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4 March 2011
Space engineering
Testing
This document is circulated to the ECSS community for Public Review START OF PUBLIC REVIEW: 4 March 2011 END OF PUBLIC REVIEW: 2 May 2011
DISCLAIMER (for drafts) This document is an ECSS Draft Standard. It is subject to change without any notice and may not be referred to as an ECSS Standard until published as such.
Foreword This Standard is one of the series of ECSS Standards intended to be applied together for the management, engineering and product assurance in space projects and applications. ECSS is a cooperative effort of the European Space Agency, national space agencies and European industry associations for the purpose of developing and maintaining common standards. Requirements in this Standard are defined in terms of what shall be accomplished, rather than in terms of how to organize and perform the necessary work. This allows existing organizational structures and methods to be applied where they are effective, and for the structures and methods to evolve as necessary without rewriting the standards. This Standard has been prepared by the ECSS-E-ST-10-03 TA Task Force, reviewed by the ECSS Executive Secretariat and approved by the ECSS Technical Authority.
Disclaimer ECSS does not provide any warranty whatsoever, whether expressed, implied, or statutory, including, but not limited to, any warranty of merchantability or fitness for a particular purpose or any warranty that the contents of the item are error-free. In no respect shall ECSS incur any liability for any damages, including, but not limited to, direct, indirect, special, or consequential damages arising out of, resulting from, or in any way connected to the use of this Standard, whether or not based upon warranty, business agreement, tort, or otherwise; whether or not injury was sustained by persons or property or otherwise; and whether or not loss was sustained from, or arose out of, the results of, the item, or any services that may be provided by ECSS.
Published by:
Copyright:
ESA Requirements and Standards Division ESTEC, P.O. Box 299, 2200 AG Noordwijk The Netherlands 2011 by the European Space Agency for the members of ECSS
Change log
ECSS-E-10-03A 15 February 2002 ECSS-E-10-03B ECSS-E-ST-10-03C Draft 12.5 4 March 2011 Never issued Second issue. The main differences between ECSS-E-10-03A and this version are: General modifications to comply with ECSS rules better identifying the requirements and moving to Handbook the standard values; The lists of abbreviated terms, terms and definitions have been updated; Clauses on Overall System Testing were merged in a unique new clause; Clauses on Functional and performance tests were merged in single clauses at all levels; For all clauses, minor modifications to ensure consistency with other ECSS standards have been done; Others (EMC as example) First issue
Table of contents
Change log...........................................................................................................3 1 Scope...............................................................................................................6 2 Normative references.....................................................................................8 3 Terms, definitions and abbreviated terms...................................................9
3.1Terms from other standards.................................................................................9 3.2Terms specific to the present standard...............................................................16 3.3Abbreviated terms..............................................................................................21
4 General requirements..................................................................................24
4.1Test programme.................................................................................................24 4.2Development test................................................................................................24 4.3Test management...............................................................................................25 4.3.1General..................................................................................................25 4.3.2Test reviews...........................................................................................25 4.3.3Test documentation................................................................................28 4.3.4Anomaly or failure during testing............................................................29 4.3.5Test data................................................................................................29 4.4Test conditions, tolerances, and accuracies.......................................................29 4.4.1Test conditions.......................................................................................29 4.4.2Test tolerances.......................................................................................30 4.4.3Test accuracies .....................................................................................32 4.5Test Objectives ..................................................................................................34 4.5.1General requirement...............................................................................34 4.5.2Qualification testing ...............................................................................34 4.5.3Acceptance testing.................................................................................35 4.5.4PFM Testing...........................................................................................35 4.6Retesting............................................................................................................36 4.6.1Overview................................................................................................36
ECSS-E-ST-10-03C Draft 12.5 4 March 2011 4.6.2Implementation of a design modification after completion of qualification ......................................................................................................... 36 4.6.3Storage after acceptance testing............................................................36 4.6.4Space segment element or equipment to be re-flown.............................37 4.6.5Flight use of qualification Space segment element or equipment...........37
Figures Figure3-3-1: Space system breakdown..........................................................10 Tables Table 4-1: Allowable tolerances......................................................................31 Table 4-2: Test accuracies...............................................................................33 Table 5-3: space segment equipment qualification test baseline...............41
1 Scope
This standard addresses the requirements for performing verification by Testing of space segment elements and space segment equipment on ground prior to launch or re-launch. The document is applicable for tests performed on Qualification models, flight models (tested at acceptance level) and Proto flight models. The standard provides: Requirements for test programme and test management, Requirements for retesting, Requirements for redundancy testing, Requirements for environmental tests, General requirements for functional and performance tests,
NOTE Specific requirements for functional and performance tests are not part of this standard since they are defined in the specific project documentation. Requirements for qualification, acceptance, and proto-flight testing including qualification, acceptance, and proto-fight models test margins and duration, Requirements for test factors, test condition, test tolerances, and test accuracies, General requirements for development tests,
NOTE Development tests are specific and are assumed to be addressed in various engineering discipline standard. Only generic requirements about the status of development model tests results are addressed in this standard. Content of the necessary documentation for testing activities (e.g. DRD).
