edm reaction control system pressure regulator...

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EDM REACTION CONTROL SYSTEM

Pressure Regulator Technical Requirements

Specification

The validations evidence are kept through the documentation management system.

Written by Responsibility

Unit technical responsible

Verified by

RCS Product Assurance manager

Propulsion Design Group manager

EDS Technical Manager

Approved by

RCS Project Manager

ExoMars Project Manager

Documentation Manager

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CHANGE RECORDS

ISSUE DATE § CHANGE RECORDS AUTHOR 01 16/12/2009 First Issue for PR RFI after mission redirection RCS Team 02 Draft 14/04/2010 Second issue for PR Pre-TEB review RCS Team

02 15/06/2010 After Pre-TEB review RCS Team

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TABLE OF CONTENTS

1 Scope ..............................................................................................................6

2 general ............................................................................................................7

2.1 ExoMars mission overview ................................................................................7 2.2 Standards ..........................................................................................................9 2.3 RCS Applicable and normative documents .....................................................10

2.3.1 ESA documents....................................................................................................10 2.3.2 TAS-I documents ..................................................................................................10 2.3.3 TAS-F documents.................................................................................................11

2.4 Informative documents. ..................................................................................11 2.5 Order of Precedence. ......................................................................................11 2.6 Acronyms, symbols and abbreviations ...........................................................12 2.7 Terminology.....................................................................................................14 2.8 Conventions .....................................................................................................16

3 Performances Requirements..........................................................................17

3.1 Use, Mission, Criticality ...................................................................................17 3.2 Functional Requirements.................................................................................19

3.2.1 Medium Requirements ..........................................................................................19 3.2.2 Pressure requirements..........................................................................................19 3.2.3 Adjustment conditions ...........................................................................................21 3.2.4 Leakage ...............................................................................................................21 3.2.5 Flow rate ..............................................................................................................22 3.2.6 Total Mass flow.....................................................................................................22 3.2.7 Response Time ....................................................................................................22 3.2.8 Miscellaneous.......................................................................................................22 3.2.9 Cleanliness...........................................................................................................23

3.3 Operational requirements ..............................................................................24 3.3.1 Reliability..............................................................................................................24 3.3.2 Maintenance.........................................................................................................25 3.3.3 Maintainability requirements ..................................................................................25 3.3.4 Availability ............................................................................................................25 3.3.5 Lifetime ................................................................................................................25 3.3.6 Life cycles ............................................................................................................26 3.3.7 Handling and transportation ..................................................................................26

4 Planetary Protection ......................................................................................27

5 Environmental requirements..........................................................................28

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5.1 Mechanical Environment.................................................................................29 5.1.1 Launch .................................................................................................................29 5.1.2 Cruise and coast...................................................................................................33 5.1.3 Entry ....................................................................................................................33 5.1.4 Descent................................................................................................................33

5.2 Thermal Environment......................................................................................35 5.3 Operational pressures ....................................................................................35

5.3.1 Launch, Cruise, Coast and Entry ...........................................................................35 5.3.2 Descent................................................................................................................36

5.4 Radiation .........................................................................................................36 5.4.1 Ground.................................................................................................................36 5.4.2 Launch .................................................................................................................36 5.4.3 Cruise and coast...................................................................................................37 5.4.4 Entry ....................................................................................................................37 5.4.5 Descent................................................................................................................37

5.5 Particulate and atmosphere environment......................................................37

6 Interfaces ......................................................................................................38

6.1 Mechanical Interfaces .....................................................................................38 6.1.1 Unit reference frame .............................................................................................38 6.1.2 Unit dimensions ....................................................................................................39 6.1.3 Mass properties ....................................................................................................40 6.1.4 Mounting feet interface..........................................................................................40 6.1.5 Interface with tubing..............................................................................................41

6.2 Thermal Interfaces ..........................................................................................42 6.3 Power Interfaces..............................................................................................42 6.4 Electrical Signal Interfaces ..............................................................................42 6.5 Bonding ...........................................................................................................42

7 Design Guidelines and Construction Requirements .......................................44

7.1 Standards [DESI] .............................................................................................44 7.2 Parts, materials and processes .......................................................................44

7.2.1 Parts and material.................................................................................................44 7.2.2 Process ................................................................................................................47

7.3 Mechanical Design Requirements...................................................................51 7.3.1 Unit internal layout and interfaces..........................................................................51 7.3.2 Stiffness ...............................................................................................................51 7.3.3 Strength ...............................................................................................................51

7.4 Thermal Design Requirement .........................................................................53 7.4.1 Justification of thermal characteristics....................................................................53

7.5 Electrical Design Requirements.......................................................................53 7.6 Identification and marking .............................................................................53 7.7 Protections.......................................................................................................55

7.7.2 Methods of preservation and packaging.................................................................55

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7.8 Safety...............................................................................................................56 7.8.1 Workmanship .......................................................................................................56 7.8.2 Interchangeability .................................................................................................57

8 Required Verification .....................................................................................58

8.1 Quality assurance provisions ..........................................................................58 8.1.1 Responsibility .......................................................................................................58 8.1.2 Quality Assurance Activities ..................................................................................58 8.1.3 Classification of Tests ...........................................................................................58 8.1.4 Failure Criteria ......................................................................................................59 8.1.5 Non-Conformance/Failure Reporting System .........................................................59 8.1.6 Acceptance Data Package ....................................................................................59

8.2 Verification requirements ...............................................................................60 8.2.1 Verification /Testing requirements..........................................................................60 8.2.2 Verification/ Levels and durations ..........................................................................61 8.2.3 Verification/Test Sequence....................................................................................63 8.2.4 Verification Sequences .........................................................................................64 8.2.5 Test Methods........................................................................................................67 8.2.6 Test Documentations ............................................................................................76

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1 Scope

This component specification defines the requirements for performance, design, manufacturing, handling, testing and delivery of the

PRESSURE REGULATOR (PR) to be used on the liquid Reaction Control System of the ExoMars Descent Module. The function of the component is to reduce the high helium storage pressure to a regulated nominal pressure level for pressurisation of the hydrazine propellant tanks. The second issue of this document is written in the frame of the PR Pre-TEB review.

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2 general

2.1 ExoMars mission overview

Establishing if life ever existed on Mars is one of the outstanding scientific questions of our time. To address this important goal, the European Space Agency (ESA), in cooperation with NASA, has established the ExoMars Programme to investigate the Martian environment and to demonstrate new technologies paving the way for a future Mars sample return mission in the 2020's. Two missions are foreseen within the ExoMars programme: one consisting of an Orbiter plus an Entry, Descent and Landing Demonstrator (to be launched in 2016) and the other, with a launch date of 2018, consisting of two rovers. Both missions will be carried out in cooperation with NASA.

Elements of the ESA-NASA ExoMars programme 2016-2018 Credit: ESA

The ExoMars programme will demonstrate a number of essential flight and in-situ enabling technologies that are necessary for future exploration missions, such as an international Mars Sample Return mission. These include: • Entry, descent and landing (EDL) of a payload on the surface of Mars; • Surface mobility with a Rover; • Access to the subsurface to acquire samples; and • Sample acquisition, preparation, distribution and analysis.

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At the same time a number of important scientific investigations will be carried out, for example: • Search for signs of past and present life on Mars; • Investigate how the water and geochemical environment varies • Investigate Martian atmospheric trace gases and their sources. The 2016 ESA-led mission, to be launched by NASA, includes a Mars Orbiter and an Entry, Descent and Landing Demonstrator Module (EDM). The Orbiter will carry scientific instruments to detect and study atmospheric trace gases, such as methane. The EDM will contain sensors to evaluate the lander’s performance as it descends, and additional sensors to study the environment at the landing site. The 2018 mission is a NASA-led mission and includes two rovers, one European and the other American. Both rovers will be transported in the same aeroshell and will be delivered to the same site on Mars. The ESA Rover will carry a drill and a suite of instruments dedicated to exobiology and geochemistry research. Establishing whether life ever existed or is still present on Mars is of the highest scientific interest. To achieve this objective, ESA is preparing the ExoMars interplanetary mission where the main goals will be to deploy a mobile exobiology instrumentation package on the Martian surface to perform in-situ soil sample analyses. The objective will also be to enhance the knowledge of the Mars environment and geophysics in the scope to identify and characterize possible hazards before landing of other spacecrafts or humans.

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2.2 Standards

Ref. Document Reference Title

S1 TT.I.735 ISOPROPYL ALCOHOL

S2 MSC.C.20 DISTILLED DE-IONISED WATER

S3 MIL.P.27401 PROPELLANT PRESSURIZING AGENT, NITROGEN

S4 MIL.P.27407 PROPELLANT PRESSURIZING AGENT, HELIUM

S5 MIL.P.27415 PROPELLANT PRESSURIZING AGENT, ARGON

S6 MIL.STD.22 WELD JOINT DESIGN

MIL-P-26536 HYDRAZINE (HIGH PURITY GRADE)

S8 MIL-P-26536 Amendment 1

Performance specification propellant, HYDRAZINE (High Purity Grade)

S9 MIL.STD.889 DISSIMILAR METALS

S11 MIL STD 1522 STANDARD GENERAL REQUIREMENTS FOR SAFE DESIGN AND OPERATION OF PRESSURIZED MISSILE AND SPACE SYTEMS

S13 ECSS-E-ST-35-06 Cleanliness requirements for spacecraft propulsion components, subsystems and systems

S15 ARP 901 Aerospace recommended practice bubble point test method

S16 FED STD 209 Clean room and Workstation requirements, Controlled environment

NAS 1514 WELD DISCONTINUITIES – RADIOGRAPHIC STANDARDS S20

AMS 2634 ULTRA SONIC

ASTM-E-1417

Standard Practice for Liquid Penetrant testing S21

DIN EN 571-1 Non-destructive testing - penetrant testing - Part 1 : general principles

MIL-STD-453 STANDARD PRACTICE FOR RADIOGRAPHIC INSPECTION S22

DIN EN 1435 Non-destructive testing of welds – Radiographic Testing of welded joints

S23 MIL-STD-2219 FUSION WELDING FOR AEROSPACE APPLICATIONS

AMS-STD-1595 QUALIFICATION OF AIRCRAFT, MISSILE AND AEROSPACE FUSION WELDERS AND WELDING OPERATORS

S24

DIN EN 1418 Welding personnel – Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanized and automatic welding of metallic materials

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AMS 2680 S25

AMS 2681 ELECTRON BEAM WELDING (EBW)

S30 CSG-RS-10A/21A/22A CSG safety regulations

S31 EWR-127-1 Eastern and Western Range Safety Requirements.

S32 USAF letter Interim safety requirements for Design, Test and Ground Processing of flight Graphite Epoxy Composite over wrapped pressure vessel at Kennedy Space Center, Cap canaveral air force station and VAFB.

