USA SAFER Panel Meeting Minutes 27 July 2000
The SAFER Panel met at JSC on July 27, 2000 in Building 1 room 360 at 10:00 a.m.
Meeting participants:
Panel Chair XA/ Anh Huynh
Panel Secretary HSMS/Theresa Elms
Panel Members CB/ Claude Nicollier
DX/ Alan Groskreutz
ER/ Charlie Price, Richard Pedersen
NC/ Ron Cook
NT/ Bill Lilly,
NX/ Robert Cooke
USA/ Armon Knight
The following items were discussed:
1. Flight Readiness
- STS—106 (2A.2b) Manifest Support
SAFER certification for launch/landing in the SpaceHab was successfully completed. SAFER —305 processing for SpaceHab will continue through today (07/27/00) at KSC.
The two SAFER —307 units will be shipped on 8/2/00 to support the STS-106 bench review.
NT/Bill Lilly will contact NT/Richard Bussey to coordinate an inspection by Robert Cooke of the flight circuit board for the —305 battery which was dropped during removal from the chamber after hot burn-in testing.
- STS—92 (3A) Manifest Support
SAFERs S/N 1004 and S/N 1006 need to be fit checked with the corresponding flight EMUs (TMG installed) to verify the EMU TMG orientation does not interfere with the attachment of the SAFER to the EMU. Presently the flight EMUs are being processed and are not available for the fit check. At the present time the best option may be to perform a fit check immediately after the STS-92 bench review.
2. FIAR/DR Closure Status
- JSC-ER0020, -305 Battery erratic reset and count-up/down (Open 546 days)
JSC-ER0021, -303 Battery erratic reset and count-up (Open 465 days)
JSC-ER0020 and JSC-ER0021 will be addressed at the —305 Battery DCR on 7/31/00.
- JSC-ER0023, VRL Software Anomalies (Open 184 days)
NT/Rafiq Hashmani will provide the closure rationale to NC/Ron Cook on 7/31/00.
- JSC-ER0024, -305 Battery Gauge Board Electrical Short During Burn-in Test (Open 136 days)
JSC-ER0024 is still in review.
- JSC-ER0027, Thruster Firing Failure at 150 deg. F (Open 136 days)
JSC-ER0027 is still in review.
3. Configuration Control
- Hardware/Software Configurations
No change.
- CR Implementation
- CR H-0670 R1, AAH LED Function Modification
The new software with the AAH LED function modification will be loaded into two flight units today 07/27/00.
The remaining flight units and the VRL lab unit will also need the updated software.
- CR H-0683, On-Orbit Stowage Bag
Two Class I on-orbit stowage bags were delivered to USA Bond on 07/24/00. Deliver of the remaining two Class III on-orbit stowage bags is scheduled for 09/15/00.
- CR H-0749, SAFER On-Orbit Trainer
The Project Management Plan (PMP) for the SAFER on-orbit trainer has been released for review.
- CR H-0752 R1 Inhibit Plug Installation Verification
XA, CB, ER, and HSMS will meet in the SAFER Lab on 07/28/00 to discuss new inhibit plug installation verification options.
- CR H-0753 R1 Power Switch Guard Modification
The cutout in the new power switch guard allows a finger to trigger the power switch thus this design must be reconsidered.
- CR H-0760 SAFER NBL & 1-G Hi-Fi Mockup Upgrades
The right latch on SAFER Mockup S/N MU002 was disassembled for failure analysis. The analysis determined that the Ratchet (P/N 10705010059) inner threading is binding on the outer threading of the Shaft (P/N 10705010056). The latch needs to be replaced. Root cause is not known, with possible contributing factors such as excessive wear and incorrect usage.
- CR H-0788, -305 SAFER Battery Design, Fabrication & Implementation
No change.
Proposed CR’s
- CR H-0806,-307 Rechargeable Battery CR
On hold pending funding from XA in the next fiscal year.