Due to the specific aspects of the following types of test, this Standard does not address: Space system testing (i.e. testing above space segment element), in particular the System Validation Test. In orbit testing, Testing of space segment subsystems, NOTE Tests of space segment subsystems are often limited to functional tests that, in
NOTE For verification software, ECSS-E-ST-40 and ECSS-Q-ST-80 apply. Tests of stand alone rocket motors,
Tests of launcher segment and launch facilities, Tests of facilities and ground support equipment, Tests of ground segment.
The requirements on the systems engineering process are gathered in ECSS-E-ST-10; specific aspects of the SE process are further elaborated in dedicated standards, in particular: ECSS-E-ST-10-06, ECSS-E-ST-10-02 and ECSS-E-ST-10-03 (the present standard). These standards are based on the same principles, process and documentation model. Error: Reference source not found gives recommendation and guidelines for the generation of the compliance and verification matrices to be derived from this standard. This standard may be tailored for the specific characteristic and constrains of a space project in conformance with ECSS-S-ST-00.
2 Normative references
The following normative documents contain provisions which, through reference in this text, constitute provisions of this ECSS Standard. For dated references, subsequent amendments to, or revision of any of these publications do not apply. However, parties to agreements based on this ECSS Standard are encouraged to investigate the possibility of applying the more recent editions of the normative documents indicated below. For undated references, the latest edition of the publication referred to applies. ECSS-S-ST-00-01 ECSS-E-ST-10-02 ECSS-E-ST-20 ECSS-E-ST-20-06 ECSS-E-ST-20-07 ECSS-E-ST-20-08 ECSS-E-ST-31 ECSS-E-ST-32 ECSS-E-ST-32-02 ECSS-E-ST-32-10 ECSS-E-ST-32-11 ECSS-E-ST-33-01 ECSS-M-ST-40 ECSS-Q-ST-10-09 ECSS-Q-ST-40 ISO 3740:2000 ECSS system - Glossary of terms Space engineering - Verification Space engineering - Electrical and electronic Space engineering - Spacecraft charging Space engineering - Electromagnetic compatibility Space engineering - Photovoltaic assemblies and components Space engineering - Thermal control general requirements Space engineering - Structural general requirements Space engineering - Structural design and verification of pressurized hardware Space engineering - Structural factors of safety for spaceflight hardware Space engineering - Modal survey assessment Space engineering - Mechanisms Space project management - Configuration and information management Space product assurance - Nonconformance control system Space product assurance - Safety Acoustics - Determination of sound power levels of noise sources - Guidelines for the use of basic standards Council directive on the approximation on the laws of the member states related to electromagnetic compatibility. Repealing directive 89/336/EEC
2004/08/EC 15/12/2004
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space system
system that contains at least a space, a ground or a launch segment NOTE Generally a space system is composed of all three segments and is supported by a supporting segment.
space segment
part of a space system, placed in space, to fulfil the space mission objectives
component
set of materials, assembled according to defined and controlled processes, which cannot be disassembled without destroying its capability and which performs a simple function that can be evaluated against expected performance requirements NOTE 1 The term "part" is synonymous. NOTE 2 The term "part" is preferred when referring to purely mechanical devices. NOTE 3 The term "component" is preferred for EEE devices.
part
see component
material
raw, semifinished or finished substance (gaseous, liquid, solid) of given characteristics from which processing into a component or part is undertaken
12
13
14
15
3.2
NOTE
3.2.2
a-weighting
adjustments typically made to acoustic measurements to approximate the response of the human ear.
