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National Aeronautics and

Space Administration

**George C. Marshall Space Flight Center**

**Marshall Space Flight Center, Alabama 35812**

**MICROGRAVITY CRYSTAL GROWTH**

**DEMONSTRATION (MCGD)**

**Project Plan**

SCIENCE

DIRECTORATE

MSFC - Form 454 (Rev. October 1992)

> Microgravity Crystal Growth
>
> Demonstration (MCGD)
>
> Project Plan

Approval Signatures:

**  **

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\_\_\_\_\_\_\_\_\_\_\_\_\_

Dr. Frank Rose, Director Date

Science Directorate

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\_\_\_\_\_\_\_\_\_\_\_\_\_

Robin Henderson, Program Manager Date

Microgravity Research Program Office

 

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\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Fred Sanders, Project Manager Date

Microgravity Crystal Growth Demonstration

REVISION LIST

MSFC PROJECT PLAN for the MICRO-GRAVITY CRYSTAL GROWTH DEMONSTRATION
(MCGD)

ORIGINAL DOCUMENT RELEASE DATE:

REVISION LETTER DATE APPROVAL

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### TABLE OF CONTENTS

1\.
Introduction......................................................................
6

2\.
Objectives........................................................................
6

3\. Customer Definition and
Advocacy.......................................... 7

4\. Project
Authority................................................................
8

5\.
Management.....................................................................
8

6\. Technical
Summary............................................................. 10

7\.
Schedules..........................................................................
11

8\.
Resources..........................................................................
11

9\.
Controls...........................................................................
12

10\. Implementation
Approach..................................................... 13

11\. Acquisition
Summary......................................................... 17

12\. Program/Project
Dependencies............................................... 17

13\.
Agreements.....................................................................
17

14\. Performance
Assurance........................................................ 17

15\. Risk
Management..............................................................
19

16\. Environmental
Impact......................................................... 21

17\.
Safety............................................................................
21

18\. Technology
Assessment....................................................... 22

19\.
Commercialization.............................................................
22

20\.
Reviews..........................................................................
22

TABLE OF CONTENTS (cont'd)

21\. Export
Control..................................................................
23

22\.
Tailoring........................................................................
23

23\. Documentation
Retention..................................................... 24

# MCGD PROJECT PLAN

**1. INTRODUCTION**

The Marshall Space Flight Center (MSFC) Science Directorate (SD) has
authorized its Science Systems Department (SSD) to complete the
Micro-gravity Crystal Growth Demonstration (MCGD). It will constitute
the payload for the MSFC Future X Small Payload Access to Space
Experiment (SPASE), authorized under contract NAS8-00111. The MCGD will
be non-retrievable and will function as a proof of concept payload for
the AeroAstro, Inc. (AA), SPASE (aka: "Bitsy") spacecraft kernel. The
primary goal of this mission is to demonstrate the capability of the
"Bitsy" as a resource for low cost, rapid access to space. The MCGD will
consist of a single fluid cell for sucrose crystal growth and will be
launched, attached to the SPASE spacecraft kernel as a Hitchhiker
payload.

To be consistent with the SPASE spacecraft kernel, MCGD will demonstrate
a streamlined, innovative, yet safe process, by which to design,
fabricate and assemble a small flight project. The minimalist approach
will be reflected in every aspect of this project plan. This plan, while
not all-inclusive, will broadly address most facets of MCGD design,
development, fabrication and delivery. Further supporting plans will be
minimized. Note that some typical flight payload requirements for the
MCGD payload (eg debris analysis, hazard analysis) are being completed
by AeroAstro at the SPASE mission level under funding and direction of
the SPASE contract and are not within the scope of the MCGD Project
Plan.

**2. OBJECTIVES**

The key word in understanding the primary objective of the MCGD is the
word "demonstration". The MCGD is being provided to allow the SPASE
spacecraft kernel to functionally demonstrate the essence of low cost
access to space. MCGD will provide data to be fed through the SPASE
spacecraft kernel and down-linked as it demonstrates its on-orbit
capabilities. MCGD is designed as a demonstration and is not intended
for scientific community peer review.