- Latch Redesign
XA, CB, ER, and HSMS will meet in the SAFER Lab on 07/28/00 to inspect the SAFER tower latches and discuss the latch redesign.
- GN2 Tank Pressure Indicator
A more detailed look at the reliability analysis on the high-pressure system is still in work.
- Extension of HCM Deployment Actuator and the Manual Isolation Valve Actuator
CR draft in work.
- IMS Labeling
CR draft in work.
- On-Orbit Stowage Bag Docking Loads
CR draft in work.
- Issues
None.
5. Special Topics
NT/Bill Lilly discussed the resolution to the battery gauge solder inspection issue. Apparently, EV had been using a degraded microscope to inspect the solder joints at the minimum magnification requirement. EM has been using a calibrated microscope at a higher level of magnification as a rule of thumb. EV will replace the degraded scope with a new calibrated instrument, and all will be following the new quality inspection procedure which requires an increased magnification when certain indications are observed during the initial inspection at the lower level of magnification. Quality will also provide a handbook to guide the inspectors in identifying the various indications which would lead to problems.
- EHB Presentation
None.
- CCB Presentation
None.
- PRCB presentation
- Action Items
None.
- NT/Bill Lilly will report back to XA as to whether calibration or inspection procedures currently exist for microscopes.
- NT/Bill Lilly will contact NT/Richard Bussey to coordinate an inspection by Robert Cooke of the flight circuit board for the —305 battery (which was dropped during removal from the chamber after hot burn-in testing).
- NT/Richard Bussey will provide AVT and QAVT information for each SAFER flight unit to ES/Joe Rogers.
Submitted by: Approved by:
(Original signed by) (Original signed by)
Theresa M. Elms Anh H. Huynh
SAFER Panel Secretary USA SAFER Panel
Item Assignee Description Status 06-01 C. Price J. Smith Evaluate the MPLM environment for launching the USA SAFER. 06/25/99: Assigned. 07/29/99: In review by ER. ER as needed will request additional information. 08/05/99: ER needs information on directional G-loads during launch, landing, and emergency landing. 08/06/99: Additional MPLM information was provided by OM/E. Smistad. 08/11/99: ER will provide a cost and schedule estimate for the additional stress analysis. 08/26/99: ER estimated a cost of 32K and a schedule for 2 months. The task will be initiated by XA on 10/01/99 with FY00 funding. 10/28/99: Partial funding has been sent to ER on 10/21/99 & 10/29/99. ER to complete the evaluation with an ECD of 01/03/00. 12/02/99: ER will provide a new ECD due to time needed to turn the effort on through a task order. 01/06/00: ER provided a new ECD of 03/15/00. 03/30/00: ER has requested a new ECD from LM. New ECD of TBD. 04/06/00: The stress analysis is complete. The memo will be out soon, ECD 04/13/00. 04/20/00: ECD TBD. 05/04/00: The stress analysis is in the LM signature loop. 05/11/00: LM/James Shu presented the results of the MPLM stress analysis to the Panel. James Shu will provide ER with a memo summarizing the results. ER will forward the memo to XA. XA will discuss the angular acceleration topic with the MPLM group and ER will discuss with ES. 05/12/00: ES confirmed the need to include the angular acceleration in the analysis. 05/16/00: Awaiting MPLM contact person to be provided by XA I&O lead for 5A.1. 05/18/00: ER provided the analysis performed by LM. 05/25/00: ER is waiting for a response from the MPLM stress analyst. New ECD: TBD. 06/15/00: ER will meet with the MPLM contact person on 06/15/00. 06/22/00: The MPLM stress analysis is presently in review with the MPLM stress analyst. 