2.3 RCS Applicable and normative documents

2.3.1 ESA documents

[NR] Name Ref

NR 003 Management Requirement Document EXM-MS-RS-ESA-00012

NR 005 Assembly Integration and Verification Requirement Document EXM-MS-RS-ESA-00006

NR 015 Document Requirements Description EXM-MS-RS-ESA-00010

NR 017 Risk Management Requirements EXM-MS-RS-ESA-00011

NR 020 Configuration and Document Management Requirements EXM-MS-RS-ESA-00008

NR 038 Mechanisms ECSS-E-ST-33-01 NR 041 Materials, Mechanical parts and processes ECSS-Q-ST-70 NR 042 Materials ECSS-E-ST-32-08 NR 043 Fracture control ECSS-E-ST-32-01 NR 044 Modal Survey Assessment ECSS-E-ST-32-11 NR 046 Structural Design and Verification of pressurized hardware ECSS-E-ST-32-02

2.3.2 TAS-I documents

[NR] Name Ref

NR 0101 Exomars Mechanical and Thermal General Design and Interface Requirements EXM-MS-SSR-AI-0003

NR 0102 Exomars Electrical General Design and Interface Requirements EXM-MS-SSR-AI-0001

NR 0104 Exomars EMC and Power Quality Requirements EXM-MS-SSR-AI-0002

NR 0105 Space Environment Requirements Specification EXM-MS-SSR-AI-0014

NR 0106 Exomars Cleanliness and Contamination Control Requirements EXM-MS-SSR-AI-0005

NR 0112 PA Requirements for Subcontractors EXM-MS-RQM-AI-0004

NR 0113 EGSE Requirements Specification EXM-MS-SSR-AI-0008

NR 0114 MGSE Requirements Specification EXM-MS-SSR-AI-0009

NR 0117 Exomars Thermal Modelling Requirements EXM-MS-RQM-AI-0022

NR 0120 Exomars Planetary Protection Requirements EXM-MS-SSR-AI-0007

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NR 0121 List of NR/IR documents, acronyms and abbreviations EXM-MS-LIS-AI-0001

NR 0122 Exomars Product Tree EXM-MS-SLI-AI-0015

NR 0164 Exomars Mechanical Environment and Test Requirements Specification EXM-MS-SSR-AI-0012

NR 0167 Thermal Environment and Test Requirements Specification EXM-MS-SSR-AI-0013

NR 0168 System Composite FEM Description report and FEM Requirements for structural Analysis EXM-MS-VRP-AI-0020

2.3.3 TAS-F documents

Refer to Specific Statement of Work ref. EXM-DM-SOW-AF-6018.

2.4 Informative documents.

[IR] Name Ref

IR 07 Exomars Planetary Protection Requirements EXM-MS-RS-ESA-00005

2.5 Order of Precedence.

In the event of conflict between the requirements of this specification and those of the documents here above, the requirements of this specification shall take precedence. If a discrepancy between this specification and those documents is identified by the supplier, such discrepancy shall be reported to Thales Alenia Space France.

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2.6 Acronyms, symbols and abbreviations

AR5-ECA Ariane 5 Etage Cryogénique A ATB Avionic Test Bench ATP Authorisation To Proceed BI Biological Indicator BOL Beginning of Life CDF Concurrent Design Facility CIDL Configuration Item Data List CM Carrier Module CSG Centre Spatiale Guyanais DDL Document Delivery List DHMR Dry Heat Microbial Reduction DIL Deliverable Item List DL Descent and Landing DM Descent Module DMC Descent Module Composite DRD Document Requirement Description DRL Document Requirements List DVM Design Verification Matrix ECSS European Cooperation for Space Standardization EDS Entry and Descent System EDM Entry, Descent and Landing Demonstrator Module EDP Entry and Descent Phase EDLS Entry Descent Landing System EGSE Electrical Ground Support Equipment EEE Electrical, Electromechanical and Electronic EIP Entry Interface Point EM Engineering Model EMC Electro-Magnetic Compatibility EMCD European Mars Climate Database EOL End of Life EQM Engineering Qualification Model EQSR Equipment Qualification Status Review EXM ExoMars FAR Flight Acceptance Review FEM Finite Element Model FM Flight Model FRR Flight Readiness Review FS Front Shield FSU Former soviet Union GMM Geometrical Mathematical Model GNC Guidance, Navigation and Control GSE Ground Support Equipment HEPA High Efficiency Particulate Air HS Heatshield ICU Interface Control Unit

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IPA IsoPropyl Alcohol IPC Industrial Policy Committee IRD Interface Requirements Document ITP Internal Thermal Protection LEOP Launch and Early Operation Phase MEOP Maximum Expected Operating Pressure MER Mars Exploration Rover MGSE Mechanical Ground Support Equipment MLI Multi Layer Insulation MOC Mission Operations Centre MOI Mars Orbit Insertion MPL Mars Polar Lander MSL Mars Sample Laboratory NASA JPL National Aeronautics and Space Administration Jet Propulsion Laboratory NCR Non Conformance Report [NR] Normative Reference PA Product Assurance PFM Proto Flight Model PP Planetary Protection ppb Parts per billion PPIP Planetary Protection Implementation Plan ppm Parts per million PR Pressure Regulator PT Product Tree QM Qualification Model RCS Reaction Control System RD Reference Document Rpm Revolutions per minute RS Requirement Specification Sol Mars Day = 24H 39min 35,245seconds SOW Statement of Work S/C SpaceCraft S/S Subsystem TAA Technical Assistance Agreement TAS-F Thales Alenia Space France TAS-I Thales Alenia Space Italy TCS Thermal Control System TEB Tender Evaluation Board TML Total Mass Loss TMM Thermal Mathematical Model TRB Test Review Board TRL Technology Readiness Level TRP Temperature Reference Point TRR Test Readiness Review TT&C Telecommand, Telemetry and Control WBS Work Breakdown Structure WP Work Package WPD Work Package Description

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2.7 Terminology

The following definitions concerning EDM Lifetimes will be considered in this document:

Name definition

EDM Lifetime

Period which covers the EDM mission i.e. all the EDM life phases from the end of AIT activities up to EDM end of life after the final manoeuvre. (including the on-ground storage if any, the transportation to launch site, the launch phase, the cruise phase, the landing operation and operations on Mars).

EDM Flight Lifetime

Period during which the EDM is no more on the ground from the start of the launch up to the end of the operations. Its includes: - Launch, Transfer, Cruise, Coast and Entry Descent and Landing on Mars surface.

EDM Operational Lifetime The Operational lifetime corresponds to Entry Descent, Landing on Mars surface and activities on Mars soil.

Launch phase The launch phase starts at the defined time of launch as per launch authority and ends at the notification of separation by the launch authority.

On Mars soil Phase Period starts when EDM landing is completed and finished at EDM end of life (EOL)

Ground storage duration The ground storage duration is the maximum duration during which the EDM is on-ground storage in a dedicated storage environment.

Storage before integration This phase starts at "T0" and ends when the RCS equipment is delivered for integration.

Integration on the spacecraftThis phase starts when the RCS equipment is delivered for integration and ends either at despatch for launch or when dismounted for storage.

Long term storage This phase can take place at any time after the equipment is integrated and up to launch.

Beginning Of Life (BOL) Date corresponding to the RCS ignition (beginning of the tip up manoeuvre during the descent phase).

End Of Life (EOL) Date corresponding to the RCS shut-down + 8 sols (Mars Day)

Table 2-1: EDM Lifetime Definitions

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Figure 2-1: EDM lifetime (refer to table 3-2)

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2.8 Conventions

In the numbering of the requirements, the convention will be Reference DM-RCSLIQ-PR-XXXX. , where the requirement number is implemented in the second part (xxxx) all along the specification. A requirement or group of requirement may be followed or preceded by comments, i.e. an explanatory text. This is intended only to assist the understanding of the requirement or its origin. The convention for requirement coding is therefore as follows:

Reference DM-RCSLIQ-PR-XXXX.

Requirement Description *Specific Comments

all pressures identified in the present requirement specification are absolute pressures.

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3 Performances Requirements

3.1 Use, Mission, Criticality

Reference DM-RCSLIQ-PR-0010.

The pressure regulator shall be used to reduce the high storage pressure level (decreasing with helium consumption) to a constant nominal pressure level for pressurization of the hydrazine propellant tanks.


The pressure regulator shall be compatible with the on-ground operations as defined in the following table.

Phase Event Duration G10 Elementary parts acceptance Supplier premises G20 Equipment assembly and acceptance Supplier premises G30 Delivery To TAS G40 Storage before propulsion subsystem assembly 2 months (TBC)

G50 Propulsion subsystem assembly and acceptance 6 months (TBC)

G60 Propulsion subsystem storage TBD months G70 Spacecraft assembly and environmental, functional tests TBD months G80 Spacecraft storage TBD months G90 Spacecraft transport to launch site TBD months

G100 Spacecraft launch site operations TBD months Total Total on-ground phase See §3.3.5.1

Table 3-1: Ground operations


The pressure regulator shall be compatible with the in-flight life as defined in the §3.3.5.2.

Phase Event Duration F10 Launch until separation from launcher Up to 2 hours

F20 Transfer, Cruise and Coast: from launcher separation to Mars operational orbit

12 months

F30 Entry and descent phase 3 days F40 Operational phase 20 s F50 On Mars soil Phase 8 sols (Mars days)

Table 3-2: In-flight life (for information)

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The pressure regulator shall withstand the following mission profile without any degradation:

Pressure Regulator Phase Description of the PR non operating /operating phas es

1) F10 + F20 + Beginning of F30 phases = From the launch up to descent beginning

No PR operation. The PR is open during the phase.

2) Part of F30 phase = RCS pressurization during descent

Pressurization of the propellant tanks. Increase of the outlet pressure (see § 3.2.2.1) from the filling pressure to the regulated pressure (see § 3.2.2.4) => operational PR phase

3) End of F30 phase = Pressurization/firing transition phase

No propellant consumption, PR on stand by (pending on temperature evolutions) Increase from the regulated pressure to the lock-up pressure (see § 3.2.2.6) => operational PR phase

4) F40 phase = RCS operating phase : Start just after Frontshield release

Propellant tanks pressure regulation to the regulated pressure (see § 3.2.2.4) => operational PR phase

Table 3-3: Description of the operational phases

Operational helium pressure Pressure Regulator Phase

Inlet Outlet

Duration of PR phase

1) F10 + F20 + Beginning of F30 phases 15 bar @ 20°C 15 bar @ 20°C ~ 12 months + 2 or 3 days

2) RCS pressurization:

175 bar 150 bar @ 50°C

15 bar @ 20°C Lock-up Pressure @ 50°C ~ 2 s

3) Pressurization/firing transition phase

150 bar @ 50°C Lock-up Pressure @ 50°C ~ 2 s

4) RCS operating phase:

150 bar @ 50°C 55bar @ 0°C

Regulated pressure @ 50°C @ 0°C ~ 20 s

Table 3-3: Description of the mission (for informat ion)

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3.2 Functional Requirements

The pressure regulator supplier shall propose a robust design allowing to meet the mission requirements in term of performances and reliability. Thus, the supplier shall bring sufficient information on the PR design and robustness allowing to implement the proposed PR design.


