SR GSLV MRR - Final.ppt

7/28/2019 SR GSLV MRR - Final.ppt

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Systems Reliability Entity

Vikram Sarabhai Space Centre

MRR 01

20th Nov 2010

GSLV F06 Mission

SR Assessment


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Solid Motors

GS1 Motor


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1. 1 GS1 Motor - S139 motor cases and Nozzle hardware

Motor cases & Nozzle hardware

- No major deviation.

No Concern


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1.2 GS1 Motor - Propellant System

Average Agni Burn Rates meet the specification.

Segment

Identification

Casting dateMargin of

Safety

Burn rate

(Spec.)

mm/s

Burn rate

(avg) mm/s

HES 75104-03-2010 to

05-03-20101.83-2.17 8.00.2 8.039

MS3 743 13-11-2009 1.57-1.80 8.00.2 8.075

MS2 733 07-08-2009 1.63-1.87 7.80.2 7.893

MS1 736 18-09-2009 1.31-1.70 7.80.2 7.735

NES 737 28-08-2009 1.68-1.91 7.80.2 7.634

No Concern


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1.3 GS1 Motor - Ignition System

Igniter & Pyro elements - No major deviations.

Earliest expiry date for TBI - Nov 2010 (3 years)

Life of TBI is extended up to May 2011 based onperformance of the following aged units tested.

5 Years 1 month 7 Units

5 Years 9 Months 2 Units

No Concern


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1. Retro (RS2 ) Motors

Motor cases

Propellant system

Nozzle, Igniters & Initiators

- No major deviations.

No Concern


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Metallic Structures


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Structure Identification Issues Status

Core Base Shroud

Assembly BS 009

Nil

Green

Aft End Closure Assembly BS 008 Nil Green

Inter Stage 1/2M Assembly BS 011 Nil Green

Inter Stage 2/3L Assembly BS 09 Nil Green

Thrust Frame Assembly BS 07 Nil Green

Inter Stage 1/2U Assembly BS 08 Nil Green

Upper Stub Adaptor BS 11 Nil Green

S1 Vehicle support blocks

MF/2313/07/02 & (238/0198/1) (XVF/757/9)

MF/2313/07/03 & (238/0197/1) (XVF/757/12)

MF/2313/07/04 & (238/0197/2) (XVF/757/14)

MF/2313/07/05 & (238/0197/3) (XVF/757/20)

Nil

Green

S2 Vehicle support blocks VE/5556/08/01 to 08 (XVF/ 664/02 to 08 &15) Nil Green

No Concern

Assessment on structures


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L40 Structures

Hardware S4 S3 S2 S1 Issues Status

SONC BS-21 TAAL-04 BS-22 TAAL-05 Nil Green

ITS TAAL-04 TAAL-05 TAAL-06 SV-02 Nil Green

SBS SV-04 BS-22 TAAL-02 TAAL-03 Nil Green

FIN BS-29 BS-23 BS-30 BS-31 Nil Green

Thermal Shroud TAAL-12 TAAL-13 TAAL-14 TAAL-15 Nil Green

Protection Plate TAAL-15 TAAL-08 TAAL-07 TAAL-16 Nil Green

Strapon Attachment hardware system Nil Green

No Concern

Assessment on structures


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Composite Subsystems


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Composite Sub

Systems Identification No

L40 Throat

S1 - ABSG/ST-79

S2 - ABSG/ST-77

S3 - ABSG/ST-76

S4 - ABSG/ST-71

GS2 Throat ABSG/ST-88

L40 Thermal Boot ABSG/L40/TB-32 to 35

CC Vanes

(CMSE Make)7th and 9th batch vanes

Pay Load AdaptorCSTD/1O2/GPLA-O7

No Concern

Assessment on Composite Sub Systems


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Raw materials change from D3

Carbon Prepreg changed from T300 / 914 to HTS / M18 due

to material non availability

PrePreg fully characterized.

Properties are comparable and found acceptable.

Process Work centre Change

CFRP Sandwich Panels realised at CMD / HAL under the

guidance of CMSE/VSSC.

Acceptable. No Concern

Assessment on PAYLOAD FAIRING BS 10-GA6102-0000-0000 (R2)


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Stage Auxiliary Systems

&Mechanical Integration


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Stage Auxiliary Systems

No Concern

SAS pyros Normal

6mm dia bolt cutter for satellite separation

system : Life expiryDecember 2010 (3 years life).VOQ test on two samples of flight batch, for

extending the life completed successfully.

Life extended to December 2011.


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Mechanical Integration

No Concern

All vehicle integration operations upto GS2

stage Normal


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Control Systems

L40 / GS2 EGC


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1.0 Gas motor bearings

Source changed from SABCA

Ball bearing

- ADR make (Split inner race)

Roller bearing

- SKF make with Indigenous steel cage


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1.0 Gas motor bearings ..

