This isapreprint orreprintofa paper intended for presentation at a conference. Because changes maybe made before formal AIAA 2001-5040 publication, thisismade available withthe understanding thatitwill notbe cited orreproduced without thepermission oftheauthor. Conference & Exhibit on International Space Station Utilization Overview Kennedy Space Center, Florida 15- 18 Oct 2001 The ISS FCF is amultidiscipline research INTEGRATION PROCESS FOR PAYLOADS facility that provides accommodations to IN THE FLUIDS AND COMBUSTION investigate combustion and fluids phenomenon FACILITY in a sustained microgravity environment. Investigations performed in a microgravity James M. Free/NASA Glenn Research Center, environment provide unique insight into the behavior of fluids and combustion science. The Marsha M. Nail/NASA Glenn Research Center combustion portion of the FCF supports Abstract investigation and observation of laminar flames, turbulent combustion, droplet and spray The Fluids and Combustion Facility (FCF) is an combustion, and other types of combustion ISS research facility located in the United States research. The fluids portion of the FCF supports Laboratory (US Lab), Destiny. The FCF is a investigation and observation of multiphase flows, boiling, condensation, colloid physics, multi-discipline facility that performs surface tension controlled flows, and other types microgravity research primarily in fluids physics science and combustion science. This facility of fluid physics research. remains on-orbit and provides accommodations Both the crew and ground operations personnel to multi-user and Principal investigator (PI) operate the FCF. The crew sets up and prepares unique hardware. The FCF is designed to the FCF payloads for semi-automated operations. accommodate 15 PI's per year. In order to allow Experiment setup involves installation of multi- for this number of payloads per year, the FCF user hardware, PI-unique hardware and samples has developed an end-to-end analytical and as well as reconfiguration of the diagnostics. physical integration process. The process The crew also performs maintenance and includes provision of integration tools, products upgrades to the facility. and interface management throughout the life of the payload. The payload isprovided with a Data collected over the course of PI experiment single point of contact from the facility and runs isprocessed and stored within the FCF. A works with that interface from PI selection portion of this data may be downlinked in near through post flight processing. The process real-time for decision making and/or engineering utilizes electronic tools for creation of interface analysis. The crew removes PI-unique hardware documents/agreements, storage of payload data and restores and/or reconfigures the facility for and rollup for facility submittals to ISS. continuing PI experiments. Additionally, the process provides integration to and testing with flight-like simulators prior to The facility is comprised of three powered, payload delivery to KSC. These simulators Active Rack Isolation System (ARIS)-equipped allow the payload to test in the flight International Standard Payload Racks (ISPRs). configuration and perform f'mal facility interface The FCF is incrementally launched with the and science verifications. The process also Combustion Integrated Rack (CIR) as the initial provides for support to the payload from the FCF deployment. The intermediate deployment through the Payload Safety Review Panel consists of the Fluids Integrated Rack (FIR) in (PSRP). Finally, the process includes support in conjunction with the CIR. The CIR and the FIR the development of operational products and the operate independently until the Shared operation of the payload on-orbit. Accommodations Rack (SAR) is added. At this Copyright © 2001 by the American Institute of Aeronautics and Astronautics, Inc. No copyright is asserted in the United States under Title 17, U.S. Code. The U.S. Government has _myalty-free license to exercise all rights under the copyright _qned herein for Governmental Purposes. All other rights are .".._.edby the copyright owner." ? Figure 1 -Fluids and Combustion Facility point the FCF is fully deployed as_shown in FCF team to understand the operational Figure 1,Fluids and Combustion Facility. resources, design interfaces and verification The FCF is designed to operate with amaximum requirements. Additionally, the payload will of 15 PI's per year. This includes NASA require a FCF ground system to which their sponsored experiments, commercial hardware can be tested prior to launch. investigations and international experiments. In order to meet the needs identified in the Need for Integration Process previous paragraph, the ISS requirements for data delivery, and the need for repeatability; it In order to accommodate ahigh volume of was determined that a structured payload payload flow through the on-orbit facility and integration process was required. the associated ground system, a well-def'med process isnecessary. Establishment of such a Process Overview process will allow aconsistent, cost-effective, and concise approach to ensure both FCF and In def'ming and developing the integration ISS requirements are satisfied. process the first step taken was to understand the end-to-end system required that would allow for As