/subsystems the temperatur ...

Y T,A

BPT-2710 GDI-305: For non-isothermal equipment/subsystems a referenc ...

Y R

3.4.2.4 Temperature Reference Point (TRP) BPT-2712 GDI-307:

The temperature reference point (TRP) shall be sel ... Y R

3.4.3 Thermal Interface Requirements 3.4.3.1 Conductive Interface BPT-2715 GDI-316:

The mounting interface shall comply with the mecha ... Y A

BPT-2716 GDI-2536: An interface filler with a coefficient of friction ...

Y R

3.4.3.2 Radiative Interface BPT-2718 GDI-322:

Equipment/subsystems shall be designed with an emi ... Y R

3.4.3.3 Internal Temperature Monitoring BPT-2720 GDI-324:

Temperature monitoring of selected points within a ... Y R

BPT-2721 GDI-325: The location, type and electrical interface of all ...

Y R

3.4.5 Thermal Control BPT-2723 GDI-331:

All thermal hardware mounted on the equipment/subs ... Y R

3.4.6 Thermal Interface Control Documents BPT-2725 GDI-333:

All equipment/subsystem thermal interfaces shall b ... Y R

3.4.7 Thermal Mathematical Model Requirements 3.4.7.2 Thermal Interface Modeling BPT-2728 GDI-336:

The Thermal mathematical model shall be provided f ... Y A

BPT-2729 GDI-337: SI units: All units used in thermal models (geomet ...

Y A

3.4.7.3 Thermal Model Correlation BPT-2731 GDI-339:

The detailed thermal model of a equipment/subsyste ... Y T,A

3.4.7.4 Reduced Thermal Model BPT-2733 GDI-341:

The consistency between reduced and detailed therm ... Y A


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BPT-2734 GDI-342: The convergence of the thermal models shall be dem ...

Y A

5.1 Mechanical Interface Datasheet BPT-2736 GDI-2760:

The mechanical and optical configuration and its i ... Y R

6.1 Thermal Interface Control Document BPT-2738 GDI-2892:

All unit thermal interfaces shall be described wit ... Y R


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Requirement/Section Cross Reference Page numbers are the pages where the sections start

BPT-104 .............3.1 ...................9 BPT-142 .............3.2.1.2.1...........12 BPT-145 .............3.2.1.2.2...........12 BPT-148 .............3.2.1.2.3...........12 BPT-151 .............3.2.1.2.4...........12 BPT-154 .............3.2.1.2.5...........12 BPT-158 .............3.2.1.3 .............12 BPT-161 .............3.2.1.4 .............13 BPT-163 .............3.2.1.5 .............13 BPT-166 .............3.2.1.6.2...........13 BPT-169 .............3.2.1.6.3...........13 BPT-172 .............3.2.1.6.4...........13 BPT-175 .............3.2.1.6.5...........13 BPT-179 .............3.2.1.7 .............14 BPT-184 .............3.2.1.7.1...........14 BPT-199 .............3.2.1.7.2.1........14 BPT-205 .............3.2.1.7.2.2........15 BPT-211 .............3.2.1.7.2.3........15 BPT-213 .............3.2.1.7.2.4........15 BPT-217 .............3.2.1.7.2.5........15 BPT-220 .............3.2.1.7.2.6........15 BPT-222 .............3.2.1.7.2.7........15 BPT-228 .............3.2.1.7.3.1........16 BPT-237 .............3.2.1.7.3.2........16 BPT-240 .............3.2.1.7.3.3........16 BPT-243 .............3.2.1.7.3.4........16 BPT-247 .............3.2.1.7.3.5........16 BPT-257 .............3.2.1.7.4...........17 BPT-264 .............3.2.1.7.5...........17 BPT-270 .............3.2.2 ................17 BPT-281 .............3.2.2.2 .............18 BPT-284 .............3.2.2.3 .............18 BPT-286 .............3.2.2.4 .............18 BPT-288 .............3.2.2.5 .............18 BPT-293 .............3.2.2.6 .............19 BPT-296 .............3.2.2.7 .............19 BPT-298 .............3.2.2.8 .............19 BPT-301 .............3.2.2.9 .............19 BPT-304 .............3.2.2.10 ...........19 BPT-307 .............3.2.2.11 ...........19 BPT-309 .............3.2.2.12 ...........19 BPT-311 .............3.2.2.13 ...........19 BPT-314 .............3.2.2.14 ...........19 BPT-316 .............3.2.2.15 ...........20 BPT-327 .............3.2.2.16 ...........20 BPT-330 .............3.2.2.16 ...........20 BPT-340 .............3.2.2.17 ...........21 BPT-349 .............3.2.3.1 .............21 BPT-378 .............3.2.3.3 .............22 BPT-381 .............3.3.1 ................23 BPT-386 .............3.3.2 ................23 BPT-409 .............3.3.4 ................24 BPT-411 .............3.3.5 ................24 BPT-412 .............3.3.5 ................24 BPT-418 .............3.3.6 ................24 BPT-420 .............3.3.7 ................25 BPT-430 .............3.3.7.1 .............26