3.2.3
3.2.4
acceptance level
test level reflecting the maximum level expected to be encountered during the flight product lifetime increased by acceptance margins
3.2.5
acceptance margin
increase of the environmental, mechanical, thermal, electrical, EMC, or operational extremes above the worst case levels predicted over the specified product lifetime for the purpose of acceptance NOTE 1 Margins can include an increase in level or range, an increase in duration or cycles of exposure, as well as any other appropriate increase in severity. NOTE 2 For thermal acceptance margin refer also to ECSS-E-ST-31.
3.2.6
accuracy
allowable error of a measured parameter The accuracy depends from the used test
3.2.7
3.2.8
3.2.9
development test
test to support the design feasibility and to assist in the evolution of the design
3.2.10
dwell time
duration necessary to ensure that internal parts or subassembly of a space segment equipment have achieved thermal equilibrium, from the start of temperature stabilisation phase
16
3.2.12
3.2.13
3.2.14
3.2.15
17
3.2.16
3.2.17
3.2.18
NOTE
18
3.2.20
notching
reduction of the input level or spectrum to limit structural responses at resonant frequencies according to qualification or acceptance loads during a vibration test
NOTE Notching is a general accepted practise in vibration testing to avoid over testing of the test article. Implementation of notching is subject to approval of launching authority.
3.2.21
operational modes
combination of operational configurations or conditions that can occur during the product lifetime for space segment equipment or space segment element
NOTE For example: Power-on or power-off, command modes, readout modes, attitude control modes, antenna stowed or deployed, and spinning or de-spun.
3.2.22
performance test
test to verify that the item under test performs according to its specifications while respecting its operational requirements NOTE Performance tests are mission specific therefore their details are not specified under this standard.
3.2.23
polarity test
test aiming to verify the correct polarity of the S/C functional chains (mainly AOCS) from sensors to actuators, through a number of interfaces and processing. NOTE 1 A polarity error can be generated throughout the development process: interface documentation, design, H/W manufacturing, S/W development, S/L AIT, S/L database. NOTE 2 A polarity error can be generated by any element of the functional chain: sensor or actuator design, sensor or actuator mounting, harness, interface units, software algorithms. NOTE 3 Polarity inversion on Safe Mode control loops can cause a satellite loss.
3.2.24
qualification level
test level reflecting the maximum level expected to be encountered during the flight product lifetime increased by qualification margins NOTE For thermal the qualification margin applies on top of the acceptance margin.
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3.2.26
3.2.27
residual life
time left before a product is no longer able to achieve minimum acceptable performance requirements, including availability
can
be
estimated
in
terms
of
3.2.28
NOTE accuracy.
resolution
minimum readable value of a quantity on a measurement system The resolution is accounted for in the
3.2.29
resonance search
exposing a product to a frequency sweep of low level sinusoidal vibrations to show possible deficiencies in workmanship, as a consequence of another environment
NOTE Resonance search signature test or low level sinusoidal vibration test.
is
also
known
as
3.2.30
3.2.31
20
3.2.32
3.2.33
temperature cycle
transition from an initial temperature to the same temperature, with excursion within a specified range including stabilization at the extreme temperatures
3.2.34
3.2.35
test block
aggregation of several tests grouped by discipline
3.2.36
allowable deviation from a defined test level without affecting the test objectives NOTE 1 The tolerance is typically specified as deviation from a specified value, or as an explicit range of allowed values. Tolerance can be symmetrical, as in 40 0,1, or asymmetrical, such as 40 -0,2/+0,1. NOTE 2 Values outside the specified tolerances are not acceptable.
tolerance
3.3
Abbreviated terms
For the purposes of this Standard the following abbreviated terms apply.