07/13/00: The MPLM stress analyst (Satya Pilla) has provided additional MPLM launch/landing environment information. James Shu is reviewing the environment information. 07/20/00: The MPLM stress analyst has indicated that the SAFER can be launched in the MPLM. XA is waiting on the official confirmation from the MPLM group. 07-04 K. Lewis Provide a video recording of 1) NSI/Pyro Valve firing, 2) dry valve seating, 3) wet valve seating, 4) dry valve self-test, and 5) wet valve self-test. 06/25/99: Assigned as action 02-03 at the STS-96 USA SAFER IFA Investigation meeting. 07/09/99: Transfer action to USA SAFER Panel. 08/05/99: Recording completed except for NSI/Pyro Valve firing. ECD of TBD, pending available opportunity. 11-05 K. Vassigh Perform crew size evaluation at the VRL to determine potential effects to the flying quality of SAFER due to the differences in crew size. 11/18/99: Assigned. 12/16/99: ECD 01/28/00. 02/03/00: DX will coordinate with the crew size evaluator. ECD of TBD. 02/17/00: ECD of 02/24/00. 02/24/00: ECD of 03/09/00. 03/17/00: New ECD of 03/24/00. 03/30/00: Crew size evaluations were completed on 03/15/00. DX will present the results to the Panel on 04/06/00. 04/06/00: New ECD of 04/13/00. 04/13/00: DX provided the results of the crew size evaluations by e-mail for review. 05/11/00: DX presented the results to the Panel. Objective data were not useful as pass/fail criteria for the flying quality of SAFER due to crew size. Subjectively, the various sizes did not impact the way that SAFER performed at the VRL. Smaller size did result in faster response to commands, as expected. DX will document the final conclusion in writing to XA, ECD 05/18/00. 05/25/00: New ECD: 06/15/00. 06/15/00: New ECD: 06/22/00. 06/22/00: New ECD: 06/29/00. 07/20/00: New ECD: 07/27/00. 12-06 B. Studak K. Vassigh D. Tani K. Vassigh S. Dawson EP will provide a recommended means to verify the level of GN2 immediately prior to airlock egress. The objective is to allow the crew to verify that there is sufficient GN2 for self-rescue as late as possible in the timeline. 12/16/99: Assigned. ECD of 01/20/00. 01/13/00: "USA SAFER Auxiliary Pressure Measurement" was presented to the panel. 01/13/00: EP will discuss with Chi Min Chang (CTSD) the possibility of using a combination strain gauge & ohmmeter type of design to measure the SAFER tank pressure. ECD of 01/20/00. 01/13/00: CB and DX will discuss whether the addition of another inhibit plug would be acceptable. ECD of TBD. 01/20/00: EP stated that the ohmmeter/strain gauge design for measuring tank pressure is not applicable to the high-pressure tank used for the SAFER. 02/03/00: DX will provide rationale as to why an additional inhibit should not be developed. ECD of TBD. 02/10/00: DX and CB will each provide XA with an official consensus that another inhibit should not be developed. 02/25/00: CB formally stated that an additional inhibit should not be developed. 03/02/00: DX formally stated that an additional inhibit plug is not required. The combination of existing inhibit plug and procedures protects inadvertent firing of the NSI. XA will summarize the findings for presentation at the EHB. 03/30/00: Presentation to EHB is on hold while DX Alan Groskreutz pursues approval of the secondary checkout on -3A and subs. 04/20/00: ECD TBD. 05/11/00: DX will provide XA with the worst case time period for EVA IVA checkout until egress for EVA. ECD 05/18/00. This number will be used to determine the level of reliability of SAFER with respect to GN2 leakage. 05/18/00: DX/Paul Boehm indicated that secondary checkout is not considered on -3A and subsequent flights at this time. XA will work with NC to refine the reliability value to determine the true need for a secondary checkout. 