Systems Reliability Entity

Vikram Sarabhai Space Centre

GSLV F06 Mission SR Assessment

MRR 01 20th Nov 2010

Solid Motors
GS1 Motor

1. 1 GS1 Motor - S139 motor cases and Nozzle hardware

Motor cases & Nozzle hardware - No major deviation.

No Concern

1.2 GS1 Motor - Propellant System

Segment Identification Casting date 04-03-2010 to 05-03-2010 13-11-2009 07-08-2009 18-09-2009 Margin of Safety Burn rate (Spec.) mm/s Burn rate (avg) mm/s

HES
MS3 MS2 MS1

751
743 733 736

1.83-2.17
1.57-1.80 1.63-1.87 1.31-1.70

8.00.2
8.00.2 7.80.2 7.80.2

8.039
8.075 7.893 7.735

NES

737

28-08-2009

1.68-1.91

7.80.2

7.634

Average Agni Burn Rates meet the specification.

No Concern

1.3 GS1 Motor - Ignition System

Igniter & Pyro elements - No major deviations.

Earliest expiry date for TBI - Nov 2010 (3 years)

Life of TBI is extended up to May 2011 based on performance of the following aged units tested. 5 Years 1 month 5 Years 9 Months 7 Units 2 Units

No Concern

1. Retro (RS2 ) Motors

Motor cases Propellant system Nozzle, Igniters & Initiators - No major deviations.

No Concern

Metallic Structures

Assessment on structures
Structure Core Base Shroud Assembly Aft End Closure Assembly Inter Stage 1/2M Assembly Inter Stage 2/3L Assembly Thrust Frame Assembly Inter Stage 1/2U Assembly Upper Stub Adaptor Identification BS 009 BS 008 BS 011 BS 09 BS 07 BS 08 BS 11 Issues Nil Status Green Green Green Green Green Green Green

Nil
Nil Nil Nil Nil Nil

S1 Vehicle support blocks

MF/2313/07/02 & (238/0198/1) (XVF/757/9) MF/2313/07/03 & (238/0197/1) (XVF/757/12) MF/2313/07/04 & (238/0197/2) (XVF/757/14) MF/2313/07/05 & (238/0197/3) (XVF/757/20)
VE/5556/08/01 to 08 (XVF/ 664/02 to 08 &15)

Nil
Green

S2 Vehicle support blocks

Nil

Green

No Concern

Assessment on structures
L40 Structures
Hardware SONC S4 BS-21 S3 TAAL-04 S2 BS-22 S1 TAAL-05 Issues Nil Status Green

ITS SBS
FIN Thermal Shroud Protection Plate

TAAL-04 SV-04
BS-29 TAAL-12 TAAL-15

TAAL-05 BS-22
BS-23 TAAL-13 TAAL-08

TAAL-06 TAAL-02
BS-30 TAAL-14 TAAL-07

SV-02 TAAL-03
BS-31 TAAL-15 TAAL-16

Nil Nil
Nil Nil Nil Nil

Green Green
Green Green Green Green

Strapon Attachment hardware system

No Concern

Composite Subsystems

Assessment on Composite Sub Systems

Composite Sub Systems L40 Throat GS2 Throat L40 Thermal Boot CC Vanes (CMSE Make) Pay Load Adaptor

Identification No

S1 - ABSG/ST-79 S2 - ABSG/ST-77 S3 - ABSG/ST-76 S4 - ABSG/ST-71

ABSG/ST-88 ABSG/L40/TB-32 to 35 7th and 9th batch vanes CSTD/1O2/GPLA-O7

No Concern

Assessment on PAYLOAD FAIRING BS 10-GA6102-0000-0000 (R2)

Raw materials change from D3

Carbon Prepreg changed from T300 / 914 to HTS / M18 due to material non availability PrePreg fully characterized. Properties are comparable and found acceptable. Process Work centre Change CFRP Sandwich Panels realised at CMD / HAL under the guidance of CMSE/VSSC. Acceptable. No Concern

Stage Auxiliary Systems & Mechanical Integration

Stage Auxiliary Systems

SAS pyros Normal

6mm dia bolt cutter for satellite separation system : Life expiry December 2010 (3 years life).

VOQ test on two samples of flight batch, for extending the life completed successfully. Life extended to December 2011.

