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8-Conf Material No License-0088 Orbital Proprietary Presented at the 19 th Conference on Quality in the Space and Defense Industries Carl Walz, Vice President,

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Presentation on theme: "8-Conf Material No License-0088 Orbital Proprietary Presented at the 19 th Conference on Quality in the Space and Defense Industries Carl Walz, Vice President,"— Presentation transcript:

1 8-Conf Material No License-0088 Orbital Proprietary Presented at the 19 th Conference on Quality in the Space and Defense Industries Carl Walz, Vice President, Human Spaceflight Operations Commercial Resupply Services for the ISS

2 8-Conf Material No License-0088 2 International Space Station Overview The International Space Station is the largest and most complex international scientific project in history. Led by the United States, the International Space Station draws upon the scientific and technological resources of 16 nations: Canada, Japan, Russia, 11 nations of the European Space Agency, and Brazil More than four times as large as the Russian Mir space station, the completed International Space Station will have a mass of about 472,000 kg. It will measure 356 feet across and 290 feet long, with almost an acre of solar panels to provide electrical power to six state-of-the-art laboratories. The station is in an orbit with an altitude of approximately 400 km with an inclination of 51.6 degrees. The orbit provides excellent Earth observations with coverage of 85 percent of the globe and over flight of 95 percent of the population. The ISS houses an international crew of 6.

3 8-Conf Material No License-0088 3 International Space Station Overview Initial resupply of the ISS was primarily accomplished by the Space Shuttle and the Russian Progress autonomous resupply vehicle. With the retirement of the Space Shuttle, additional international partner resupply capabilities have been developed and demonstrated. These vehicles include the Japanese HTV and the ESA ATV. Resupply items include water, air, food, clothing, general operational supplies, spare parts, and scientific payload items Service also includes carrying away trash and other non-serviceable items for disposal during Cygnus destructive reentry Missions purchased on a per-mission basis, regardless of amount of cargo up and down

4 8-Conf Material No License-0088 4 Low Earth Orbit Transfer Operations Drawing Upon Its 29 Years Of Satellite And Major Space Systems Development And Operations Experience, Orbital Sciences Corporation Has Embarked On A New Venture To Provide Low Earth Orbit Cargo Transfer Services To NASA’s ISS Program Under the joint NASA / Orbital Commercial Orbital Transportation Services (COTS) program, Orbital is Developing the “Cygnus” Advanced Maneuvering Space Vehicle, Which is Designed to Meet the Stringent Safety Requirements for International Space Station (ISS) Operations. The Cygnus Spacecraft Will Provide Cargo Resupply to the ISS Program under the Cargo Resupply Services Contract

5 8-Conf Material No License-0088 5 Commercial Orbital Transportation Services (COTS) –Orbital Selected In February 2008 For a Single 2011 Demonstration Mission –Safety Review Panel Phase 1 & II completed March/Nov 2009. Phase III in progress –CDR completed March 2010 –20 of 24 Milestones completed to date –Taurus Test Launch now planned for summer 2011 –COTS Demo Launch to ISS Planned for 2011 Commercial Resupply Services (CRS) –Operational Service-Phase Follow-on to COTS Demonstration –Orbital Selection December 2008 –8 Flights Over Period From 2012-2015 –Have received Authority to Proceed for 3 missions –First mission (Orb 1) planned for March 2012 COTS/CRS Summary

6 8-Conf Material No License-0088 6 Orbital COTS Systems Architecture Taurus II Cargo Operations Integrated Launch Site Operations Mission Operations Orbital COTS System Cygnus Visiting Vehicle The Orbital COTS System is comprised of 5 Major Elements

7 8-Conf Material No License-0088 7 Cygnus Overview The Cygnus vehicle is comprised of two major modules Service Module Provides all utility services to the cargo modules Manages the autonomous rendezvous to the ISS Provides required resources to allow the mission to be successfully completed Structural interface to the launch vehicle and cargo modules Integrated at Orbital’s Dulles facility Pressurized Cargo Module Supports NASA Cargo Requiring a Pressurized Environment Built by Thales Alenia Heritage: LEO Star/Star Bus Power Generation : 3.5 kW DC Power Propellant: Dual Mode N 2 H 4 /NTO or N 2 H 4

8 8-Conf Material No License-0088 8 Cygnus General Cargo Capabilities Cygnus Pressurized Cargo Module (PCM) provides pressurized volume for internal cargo delivery to ISS –Cygnus is berthed to ISS Node 2 Nadir Port utilizing the SSRMS –Up to 2000Kg Cargo can be accommodated by the Standard PCM –Up to 2700 kg Cargo can be accommodated by the Enhanced PCM Standardized Active and Passive cargo accommodations available within PCM –Passive Cargo: Cargo Transfer Bags (CTB), M-bags, Mid-Deck Lockers (MDL) –Active Cargo: Two single MDL or one Double MDL sized payloads –Disposal Cargo reloaded into Cygnus prior to Unberthing

9 8-Conf Material No License-0088 9 Trash on ISS

10 8-Conf Material No License-0088 10 Flight PCM Development Alenia on Track for PCM Delivery in 2011 PCM Cargo Integration Demo Complete!