The design of the pressure regulator shall rely on a serial dual stage architecture.

3.2.1 Medium Requirements


All components shall be able of meeting the performance requirements specified in this document when operating with the following media:

Operational media: • Gaseous Helium per S4

Other media (for test purpose): • Gaseous Helium per S4 • Gaseous Nitrogen per S3 • Deionized Water per S2 • IPA per S1 • Gaseous Argon per S5

3.2.2 Pressure requirements

3.2.2.1 Internal pressure


During operations the component shall be designed for the following internal pressure ranges (nominal): Inlet = 175 bar at 50°C to 55 bar at –10°C.

Outlet = filling pressure 15 bar to lock-up pressure (see 3.2.2.6).


The pressure regulator shall be designed for a MEOP of 300 bar at inlet.

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3.2.2.2 Safety factors


The component shall be able to sustain the following pressure test :

PROOF PRESSURE BURST PRESSURE

INLET all stages ( Note 1) 1.5 x MEOP 2.5 x MEOP

OUTLET (Note 2) 1.5 x Maximum Lock-up Pressure (refer to §3.2.2.6)

4 x Maximum Lock-up Pressure (refer to §3.2.2.6)

Notes : 1) In case of ‘open’ failure of the first stage, the inlet of the second stage shall be able to sustain up-

stream pressure. 2) A 4.0 x MEOP burst factor is retained on the outlet to accommodate the isolated system non-

operational pressures.

3.2.2.3 External pressure


The component shall meet the functional requirements with external pressure in the range from ambient to vacuum (cruise, non operational) to Mars pressure (0,007 bar).

3.2.2.4 Regulated pressure


The outlet regulated pressure shall be included within the range of 22 bar to 29 bar (adjustment capability) with an accuracy of ± 0.1 bar at adjustment conditions as defined in §3.2.3.

3.2.2.5 Regulated pressure tolerance


The tolerance of the outlet regulated pressure defined in § 3.2.2.4 for the inlet pressure range of § 3.2.2.1, temperature range of § 5.2 and for the flow range as specified in § 3.2.5 shall be ± 0,5 bar.

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3.2.2.6 Lock-up Pressure


The lock up pressure (Pl) is defined as the limit pressure at which the internal leakage requirement is not exceeded. The maximum lock up pressure, including the uncertainties, shall not exceed the regulated pressure of § 3.2.2.4 by more than 2 bar.

3.2.2.7 Surge pressure or Slam start

Reference DM-RCSLIQ-PR-0145

When PR is submitted to a surge inlet pressure, the downstream overshoot shall not exceed the lock-up pressure (Pl) increased by 1 bar.

The surge inlet pressure is defined as inlet pressure increase from P Min (defined in § 5.3.1) to 175 bar in less than 10 ms, with any downstream volume between 50 ml to 25l at outlet side.

Reference DM-RCSLIQ-PR-0146

The PR shall withstand a surge inlet pressure, defined in requirement DM-RCSLIQ-PR-0145, and its corresponding downstream overshoot and shall remain fully compliant to the performance requirements of this specification

3.2.3 Adjustment conditions Reference DM-RCSLIQ-PR-0150.

The conditions for adjustment of regulated pressure are defined as the following: - Inlet pressure : 175 bar

- Mass flow : 10 g/s

- Temperature : 20°C.

3.2.4 Leakage

3.2.4.1 Internal leakage inlet to outlet Reference DM-RCSLIQ-PR-0160.

For each stage, the leakage at lock-up shall be less than 5 x 10-3 scc/s GHe over the operational lifetime, inlet pressure range defined in § 3.2.2.1 and temperature range defined in § 5.2.

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3.2.4.2 External leakage Reference DM-RCSLIQ-PR-0170.

The external leakage defined as the leakage of any internal part through the housing to the outside shall be less than 1 x 10-6 scc/s GHe over the full lifetime (operational and non-operational), operational pressure range defined in § 5.3 and temperature range defined in § 5.2.

3.2.5 Flow rate Reference DM-RCSLIQ-PR-0180.

The flow capability range of the component for inlet pressure range as defined in § 3.2.2.1 and within acceptance temperature range as defined in §5.2 shall be at least 0 g/s to 10 g/s GHe.

3.2.6 Total Mass flow Reference DM-RCSLIQ-PR-0210.

The Pressure Regulator shall be capable of withstanding a total throughput of 1 kg GHe.

Following such an event, the regulator shall remain fully compliant to the performance requirements of this specification.

3.2.7 Response Time Reference DM-RCSLIQ-PR-0220.

The time duration to move the Pressure Regulator flow rate from the minimum one to the maximum one (and conversely), defined in § 3.2.5 and in accordance with § 5., shall be lower than 10 ms (TBC).


With a downstream volume of 25 liters the pressurization time from an initial inlet pressure of 15 bar at 20°C up to maximum regulated pressure defined in § 3.2.2.5 shall not exceed 2 s.

Following such an event, the regulator shall remain fully compliant to the performance requirements of this specification.

3.2.8 Miscellaneous

3.2.8.1 Dynamical Outlet pressure stability Reference DM-RCSLIQ-PR-0240.

When the flow rate is increased from 0 to 10 g/s Ghe in less than 10 ms, the oscillation of outlet regulated pressure defined in § 3.2.2.4 shall not exceed ± 0.5 bar at any downstream volume between 50 ml to 25l, at any operating pressure specified in § 3.2.2.1, operating media specified in § 3.2.1 and temperature range specified in § 5.2.

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When the flow rate is increased from 0 to 10 g/s Ghe in less than 10 ms, the oscillation of outlet lock up pressure (Pl) defined in § 3.2.2.6 shall not exceed + 0 bar - 0.2 bar at any downstream volume between 50 ml to 25l, at any operating pressure specified in § 3.2.2.1, operating media specified in § 3.2.1 and temperature range specified in § 5.2.

3.2.8.2 Steady State Flow Stability Reference DM-RCSLIQ-PR-0245.

At any steady state flow rate specified, the oscillation of outlet regulated pressure defined in § 3.2.2.4 shall not exceed ± 0.5 bar, at any supply pressure specified and at any operating media temperature specified.

3.2.9 Cleanliness

3.2.9.1 Particles contamination Reference DM-RCSLIQ-PR-0250.

The parts in contact with the operating media shall meet the cleanliness level specified hereafter. The allowable level of contamination found in a 0.1 litre test sample out of a total quantity of test fluid as defined in S13 (total quantity related of the inside wetted area of the unit) shall not exceed :

Particle Size (microns) Max. permissible counts per sample

> 100 0

51 - 100 1*

26 - 50 5

11 - 25 20

6 - 10 140

less than 6 no silting

NVR (non-volatile residue) less than 1 mg/100 ml

* No metallic particles greater than 50 micron allowed. If the flushing liquid can damage the unit, the use of a gaseous test sampling method may be proposed to the Customer for approval. The degree of cleanliness of the test fluid shall be 10 % maximum of the required cleanliness level of the equipment as defined here above.

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3.2.9.2 Drying Reference DM-RCSLIQ-PR-0290.

After cleanliness verification, the unit shall be dried either, with GN2 (max. temp. 45° C) filtered by a 0.2 micrometer absolute filter, or by vacuum. The required degree of dryness shall be equal to or less than 10 ppm IPA or equal to or less than -40° C for dew poi nt of GN2 at the outlet.

3.3 Operational requirements

3.3.1 Reliability Reference DM-RCSLIQ-PR-0310.

The reliability of the pressure regulator shall be greater than 0.999999 considering the failure modes of external leakage and burst over the unit lifetime. The overall reliability shall be greater than 0.99999.


The reliability requirements of other failure modes shall be as follows: Failure to close 561 FIT/Hour (TBC) Failure to open 0,56 FIT/Hour (TBC) Internal leakage 56 FIT/Hour (TBC)


Single point failure shall be avoided or the probability of occurrence shall be minimised. Failure propagation between stage (to the redundant path) shall be excluded Mobile isolation device (bellows for example) shall not be SPF.


The sharing of failure probability of occurrence among failure modes identified by FMECA shall be clearly established. Basic methodology for reliability assessment versus failure modes is the following :

external leakage : stress-strength method based on « factor of safety » and « margin of safety »,

regulators jams in open/close position, internal leakage: constant failure rate per hour and/or per cycle.

Details on way to implement a.m. methods, and rates to be used are described in reliability requirements. Others approach/data based on manufacturer background are accepted if justified. Conductive particle with a size smaller than 3 mm shall not cause a single point failure.


For each analyzed failure, mechanical and thermal impacts shall be calculated.

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3.3.2 Maintenance Reference DM-RCSLIQ-PR-0370.

No periodic maintenance shall be necessary during ground operation or the design life of the component.

3.3.3 Maintainability requirements Reference DM-RCSLIQ-PR-0380.

Equipment shall be designed to require a minimum of special tools and tests equipment to maintain calibration, perform adjustments and accomplish fault identification. No periodic maintenance for the entire duration of the ground activity should be required. Equipment shall be designed for installation and removal from the spacecraft without disassembly of the equipment.

3.3.4 Availability

N.A

3.3.5 Lifetime Reference DM-RCSLIQ-PR-0390.

The required performances shall be demonstrated all along the life time. Unless otherwise specified, acceptance temperatures shall be considered when demonstrating end of life performances.

3.3.5.1 Storage lifetime


Lifetime of equipment shall be nominally 60 months from its delivery (phase G30) until launch (end of phase G100). Refer to Table 3-1.


The equipment shall have lifetime, in unpacked status, in controlled environment of at least 48 months from beginning of phase G50 until launch (end of phase G100). Refer to Table 3-1.

3.3.5.2 Flight lifetime


The equipment shall have a nominal lifetime of at least 12 months after launch to landing on Mars.

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3.3.6 Life cycles Reference DM-RCSLIQ-PR-0430.

The component shall be capable to meet the following life cycle requirement without any degradation : 10 surge pressure (refer to DM-RCSLIQ-PR-0145) cycles for acceptance demonstration.

This number of surge must be multiplied by the life test duration factors defined in § 4.8.3.3.14 of the [NR38] for qualification demonstration.


The component shall be capable to meet the following life cycle requirement without any degradation : mechanical cycle : mechanical opening/closing = from lower extreme to upper extreme piston

position. pressure cycle : inlet and outlet Pressures TBD.