BPT-433 ............. 3.3.7.1 ............. 26 BPT-436 ............. 3.3.7.1 ............. 26 BPT-457 ............. 3.3.7.2.1 .......... 28 BPT-476 ............. 3.3.7.2.2 .......... 29 BPT-480 ............. 3.3.7.2.3 .......... 29 BPT-497 ............. 3.4.3 ................ 30 BPT-504 ............. 3.4.3 ................ 30 BPT-516 ............. 3.4.3 ................ 30 BPT-532 ............. 3.5.1 ................ 32 BPT-535 ............. 3.5.2 ................ 32 BPT-537 ............. 3.5.3 ................ 32 BPT-540 ............. 3.5.4.1 ............. 33 BPT-544 ............. 3.5.4.2 ............. 33 BPT-552 ............. 3.5.4.4 ............. 33 BPT-554 ............. 3.5.4.5 ............. 33 BPT-559 ............. 3.5.5 ................ 33 BPT-563 ............. 3.5.6 ................ 33 BPT-565 ............. 3.5.7 ................ 34 BPT-569 ............. 3.6.1 ................ 34 BPT-571 ............. 3.6.2 ................ 34 BPT-574 ............. 3.7 ................... 34 BPT-577 ............. 3.8.1 ................ 34 BPT-580 ............. 3.8.2 ................ 34 BPT-582 ............. 3.9 ................... 34 BPT-587 ............. 3.10.1 .............. 35 BPT-589 ............. 3.10.2 .............. 35 BPT-591 ............. 3.10.2.1 ........... 35 BPT-594 ............. 3.10.2.2 ........... 35 BPT-598 ............. 3.10.2.3.1 ........ 35 BPT-601 ............. 3.10.2.3.2 ........ 35 BPT-604 ............. 3.10.2.4 ........... 35 BPT-609 ............. 3.10.2.5 ........... 35 BPT-611 ............. 3.10.2.6 ........... 36 BPT-613 ............. 3.10.2.7 ........... 36 BPT-616 ............. 3.10.2.8 ........... 36 BPT-618 ............. 3.10.2.9 ........... 36 BPT-622 ............. 3.10.2.10.1 ...... 36 BPT-625 ............. 3.10.2.10.2 ...... 37 BPT-629 ............. 3.10.2.10.2 ...... 37 BPT-632 ............. 3.10.2.10.2 ...... 37 BPT-636 ............. 3.10.2.11 ......... 38 BPT-644 ............. 3.10.2.12 ......... 38 BPT-646 ............. 3.10.2.13 ......... 38 BPT-651 ............. 3.10.2.14 ......... 38 BPT-678 ............. 3.12.1 .............. 39 BPT-682 ............. 3.12.2 .............. 39 BPT-688 ............. 3.12.3 .............. 39 BPT-691 ............. 3.12.4 .............. 40 BPT-693 ............. 3.12.5 .............. 40 BPT-700 ............. 4.1.2 ................ 41 BPT-703 ............. 4.1.3 ................ 41 BPT-708 ............. 4.1.4 ................ 41 BPT-710 ............. 4.1.5 ................ 41 BPT-715 ............. 4.2 ................... 42 BPT-721 ............. 4.2.1.1 ............. 42 BPT-734 ............. 4.2.2.1 ............. 42 BPT-737 ............. 4.2.2.2 ............. 43