11 8-Conf Material No License-0088 11 Program Summary Develop Delta II/Atlas III Class Launch Vehicle and Ground System Initial Contract for COTS-Demo Launch in 2011 Launch Vehicle for Commercial Resupply System Program Goals Minimize Development NRE Minimize Recurring Costs -- Eliminated Strap-on Boosters Minimize Launch Site Infrastructure – Use Horizontal Integration/Clean Pad Concept Design for High Reliability -- Use Heritage Components Vehicle Parameters Gross Liftoff Mass: 290,000 kg Vehicle Length: 40 m Vehicle Diameter: 3.9 m Payload Fairing Diameter: 3.9 m Options 3 rd Stage Bipropellant Kit – Unavailable on First Flights 3.9 m Fairing (Orbital) CASTOR® 30 Stage 2 Motor (ATK) 3.9 m Propellant Tanks/ Stage 1 Core (Yuzhnoye) Dual LO 2 /RP AJ26 Engines (Aerojet) Taurus II Overview Avionics (Orbital)

12 8-Conf Material No License-0088 12 Cygnus Mission Operations Cygnus will be boosted into orbit by Orbital's Taurus II medium-class space launch vehicle Cygnus mission operations will be managed from Orbital's state-of-the-art Mission Control Complex in Dulles, Virginia, in concert with NASA’s Johnson Space Center in Houston, Texas. After being launched into low-Earth orbit by Taurus II, the Cygnus spacecraft has substantial maneuvering capability to transport it’s payload from a low parking orbit to the ISS or other LEO destination. After the payload mission is complete, Cygnus is steered to a safe destructive reentry over the Pacific Ocean.

13 8-Conf Material No License-0088 13 Orbital Flight Control Team New MOC 4 has been designed with larger COTS/CRS team in mind Cygnus flight control team –Includes front (real- time ops) and back room (engineering) functions –New MOC will provide those rooms and connectivity between them COTS/CRS model consistent with Industry Standards

14 8-Conf Material No License-0088 14 Taurus II Wallops Footprint H-100 Cargo Processing V-55 Payload Fueling HIF Pad 0A 8.53 Miles 1.1 Miles 2.46 Miles

15 8-Conf Material No License-0088 15 COTS/CRS Top Level Launch Site Concept of Operations Launch Pad Cygnus Fueling Cygnus Mate to Payload Adapter/ Sep System Cargo Late Load Demonstration Cygnus to LV Integration & Encapsulation NASA Cargo TAS-I Pressurized Cargo Module Orbital Taurus II Launch Vehicle V-55 Payload Fueling Facility Horizontal Integration Facility (HIF) P/L EGSE Vault Roll-out and Erection Launch Preparation and Launch SM Integrated System Test PCM Checkout Cargo Storage, Process and Load SM-PCM Mate Cygnus Integrated Test Cygnus Mass Properties H-100 Payload Processing Facility Orbital Service Module Horizontal Integration Facility (HIF) Launch Pad

16 8-Conf Material No License-0088 16 Taurus II First Stage in HIF

17 8-Conf Material No License-0088 17 Taurus II Launch Pad at Wallops

18 8-Conf Material No License-0088 18 Cygnus Design Process “Bakes” In Success Strong recipe for success –Orbital’s strong systems engineering –Along with ISO and AS9100 Processes –Along with vigilant and independent Safety and Mission Assurance Coupled with a highly involved customer – NASA –Expert insight through COTS and CRS programs –Independent Safety Review Panel required additional design requirements above those required for non-human space missions –Extensive verification activity to prove design works and is safe to complete mission successfully, and safely

19 8-Conf Material No License-0088 19 NASA Insight and Oversight for Cygnus and Taurus II Insight –Commercial Crew and Cargo Program Office –International Space Station Program Office –JSC Mission Operations Directorate –NASA Launch Services Program Oversight –JSC Safety Review Panel