Abbreviation AFT
Meaning
abbreviated functional test
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ECSS-E-ST-10-03C Draft 12.5 4 March 2011 AIT AITP AIV AVT CCB CoG DRD DTR TDmin TDmax EEC EGSE EM EMC EMCCP ESD FFT FM FOP GSE HFE HMI ICD LCDA LEOP MDP MoI NC NCR NRB OSPL PFM PIM PSD PT PTR QM r.m.s. RF RFT SEP SFT
assembly integration and test assembly integration and test plan assembly integration and verification acceptance vibration test configuration control board centre of gravity document requirements definition design temperature range design temperature minimum design temperature maximum European Electromagnetic Compatibility electrical ground support equipment engineering model electromagnetic compatibility electromagnetic compatibility control plan electrostatic discharge full functional test flight model flight operation plan ground support equipment human factors engineering human-machine interface interface control document launcher coupled dynamic analysis launch and early orbit phase maximum design pressure moment of inertia noise criterion nonconformance report nonconformance review board overall sound pressure level protoflight model passive intermodulation power spectral density performance test post test review qualification model root-mean-square radio frequency reduced functional test system engineering plan system functional test
22
ECSS-E-ST-10-03C Draft 12.5 4 March 2011 SPL SRS SVT TB TC TCS TM TPRO TR TRP TRPT TRR TV T
Q
sound pressure level shock response spectrum system validation test thermal balance telecommand thermal control system telemetry test procedure test review temperature reference point test report test readiness review thermal vacuum qualification temperature acceptance temperature design temperature operating temperature non operating temperature temperature start up test specification telemetry, tracking and command travelling wave tube verification control document verification plan
TA TD T
OP
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4 General requirements
4.1 Test programme
a. A coherent test programme shall be established, encompassing each verification stage and level to implement the verification by testing. NOTE 1 The testing program is performed incrementally at different product decomposition levels. NOTE 2 Refer to clause 3.1 for determining the type of item for which the test program is defined (i.e. space segment equipment or space segment element), in particular the example table. NOTE 3 The number and type of testing levels depends upon the complexity of the project and on its characteristics in accordance with the Verification program (see ECSS-E-ST-10-02). NOTE 4 The testing levels of decomposition for a space product considered in the present Standard are space segment equipment, space segment element, element and overall system. The customer and the supplier shall agree the need to treat a space segment element as a space segment equipment. This is typically the case for small instrument. c. Test plans and test requirements (including in particular pass/fail test criteria) shall be derived from the product requirements, verification plan and verification control document (VCD). VCD, verification plan and verification stages
b. NOTE
Test procedures shall be derived from test requirements and test plans. Test program and its implementation shall be in conformance with safety requirements of ECSS-Q-ST-40.
4.2
Development test
a. Development test of a product shall be completed prior to the start of its formal qualification testing.
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4.3
Test management
4.3.1
a. b.
General
The supplier shall assign clear responsibility for the implementation of the test programme and record it in the AIT plan. The customer, or its duly appointed representative, shall have the right to participate to all test phases.
4.3.2
4.3.2.1
a.
Test reviews
Test program
The test programme shall start with a general TRR and end with a general TRB.
NOTE An AIT programme is composed of several test blocks linked to the type of activity: Integration Alignment Leak/proof pressure
Mechanical (sinus, acoustic, random, modal survey tests, shock) b. 1. 2. EMC conducted EMC radiated/auto-compatibility/RF Thermal (TB/TV/Thermo optical test) Functional and performance test Final preparation
Each test block shall include the following formal reviews: test readiness review (TRR); intermediate key point, when relevant;
NOTE Depending on the nature of the test, the customer can decide to establish additional key-points between formal reviews. Typical examples are transition between level and axes in vibration tests and transition between tests phases in TV/TB tests. 3. 4. post test review (PTR); test review board (TRB).
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4.3.2.2
a. b.