apayload carder, FCF is responsible for groundbreaking research in the areas of fluid systematically ensuring that each flight to the physics and combustion science. The system ISS and FCF presents the highest quality and that is currently being developed consists of amount of science return in the safest and most three layers: Principal Investigator (PI), FCF and efficient manner. ISS. It became clear that an understanding of each layer and how they fit into the overall The increment and planning period structure system was necessary. In understanding the PI defined by ISS and the aggressive payload layer, GRC drew on its history of flying throughput of the facility have resulted in a experiments aboard the Shuttle and Mir. To significant overlap of work. During each phase understand the ISS level, GRC drew upon its the payload will require information and interaction with the ISS Payloads Office, assistance from the facility in order to complete particularly in the development of the ISS planning, to design required analyses and to payload requirements and integration process. perform testing to ensure compatibility with the Understanding of the FCF layer was provided by on-orbit hardware. To complete this work the the direct interaction with the FCF development payload will require regular interaction with the 2 American Institute of Aeronautics and Astronautics i team. The system was then def'med at a top level The FCF Payload Planning Process is the set of as shown in Figure 2. activities developed to address the above responsibilities. The process includes resource I....1 NRA . l_lSS ions guideline development, collection and Although it represents ahigh degree of roll-up, management of payload resource requirements the figure allowed the FCF integration team the data, and resource analysis that results in a ability to clearly see the how the system works payload being manifested on the FCF for a with FCF as the carrier of the PI hardware tothe particular ISS increment or increments. ISS. Resource Development P_y!o_d_ P!_n_njng The allocation of resources down to the facility In order to properly establish an early interface level has been problematic and unclear in the to the FCF payload projects to convey resource early stages of increment development for ISS. availability, a payload planning function was The primary document for conveying the developed. The payload planning function has available utilization resources for future four primary responsibilities: increments is the ISS Operations Summary Document. In order to provide an FCF payload 1) Provide a rolled-up set of the FCF with a resource "envelope" or guideline, the required resources to ISS GRC payload planning group worked with the 2) Perform an integrated FCF resource Microgravity Research Program Office (MRPO) analysis to develop arepresentative percentage of the 3) Develop an FCF traffic model resources to apply to the Microgravity Science 4) Provide the initial integration Division (MSD). This percentage was process interface to payload project determined to be 9.5% of the total utilization teams resources presented in the Operations Summary Document. The appropriate percentage of the MSD allocation is then determined for the FCF 3 American Institute of Aeronautics and Astronautics J • and can be used for planning purposes. launch and return flights for all payloads Nominally, resource allocation to MSD would managed or sponsored by GRC/MSD. It isthe not be received until after payloads are primary strategic and tactical planning tool to manifested at the L-24 milestone. This early forecast and track the long-term usage of the resource analysis performed by the planning FCF. The FCF portion of the traffic model is group allows a payload project and the FCF developed as a system including both fluids and project to obtain an early picture of what combustion payloads. An example of the traffic resources will be available for the increment or model is shown in Figure 3. This traffic model increments on which they will be flying. will be continually validated against projected ISS resource allocations and each update is Resource Analysis published and reviewed with the GRC MSD management. Once the planning group has developed the available resources, they are then able to analyze Initial Process Interface the feasibility of flying a specific payload complement during a given increment. The In order to meet the early need for planning data, analysis consists of totaling up resource the payload project interfaces with the planning requirements data submitted to the planning group as early as L-54. This early interface group from the payload project, performing a allows an introduction to the entire integration roll-up with facility requirements, and then process. Therefore, the payload planning comparing the required resources to the representative serves as the early integration theoretical available resources. The categories interface or integration manager. With the compared are: upmass, launch stowage, on-orbit assistance of other integration personnel, the stowage, crew time, energy and downmass. This planningrepresentative provides an integration analysis is then used in the development of the process overview to the payload project team at a GRC/MSD ISS Utilization Traffic Model. kickoff meeting. This early interaction between the project team and the FCF integration team Traffic Model allows the payload project to have a single point of contact throughout the payload's entire The GRC/MSD ISS Utilization Traffic Model is lifecycle. Additionally this early interface allows -- w ,va Fill'/ FY07 FY07 1_1'08 FY08 FI08 FY08 Fio,, Fio,, Fio,, _o,, -too mo mo mo PP JanT-MuDar APrIu.JDun luTl-BSDep " OctI-ID_Dec JanT-MBDar Ap_TJBuDn" Ju-li-lS_eDp " OcTt-BDit__ ' .TaT_B_DMar, ApT_BluDn J'uTIB-SDep OcTt-BDDec Jan-TMBaDr AprT-BJuDn lulT-5B_D Flight TBD TBD TBD I-BD _ TBD leo Itsl._ TBD TBD TBD TBD TBD " TBD TBD TBD TBD TBD _UD T-BD TBD TBD .... -1-uu TBD TBD TBD TBD TBD TBD TBD TBD Faciliete Comlmsfi Dn Sde_e Payload OOC • O0,, O0 o0 C • o¢_o() 9c O() oc OC _ r:m,MCe_-A Z":" Non-GR Payload Payload • t[:]@ > [3 0 .