20 8-Conf Material No License-0088 20 Safety and Mission Assurance Approach on COTS/CRS Partnership with selected team members having strong experience in NASA human space missions Disciplined process for system requirements flowdown and verifications – supported by Cradle requirements management database Clear understanding of fault tolerant system designs and their implementation – supported by top-down system analyses and probabilistic risk assessment Strong interaction between S&MA, system engineering, and other engineering disciplines Firm baseline of proven design and process standards for flight hardware and software - refined during 29 years of successful NASA, DOD and commercial space programs Effective selection and control of critical suppliers High Technology Readiness Level Components Safety and Mission Assurance approach to Orbital‘s Human Space missions emphasizes effective integration of system engineering disciplines, and mature and disciplined processes for design, procurement, production, verification

21 8-Conf Material No License-0088 21 QMS and Continuous Improvement Orbital’s Quality Management System (QMS) is registered to ISO 9001:2000 and AS 9100 –Third party registration by the British Standards Institution –Implemented as a series of standard business practices –Mandatory employee training includes: business ethics; safety; risk management; design and workmanship standards; etc. –Includes an internal audit system to monitor ISO and AS compliance –Overseen by a Continuous Improvement management team to improve and refine our business procedures ISO 9001:2000 and AS9100 assessment was recently performed (November 2010) with no major findings Dulles and Chandler S&MA management are active NASA team members: –Quality Leadership Forum –Joint Audit Planning Committee –Aerospace Space Quality Improvement Council

22 8-Conf Material No License-0088 22 Reliability Analysis Lab Reliability Analysis Lab Capabilities Part and material qualification/ acceptance Particle impact nose detection (PIND) Prohibited material screen Destructive Physical analysis (DPA) Material properties PCB coupon exam Part functional verification Life test Failure investigation Dynamic and static X-ray Destructive examinations Failure simulations IR&D / process qualifications Coupon preparation and testing Material properties and stress tests

23 8-Conf Material No License-0088 23 S&MA Institutional Practices Electrical, Electronic, Electromagnetic (EEE) parts –Selection from NASA EEE-INST-0002 and Orbital Preferred Parts List (PPL) –Compatibility with mission Total Dose and Single Event radiation requirements verified by test data –Traceability maintained to lot date code and/or serial number Materials selected from heritage programs and for verified compatibility with space environment –Vacuum stability, flammability, toxicity –Resistance to stress corrosion cracking –Cadmium, zinc and pure tin plating strictly prohibited – verified by lot sample inspection Process and workmanship standards based on high reliability NASA, MIL and industry standards –NASA-STD-8739 series for soldering, wiring, bonding –PWB design and fabrication to IPC standards –Strict ESD and FOD controls, with 100% training by engineering, assembly, test and quality personnel

24 8-Conf Material No License-0088 24 Supplier Assurance & Control Strong supplier achieved through: –Capability and Quality Surveys performed by a Cross-Functional Team –Benchmarking our Supplier requirements with other top Aerospace Contractors –Use of a Suppler Rating System, providing monthly reporting of quality and delivery performance, as well as responsiveness to any Supplier Corrective Action Requests –Managing, monitoring, and reporting to Orbital management the impact of supplier changes affecting facilities, management or processes –Reducing the Supplier Database for reduced risk and improved efficiencies Certified Supplier Program –Identifies top rated suppliers through past performance –Designates supplier’s Quality Representative with authority to accept Orbital product –Orbital oversight maintained through mandatory inspection points (MIP) and metric reporting Strong performance from our team members and suppliers is absolutely critical to success of our Space programs

25 8-Conf Material No License-0088 25 Manufacturing, Integration, Test All flight hardware builds are to approved and CM released documentation –Assembly drawings and parts lists, with approved ECNs –Detailed work instructions Hardware identification, traceability, history –End Item Data Package (EIDP) provides configuration, traceability, nonconformance and accptance results at all levels of assembly Receiving, in-process and final inspection/test points are clearly identified at all levels, and performed to documented and approved procedures Material Review Board (MRB) implemented for manufacturing anomalies, with participation of flight assurance, engineering and program management Failure Review Board (FRB) –Conducted for all failure after start of function testing –Chaired by program Flight Assurance Manager, with engineering, systems, I&T and program participation

26 8-Conf Material No License-0088 26 COTS/CRS Safety Implementation Process Cygnus safety requirements defined in the COTS Interface Requirements Document (IRD), with specific requirements for control of Catastrophic and Critical hazards –Has been overriding consideration in Cygnus design trades, from inception of the program –Redundancy in critical hardware functions Follows “phased” safety review process with JSC/ISS Safety Review Panel (SRP) First Review (Phase I) conducted in February 2009, with 80% of the SRP’s attention directed to the Cygnus “Collision” hazard report Cygnus Phase II safety review (for detailed design phase) was successfully completed in November 2009 Follow-on reviews have been held to brief the SRP on design updates and testing issues Next SRP milestone is the submittal of the Phase III data package summer 2011

27 8-Conf Material No License-0088 27 Thank You!


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