05/25/00: Reliability will work with EP/Bill Studak to determine if the reliability numbers for prevention of high pressure leaks can be improved for the SAFER. New ECD: 6/30/00. 06/22/00: XA proposes: 1) modified transducer with dual output (independent power, avionics, display) OR 2) add new transducer. 00-02-08 K. Lewis A. Huynh ER will initiate a stress analysis to determine how far the HCM deployment actuator and manual valve can be extended. 02/17/00: Assigned. ECD TBD. 02/24/00: EV/James Shu stated that the SAFER actuator supporting bracket needs to be changed if the actuator is extended. 05/04/00: The stress analysis is on hold while the small and x-large EMU managers perform SAFER reach evaluations with suited subjects to determine how far to extend the actuators. ECD: 05/19/00. 05/25/00: XA will initiate a CR for 2" extension to the actuators. 00-02-09 K. Vassigh Panel Members DX will modify the Latch Redesign CR to investigate options to allow the “pre-load screw” to end its counter-clockwise travel in a firm stop, preventing potential jamming of the screw. 02/24/00: Assigned. ECD TBD. 03/23/00: DX will coordinate with CB to determine which organization (CB or DX) will be implementing the Latch Redesign CR. 03/30/00: DX or CB will initiate the latch redesign CR by 4/06/00. 04/13/00: New ECD 04/20/00. 04/20/00: ECD TBD. 05/04/00: DX will initiate the Latch Redesign CR, ECD TBD. 05/25/00: New ECD: 06/15/00. 06/15/00: DX/Kenny Vassigh distributed the revised Latch Redesign CR for panel review and comments. Panel members will review and provide concurrence or comments on the Latch Redesign CR by 06/22/00. 06/22/00: XA has reviewed the CR and has provided DX with comments. DX to submit modified CR and a presentation to the EHB by 06/29/00. 06/29/00: DX presentation to EHB has been postponed until 07/12/00. 07/13/00: DX presentation to EHB. New ECD: 07/19/00. 07/27/00: 00-04-11 P. McCartney K. Vassigh Provide a video of the on-orbit trainer evaluation (SSC vs. new laptop) as shown at the VRL and more technical information on the data rate specifications. 04/20/00: Assigned. ECD TBD. 06/15/00: DX will record on-orbit trainer evaluation (the SSC vs. new laptop) on video. ECD TBD. 00-05-01 K. Lewis T. Elms A. Huynh ER will evaluate SAFER launch/ landing loads in the SpaceHab. HSMS will locate SpaceHab Load Requirements. 05/04/00: Assigned. ECD 05/20/00. 05/25/00: XA provided launch/ landing load requirements to ER. Waiting for ER discussion with contact person from SpaceHab. ECD of 06/01/00. 06/15/00: ER/Kevin Lewis requested James Shu contact the LESC stress analyst to determine if the IDD document prepared by LESC includes angular accelerations for the SpaceHab loads. XA will investigate if different loads apply to the SpaceHab rack. New ECD TBD. 06/29/00: SpaceHab determined that SAFER will not be stowed in the rack, only on the floor. ER is expected to complete the loads analysis by 07/25/00. 00-05-06 K. Lewis ER will determine the cost to build one more flight SAFER. 05/18/00: Assigned. ECD 06/16/00. 06/22/00: New ECD: TBD. 06/29/00: XA requests that ER look into getting a contractor to build another flight SAFER. 07/13/00: New ECD: 9/30/00. 00-05-07 K. Lewis T. Elms ER will investigate the problem with the weight relief lifting sling and the SAFER latches. 05/18/00: Assigned. ECD 06/01/00. 05/25/00: HSMS will verify that a comprehensive procedure is used to operate the weight relief lifting sling in order to prevent any damages to the SAFER latches. 06/15/00: New ECD 07/06/00. 07/06/00: HSMS determined that a comprehensive procedure to operate the weight relief lifting sling did not exist and that one needed to be written and released as a SSA Class III operational procedure. ECD 08/18/00. 