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 Level Alignment(OLA) Qualification
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.
Onboard Level Alignment(OLA) Qualification
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No Concern
Onboard Level Alignment(OLA) Qualification
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
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