A TRR shall be held before the start of the test activity to verify that all conditions allow to proceed with the test. The TRR shall address the following topics: 1. test documentation availability and suitability, including approved test plan, approved test specification, approved test procedures, approved measurement point plan, approved test facility, approved readiness report, approved test planning, and acceptance data package; test product configuration; test configuration/set-up; inspection status KIP, MIP, or both report; test facility, environmental conditions, test instrumentations, calibration, maintenance status; cleanliness condition, hazard safety; ground support equipment (GSE) and infrastructures; open non conformances; waivers status, and deviations; personnel qualification and availability; results from test rehearsal using the test facility with or without the product under test; test pass/fail criteria completeness as documented in the test procedure; assignment personnel; of responsibilities, and availability of test
test schedule.
NOTE The level of details according to which each topic is addressed, is different for the general test program TRR than for each block test TRR. c. The following parties shall participate to the TRR: 1. 2. 3. 4. 5. 6. 7. the chairman, who is the product assurance manager of the authority responsible for the test; product assurance from all involved parties; project engineer from all involved parties; AIT from all involved parties; Specialists, when necessary from all involved parties; facility representative; other as relevant.
NOTE For example launcher authority for tests related to launcher interface or other company representative that will take over the responsibility of the hardware after delivery. d. e. All the open points shall be clearly identified and actions assigned with closure date before the execution of the test. The output of the TRR shall be a decision to proceed or not with the test.
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4.3.2.3
a.
A PTR shall be held in order to formally declare the test completed and allow the release of the test article and test facility for further activity The PTR shall address the following topics: 1. verification that all test data are acquired, recorded, and archived in conformance with the test speciation and test procedure requirements; verification that all test anomalies and NCR raised during the test have been initially processed and all inspection and test data needed and requiring the test configuration have been acquired; confirmation that tests have been performed according to the test plan, the test specification and the test procedures (with the exceptions of what is covered by NCR); status of compliance of the test specimen to the relevant requirement; post test status of GSE; post test product configuration based on inspection and cleanliness report.
b.
2.
3.
4. 5. 6. c. d. e.
All the open points shall be clearly identified and actions assigned for their closure. The test set up shall not be dismounted prior to the authorisation given by the PTR. The following parties shall participate to the PTR: 1. 2. 3. 4. 5. product assurance; project engineer; AIT; facility representative; other, including specialist, as relevant.
NOTE For example launcher authority for tests related to launcher interface or other company representative that will take over the responsibility of the hardware after delivery.
4.3.2.4
a. b.
A TRB shall be held to review all results and conclude on the test. The TRB shall address the following topics: 1. 2. purpose: to review all results and conclude on the test; inputs for the TRB: AIT test report as per facility report when relevant, inspection cleanliness report, list of NCR, copy of NCR with the related NRB minute of meeting, deviation; ECSS-E-ST-10-02, report including raised during test list of procedure
3. 4.
compliance with the test specification, and variations to the test plan; status of compliance of the test specimen to the relevant requirement;
27
NOTE For example launcher authority for tests related to launcher interface or other company representative that will take over the responsibility of the hardware after delivery.
4.3.3
4.3.3.1
Test documentation
General
Clauses 4.3.3.2 to 4.3.3.5 define the Test documentation (Test plan, Test specification, Test procedure, and Test report) generated at all product levels. These documents are derived from the System Engineering Plan (SEP), and from the Verification Plan (VP).
4.3.3.2
a. b. c.
The supplier shall establish the AITP in conformance with the DRD in Error: Reference source not found. The agreed AITP shall be available at the TRR of the test campaign. The way the requirement 4.3.3.2.1a is achieved, shall be agreed between the customer and the supplier.
4.3.3.3
a. b. c.
The supplier shall establish the TSPE in conformance with the DRD in Error: Reference source not found. The agreed TSPE shall be available at the relevant test block TRR and on time to allow procedure preparation. The way the requirement 4.3.3.3.1a is achieved, shall be agreed between the customer and the supplier.
4.3.3.4
a. b. c.