No Concern

Mechanical Integration

All vehicle integration operations upto GS2 stage Normal

No Concern

Control Systems
L40 / GS2 EGC

1.0 Gas motor bearings

Source changed from SABCA Ball bearing - ADR make (Split inner race)

Roller bearing - SKF make with Indigenous steel cage

1.0 Gas motor bearings ..

ISSUE ADR ball bearing seizure observed in 1 out of 4 assemblies during acceptance tests of flight gas motors. Analysis Root cause identified as misalignment caused by interference fit between rotor - bearing interface & improper shaft shoulder corner radius.

Corrective actions
Clearance fit ensured by rework of the rotor. Relief provided at the shaft shoulder.

1.0 Gas motor bearings ..

Bearing specification meets design requirements.

Qualification of 3 sets of bearings through gas motor & system level tests.
Run away condition test (9300rpm) in hot air at 300 deg C. Acceptance tests carried out on 8 sets of flight gas motors L110 Injector level hot tests on 2 qualification hardware. Performance normal

No Concern

3. Solenoid Valve
ISSUE: Failure of CADD make Solenoid Valve - Leakage seen during qualification cycling tests. ANALYSIS: Jamming observed between plunger and bobbin due to inadequate clearances . (-1 micron against 21 microns reported by M/s Raghav
aerospace. Spec: 25 to 75 microns).

CORRECTIVE ACTION: LPSC make valves were used for F06. Clearance at the interface in the range of 80 microns. The performance of these valves satisfactory during acceptance tests
SR views: Measurement inadequacy at work centre needs correction. Clearances also to be included in FCD list.

No Concern

4.RCI servo valve

ISSUE

Failure of RCI servo valve : The servo valve spool got stuck during component level acceptance tests (during 10 mA flow test ).
ANALYSIS

FA in progress However, for GSLV F06 MOOG servo valve is used. SR views:
FA of RCI servo valve to be completed

No Concern For F06

5. EGC Pump Case drain plumbing

ISSUE Leakage observed at the pump case drain plumbing joint during L110 D2 hot test failure observed in the tube flare interface . ANALYSIS

Failure suspected to be due to excess vibration caused by plumbing configuration.

SR views: Impact on similar joints of L40 & GS2 EGC system to be studied. FA to be closed.

L40/GS2 EGC SYSTEMS

The performance of the EGC Packages during the tests at lab and at SHAR is normal.

AVIONICS SYSTEMS

PFA Recommendations from D3

Issue: Noise seen in analog Z rate channel for rates greater than -10deg/s. Maximum roll rate experienced during flight is -14 deg/s.

Analysis: Traced to abnormal behavior of opamp inside NIM for inputs greater than -10 deg/s. Action: Design modified to clip input to -10 deg/s at the input of op-amp for analog rate channels.

No Concern

PFA Recommendations from D3

Issue: The Y rate was in error as 1. The Y gyro was isolated, due to large rate build up in the cryo stage. 2. The Z rate was saturated at -10 deg/s and hence the computed analog Y rate from X1 and Z rates was saturated Analysis: However, the Z1 was not saturated and the analog Y rate would have been normal, if computed from Z1 and X rates. Action: Analog rate Z1 is also made use of in the rate channel processing. Error handling, navigation, REX software modules modified to take care of this requirement.

No Concern

ISSUES : Anomaly in CSCE RVDT Excitation

ISSUE: For P4 loop Command and RVDT feedback not matching (error upto 3.5) High noise in RVDT feedback monitoring (4.6pp). Amplitude reduction and distortion in RVDT excitation (40V p-p, 1KHz)
In other loops, good match between command & feedback and the noise in RVDT feedback is within 1.

ANALYSIS:

The reason is noise pick up through PCB tracks of frequency fixing capacitors of AD698 LVDT signal conditioning IC Capacitors repositioned by mounting on top of the IC and the original tracks disconnected for all the four loops.

ACTION:

RVDT Excitation measurement and Linearity tests at SHAR show good performance.