Number of cycles must be representative of pressure regulator life cycles including : - elementary parts and equipment tests to be defined by Supplier, - propulsion subsystem tests, EDM test and in flight life cycles to be defined by Customer. The global load history taking into account life test duration factors defined in § 4.8.3.3.14 of the [NR38] shall be approved by Customer.

3.3.7 Handling and transportation

TBD

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4 Planetary Protection

The issue of planetary protection concerns the minimization of biological cross-contamination between Earth and other planets. At present, whilst questions related to the existence of past or present life on Mars still remain unresolved, spacecraft visiting the planet must observe precautions in order not to impact the mission results.

DHMR is the preferred method of sterilization. Dry heat inactivates micro-organisms by the disruption of cellular components, principally by oxidation. Thermal conductivity must allow sufficient heat to be delivered to the whole product for the required duration.


The pressure regulator shall withstand a dry-heat process described as follow TBC without any degradation:

Temperature Duration

Surface & encapsulated 125°C 120 hours

Table 4-1 Duration and temperature of DHMR process


To avoid degradation of materials and improve treatment efficiency, materials selection and flight hardware design shall take into account compatibility and suitability with cleaning, sterilization and bioburden assays.


The pressure regulator supplier’s barrier design solutions shall be approved by the prime.


The flight hardware (and delivered GSE) shall be compatible with alcohol wiping (IPA or ethanol at 70% concentration)


The flight unit shall be delivered to Prime with an average surface bioburden density less than 30 000 spores/m².

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5 Environmental requirements

Unless otherwise noted, the equipment shall be designed to meet the requirements of the applicable unit specification prior to exposure, during exposure (where applicable), and after exposure to the environments specified herein. Environments experiences during equipment fabrication, transportation and storage shall be controlled to be significantly less severe than the environments specified in the following paragraphs. Reference DM-RCSLIQ-PR-0520.

The Pressure Regulator shall be designed to meet the requirements while the environment specified in §4, §5 and §6 of [NR 0164] for ground activities and EDM lifetime without any deformation or alteration of their structural or functional performances.


The Pressure Regulator shall be designed to operate in meeting the requirements on all applied environment and induced loads on particularly :

Mechanical environment o Quasi Static o Sinusoidal vibration o Random vibration o Shock o Gravity

Thermal environment Operational pressure Radiation

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5.1 Mechanical Environment

Out Of Plane = OOP = direction perpendicular to mounting plane (refer to section 6.1) In Plane = IP = directions included in mounting plane Center of Gravity = CoG = Equipment center of gravity All load cases to be applied at CoG of the unit. The gravity taken into account for Pressure Regulator design shall be the terrestrial one : g= 9,80665 m. s-². 5.1.1 Launch Reference DM-RCSLIQ-PR-0540.

The following table identifies the design load factor to be applied to the element CoG for design, with the following rules : - these values are design and thus already include uncertainty factor. - they have to be considered as acting in +/- direction. - When not specifically identified, they have to be considered as acting simultaneously.

Case OOP IP (Y) IP (Z) n° 1 28 25 25 n° 2 28 25 -25 n° 3 28 -25 25 n° 4 -28 25 25 n° 5 28 -25 -25 n° 6 -28 -25 25

n° 7 -28 25 -25 n° 8 -28 -25 -25

Table 5-1 Pressure Regulator Design load factor

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The Pressure Regulator shall withstand the following sine qualification and acceptance loads. The following tables identify the sine qualification loads to be applied at element interfaces. This levels in plane (IP) and out of plane (OOP) are defined as function of the equipment mass in hard-mounted conditions.

Example of Sine Vibration Levels for an equipment with a mass équals to 2Kg

1

10

100

1 10 100

Frequence F(Hz)

Acc

eler

atio

n le

vel (

g)

Sine Vibration OOP Sine Vibration IP

Table 5-2: Sine qualification levels

Table 5-3 Sine Acceptance levels

Remark: For mass equipment between two specified values, th e upper limit shall be considered. ( e.g.: if total mass of an equipment = 0,8 Kg then qualification levels to be considered are respectively OOP= 74g ; IP= 44g ) .

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The Pressure Regulator shall withstand the following random qualification and acceptance loads. The following tables identify the random qualification loads to be applied at element interfaces. They are coming from the system vibro-acoustic analysis and are defined as function of the equipment mass in hard-mounted conditions.

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Mass (kg) Random OOP [g2/Hz] Random IP [g2/Hz]

0.5 1 2 3 4 5

0.96 0.74 0.51 0.4 0.34 0.29

0.41 0.32 0.22 0.17 0.14 0.13

Table 5-4 Random qualification levels

Mass (kg) Random OOP [g2/Hz] Random IP [g2/Hz]

0.5 1 2 3 4 5

0.48 0.37 0.26 0.2 0.17 0.15

0.2 0.16 0.11 0.08 0.07 0.06

Table 5-5 Random acceptance levels

Remark: For mass equipment between two specified values, th e upper limit shall be considered. ( e.g.: if total mass of an equipment = 0,8 Kg then qualification levels to be considered are respectively OOP= 0,48 g2/Hz ; IP= 0,2 g2/Hz ) .


The RCS elements shall be compatible of the following shock qualification and acceptance levels (SRS) :

Frequency [Hz] Qual SRS (Q=10) [g] 100 300

2000 10000

25 400 1500 1500

Table 5-6 Shock qualification levels at RCS element interfaces

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5.1.2 Cruise and coast


The Pressure Regulator shall be compatible of : - an acceleration (design load) of 0,65g in any direction. - and a maximum EDM rotation velocity of 2,5rpm, considering the PR located at 1.5m(TBC) from the EDM rotation axis.


At end of cruise, the Pressure Regulator shall be compatible of the shock level (qualification load) generated at RCS element interface during EDM/CM separation : Level : identical than DM-RCSLIQ-PR-0570.

5.1.3 Entry


The PR shall be designed to function properly after about 180s of exposure to 15,25g static acceleration loads (design load), to external pressure equals to 800 Pa and within the environment defined in §5.2.

UNIT Axis Design load (g ) OOP 15,25

Table 5-7 Static acceleration during entry phase

5.1.4 Descent Reference DM-RCSLIQ-PR-0620.

The Pressure Regulator shall withstand the additional following static acceleration loads (qualification loads) defined hereafter and within the environments defined in §5.4 and §5.3.: - 15,5g max (TBC) due to parachute inflation and an external pressure equals to 800 Pa due to aerodynamic forces. This environment corresponds to a deceleration of the EDM, along an axis included in a cone with 20°TBC half opening angle around OOP ax is. Nota : this static load shall not to be superposed to the levels defined in tables 5-1 and 5-8 , because acting at different instants.


The Pressure Regulator shall be designed to operate after ejection of the frontshield that generates the following shock level (qualification load) at RCS elements interfaces : Level : identical than DM-RCSLIQ-PR-0570

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The mechanical environment due to retrorocket firing is covered by launch design load, refer to req. DM-RCSLIQ-PR-0540, and impact design load, refer to req. DM-RCSLIQ-PR-0650.


The pressure regulator shall withstand the following design loads generated by the impact on Mars soil: 100g quasi-static in any direction within a cone with 35°TBC half opening angle around OOP axis. Dynamic shock defined below: The maximum generated qualification shock response spectrum is :

Frequency [Hz] Qual SRS (Q=10) [g] 10 100

1000 10000

20 200 650 650

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5.2 Thermal Environment


During the all the PR lifetime, the unit shall be designed to withstand the qualification temperature for the unit configuration given here below and according to the temperature levels given hereafter :

Operating temperature Non operating temperature (1)

UNIT T Min (°C) T Max (°C) T Min (°C) T Max (°C)

T° range - 20 + 50 - 10 + 50

Acceptance T° range - 25 + 55 - 15 + 55

Qualification T° range - 30 + 60 - 20 + 60

Table 5-8 temperatures (1)The non operating temperature is defined here as th e thermal environment supported by the pressure regulator when it is empty.

5.3 Operational pressures

5.3.1 Launch, Cruise, Coast and Entry Reference DM-RCSLIQ-PR-0720.

During the launch, cruise, coast and entry (correspond to F10 + F20+beginning of F30 : refer to Tables 3-3 and 3-4), the unit shall be designed to withstand the following range of operational pressures:

P Min (bar) P Max (bar)

Operational Inlet pressures 12 at -10°C (1) 19 at 50°C (1)

Operational Outlet pressures 12 at -10°C (1) 19 at 50°C (1)

Table 5-9 Launch pressures in the pressure regulato r (1) This maximal pressure corresponds to pressure/tempe rature evolutions taking into account a filling pre ssure of 15 bar at 20°C.

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5.3.2 Descent

5.3.2.1 Before subsystem pressurization Reference DM-RCSLIQ-PR-0750.

During the descent phase (corresponds to F30 : refer to Tables 3-3 and 3-4), the unit shall be designed to withstand the following range of operational pressures:


Operational Inlet pressures 12 at -10°C 19 at 50°C

Operational Outlet pressures 12 at -10°C 19 at 50°C

Table 5-10 Descent inlet pressures in the pressure regulator

5.3.2.2 During pressurization and firing


During the descent phase (corresponds to end of F30 + F40 : refer to Tables 3-3 and 3-4), the unit shall be designed to withstand the following range of operational pressures:


Operational Inlet pressures 55 at -10°C 175 at 50°C

Operational Outlet pressures 12 at -10°C See § 3.2.2.1

Table 5-11 Descent inlet pressures in the pressure regulator

5.4 Radiation

5.4.1 Ground Reference DM-RCSLIQ-PR-0770.

No specific radiations environment is defined for this phase.

5.4.2 Launch Reference DM-RCSLIQ-PR-0780.


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5.4.3 Cruise and coast


The pressure regulator shall withstand a total ionizing dose of 10 Krad (Si) without any degradation. (TBC)

5.4.4 Entry Reference DM-RCSLIQ-PR-0800.


5.4.5 Descent Reference DM-RCSLIQ-PR-0810.


5.5 Particulate and atmosphere environment


The pressure regulator shall be compliant with § 3.6 of [NR 0101].

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6 Interfaces


The equipment shall be designed so as to ensure compatibility and proper interaction with the other equipments under all specified environmental conditions.


Each equipment interface will be controlled by Interface Control Documents (ICD) providing mechanical properties and thermal data. Each ICD shall comply with the 4.13.1 of [NR 0101].