ISSUE

ADR ball bearing seizure observed in 1 out of 4assemblies during acceptance tests of flight gas

motors.

Analysis

Root cause identified as misalignment caused byinterference fit between rotor - bearing interface &

improper shaft shoulder corner radius.

Corrective actions

Clearance fit ensured by rework of the rotor. Relief

provided at the shaft shoulder.


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1.0 Gas motor bearings ..

Bearing specification meets design requirements.

Qualification of 3 sets of bearings through gas motor &

system level tests.

Run away condition test (9300rpm) in hot air at 300 deg C.

Acceptance tests carried out on 8 sets of flight gas motors

L110 Injector level hot tests on 2 qualification hardware.

Performance normal

No Concern


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3. Solenoid Valve

ISSUE:

Failure of CADD make Solenoid Valve

- Leakage seen during qualification cycling tests.ANALYSIS:

Jamming observed between plunger and bobbin due to inadequate

clearances . (-1 micron against 21 microns reported by M/s Raghavaerospace. Spec: 25 to 75 microns).

CORRECTIVE ACTION:

LPSC make valves were used for F06.

Clearance at the interface in the range of 80 microns.

The performance of these valves satisfactory during acceptance tests

No Concern

SR views: Measurement inadequacy at

work centre needs correction.

Clearances also to be included in FCD list.


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4.RCI servo valve

ISSUE

Failure of RCI servo valve : The servo valve spool gotstuck during component level acceptance tests (during

10 mA flow test ).

ANALYSIS

FA in progress

However, for GSLV F06 MOOG servo valve is used.

No Concern

For F06

SR views:

FA of RCI servo valve to be completed

EGC P C d i l bi


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5. EGC Pump Case drain plumbing

ISSUE

Leakage observed at the pump case drain plumbing

joint during L110 D2 hot test failure observed in the

tube flare interface .

ANALYSIS

Failure suspected to be due to excess vibration

caused by plumbing configuration.

SR views: Impact on similar joints of L40 & GS2 EGC system

to be studied. FA to be closed.

L40/GS2 EGC SYSTEMS


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L40/GS2 EGC SYSTEMS

The performance of the EGC

Packages during the tests at lab andat SHAR is normal.


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AVIONICS SYSTEMS

PFA R d ti f D3


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PFA Recommendations from D3

Issue: Noise seen in analog Z rate channel for rates greaterthan -10deg/s. Maximum roll rate experienced during

flight is -14 deg/s.

Analysis:Traced to abnormal behavior of opamp inside NIM forinputs greater than -10 deg/s.

Action: Design modified to clip input to -10 deg/s at the input

of op-amp for analog rate channels.

No Concern

PFA R d ti f D3


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Issue: The Y rate was in error as

1. TheY gyro was isolated, due to large rate build up inthe cryo stage.

2. The Z rate was saturated at -10 deg/s and hence thecomputed analog Y rate from X1 and Z rates wassaturated

Analysis:However, the Z1 was not saturated and the analogYrate would have been normal,if computed from Z1and X rates.

Action:Analog rate Z1 is also made use of in the rate channelprocessing.Error handling, navigation, REX software modulesmodified to take care of this requirement.

No Concern

PFA Recommendations from D3

ISSUES A l i CSCE RVDT E it ti


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ISSUE:

For P4 loop

Command and RVDT feedback not matching (error upto 3.5) High noise in RVDT feedback monitoring (4.6pp).

Amplitude reduction and distortion in RVDT excitation (40V p-p, 1KHz)

In other loops, good match between command & feedback and the

noise in RVDT feedback is within 1.

ANALYSIS: The reason is noise pick up through PCB tracks of

frequency fixing capacitors of AD698 LVDT signal

conditioning IC

ACTION: Capacitors repositioned by mounting on top of the IC and

the original tracks disconnected for all the four loops.

RVDT Excitation measurement and Linearity tests at SHAR show good

performance.

ISSUES : Anomaly in CSCE RVDT Excitation

No Concern

Bias shift in ZA3 channel RESINS FM34


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Issue: FM34, the identified package for GSLV F06 mission has

undergone EB phase-1 and vibration checks at VMC.

Performance was normal. During post vibrationcalibration at IISU, a bias shift of 1.6 mg was observed

in ZA3 accelerometer during multi position tests.

Action: FM-20 is used as the flight package for GSLV-F06. EB

Autonomous and Complex checks with CS-6 stagecarried out with replaced package at TCX, SHAR.

Performance normal.