The supplier shall establish the TPRO in conformance with the DRD in Error: Reference source not found. The TPRO, derived from the agreed test specification, shall be available at the relevant test block TRR The way the requirement 4.3.3.4.1a is achieved, shall be agreed between the customer and the supplier.
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4.3.3.5
a.
The supplier shall establish the TRPT in conformance with the DRD in Annex C of ECSS-E-ST-10-02.
NOTE The test report describes test execution, results and conclusions in the light of the test requirements. It contains the test description and the test results including the as-run test procedures, the considerations and conclusions with particular emphasis on the close-out of the relevant verification requirements including any deviation. b. The TRPT shall be available prior to the TRB.
4.3.4
a. b. c. d.
Any failure or anomaly during testing shall be recorded. All nonconformances shall be reported in conformance with ECSSQ-ST-10-09. The nonconformance review board (NRB) shall agree on the course of actions to pursue to close the NCR. The NRB shall decide on the necessity and extent of any retest activity in order to demonstrate the correctness of the disposition made.
4.3.5
a. b. c.
Test data
Test measurements and the environmental conditions shall be recorded for subsequent evaluation. A database of parameters shall be established for trend analysis. Trend analysis shall be performed using test data acquired across test sequences.
4.4
Test conditions
NOTE This can be done using previous mission flight data, relevant ground environments, analytical prediction, relevant previous test results, or a combination thereof. b. c. Tests shall be performed simulating the mission envelope, including operational and non operational conditions with margins. For products which are tested in an environment different from the one in which it is expected to operate, the possible differences in behaviour shall be accounted for test levels and duration.
NOTE In this case, the test levels and duration are modified based on analyses. For example to prevent effects of convective heat transfer that reduce thermal gradients. d. Test facilities, tools and instrumentation shall not prevent to fulfil the tests objectives.
29
The combination of test set up, test levels durations, and operational modes shall not create conditions that can induce failures.
4.4.2
a.
Test tolerances
Tolerances for functional and performance tests shall be specified in test error budgets and agreed by the customer prior to start of test. For the purpose of 4.4.2.1.1a test tolerances shall include test instrumentation accuracy.
b.
NOTE The tolerances specified in Table 4 -1 are the allowable ranges within which the test parameters can vary, they include instrumentation accuracy. c. Quantitative requirements demonstrated by measured test values shall account for test inaccuracies and tolerances, and then shall be compared with the specified requested values. The tolerances specified in Table 4 -1 shall be applied to the test values. The tolerances specified in Table 4 -1 which have been detected and justified as not valid in conformance with Error: Reference source not found shall be modified with customer approval.
d. e.
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Tolerances
Low High
Tmin 4
200 K < T 373 K
+0
Tmax 0
Tmax 0
2K 1K < 0,5 K
+3
+4
Tmin 3
100 K < T 200 K 40 K < T 100 K 10 K T 40 K T< 10 K
+0
6. Random vibration
Amplitude (PSD, frequency resolution better than 10Hz) 20 Hz - 1000 Hz 1000 Hz - 2000 Hz Random overall g r.m.s. -1 dB / +3 dB 3 dB 10%
7. Acoustic noise
Sound pressure level, Octave band centre (Hz) 31,5 63 125 250 500 1000 2000 Overall Sound pressure level homogeneity per octave band -2 dB /+4 dB -1 dB /+3 dB -1 dB /+3 dB -1 dB /+3 dB -1 dB /+3 dB -1 dB /+3 dB -1 dB /+3 dB -1 dB /+3 dB +/- 2 dB
8. Microvibration susceptibility
Forces or torque 10 % To be related to the external forces that are applied to extrapolate the transfer functions
31
Tolerances
9. Shock
Response spectrum amplitude (1/12 octave centre frequency or higher) Shock level - 3dB/ + 6 dB
4.4.3
a.
Test accuracies
Accuracies for functional and performance tests shall be specified in test error budgets and agreed by the customer prior to test performance The accuracy of test instrumentation shall be accordance with approved calibration procedures. verified in
b. c. d.