6.1 Mechanical Interfaces

6.1.1 Unit reference frame


The Unit Coordinate Frame (UN) is a right-handed, orthogonal coordinate system, fixed to the unit geometry, and defined as follows: • one of the attachment holes of the unit shall be chosen as the Reference Hole which shall be identified by an engraved letter "R" on the unit • the O-UN origin shall be located at the centre of the Reference Hole at the level of the mounting interface plane • the X-UN axis shall be perpendicular to the mounting interface plane, pointing positively towards the unit • the Y-UN- and Z-UN axes shall be oriented such that the unit will be included inside the +Y/+Z quadrant of the mounting interface plane. Moreover, if the unit has a rectangular shape, the +Y and +Z axes shall be parallel to the sides of the unit Inertial Reference Frame. C : parent specification on [NR 0101] is MS-METH-0110

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6.1.2 Unit dimensions


The overall dimensions and associated tolerances of the unit shall comply with the 4.13.4 of [NR 0101] and following figure :

A

L

H

W

I O

1/4" inlet side

1/2" TBC outlet side

Flow direction

A : Interface Plane

Pressure Regulator dimensions

L : total Length < 220 mm

H : Height < 125 mm

W : Width < 60 mm

I : inlet tubing length > 35 mm

O : outlet tubing length > 40 mm

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6.1.3 Mass properties

6.1.3.1 Mass


The predicted equipment mass (including maturity margin and uncertainties) shall be lower than 2.5 kg .


The mass of any unit intended for Proto-flight, Flight or Flight Spare(s) shall not deviate from the Qualification model by more than + 2 %.


The accuracy of the measurement mass shall be as defined in §8.2.1.4.

6.1.3.2 Moments of inertia Nominal moments of inertia of each unit shall be recorded in the ICD.


Inertia of any unit intended for Protoflight, Flight or Flight Spare(s) shall not deviate from the Qualification model by more than TBD %.


Measurements of inertia shall be as defined in §8.2.1.4.

6.1.4 Mounting feet interface


The Pressure regulator shall be compliant with §4.9 of [NR 0101].

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6.1.5 Interface with tubing Reference DM-RCSLIQ-PR-0960.

The component shall interface with the tubing system of the RCS as follows :

Table 6-1 – Tubing interfaces


The tube ends shall be prepared for TIG welding.


The tube ends shall be referenced to a datum (e.g. centre line, mounting face, ...), and all interface data shall be incorporated into the interface control drawing/document for the component.

Pressure regulator

Tubing Material Titanium alloy :

Ti 3 Al 2.5V

inlet (1/4” HP) 6,35 + 0.1/-0 mm

Outer diameter (OD) outlet (½” BP) 12,7 + 0.1/-0 mm

(TBC)

inlet 0,71 ± 0,05 mm Wall thickness

outlet 0,89 ± 0.1 mm (TBC)

inlet ≥ 35 mm Tube length

outlet > 40 mm

Tube safety factor ≥ 4

Deviation of the perpendicular plane to the tube axis < TBD mm

inlet ≥ 30 mm Distance between the tubing axis and the mounting plane

outlet ≥ 50 mm (TBC)

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6.2 Thermal Interfaces


The thermal interface requirements shall be compliant with the section 5 of the [NR 0101] and [NR 3101].


Any thermo-optical characteristics defined in IDS/ICD shall be the result of measurement. Justification of the values shall be supplied to TAS-F.


All units housing shall present an emissivity higher than TBD, excepted the contact area with the Spacecraft and electrical/RF parts, unless otherwise specified by the Prime. For external units having radiative surfaces with functional requirements, the coating thermal characteristics shall be designed and defined by the Contractor and approved by the Prime.

6.3 Power Interfaces

N.A.

6.4 Electrical Signal Interfaces

N.A.

6.5 Bonding


The preferred method is bonding direct metal contact between the component mounting flange surface and the supporting structure.


Additionally the component shall have an attachment point for bonding between component and structure preferably a component mounting hole.

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The attachment point shall have a minimum paint free area around the hole, so that a soldering tag can be placed under the head of respective bolt (e.g. equipment bolt).


The unit design shall ensure that the DC resistance between any metallic part of the unit and the satellite interface shall be less than:

5 mΩ (test at 100 mA)

This corresponds to the performance of the metal/metal contact or grounding strap.

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7 Design Guidelines and Construction Requirements


Each unit delivered for integration into the satellite for qualification or flight and for flight spare(s) shall meet the requirements of this specification and, in particular, will have passed the applicable inspections and tests described in Section §8.

7.1 Standards [DESI]


Standard ESA or MIL parts shall be used wherever suitable for the purpose intended provided that the parts conform to the requirements of this specification.

7.2 Parts, materials and processes

7.2.1 Parts and material

Materials shall meet the following outgassing requirements at 125°C, 1x10 -6 Torr, for 24 hours : Reference DM-RCSLIQ-PR-1050.

The Total Mass Loss (TML) shall be less than 1% the original mass of the sample at the minimal and the maximal applicable temperature level with identification of species C : parent specification on [NR 0105a] is DM-EDS-2550.


The Equivalent Recovered Mass Loss (RML) shall be lower than 0,1 % of the original mass of the sample at the minimal and the maximal applicable temperature level with identification of species. C : parent specification on [NR 0105a] is DM-EDS-2550.


The Collected Volatile Condensable Material (CVCM) shall be less than 0.1% of the total mass of the sample at -50°C (TBC). C : parent specification on [NR 0105a] is DM-EDS-2550.


The selection, documentation, qualification, approval and control or all parts and materials shall be in accordance with the Parts Materials Lists (see the Product Assurance Plan NR 0112 [§ 8]).

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All parts and materials used shall be of a standard appropriate to spacecraft used and where possible shall be identical to those used for similar satellite applications.


The Supplier shall provide the Customer with the material and part list, which includes and details materials in contact with propellant.

7.2.1.1 Corrosion


The unit shall meet the requirements specified in &8.13 and &8.14 of [NR 0112].


All structural materials must comply with table I of ECSS-Q70-36-A. Selected materials which are not inherently resistant to corrosion shall be suitably protected against the anticipated corrosion environment. Dissimilar metals, as defined in MIL-STD-889 shall not be used in intimate contact without suitable protection against galvanic corrosion. Where the use of dissimilar metals in contact cannot be avoided, adequate insulation between the metals or approved plating on one of the surfaces shall be used.

7.2.1.2 Magnetic materials


Non-magnetic materials shall be used for all parts of equipment except where magnetic materials are essential to the function of the equipment. In this case they will be subject to TAS approval at EQSR.

7.2.1.3 Moisture and fungus resistance


Only those materials shall be used which will resist degradation from moisture and fungi.

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7.2.1.3.1 Threads and locking devices


All threaded fasteners, covers etc... shall provide suitable locking features to prevent motion or degradation of the equipment. Acceptable thread locking devices: lockwire self-locking nuts self-locking bolts castle nuts with cotter pins thread locking adhesives.

Star washers and simple jam nuts shall not be used. All locking devices shall be listed in a Parts and Materials List and need approval from the customer.

1

7.2.1.3.2 Lubricants


No lubrication oils or greases shall be used on the component.

7.2.1.3.3 Compatibility


The unit shall meet the requirements specified in § 8.12 and & 8.15 of [NR 0112].


The component and any materials part of the manufacturing and assembly shall be internally compatible with the media specified in §3.2 herein such that pollution of materials in contact with Hydrazine is avoided. Glue and products used for ungluing shall be compatible with the units materials. The manufacturer shall specify the products used for gluing and ungluing, the processes if applicable and the restrictions. All materials used on the component shall prevent from pollution of the operating media as Hydrazine per MIL-PRF-26536 E and its Amendment 1. The external surface of the unit shall also be designed to be cleanable with isopropyl alcohol.

7.2.1.3.4 Surface finish treatment Reference DM-RCSLIQ-PR-1190.

All external surfaces of flight hardware (including structural elements but excluding alignment references) shall have a surface treatment which shall prevent corrosion of the surface. C : parent specification on [NR 0101] is MS-METH-0200

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a. Materials without treatment

No surface treatment is requested for stainless steel, beryllium, Silver, glass fibre or Carbon Fibre, except for specific needs as thermal control.

b. Materials with required treatment Surface treatment is requested for:

Aluminium alloys (except e.g. 5056 alloy & 1050)

Magnesium and its alloys.

c. Materials with proposed treatment Surfaces treatment may be necessary for:

Titanium and its alloys Copper.

d. Other treatments d1. Cadmium Cadmium plating is forbidden.

d2. Metal couples

Metal couples requirements are defined in the [NR 0112]

7.2.2 Process Reference DM-RCSLIQ-PR-1210.

Processes used for qualification and flight model hardware shall be in accordance with the Processes requirements (see the Product Assurance Plan NR 0112 [§ 8.18]).


All processes used in the manufacturing of the component shall be compatible with the performance requirements of the units and its environmental criteria.

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7.2.2.1 Welding requirements

7.2.2.1.1 Welding general


Subcontractor shall design and size weld interface regarding environmental and functional loads. After sizing, subcontractor has to define weld geometry (depth penetration, width) and determine type and values of allowable defects (pores, cracks, allowable offset regarding weld interface, ...). Subcontractors will then define acceptance criteria of allowable defects in order to freeze minimal defect to be detected. This analysis shall be reported in Failure Mechanical Analysis document, which shall be verified and approved by customer.


The welding technique shall be such to achieve a maximum joint efficiency with a minimum of heat input and shrinkage. The joint design shall be in conformance with S6. All welding shall be in conformance with accepted welding practices to avoid interstitial contamination, metal vapor condensation and temper colors.


It is recommended to avoid metal/metal welding for the bellow manufacturing. In case of bellow metal/metal welding can not be avoided, quality controls rules and NDI shall be provided according to applicable standards : refer to § 2.2.

Reference DM-RCSLIQ- PR-1233.

All welding shall be done only in accordance with the following processes : GTAW (Tungsten Inert Gas) per S23 EBW (Electron Beam Welding) per S25 Inert shielding gas shall be vaporized liquid argon per S23.


Operators certification: - All operators performing fusion welding shall be certified per S23 - All operators performing electron beam welding shall be certified per S25 The weld operators certification shall be conform to S24

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7.2.2.1.2 Qualification


Qualification shall show that particular parameters setting of a specific weld machine will produce an acceptable repeatable productivity of weld. Qualification shall be performed prior to welding the first production assembly of a new design in accordance with the here above welding processes.

7.2.2.1.3 Pre weld requirements


Prior to welding, an in-situ weld qualification procedure will be demonstrated. The details of this process is as follows: see S20. 1) In this procedure, the supplier shall weld a pre-weld simulated weld joint sample to set and verify the weld schedule. 2) Metallographic examination of the pre-weld simulated weld joint sample (by sectioning) to verify correct EB weld machine settings. 3) Upon successful results, the supplier shall weld a second simulated weld joint sample having an effective weld length (for inspection) of approximately 2 inches. This joint will be X-ray examined to confirm adherence to NAS Class III weld standards. Step 1-3 will be repeated until a successful X-ray is obtained. The number of times that step 1-3 will be repeated shall be at the sole discretion of the supplier. If the supplier is unsuccessful in obtaining a weld sample that meets NAS 1514 Class III requirements, then the CUSTOMER shall be notified.