-...-.__,_, Accelerati, Mea_urem, tt Payloada Ml!O_ V V V V •o Vo Discipline Mini-Facility Combustion Science Fluid Physic. Figure 3 - Sample Traffic Model 4 American Institute of Aeronautics and Astronautics communicatioofndesignrequirementotsthe 4. Provide payload projects with a single payloapdrojectT.hecompletceontenotfthe point of contact for resolution of all FCF and kickoffmeetinwgillbediscusseindalatter ISS matters section. Integration Process Ground Rules To match the ground rule of minimum documentation and a comprehensive set of The development of the integration process was requirements, it was determined that a single conducted at GRC by a diverse team. The point of contact would simplify the integration purpose of the diversity was to ensure that all process. This allows the payload to consistently know where to look for inputs and know where entities responsible for designing, utilizing and to submit required information. This interfaces operating the FCF would be represented. The is discussed in a latter section. participants in the integration process development team included Payload Project 5. Provide the payload project with Managers, Science Discipline Interface autonomy in the ISS safety process as Managers, FCF Rack Managers, Operation applicable Personnel and Integration Process Developers. A strong sentiment among the process The initial product of this team was the development team from the payload side was the development of integration process ground rules. need for freedom of operation in the safety The purpose of the ground rules was to establish submittal and approval process. The PSRP also a set of guidelines or criteria against which each agrees with this method. Details of this to the processes, documents and/or requirements implementation are in a latter section. could be compared against for validity and acceptability. The ground rules developed were: Payload Interfaces 1. Minimize the amount of documentation In def'ming the methods by which the FCF required to integrate an FCF payload integration team would interface with the payload, itwas determined that a lead for each 2. Provide the payload with payload would be necessary. This individual, comprehensive source for all requirements known as the Integration Manager, would then (FCF,MRPO,ISS, STS) be solely responsible for the successful integration and operation of the payload in the The primary concern of payload projects as FCF. The Integration Manager would transition discussed in the development team was the from the payload planning representative, as amount of documentation in place with ISS and mentioned earlier, around the L-42 timeframe. the impact that would have on the payload's The primary responsibilities of the Integration integration into the FCF. In order to allay this Manager are to act as the single point of contact fear, it was determined that the best effort would with the payload project for integration issues; be made to combine documents/requirements as provide detailed technical guidance in the area of possible. FCF interface and integration including access to the FCF engineering discipline team; preparation 3. Keep consistency with ISS and and submittal of integration, training and EXPRESS Rack documentation structure operations documentation; design review support where possible and execution in the area of FCF interface and integration; and liaison to the FCF Increment Because of FCF functions as a carrier for Manager on the payloads behalf. payloads and as well as a payload itself to ISS, it was determined that maintaining consistency Because of the number of payloads flying within with ISS documents and data structures was the FCF during any one increment as evidenced important for requirements and data traceability in earlier figures, a single point of representation during roll-ups. for FCF on a specific increment isrequired. The FCF Increment Manger acts as the individual responsible for the overall increment programmatic interface and reporting. In this 5 American Institute of Aeronautics and Astronautics rolet,heFCFIncremeMntanagearctsasthe interfacteotheISSforFCFincludinagll payloadwsithintheincremenTt.hisindividual Interaction between the FCF Ground Processing isappointeadtapproximate1l-y30i,ntimeto Team and the FCF Operations Team will be solidifytheeffortsforthegivenincremenint coordinated through the Increment Engineer. supporotfthemanifesretquesatndduringthe manifestinpgrocessT.heindividuaallso A figure showing the general integration representhtseFCFtotheISSPayloaMdission