All test instrumentation shall be within the normal calibration period at the time of the test. Any anomaly of test instrumentation, detected at the first calibration sequence after the test, shall be reported as nonconformance. The accuracy of measurement shall be as follows: 1. 2. as per Table 4-2 for the parameters listed, or at least one third of the tolerance of the variable to be measured.
e.
32
Accuracy
4. Leak rate
.
One magnitude lower than the system specification, in Pa m3 s-1 at standard conditions (1013,25 Pa and 288,15 K).
6. Temperature
above 200K 100 K < T 200 K 40 K < T 100 K T< 40 K
8. Acceleration and static load 9. Frequency 10. Acoustic noise 11. Strain 12. EMC 13. ESD
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4.5
Test Objectives
4.5.1
a.
General requirement
When preparing the overall test program of a space segment element tests linked to compatibility with ground and launch segment shall also be included. This covers in particular the system
4.5.2
a.
Qualification testing
Qualification testing shall be performed to provide evidence that the space segment element or equipment performs in accordance with its specifications in the intended environments with the specified qualification margins.
NOTE This evidence is used, further to analysis as relevant, to provide directly or indirectly (i.e. via verification reports (see ECSS-E-ST10-02 Annex F) the elements for the close-out of the VCD (see ECSS-E-ST-10-02 Annex B). b. Qualification testing shall be conducted on dedicated qualification models except when using protoflight approach.
NOTE The Qualification test program requirements are defined in ECSS-E-ST-10-02 requirement 5.2.4.2b and the model built standard detailed in ECSS-E-HB-10-02. c. Qualification testing shall be completed and design improvements or modification incorporated and qualified prior to the authorization for the flight product manufacturing. Upon achievement of qualification the design files shall not be modified. In case destructive tests are needed (e.g. Burst test), a representative model different from the QM shall be used or the test shall be performed at the end of the qualification program. This model could be simplified but need to
d. e.
The qualification environmental conditions shall stress the hardware to more severe conditions than those expected to occur during the flight model lifetime in the following disciplines: shock, pressure cycling.
NOTE To fulfil this requirement, flight model ground testing phases, is accounted for with adequate margin. g. h. The qualification test shall be performed at qualification level and qualification duration. The qualification test margin for levels and duration shall be as specified in Error: Reference source not found for space element equipment and in Error: Reference source not found for space segment element levels.
NOTE The test durations identified in Error: Reference source not found and Error: Reference source not found are the minimum values.
34
4.5.3
a.
Acceptance testing
Acceptance testing shall be performed to provide evidence that the space segment element or equipment performs in accordance with the specifications in the intended environments with the specified acceptance margins.
NOTE This evidence is used, further to analysis as relevant, to provide directly or indirectly (i.e. via verification reports (see ECSS-E-ST10-02 Annex F) the elements for the close-out of the VCD (see ECSS-E-ST-10-02 Annex B). b. Acceptance testing shall be performed on each flight product, except the one used as Protoflight, to assure freedom from workmanship defects and flawed materials in conformance with ECSS-E-ST-10-02. The acceptance program shall be performed after a qualification program has been completed (as per clause 4.5.1 or clause 4.5.4.) with a model built from the same design file. The acceptance test shall be performed at acceptance level. The acceptance test margin for levels and duration shall be as specified in Error: Reference source not found, for space element equipment and in Error: Reference source not found for space segment element levels,
c.
d. e.
NOTE The test durations identified in Error: Reference source not found and Error: Reference source not found are the minimum values.
4.5.4
4.5.4.1
PFM Testing
Overview
Protoflight testing is the combination of the qualification and acceptance testing objectives on the first flight model. The protoflight approach can be applied at each level of decomposition of space system. For space segment elements a protoflight approach should include test on a structural model.
4.5.4.2
a.
Requirements
Protoflight testing shall be performed on the first flight model to provide evidence that the space segment element or equipment performs in accordance with the specifications in the intended environments with the specified qualification margins and to confirm its readiness for delivery and subsequent usage: free from workmanship defects and flawed materials.
NOTE This evidence is used, further to analysis as relevant, to provide directly or indirectly (i.e. via verification reports (see ECSS-E-ST10-02 Annex F) the elements for the close-out of the VCD (see ECSS-E-ST-10-02 Annex B) b. In case destructive tests are needed (e.g. Burst test), a representative model different from the PFM shall be used or the test shall be performed at the end of the qualification program.