7.2.2.1.4 On Flight Models Pre-weld requirements


Prior to any welding, the following steps shall be taken to insure conformity to the requirements of this specification : (a) The optimum ranges of all welding machine variables shall be determined in order to maintain the required high standards of repeatable productivity of acceptable welds. (b) Employing the optimum setting determined in (a) above, weld samples shall be made. The sample shall pass the visual and x-ray inspection. The required weld penetration shall be verified either by visual inspection or by micro section. (c) Upon successful results, the supplier personnel (Weld engineer) will authorize the weld technician to proceed to weld the actual part/engine in accordance with existing weld procedures and standards.

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7.2.2.1.5 Weld inspection The herebelow standards can be replaced by equivale nt ones to be presented by supplier and accepted by customer.


a) All welds shall be inspected per requirements of applicable processes. b) Weld inspection shall be controlled by supplier. c) Individual Process Control - Each weld made on the component shall be witnessed by the Weld Engineer, and shall have the following parameters verified and documented in the shop traveler:

1) Weld depth of penetration as seen on the weld sample(s) shall be documented by photomicrograph.

2) Correct Weld Schedule being used. 3) Surface of weld on samples and parts meets weld specification (S23 &S25 requirements) 4) Cross-section of weld sample shall meet the welding specification (S23 & S25 requirements) .

d) Shop traveller and ADP shall content: 1) Samples and part/engine X-ray examination reports with the associated X-ray films. (i.e. weld film

traceability). Those reports shall clearly show the compliance with NAS 1514 Class III requirements .

7.2.2.1.6 Inspection requirements


All welds shall meet the requirements of S20


X-ray inspection requirements will be waived for those welds, which cannot be verified due to configuration or size provided such parts meet the following requirements :

- Component shall pass a proof pressure test. - Leakage shall not exceed 1 x 10-6 scc/sec of GHe at MEOP.

• Such a waiver shall be submitted to CUSTOMER approval

7.2.2.1.7 Weld dressing


The outside of all welds shall be in accordance with S6. The surface exposed to the flow stream shall have a surface finish of 1,6 µm rms.

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7.3 Mechanical Design Requirements

7.3.1 Unit internal layout and interfaces


The internal layout of the units shall take into account: the fluid requirements the thermal control requirements the alignment and center of mass requirements the vibration requirements an easy access to all electrical connectors an easy mounting and removal (including operation on the launch site) a provision to avoid mismating the flatness of mounting planes a forced or natural venting.

The unit layout and method of fixation shall be indicated in the ICD/IDS.

7.3.2 Stiffness Reference DM-RCSLIQ-PR-1260.

The pressure regulator frequencies in full conditions shall be higher than 140 Hz, considering hard mounted condition at mechanical interfaces.

7.3.3 Strength Reference DM-RCSLIQ-PR-1270.

The RCS elements shall be sized under environment of all specified mission phase (from ground until RCS end of mission) with the following principia : Consideration of residual stress of previous mission phase superposition of the related environments defined in present document (example : superposition of

acceleration effect + stress generated by thermoelastic)


As a minimum (non exhaustive), the following source of stress on elements are identified and have to be considered : - internal stress due to manufacturing - stress due to assembly (impact of manufacturing tolerance …) - AIT configuration (can differ from flight configuration, especially fixation conditions. As an example, handling can be done toward dedicated specific interfaces) - ground test environment and associated boundaries conditions - flight environments (mechanical, thermal, …) C : parent specification on [NR0101] is MS-METH-0510.

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The strength MoS shall be positive in all mission phase.


The margin philosophy for MoS calculation shall be in accordance with the rules specified in [NR0101] and depends on the type of loads specified in [NR0164] (limit, design or qualification loads). For clarification, the actual specified logic ([NR0101] and [NR0164]) is recalled here under :

Design loads : DLFMEVT-0330 and 0370 DL (1.25)

Kq = 1MTGDIR Fig 4331

sineMEVT-0340 and 0380 QL (1.25)


Predicted massMETH-1610

Kq = 1GDIR Fig 4331

ShockMEVT-0400 QL (1.25)

FEM Model factor KmMETH-570 1,1 to 1,2

Minimum Safety factors (FOS)METH-0630 - NR048 §4.4.2. Factor variable upon verification by test or analysis- NR046 for pressurized HW

Material allowablesMETH-1960

typA for SPF, otherwise typB

MS > 0METH-530

Mass best engineering estimate

Maturity mass marginMETH-0590

Mechanism shockMEVT-400 QL (1.25)

Kq = 1, MTGDIR Fig 4331

Entry QSL and pressureMEVT-0220 DL (1.25)

Thermal cartographyTBD LL


IF distortionTBD LL

Kq : +3dB MTGDIR Fig 4331

AcousticMEVT-0120 and 0130 LL

Kq : +0dBMTGDIR Fig 4331

RandomMEVT-0390 QL (+3dB)

Parachute loadsMEVT-0230, 0240 DL (1.25)

KQ = 1MTGDIR Fig 4331

RCS firingMEVT-0260 LL

FEMThermoelastic factor EDS B2 PM3 Kq = 1,25

Additional (Kld, …)METH-580 and 650 (NR048 §4221, …) case-by-case

When necessaryKQ = 1,25EDS B2 PM3

DM/CM sep., FS jett., Lander release

Launch, cruise, entry, descent

Strength analysis

Load derivation

L or Qual Load TBC

Design loads : DLFMEVT-0330 and 0370 DL (1.25)


sineMEVT-0340 and 0380 QL (1.25)


Predicted massMETH-1610

Kq = 1GDIR Fig 4331

ShockMEVT-0400 QL (1.25)

FEM Model factor KmMETH-570 1,1 to 1,2

Minimum Safety factors (FOS)METH-0630 - NR048 §4.4.2. Factor variable upon verification by test or analysis- NR046 for pressurized HW

Material allowablesMETH-1960

typA for SPF, otherwise typB

MS > 0METH-530

Mass best engineering estimate

Maturity mass marginMETH-0590

Mechanism shockMEVT-400 QL (1.25)

Kq = 1, MTGDIR Fig 4331

Entry QSL and pressureMEVT-0220 DL (1.25)

Thermal cartographyTBD LL


IF distortionTBD LL

Kq : +3dB MTGDIR Fig 4331

AcousticMEVT-0120 and 0130 LL

Kq : +0dBMTGDIR Fig 4331

RandomMEVT-0390 QL (+3dB)

Parachute loadsMEVT-0230, 0240 DL (1.25)

KQ = 1MTGDIR Fig 4331

RCS firingMEVT-0260 LL

FEMThermoelastic factor EDS B2 PM3 Kq = 1,25


When necessary


When necessaryKQ = 1,25EDS B2 PM3

DM/CM sep., FS jett., Lander release

Launch, cruise, entry, descent

Strength analysis

Load derivation

L or Qual Load TBC

In case of inconsistency with [NR0101] or associated NR margin philosophy, the subcontractor is willing to report it and consider present document as superseding until discussion with EXOMARS Prime concludes.


The above margin philosophy shall be completed on a case by case basis, according to MS-METH-0650 of [NR0101] (especially about pressure vessels and considered failure modes).

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7.4 Thermal Design Requirement


The Pressure Regulator shall be designed to withstand all thermal environmental loads of qualification level without any performance degradation as defined in § 5 of [NR 0101] and [NR 3101].

7.4.1 Justification of thermal characteristics Reference DM-RCSLIQ-PR-1330.

The thermo-optical characteristics of the Pressure Regulator shall be given by the supplier and justified.


The emissivity shall be provided when the Pressure Regulator is non operating.


For the conductive coupling, if values are temperature dependent, a table with conductivity versus node i/j shall be provided. If uncertainties remain on the conductance values, the percentage of those shall be provided.

7.4.1.1 Temperature sensors Reference DM-RCSLIQ-PR-1360.

The supplier shall provide flat surfaces for thermistor implementation in an area representative of the reference temperature (RT0). This area shall be coating free and shall have a minimum dimension of 20mm x 20 mm (TBC).

7.5 Electrical Design Requirements

N.A

7.6 Identification and marking


The Pressure Regulator shall be permanently marked in an visible area after integration on EDM platform with an identification with the following data: • manufacturer’s trade name or trade name • manufacturer’s part identification number including index • manufacturer’s serial number/lot number • configuration item number

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As a general guideline, reuse of already existing elements shall be preferred to development of specific parts.


Marking shall not degrade equipment performance.


The location of the identification shall be shown in the interface control drawing of the component.


Where the physical size precludes a complete identification it shall be marked at least with the configuration item serial number.


For all other identification data, a “bag and label” techniques shall be employed.

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7.7 Protections

7.7.1.1 Protective coating


Where materials used in the construction of the component are subjected to deterioration when exposed to climatic and environmental conditions likely to occur during service usage, they shall be protected against such deterioration in a manner that will in no way prevent compliance with the performance requirements of this specification. The use of any protective coating that will crack, chip, or scale with age or extreme of climatic and environmental conditions shall be avoided.

7.7.2 Methods of preservation and packaging

7.7.2.1 Preservation and packaging


For transportation and storage, any ports open to the external atmosphere, shall be sealed by cap fittings with inserted polyethylene sealing cones or by cover caps that are designed to avoid release of particles during installation on hardware.


The Supplier shall be responsible for all preservation and packaging for delivery in accordance with the standards as needed to provide protection of the pressure regulator for the handling and transportation environments.


Each subassembly, unit and part shall be shipped with sufficient packing provisions to prevent damage during transportation. Special covers shall protect optics, connectors, mounting surfaces subject to alignment procedures and all sensitive parts.


The units must be capable of being transported by road, rail or sea while packaged in their shipping container and must meet the requirements of this specification at the point of delivery.

7.7.2.2 Preparation for storage delivery


Each unit shall be delivered in accordance with the requirements specified in the Statement of Work.

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7.7.2.3 Retention of cleanliness


The unit shall be sealed for retention of cleanliness and contamination using bio-bag. Such kind of bio-bag will be provided by the prime.

7.8 Safety


Throughout the entire program, approved methods of safety shall be applied for testing and handling of the component.


Technicians shall be required to take all necessary precautions while handling the components.


All dangerous tests shall be performed in an enclosed, i.e. tests involving pressurization.


Safety requirements of [NR 0112] section 6 shall be applicable.


The design of the units shall be capable of sustaining a failure and retaining the property not to cause injury to personnel or damage to the launch vehicle and spacecraft.


The units shall be designed and manufactured with compatible materials in such a manner that all hazards associated with the unit are eliminated or minimized and controlled.

7.8.1 Workmanship Reference DM-RCSLIQ-PR-01560.

The workmanship shall be in accordance with manufacturing and process standards that are documented, controlled and approved.

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7.8.2 Interchangeability Reference DM-RCSLIQ-PR-1570.