07/13/00: HSMS has written a procedure detailing how to attach the SAFER to the EMU when using a weight relief lifting sling. The procedure is presently in review with Steve Anderson of the SSI group. 07/20/00: HSMS/T. Elms received comments to incorporate from ILC/Steve Anderson. Next the procedure needs to be reviewed by ER. 07/27/00: HSMS is searching for a picture showing the EMU/SAFER in the weight relief lifting sling. 00-06-01 K. Lewis ER will provide DX with a video tape of the following operations for training: class III PLSS & SAFER engineering unit) SAFER Transfer/Stow ops (both the launch/entry and on-orbit stowage bags from USA/FCE) 06/15/00: Assigned. ECD TBD. 07/13/00: DX and ER will develop a mutually agreed schedule to complete the activities. 00-06-02 D. Tani C. Nicollier CB/Dan Tani will inform the crew of the switch guard being installed upside down on one of the STS-101 SAFER units for landing, and will provide any feedback from the crew. 06/15/00: Assigned. ECD of 06/22/00. 07/13/00: New ECD: TBD. 00-07-01 F. Davies EP/Frank Davies will provide XA with the following —305 battery information on the battery calendar: Delivery Dates for all 20 batteries Delivery Configurations Launch Dates Bench review dates Quantity of activated and quantity of inactivated batteries 07/06/00: Assigned. ECD 07/13/00. 07/13/00: New ECD: TBD. 00-07-02 K. Lewis & A. Knight ER/Kevin Lewis and USA/Armon Knight need to develop a fitcheck plan for STS-92 (3A). 07/06/00: Assigned. ECD:07/20/00. 00-07-03 R. Bussey Contact QA/Bill Lilly to investigate the discrepancy between EV and EM on solder inspection specifications as observed on the —305 battery gauge boards. 07/06/00: Assigned. ECD: 07/20/00. 07/20/00: RN/Richard Bussey reported (by e-mail) that Bill Lilly stated the following: EV used a 10x setting on the microscope to inspect the boards and EM used a 30x setting. Therefore, EV could not see what EM could see. Mr. Lilly has promised to level the playing field by directing all facilities that they use 10x settings on their scopes. 07/27/00: NT/Bill Lilly and NX/Bob Cooke presented a summary of the optical inspection requirements necessary for various electrical fabrication tasks. EV will replace the degraded scope with a new calibrated instrument, and all will be following the new quality inspection procedure which requires an increased magnification when certain indications are observed during the initial inspection at the lower level of magnification. Quality will also provide a handbook to guide the inspectors in identifying the various indications which would lead to problems. Closed. 00-07-04 K. Lewis & E. Darcy Provide delivery dates for the 4th battery for STS-106 and for the remaining 16 batteries to be transferred to USA. 07/13/00: Assigned. ECD 07/27/00. 00-07-05 M. Hembree Investigate if the ERCM will be used in an EVA before the DTO, creating a glove cut hazard on the tether. 07/20/00: Assigned. ECD 08/10/00. 00-07-06 All Submit any post-flight DTO for the STS-92 crew to DX/Mike Hembree. 07/20/00: Assigned. ECD 08/10/00. 00-07-07 D. Tani Provide a consensus on DTO pass/fail criteria for STS-92 DTO 689. 07/20/00: Assigned. ECD 08/10/00. 00-07-08 M. Hembree Provide a DTO backup plan in case of RMS failure. 07/20/00: Assigned. ECD 08/10/00. 00-07-09 W. Lilly Report back to XA as to whether calibration or inspection procedures currently exist for microscopes. 07/27/00: Assigned. ECD 08/10/00. 00-07-10 W. Lilly Contact NT/Richard Bussey to coordinate an inspection by Robert Cooke of the flight circuit board for the —305 battery (which was dropped during removal from the chamber after hot burn-in testing). 07/27/00: Assigned. ECD 08/10/00. 00-07-11 R. Bussey Provide AVT and QAVT information for each SAFER flight unit to ES/Joe Rogers. 07/27/00: Assigned. ECD 08/10/00.