BPT-740............. 4.2.2.2............. 43 BPT-742............. 4.2.2.3............. 43 BPT-745............. 4.2.2.4............. 43 BPT-747............. 4.2.2.5............. 43 BPT-749............. 4.2.2.6............. 44 BPT-754............. 4.2.3.1............. 44 BPT-757............. 4.2.3.2............. 45 BPT-761............. 4.2.3.3............. 46 BPT-764............. 4.2.3.4............. 46 BPT-766............. 4.2.3.5............. 46 BPT-771............. 4.3.1................ 46 BPT-778............. 4.3.2................ 46 BPT-784............. 4.3.4................ 47 BPT-796............. 4.3.6................ 48 BPT-798............. 4.4................... 48 BPT-800............. 4.4.1................ 48 BPT-805............. 4.4.1.2............. 48 BPT-807............. 4.4.1.3............. 49 BPT-834............. 4.4.3.1............. 50 BPT-856............. 4.4.3.3............. 51 BPT-900............. 4.4.4................ 51 BPT-911............. 4.4.8................ 53 BPT-912............. 4.4.8................ 53 BPT-914............. 4.4.8................ 53 BPT-924............. 4.4.9................ 54 BPT-926............. 4.4.11.............. 55 BPT-947............. 4.4.12.1........... 56 BPT-951............. 4.4.12.2........... 56 BPT-953............. 4.4.12.4........... 56 BPT-956............. 4.4.12.5........... 56 BPT-959............. 4.4.12.6........... 56 BPT-961............. 4.4.12.7........... 57 BPT-964............. 4.4.12.8.1 ........ 57 BPT-974............. 4.4.12.8.2 ........ 57 BPT-979............. 4.4.12.9........... 57 BPT-982............. 4.4.13.............. 57 BPT-1009........... 4.4.15.............. 58 BPT-1020........... 4.4.16.............. 58 BPT-1023........... 4.5................... 59 BPT-1026........... 5.1................... 60 BPT-1029........... 5.1.1................ 60 BPT-1037........... 5.1.2................ 60 BPT-1039........... 5.1.3................ 60 BPT-1042........... 5.2................... 60 BPT-1045........... 5.3................... 61 BPT-1049........... 5.4................... 61 BPT-1067........... 3.2.1.1.2.......... 10 BPT-1071........... 3.2.1.7.2.......... 14 BPT-1085........... 3.2.2.1............. 18 BPT-1092........... 3.2.3.1............. 21 BPT-1093........... 3.2.3.2............. 21 BPT-1095........... 3.2.3.2............. 21 BPT-1096........... 3.3.3................ 24 BPT-1100........... 3.4.1................ 29 BPT-1101........... 3.4.2................ 30 BPT-1102........... 3.4.4................ 32 BPT-1103........... 3.5.4.3............. 33


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BPT-1105 ...........3.11 .................39 BPT-1106 ...........4.2.1.2 .............42 BPT-1107 ...........4.3.5 ................48 BPT-1109 ...........4.4.1.4 .............49 BPT-1110 ...........4.4.2 ................49 BPT-1111 ...........4.4.3.2 .............50 BPT-1116 ...........5.5 ...................61 BPT-1173 ...........3.2.1.1.2.1........11 BPT-1177 ...........4.3.3 ................47 BPT-1617 ...........4.4.18 ..............59 BPT-1626 ...........4.4.10 ..............55 BPT-1631 ...........4.4.10.1 ...........55 BPT-1636 ...........4.4.10.2 ...........55 BPT-1715 ...........4.4.7.1 .............52 BPT-1727 ...........4.4.7.2 .............52 BPT-1730 ...........4.4.7.3 .............52 BPT-1733 ...........4.4.7.4 .............52 BPT-1736 ...........4.4.7.5 .............52 BPT-1740 ...........4.4.12.3 ...........56 BPT-1746 ...........4.4.19 ..............59 BPT-1751 ...........4.4.5 ................51 BPT-1756 ...........4.4.7.6 .............53 BPT-1763 ...........4.4.17 ..............58 BPT-1773 ...........4.4.6.1 .............52 BPT-1776 ...........4.4.6.2 .............52 BPT-1779 ...........3.2.1.6.1...........13 BPT-1824 ...........3.2.1.7.3.5........16 BPT-2013 ...........3.4.3 ................30 BPT-2014 ...........3.4.3 ................30 BPT-2016 ...........3.4.3 ................30 BPT-2533 ...........3.2.2.16 ...........20 BPT-2557 ...........3.1 ...................9


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