All like parts shall have the same part number. Each equipment item shall be directly interchangeable in identical form, fit and function with other equipment of the same part number. The performance characteristics shall permit equipment with same P/N to be interchanged with a minimum of adjustments and re-calibrations. The equipment must be of the same qualification status and reliability to meet interchangeability requirements.

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8 Required Verification

8.1 Quality assurance provisions

8.1.1 Responsibility Reference DM-RCSLIQ-PR-1580.

The supplier shall be responsible for verifying all the requirements of this specification in accordance with the Statement of Work and Product Assurance Requirements. Verification shall be accomplished by one of the following methods: 1. Analysis. 2. Similarity. 3. Test. 4. Reviews.


TAS and its Customer reserves the right to witness any of the tests laid down in this specification. Mandatory inspection points shall be mutually agreed to by Prime and supplier during the CDR on the basis of the manufacturing and inspection plan to be provided by the supplier. Details of performance of these verification/tests will be defined in the test procedure which has to be prepared by the supplier of the component. This test procedure will be the basis for the performance of this verification/tests and will give the basis for the test report (using test formats). The test procedure shall be approved by TAS prior to commencement of tests. The component manufacturer will notify prime’s representatives at least five working days prior to commencement of test for source monitoring of testing.

8.1.2 Quality Assurance Activities Reference DM-RCSLIQ-PR-1600.

The QA activities have to conform with NR 0112.

8.1.3 Classification of Tests Reference DM-RCSLIQ-PR-1610.

Qualification and acceptance testing shall be performed in accordance with the test sequence specified in §8.2.

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8.1.3.1 Qualification


The PR shall be qualified to demonstrate design adequacy and compliance with system requirements. Qualification shall be demonstrated either by qualification testing of a flight standard pressure regulator in accordance with §8.2.4.1 or by proving previous qualification to an equivalent standard (similarity), or by analysis.

8.1.3.2 Acceptance


All flight standard units produced shall undergo acceptance tests in accordance with §8.2.4.2.

8.1.4 Failure Criteria Reference DM-RCSLIQ-PR-1640.

The pressure regulator shall exhibit no failure, malfunction or out of tolerance performance degradation as a result of he examinations and tests specified herein.

8.1.5 Non-Conformance/Failure Reporting System


This item is described in [NR0112].

8.1.6 Acceptance Data Package Reference DM-RCSLIQ-PR-1660.

The supplier shall submit together with the hardware a data package which comprises the documents listed in the generic SOW.

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8.2 Verification requirements

Test environments and relevant requirements are specified in the [NR 0164] and [NR 0167]. Major requirements are reminded hereafter.

8.2.1 Verification /Testing requirements

8.2.1.1 General Reference DM-RCSLIQ-PR-1670.

All measurements and tests performed under ambient conditions shall be conducted within the following ambient conditions :

- Pressure: 710 mm Hg < P < 815 mm Hg

- Temperature: 22°C + 5°C

- Relative Humidity < 60 % - Cleanliness room Class 100 000


Actual ambient test conditions should be recorded regularly during the tests.

C : parent specification on [NR 0164] is MS-MEVT-0410


In case of ambient conditions exceeding the allowable limits, the decision not to test or to halt any test in progress shall lie with the responsible Test Manager who must have adequate evidence that there will be no adverse influences on component performance. However, the temperature of the unit shall not be allowed to exceed the specified range. C : parent specification on [NR 0164] is MS-MEVT-0410

8.2.1.2 Tolerance Levels Reference DM-RCSLIQ-PR-1700.

The test level tolerances shall be in accordance with [NR0164].

8.2.1.3 Cleanliness Reference DM-RCSLIQ-PR-1710.

Refer to [NR0106].

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8.2.1.4 Measurements Reference DM-RCSLIQ-PR-1720.

Refer to [NR0164].

8.2.1.5 Temperature Stabilization


Time shall be allowed for the equipment to reach required temperatures during testing. Temperature stabilization has been reached when all temperature readings are within 3°C of the specified temperatu re.

8.2.1.6 Test devices Reference DM-RCSLIQ-PR-1750.

If specific test devices requested by the Supplier need to be used for test purposes, then such devices shall be dismounted before flight. If these units couldn't be dismounted before flight, the following requirements shall be taken into account: - test units shall not cause any trouble to flight equipment (electrical, electromagnetic, mechanical,...) - electrical circuits shall be grounded.

8.2.2 Verification/ Levels and durations Reference DM-RCSLIQ-PR-1760.

The qualification and acceptance test levels and duration shall be the predicted flight/ground maximum mechanical environmental loads, identified in §5.1 of this document, increased by qualification/acceptance factor and relevant duration. In next table the qualification and acceptance factors are reported.

While the logical flow behind their derivation is synthesized in the following pictures:

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Figure 8-1: Qualification (=Design) Loads Derivatio n

Figure 8-2: Acceptance Loads Derivation

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8.2.3 Verification/Test Sequence


The verification/test shall be performed in accordance with the following paragraphs: The tests listed herein are a minimum. A complete, Design Verification Matrix shall be established showing adequacy of analyses, inspection, measurements and tests proposed. Final test plans shall be submitted to Prime for approval : - Pressure regulator qualification plan - Pressure regulator acceptance plan Sequences specified in §8.2.4.1 and §8.2.4.2 are indicative and will be finalized with mutual agreement between the Supplier and the Prime.

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8.2.4 Verification Sequences

8.2.4.1 Qualification Test Matrix


The tests on QM shall include, as a minimum, the indicated sequence defined in the following table. In case of a new qualification, the qualification test plan shall be provided to the Customer for approval.

VERIFICATION SEQUENCE PARAGRAPH REQUIREMENT TESTS

NDI : bellow welding inspection 7.2.2.1

Initial inspection and examination - visual inspection - configuration - interface requirements - part, materials and processes - identification and marking - interchangeability - workmanship

6. 6. and 7.3.1

7. 7.6

7.8.2 7.8.1

8.2.5.2.1

8.2.5.2.2 and 8.2.5.3

Planetary Protection 4 8.2.5.2.3

Proof pressure test 3.2.2 8.2.5.4.1.1

Functional tests at ambient temperature - regulation test - internal leakage - external leakage - surge pressure - maximum flow capability - outlet pressure stability - steady state flow stability - response time

3.2.2.4 and 3.2.2.5

3.2.4.1 3.2.4.2 3.2.2.7

3.2.5 and 3.2.6 3.2.8.1 3.2.8.2 3.2.7

8.2.5.4.2

8.2.5.4.6.2 8.2.5.4.6.1 8.2.5.4.3 8.2.5.4.3 8.2.5.4.4 8.2.5.4.5 8.2.5.4.3

Vibration tests - resonance search - sinus vibration (constant acceleration) - resonance search - random vibration - resonance search

5.1 8.2.5.7

Functional tests at ambient temperature - regulation test - internal leakage - external leakage - surge pressure - maximum flow capability

3.2.2.4 and 3.2.2.5

3.2.4.1 3.2.4.2 3.2.2.7

3.2.5 and 3.2.6

8.2.5.4.2

8.2.5.4.6.2 8.2.5.4.6.1 8.2.5.4.3 8.2.5.4.3

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- steady state flow stability 3.2.8.2 8.2.5.4.5

Shock test - resonance search - shocks - resonance search

5.1 8.2.5.8

Functional tests at ambient temperature - regulation test - internal leakage - external leakage - surge pressure - maximum flow capability - steady state flow stability

3.2.2.4 and 3.2.2.5

3.2.4.1 3.2.4.2 3.2.2.7

3.2.5 and 3.2.6 3.2.8.2

8.2.5.4.2

8.2.5.4.6.2 8.2.5.4.6.1 8.2.5.4.3 8.2.5.4.3 8.2.5.4.5

Quasi-Static Load/Spin 5.1 8.2.5.6

Thermal cycling - 8 high/low cycles (inc functional tests)

5.2 8.2.5.5

Life cycle test 3.3.6 8.2.5.4.7


3.2.2.4 and 3.2.2.5

3.2.4.1 3.2.4.2 3.2.2.7

3.2.5 and 3.2.6 3.2.8.2

8.2.5.4.2

8.2.5.4.6.2 8.2.5.4.6.1 8.2.5.4.3 8.2.5.4.3 8.2.5.4.5

Cleanliness verification and drying 3.2.9

Final Examination 8.2.5.2.4

Burst pressure test 3.2.2 8.2.5.4.1.2

End item acceptance test 8.2.5.2.5

Table 8-1 : Qualification Matrix

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8.2.4.2 Acceptance Test Matrix


The tests on FM shall include, as a minimum, the indicated sequence defined in the following Table.


NDI : bellow welding inspection 7.2.2.1

Initial inspection and examination - visual inspection - configuration - interface requirements - part, materials and processes - identification and marking - interchangeability - workmanship

6. 6. and 7.3.1

7. 7.6

7.8.2 7.8.1

8.2.5.2.1

8.2.5.2.2 and 8.2.5.3

Proof pressure test 3.2.2 8.2.5.4.1.1


3.2.2.4 and 3.2.2.5

3.2.4.1 3.2.4.2 3.2.2.7

3.2.5 and 3.2.6 3.2.8.2

8.2.5.4.2

8.2.5.4.6.2 8.2.5.4.6.1 8.2.5.4.3 8.2.5.4.3 8.2.5.4.5

Vibration tests - resonance search - sinus vibration (constant acceleration) - resonance search - random vibration - resonance search

5.1 8.2.5.7

Thermal cycling - 6 high/low cycles (inc functional tests)

5.2 8.2.5.5

Cleanliness verification and drying 3.2.9

Planetary protection inspection 8.2.5.2.3

Final Examination 8.2.5.2.4

End item acceptance test 8.2.5.2.5

Table 8-2 : Verification Matrix

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8.2.5 Test Methods


During all tests to be performed, the test data and parameter values have to be continuously recorded.

8.2.5.1 Initial Full Functional Performance tests


Prior to conducting any of the tests identified in this section, the test item shall be operated under ambient conditions, and a record shall be made of all data necessary to determine compliance with the required performance in the subsequent performance tests conducted before, during and after the environmental exposure. The only exceptions to this requirement are for those items which cannot be tested realistically in ambient conditions. In such cases, initial testing shall be designed to prove compliance as far as possible without causing damage to the test item.

8.2.5.2 Inspections and examinations

8.2.5.2.1 Visual inspection Reference DM-RCSLIQ-PR-1910.

The equipment shall be examined visually to verify that there are no handling damages.

8.2.5.2.2 Configuration verification Reference DM-RCSLIQ-PR-1920.

The configuration of the unit shall be in accordance with the Configuration Item Data List.

8.2.5.2.3 Planetary protection inspection Reference DM-RCSLIQ-PR-1930.

The prime will perform biorburden sampling at delivery. The pressure regulator shall meet the biorburden level specified in § 4 (the biorburden level will be defined in further specification issue).