interface structure is shown in Figure 4. Integration Team (PMIT) forum. Requirements Flow and Documentation Additional personnel with whom the payload project will have occasional interaction include The primary integration process ground rule was the Increment Engineer, Science Discipline Interface Managers and the Utilization Scientist. to develop a comprehensive source of all requirements for the payload and to minimize the llae Increment Engineer has the responsibili,_, for ensuring technical compliance with all FCF amount of documentation required of the and ISS requirements via verifications prior to payload project. Figures 5and 6represent the flow/distillation of requirements from levels submittal to ISS. The FCF Increment Engineer acts as the competent technical authority for the above the payload into a unique set of payload required documents. integration engineers. The Science Discipline Interface Managers continue as payload advocates during the development of FCF As the figures show, the integration process has upgrades and in general FCF been developed such that the payload project is integration/interface forums. The Utilization required to refer to only one document to obtain all payload technical and interface requirements Scientist works directly with the Principal fi'om the FCF. This document is the Interface Investigators for each payload during the Definition Document (IDD). The IDD contains development of science priorities internal to the FCF and with the ISS Increment Scientist for all interfaces and requirements for integrating to development of science priorities on ISS. Figure 4 - Payload Project Interfaces INTERNATIONAL SPACE STATION (ISS) Facility, Payload Engineering and Integration (OZ2) Payload Integration Manager (PIM) ,",F,l _,_,sT 1 FCF Increment Engineer PD SpeeifieSAMS Payload Project Teams PD Specific Phase 'B' Managers (Fluids/Combustion Interface klana_ers I:Ct" trlcrement En_ineerit_ Team (Example Functions1 ,. .. , , , • Sal'el_ Lead I Tllerlnai I c"ld / I P_,_.er 1e:ld I ' . " [ "' ][ ..... [X,l ,,_v_tc1.n..,..I. .... 6 American Institute of Aeronautics and Astronautics I ISSDocumentation PDDocumentation FCF IPDocumentation OtherDocumentation FCFDocumentation Figure 5 - Requirements Flow (Part 1) aspecific FCF rack. The payload project team, plan in a similar process as the ICD is from the with the guidance of the Integration Manager, IDD based on the interfaces and requirements selects from the IDD those interfaces and selected in the applicability matrix. These requirements that are applicable to their specific verifications, where required by ISS, are then payload via an applicability matrix. The rolled up into a single submittal for the specific Integration Manager then develops apayload rack and total FCF. specific Interface Control Document (ICD) which isjointly signed by the Integration A payload, in conjunction with the Integration Manager and the payload Project Manager. The Manager, also develops an Integration payload project isthen required to show payload Agreement (IA). The IA consists of the main compliance to the interfaces and requirements in volume and the data sets. This structure is the ICD by the Payload specific Verification identical to the previous ISS structure with the Plan (PVP). The PVP is derived from ageneric exception of tailoring for FCF and payload project unique roles, responsibilities, resources :;!:-ii2_i!iiiiii;ii::ii!i!!:,!i_i: I [_ ISSDocumentation __.'_'.-_1 PDDocumentation • I I I _ _ii FCF IPDocumentation OtherDocumentation FCF Documentation *Onetimesubmittal forallFCF racks,payloadsandupgrades Figure 6 - Requirements Flow (Part 2) 7 American Institute of Aeronautics and Astronautics andprovisionsA.swiththeverifications, dates of FCF products to ISS. The detailepdayloaidncremenretquiremenatrse rolledupandsubmittetodISSasaspecifircack interdependence of the schedules requires close ortotalFCFsubmittaTl.hepayloaddatasets scrutiny and discussion between the payload willalsoberolledupwiththeFCFdatasetsbut, project team and the FCF integration team to ensure that shortfalls in payload deliveries do not itiscurrentleynvisionethdatthepayloadswill impact the FCF deliveries to ISS. havethecapabilittyosubmittherequired informatiodnirectlytoPDL;theFCFintegration teamwillbeabletoviewandrollupthedata An important event noted on the template is the withinPDL;andthedatacanthenbesubmitted Integration Kickoff meeting. As referenced asaspecifircackorFCFcombineddataset. earlier in the paper, the kickoff meeting occurs early in the payload development phase typically after the payload has completed the Science Integration Template Concept Review (SCR). At this meeting the In order to provide a payload project with a payload will receive a comprehensive schedule of deliverables to the FCF integration presentation of the end-to-end integration team and to track upcoming design and flight process. Additionally, the payload will receive a set of applicable documents including the FCF L-48 L-42 1.,-36 L-30 L-24 L-18 L-12 I,-6 L-0 iw Kicko!,!ff !!I lI ll II ]l Ii lI !I A MeR_tI:ibIngR 1[I --, PIeIR!,...................... II_!_.'............. CI__!R ....... :, II1II1 PSRIAR[l!tI1| III!........ '! !' i;............. i" ,!,, IPAreMliVm PIG,D¢im BIAa_MVlir_,B_aIGsDi_liIAnBeA_d4lle1ndia n,_ IllI1 II,:1 1I11 PPre!l/iPm I_ IAPArte_ldimenda !III !I1I !: I1 i i Crew BaPsVePline ,,_ II I! I, I !