35
The protoflight test margin for levels and duration shall be as specified in Error: Reference source not found for space element equipment and in Error: Reference source not found for space segment element levels. NOTE 1 The general approach is to select: test levels: as qualification levels; test durations: as acceptance durations. NOTE 2 The test durations identified in Error: Reference source not found and Error: Reference source not found are the minimum values.
4.6
Retesting
4.6.1 Overview
ECSS-E-ST-10-02 identifies several situations, in which re-verification is required. However, as the scope and the nature of retesting differ so much, test requirements are defined on a case-by-case basis. Examples of cases involving retesting are described in clauses 4.6.2 to 4.6.5 below.
4.6.2
a.
The configuration control board (CCB), as per ECSS-M-ST-40, shall convene to evaluate and decide the extent of the qualification test sequence to be repeated.
4.6.3
a. NOTE manual. b.
The supplier shall identify the testing requirements during storage and post-storage. The information can be presented in the user For space segment equipment that can degrade, periodicity of periodic tests shall be estimated by analysis and tests for customer approval. Frequency of retesting shall be estimated with the scope of keeping the know-how of testing. Periodic tests shall be performed with a frequency identified in 4.6.3.1.1b and 4.6.3.1.1c. Storage configuration shall be agreed with the customer in particular for the deployable mechanisms.
c. d. e.
NOTE If deployable mechanisms are stored assembled with the space segment elements, the flight tension can be reduced. f. The periodic tests during storage shall cover:
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NOTE Example of age sensitive space segment equipment: Travelling wave tubes (TWTs), tape recorders, batteries and special lubricated mechanisms valves and motors. g. h. i. The additional tests to the one listed in clause 4.6.3.1.1f shall be identified for customer approval. The storage procedure shall be submitted to the customer for approval. Solar arrays should be stored in a gaseous Nitrogen environment.
NOTE This recommendation is also relevant for the solar panels, integrated with the photovoltaic assembly, during any transportation phase, and during any long term storage phase after a successful solar panel DRB (Delivery Review Board).
4.6.4
a.
Space segment element or equipment to be re-flown shall be retested before the new flight in accordance with the verification program of the new mission. Readiness for the subsequent flight shall be assured in accordance to the acceptance test criteria. High level (system or element) functional testing shall be performed in preference to individual low level tests.
b. c.
NOTE Post-landing testing is performed on space products to be recovered at the end of mission and on products which are re-flown.
4.6.5
a. b.
Use of qualification Space segment element or equipment shall not be allowed unless agreed by the customer. Additional testing of qualification Space segment element or equipment subsequently selected for flight shall be compatible with the residual life. This is done when the customer considers the
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b.
c.
NOTE Those tests provide the criteria for judging the integrity of the space segment equipment thought the overall test program. The results of both tests should be identical within the test tolerances. d. Additional tests (PT, FFT or RFT as relevant) shall be performed during the thermal test.
NOTE The space segment equipment is expected to be operative under these conditions (exceptions solar panels and antenna feeds during thermal vacuum tests). e. RFT shall be performed, before and after each environmental test blocks as well as transportation. This test allows verifying the integrity of the
Full functional or performance tests shall be also performed while the environment is being imposed, if the space segment equipment is expected to be operational under that environment. Space segment equipment, if operated during ascent and descent, shall be powered during the environmental tests and parameters monitored to detect intermittent or persistent failures during the test, and for each axis of mechanical tests. Any space segment equipment pressurized during ascent shall be tested as specified in ECSS-E-ST-32-02 Clause 5.4.4, and verified for internal pressure decay. Adjustable protection functions shall be tested. Where space segment equipment falls into two or more types of the required tests specified for each type shall be applied.
g.
h.
i. j.
NOTE For example: A star sensor can be considered to fit both electronic space segment equipment and optical space segment
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5.2
b.
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Humidity
Life test
Burn-in
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Mechanical
Physical properties
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