8.2.5.2.4 Final examination Reference DM-RCSLIQ-PR-1940.

The equipment shall be examined visually to verify compliance with: - no handling damages

- workmanship

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8.2.5.2.5 End Item acceptance Reference DM-RCSLIQ-PR-1950.

After completion of all acceptance tests, the quality assurance responsible shall perform a final inspection of the hardware. Accepted items shall be appropriately sealed by the supplier's QA and released for storage or transportation.

End item acceptance shall include proper review of the documentation.

8.2.5.3 Determination of mass, moments of inertia and centre of gravity


The mass shall be determined by weighing. The mass of the equipment shall be in accordance with §6.1.3. The moment of inertia and the centre of gravity may be determined by analysis.

8.2.5.4 Performance tests Reference DM-RCSLIQ-PR-1970.

The functional requirements specified in § 3.2 have to be verified by test.

8.2.5.4.1 Pressure requirement

8.2.5.4.1.1 Proof pressure test Reference DM-RCSLIQ-PR-1980.

The proof pressures shall be applied for a duration 5 minutes with gaseous Helium to the inlet and outlet of each stage according to [NR046].


Any evidence of permanent set or failure of any kind shall be cause for rejection.


Inlet and outlet pressures shall be recorded.

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8.2.5.4.1.2 Burst pressure test Reference DM-RCSLIQ-PR-2010.

Burst pressure shall be applied for a duration of 5 minutes with gaseous Helium to the inlet of each stage and to the outlet.


The burst test shall be performed on a flight representative model (e.g. : operational regulator with bellows, poppet valve ...).


No regulator body rupture and no internal regulator rupture shall occur at the burst pressure (e.g. : at the inlet burst pressure the regulator shall not leak - internal leakage). Actual burst pressure shall be provided by the manufacturer.


Inlet and outlet pressures shall be recorded.

8.2.5.4.2 Regulation test Reference DM-RCSLIQ-PR-2050.

The component shall be tested in order to cover the range of inlet pressure as defined in § 3.2.2.1, the range of gas flow as defined in § 3.2.5. A minimum of 24 points shall be tested starting from highest Pressure. (3 pressures , 4 flow rates, 2 stages). Regulated pressure shall be verified for both stages and for each stage.

8.2.5.4.3 Surge pressure, maximum flow capability and response time Reference DM-RCSLIQ-PR-2060.

Supply pressure, downstream pressure, flow rate and supply temperature shall be continuously recorded. These tests shall be done for each stages and for both stages together.

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8.2.5.4.4 Outlet pressure stability Reference DM-RCSLIQ-PR-2070.

An outlet regulated and lock-up pressure stability tests shall be performed for each stage. During qualification and acceptance tests, the regulated pressure evolution shall be lower than : ± 200 mb (TBC) before and after each environment tests (Vib or thermal) ± 300 mb (TBC) before and after the whole environment tests (Vib and thermal)

The scheme below explain this requirement. This requirement is applicable for each measurement point. A measurement point is a point with a temperature point (Tamb, Tmax or Tmin) , a flow rate point (0 ; 5 ; or 10 g/s), an inlet pressure point(55 ; 175 ; 300b). Supply pressure, downstream pressure, flow rate and supply temperatures shall be continuously recorded.

8.2.5.4.5 Steady state flow stability Reference DM-RCSLIQ-PR-2080.

Acceptance and qualification tests shall be performed with the following flow rates : 0.1 g/s GHe, 5 g/s GHe, 8 g/s Ghe, 10 g/s GHe.

Supply pressure, downstream pressure, flow rate and supply temperatures shall be continuously recorded. These tests shall be done for each stage and for both stages.

P0 : P ref initial (after adjustment)

P ref after vib and before TC Criteria : ± 200 mb max/P0

P ref after vib and after TC criteria : ± 200 mb max / P1 and ± 300 mb /P0

P1 P2

P0

Regulated pressure

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8.2.5.4.6 Leakage test

8.2.5.4.6.1 External leakage Reference DM-RCSLIQ-PR-2090.

According to [NR046], the pressure regulator shall be sealed and pressurized up to MEOP with Helium for at least 30 minutes. The external leakage shall not exceed the limits specified in § 3.2.4.2.The leakage shall be measured with a mass spectrometer.

8.2.5.4.6.2 Internal leakage Reference DM-RCSLIQ-PR-2100.

According to [NR046], the internal leakage shall be measured at the lock up pressure for the following inlet pressures :

- the high pressure MEOP specified in § 3.2.2.1. - at 175 bar. - at 55 bar.

8.2.5.4.7 Life cycle test Reference DM-RCSLIQ-PR-2110.

The pressure regulator shall be subjected during qualification to endurance tests to demonstrate compliance with 3.3.6 for : surge pressure cycles. mechanical and pressure cycles.

Load history will be defined later with the supplier in order to be representative of the pressure regulator life cycles.

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8.2.5.5 Thermal cycling

Unit qualification and/or acceptance thermal cycling tests of low voltage units and unit with a design not affected by ambient pressure conditions may be conducted at ambient pressure. Due to the fact that the design doesn’t affected by ambient pressure the thermal cycles shall be conducted at ambient pressure . Reference DM-RCSLIQ-PR-2120.

The pressure regulator shall be subjected to a thermal vacuum cycling test. Refer to following Figure. For any new qualification program, at least 8 high/low temperature cycles shall be performed to qualification limits. Also, for new qualification program, start-up will be performed.

The thermal cycle tests shall be performed with the temperatures specified in §5.2. During thermal testing, functional tests shall be performed to verify the unit performance :

- at ambient pressure at the beginning and the end of the test.

- In vacuum, at the end of the first and the last hot and cold steady state phases.T

The tests to be performed shall be as minimum :

- regulation test - §8.2.5.4.2 - internal leakage - §8.2.5.4.6.2

- external leakage - §8.2.5.4.6.1

- surge pressure - §8.2.5.4.3 - steady state flow stability - §8.2.5.4.5

The Supplier can propose different sequences which shall be submitted to the Customer for approval.

The vacuum before first turn on shall be 10-5 hPa. During cycling, temperature shall be continuously monitored.

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Figure 8.3 Thermal Cycle Profile

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8.2.5.6 Quasi-Static Loads test Reference DM-RCSLIQ-PR-2140.

The acceleration test shall be performed if the sine vibration test does not cover the static load cases given in § 5.1. Test duration shall be one minute in each axis direction.

8.2.5.7 Vibration tests


The Equipment shall be representative mounted as defined in §6. to a fixture through its normal I/F points. The Equipment’s to Test Fixture fixation system shall be mechanically identical to the flight one. C : parent specification on [NR 0101] is MS-METH-0560.


The unit shall be vibrated in each of its three reference axes by applying a sinusoidal forcing input at its mounting plane, sweeping up and down in the required frequency domain with the established rate applying the levels defined in § 8.2.2. C : parent specification on [NR 0101] is MS-METH-0560.


Before and after the testing a low sine sweep shall be performed on each of the three axes, for unit integrity evaluation. The level of the low sine sweep shall be 0.5g from 0 to 2000 Hz and a sweep rate of 2 Oct/min. C : parent specification on [NR 0164] is MS-MEVT-0480.


A complete functional test shall be performed before and after the sinusoidal vibration test.


Units, which are operating during launch, shall be operated and monitored during testing.

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8.2.5.7.1 Resonance Search


Before and after the Vibration Tests (Sinusoidal and Random) a resonance search test shall be performed on each axis as follows:

- Acceleration Amplitude : 0.5 g

- Frequency : 0 to 2000 Hz

- Sweep Rate : 2 Oct/min

A shift greater than 10% is forbidden.

8.2.5.7.2 Sinusoidal Vibration


The levels defined in §5.1 shall be applied along each of the equipment axes.

The sweep rate that shall be taken into account for the tests is defined in §8.2.2. The tests duration are defined in §8.2.2. The test configuration shall be representative to the launch configuration (Interfaces, Orientation versus gravity). The orientation of the unit could be different for test facilities and submitted to customer approval. All the requests for notching shall include the random input level that leads to the design limit (null safety margin). The test shall be performed with the boundary conditions defined in the § 6.1.

8.2.5.7.3 Random Vibration


The levels defined in §5.1. shall be applied along each of the equipment axes.

The tests duration are defined in §8.2.2.

The test configuration shall be representative to the launch configuration (Interfaces). The orientation of the unit could be different for test facilities and submitted to customer approval. The test shall be performed with the boundary conditions defined in the § 6.1.

8.2.5.8 Pyrotechnic shocks


The levels defined in §5.1. shall be applied along each of the 6 directions of the equipment.

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8.2.5.8.1 Radiations Reference DM-RCSLIQ-PR-2240.

The component shall be able to withstand a total radiation dose specified in §5.4. over the mission operational lifetime.

The supplier shall also indicate the current qualified level.

8.2.5.8.2 EMC-Test

N/A

8.2.6 Test Documentations

8.2.6.1 Test Procedures


The Subcontractor shall establish procedures for performing all required tests in accordance with detailed test plans approved by the customer. The test plans shall be based upon the specified performance, a failure modes and effects analysis, and the test requirement. The test procedures to be used in conducting required tests shall be detailed so that there is no doubt as to what is to be done. The pass-fail test criteria shall be determined prior to the start of every test. Pattern or lot associated failures that may occur shall be identified as potentially critical failures. Corrective action for potentially critical failures, including retest requirements, shall be approved by the customer. The test plans and procedures shall provide traceability to the test requirements.

8.2.6.2 Test Reports


Following completion of formal tests, test reports shall be prepared as defined in the Statement of Work provided by the customer.

8.2.6.3 Test Failure


If an equipment fails, malfunctions or out-of-tolerance performance occurs during or after a test, the test shall be discontinued as appropriate and a NCR has to be issued.

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8.2.6.4 Failure Definition


A failure shall include, but not be limited to, an occurrence of any of the following: APPENDICES : Equipment performance functionally beyond the design limits, test specification, criteria, or procedures. This applies to qualification, and acceptance tests.

APPENDICES : Intermittent or erratic equipment performance.

APPENDICES : Necessity of repeated adjustment to sustain acceptable equipment operation, initial or setup adjustments excepted.

APPENDICES : Equipment operation which has unexplainable drift from initial or setup performance conditions. This applies even though equipment performance may still be within specification limits.

APPENDICES : Overstress of end-item hardware caused by test equipment when an evaluation of the overstress has not or cannot be ascertained.

APPENDICES : Part failure.

APPENDICES : Any deviation with respect to the Test Procedure as agreed during the TRR.

APPENDICES : Any failure of test equipment.

8.2.6.5 Test Failure Procedures


The Test Failure Procedure to be applied is defined in the document applicable documents TBW. NOTE: Test failure reporting procedures shall start at the first powered operation of Proto-flight and Flight Models and shall continue through qualification and flight hardware.

End of the document