_TrainingDSiPlanningDS ,I ConfigDS :_ !I I 1 II !I I, : 1l I, :I Pha_ 0/I PMseII 1 t PhaseIII II II:I1 "I1I! Safe_:!.R...vw Safet:l_Rvw [,l i!, SafetyRvw :!! +III--_ !:II [II :I ll, ll, : , !I I1 I ' : Engineering _ 1I FIVT ! !II I ,, [::Model Tests _,_: _,i O@n-D_ocskc i1 Figure 7 - Integration Template milestones atop level integration template was Payload Accommodations Handbook, IA blank developed. The template, Figure 7, serves as the book, IDD and the FCF GPVP. starting point for development of a payload unique integration schedule. As the payload progresses through the design phase, the FCF integration team, through the Integration Manager, provides support to the payload project at payload reviews to ensure The integration schedule is the working complete coverage of issues that affect the agreement between the FCF integration team and design or implementation of the carrier the payload project team for delivery of interfaces. This support includes the products, hardware or data. The delivery dates development of draft IAs, ICDs and PVPs. on the schedule are closely tied to the delivery 8 American Institute of Aeronautics and Astronautics Finallyt,herearetwoFCFuniquereviewtshat during the package development and during the .:_. .... . qP "Simulators "Component •Ground Integration Unit -Diagnostic •Engineering Design Unit •Final Verification •KSC Off-line Processing •Trial Hardware •Engineering Model •Flight Unit •Final Flight Preparations .Brassboard "Breadboard Figure 8 - FCF Ground Processing are part of the integration template: Increment presentation of the referenced phase. The FCF Requirements Review and the increment integration team collates all phase 3data Acceptance Review. These reviews are in place packages into a single FCF submittal to the to identify and assess compliance with all PSRP. This package represents a picture of all increment-unique requirements imposed on the FCF operational configurations and the FCF by the payloads. The reviews are chaired associated safety controls for those •by the Increment Manager and require configurations. The FCF integration team then participation by the payload projects that have presents this integrated assessment to the panel payloads operating within the FCF for the given with the payload projects' support. increment. Gro,___dn_Processi_n_g Sofe_ Proce__: The payload ground processing for FCF consists The payload safety process closely follows the of four phases as discussed in the following text process in place by the Payload Safety Review and shown graphically in Figure 8. Panel (PSRP). he first ground processing phases begins early on in the payload development and may continue The payload project has complete responsibility through early flight hardware development for compliance of their payload with all safety depending on the payloads needs. In this phase a requirements enforced by the ISS Program. The suite of FCF simulators ismade available to the FCF imposes no additional requirements on the payload project team. The simulators include payload. Development of the safety data science diagnostics or FCF rack simulators. The packages and safety specific verifications are the payload project can use these simulators to test responsibility of the payload project. scientific phenomena measurement capabilities Additionally, the payload project team is or to test payload equipment operation with FCF responsible for presentation to the PSRP ofthe supplied resources such as power or cooling. phase 0,1,and 2payload safety data packages. The FCF integration team acts in a support role 9 American Institute of Aeronautics and Astronautics The second ground processing phase consists of as closure for many of the items in the PVP. testing the payload engineering model or in some This isthe only ground processing phase which cases the flight unit in an FCF rack Experiment all payloads must complete. Development Unit (EDU). The EDU provides a functional equivalent of the FCF rack but does The fourth and f'mal phase consists of the not contain flight interfaces. The EDU ismade payload processing at the Kennedy Space Center available to the payload during the payload (KSC). Because there will not be a FCF engineering model test phase. This early system simulator at KSC, this is not anticipated to be an test availability allows the payload project time extensive test phase to avoid nullifying to make any corrections or modifications prior to verifications performed at GRC. It is understood proceeding with flight unit fabrication. that some payloads may require abrief aliveness test or maintenance of some consumables prior The third phase of ground processing occurs to launch. after the payload project has tumed over the flight unit to the FCF integration team. This Oper_tio_n_s phase is the payload final interface verification testing and occurs in the FCF Ground Integration The operations process includes all Unit (GIU) at GRC. The GIU is a flight documentation, hardware, and personnel support equivalent unit and contains all interfaces that to assure that the FCF and its payloads operate as are in the flight rack. These verifications serve planned. This process begins with flight and !SS Figure 9 - FCF Operations 10 American Institute of Aeronautics and Astronautics