No Concern

Bias shift in ZA3 channel - RESINS FM34

Issue: FM34, the identified package for GSLV F06 mission has undergone EB phase-1 and vibration checks at VMC. Performance was normal. During post vibration calibration at IISU, a bias shift of 1.6 mg was observed in ZA3 accelerometer during multi position tests. Action: FM-20 is used as the flight package for GSLV-F06. EB Autonomous and Complex checks with CS-6 stage carried out with replaced package at TCX, SHAR. Performance normal.
Short term Stability Rate channel Spec Acceleration channel Spec 0.23 /hr (X) 0.3 /hr 185 g (YA) 250 g Day to day Stability 0.08 /hr (Z1) 0.32 /hr 166 g (YA) 675 g

No Concern

Avionics Package Details

No. of NGC Packages : 22 No. of Failures SPS-CS, FM03 SPS-GS2, FM02 Diode CS GK :3 : 1 Capacitor failure CLR 79 : 1 (poor isolation Workmanship related) : 1 Connector related

All failures closed by FAB

No. of Deviations :8

All deviations are very minor & closed by NCRB

Avionics Package Details

No. of TTC&P Packages No. of Failures : 175 :2

ATS Stack E1162( DAUII) ATS Stack L40 S2(DAU1)

: 1 PCB failure : ADS 1218 IC

All failures closed by FAB No. of Deviations : 35

All deviations are very minor & closed by NCRB

CRYO Stage Control Electronics - MRC / AVR Torque

The torque levels measured are low and less than 5 Nm at 400 HZ and 9.5 Nm at 200Hz. The torque levels are comparable for CSCE Single box and 3 box AMC configurations for the same actuators The torque varies from actuator to actuator measured with the same Electronics and same method.

MRC / AVR Torque

MRC/AVR Torque measurements at 400Hz and 200 Hz for CSCE FM01 ( AMC Version, 3 box) and single box are as follows.
Mock up 1 (Old Mock up)
MRC Torque in Nm AVR Torque in Nm

Mock up 2 (New Mock up)

MRC Torque in Nm AVR Torque in Nm

200 Hz
3 Box (AMC Versi on)

400 Hz

200 Hz

400 200 Hz 400 Hz Hz

200 Hz

400 Hz

9.5

9.5

11

Single Box (28V, 2.5A)

4.5

Requirement : Torque > 8 Nm

The actuator movement is at 200Hz when algorithm is engaged and at 400Hz only during the initial phase and at shutdown.

Mission & Software

Mission Changes in Mission Design

Launch Azimuth changed from 106 deg to 104 deg C15 GK Cryo Stage with 15 ton propellant loading Introduction of GAINS in piggy back mode Introduction of On-board Alignment

Verification

of Trajectory & DAP design inputs Assessment of mission requirements documents QA audit of DRT Actions --- Completed

No Concern

Flight Software
Major changes from D3 Implementation of Onboard Level Alignment in Navigation S/W. E2PROM Checksum Computation in Flight mode in Major Cycle periodicity

Passing of Z1 analog rate to navigation for RESINS rate computation (based on GSLV-D3 PFA recommendation)
Interface changes due to addition of GAINS package (in piggy back mode) and PRISM in place of SDAM in the NGC system MRC / AVR Algorithms related to GK Stage (three different regimes of operation) All mandatory Verification & Validation activities completed.

No Concern

Checkout Software
Major Changes Changes for Onboard Level Alignment and GK Stage Automatic Launch Sequence (ALS) Timing Changes New Linux Based Supervisory Checkout Console Verification & Validation Status Requirements and Design Reviews Code Inspection Module Level Testing of ALS Software Changes System Level T&E - Completed

No Concern

Simulation and Testbed Software

Major Changes SITARA and ICOMETS Changes for OLA and GK Stage OILS/HLS/ALS Testbed changes for OLA and GAINS introduction Verification & Validation Status Requirements and Design Reviews Code Inspection of SITARA and ICOMETS Software Code Inspection of OILS/SIP/IPT Test bed Software Data Verifications for all Simulation Runs Independent Analysis of all Simulation Results

- Completed

No Concern

Onboard Level Alignment(OLA) Qualification

Onboard software Verification & Validation Implementation correctness of OLA in Navigation and NGCP-REX software verified as part of Code inspection and Module level tests. Validated with additional cases in NGC simulation tests. Independently analyzed the impact of Onboard Level Alignment in various components of NGC software. Ground software Verification & Validation Implementation correctness of OLA in BIU and HCS software verified as part of Code inspection. Additional tests conducted at Checkout system level T&E Independently analyzed the impact of Onboard Level Alignment in checkout software.

No Concern

Onboard Level Alignment(OLA) Qualification Overall performance

Sign check carried out with OLA enabled. Ensured the correctness of end-to-end signal flow. All vehicle level checks carried out with OLA enabled. Special Task Team reviewed the implication of OLA introduction in NGC Software Performance of On-board Level Alignment normal

No Concern

THANK YOU