No Concern

Bias shift in ZA3 channel - RESINS FM34

Short term Stability Day to day Stability

Rate channel 0.23 /hr (X) 0.08 /hr (Z1)Spec 0.3 /hr 0.32 /hr

Acceleration channel 185 g (YA) 166 g (YA)Spec 250 g 675 g

A i i P k D t il


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Avionics Package Details

No. of NGC Packages : 22

No. of Failures : 3SPS-CS, FM03 : 1 Capacitor failure CLR 79

SPS-GS2, FM02 : 1 (poor isolation Workmanship related)

Diode CS GK : 1 Connector related

All failures closed by FAB

No. of Deviations : 8

All deviations are very minor & closed by NCRB

A i i P k D t il


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Avionics Package Details

No. of TTC&P Packages : 175

No. of Failures : 2

ATS Stack E1162( DAUII) : 1 PCB failureATS Stack L40 S2(DAU1) : ADS 1218 IC

All failures closed by FAB

No. of Deviations : 35

All deviations are very minor & closed by NCRB

CRYO St C t l El t i MRC / AVR T


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The torque levels measured are low and less than 5

Nm at 400 HZ and 9.5 Nm at 200Hz.

The torque levels are comparable for CSCE Single boxand 3 box AMC configurations for the same actuators

The torque varies from actuator to actuator measured

with the same Electronics and same method.

CRYO Stage Control Electronics - MRC / AVR Torque

MRC / AVR Torque


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Mock up 1 (Old Mock up) Mock up 2 (New Mock up)

MRC

Torque in Nm

AVR

Torque in Nm

MRC

Torque in Nm

AVR

Torque in Nm

200 Hz 400Hz 200Hz 400Hz 200 Hz 400Hz 200Hz 400Hz

3 Box

(AMC

Versi

on)9.5 5 9.5 5 8 3 11 5

Single

Box

(28V,

2.5A)

8 4 9 4.5 - - - -

Requirement : Torque > 8 Nm

MRC/AVR Torque measurements at 400Hz and 200 Hz for CSCE FM01

( AMC Version, 3 box) and single box are as follows.

MRC / AVR Torque

The actuator movement is at 200Hz when algorithm is engaged and at

400Hz only during the initial phase and at shutdown.


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Mission &

Software

Mi i


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No Concern

Mission

Changes in Mission Design

Launch Azimuth changed from 106 deg to 104 deg

C15 GK Cryo Stage with 15 ton propellant loading

Introduction of GAINS in piggy back mode

Introduction of On-board Alignment

Verification of Trajectory & DAP design inputs

Assessment of mission requirements documents

QA audit of DRT Actions--- Completed

Fli ht S ft


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Flight Software

Major changes from D3

Implementation of Onboard Level Alignment in Navigation S/W. E2PROM Checksum Computation in Flight mode in Major Cycle

periodicity

Passing of Z1 analog rate to navigation for RESINS rate

computation (based on GSLV-D3 PFA recommendation)

Interface changes due to addition of GAINS package (in piggy

back mode) and PRISM in place of SDAM in the NGC system

MRC / AVR Algorithms related to GK Stage (three different

regimes of operation)

All mandatory Verification & Validation activities completed.

No Concern

Checko t Soft a e


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Checkout Software

Major Changes

Changes for Onboard Level Alignment and GK Stage Automatic Launch Sequence (ALS) Timing Changes

New Linux Based Supervisory Checkout Console

Verification & Validation Status Requirements and Design Reviews

Code Inspection

Module Level Testing of ALS Software Changes

System Level T&E

- Completed

No Concern

Simulation and Testbed Software


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Simulation and Testbed Software

Major Changes

SITARA and ICOMETS Changes for OLA and GK Stage OILS/HLS/ALS Testbed changes for OLA and GAINS

introduction

Verification & Validation Status

Requirements and Design Reviews

Code Inspection of SITARA and ICOMETS Software

Code Inspection of OILS/SIP/IPT Test bed Software

Data Verifications for all Simulation Runs

Independent Analysis of all Simulation Results

- Completed

No Concern

Onboard Level Alignment(OLA) Qualification


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No Concern


Onboard software Verification & Validation

Implementation correctness of OLA in Navigation andNGCP-REX software verified as part of Code inspectionand Module level tests.

Validated with additional cases in NGC simulation tests.

Independently analyzed the impact of Onboard Level

Alignment in various components of NGC software.

Ground software Verification & Validation

Implementation correctness of OLA in BIU and HCSsoftware verified as part of Code inspection.

Additional tests conducted at Checkout system level T&E

Independently analyzed the impact of Onboard LevelAlignment in checkout software.



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No Concern


Overall performance Sign check carried out with OLA enabled.

Ensured the correctness of end-to-end signal flow.

All vehicle level checks carried out with OLA enabled.

Special Task Team reviewed the implication ofOLA introduction in NGC Software

Performance of On-board Level Alignment normal


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THANK YOU

SR GSLV MRR - Final.ppt

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