The primary MCGD goal is scientific and straightforward, ultimately
intended to provide data transfer throughout the mission and to provide
some insight into the mechanism of sucrose crystal growth in a prolonged
and undisturbed microgravity environment. A secondary MCGD goal is to
employ extensive thermal instrumentation to quantify thermal design data
for future experiments. Various thermal models have been employed to
characterize the internal thermal environment of the MCGD canister.
Verification of some or all of these models (through the use of MCGD
orbital thermal data) would be both useful and valuable for similar
follow-on flights. Accomplishment of either MCGD goal will require
successful transmittal of data through Bitsy to the ground station and
would thus constitute proof of the Bitsy's mission support capabilities.

The mechanism of sucrose crystal growth is expected to be demonstrated
as follows. The face growth rate of a sucrose crystal will be measured
as a function of the solute super-saturation, as defined by the growth
temperature, in a pure microgravity environment. Due to the
microgravity, the transport of the solute will be purely by diffusion.
The measured rate of diffusive flux will thus be a function of the
interfacial solute super-saturation. The measured rate of diffusive flux
will be utilized to determine the super-saturation based upon prior
ground based experimentation. The obtained data will be video
down-linked through the SPASE spacecraft kernel and will then be modeled
to characterize the solute concentration gradient profile about the
crystal. Although one downlinked sucrose crystal growth cycle would
constitute mission success, it is hoped that this on-orbit technology
demonstration will be run repeatedly by manipulation of the growth
solution temperature. If so, the sucrose crystal could be grown,
dissolved and re-grown, repeatedly.

Innovation will be attempted in several aspects of the MCGD process.
Specifically, in an effort to demonstrate simplified and cost-effective
acquisition/fabrication, the MCGD will intentionally utilize Commercial,
Off the Shelf (COTS) items in the broadest practical sense. Regardless
of this stated objective, no hardware/component compromises will be made
that would impact mission safety. The Future X SPASE spacecraft kernel
is not designed for on-orbit or post-flight recapture. All MCGD crystal
growth data will be recorded via an on-board, digital, video camera and
down-linked to a ground station. One successful cycle of MCGD video data
transfer would represent the first video data capture of orbital
free-flyer crystal growth. Also, it would reveal the results from the
first crystal growth ever completed in an absolute microgravity
environment. In summary, the MCGD is intended to provide scientific data
to exercise the Future X SPASE spacecraft kernel, and likewise is
striving to achieve modest scientific goals, innovative processes,
reduced costs and prompt delivery.

**3. CUSTOMER DEFINITION AND ADVOCACY**

The MCGD has two customers. The MSFC Micro-gravity Research Project
Office (MRPO) is funding the MCGD and constitutes the primary MCGD
customer. However, the delivery of the MCGD flight hardware will be
directly to the AA SPASE Mission Project Manager. MCGD is to be the
payload for the initial proof of concept flight for the Future X SPASE
(aka: "bitsy") spacecraft kernel. The MCGD Project Manager will provide
regular project status to the funding customer, MRPO. The MSFC MCGD
Project Manager will maintain a close and regular technical working
relationship with AA personnel. The MCGD Project Team will communicate
regularly with the AA engineering staff throughout the MCGD development
and fabrication process to ensure customer advocacy and satisfaction
with the end product.

**4. PROJECT AUTHORITY**

The MSFC Science Systems Department (SSD) and MRPO have signed a letter
of intent and commitment of funding for the MCGD. MSFC/SD has also
provided a letter of commitment to AA, declaring that MSFC/SD will
design, fabricate, test and deliver the MCGD for flight on the Future X
SPASE Mission, mounted to the AA Bitsy kernel. MCGD Project Manager
authority/responsibilities will cease after on-orbit release and payload
checkout except for the provision of mission support as required and
post flight data analysis and the final report.

**5. MANAGEMENT**

The managerial approach to achieve completion of the MCGD will follow
the latest revision of MPD-1280.1, but will be tailored as a small
project per guidance and flexibility provided by NASA Procedures and
Guidelines 7120.5A.

Management Responsibilities: The MCGD PM will ensure that the MCGD and
mission support tasking assigned to MSFC/SD is completed in an
expedient, quality conscious and cost effective manner. MSFC/SD will
coordinate with the AA SPASE Project Manager and his engineering staff,
to assure that the MCGD and the Future X SPASE Bitsy kernel are
compatible in fit, function, performance, safety and schedule. AA,
MSFC/Science Directorate, MSFC/Pathfinder Program Office (TD14) and the
Goddard Space Flight Center (GSFC) will respectively perform the
following roles and responsibilities:

AeroAstro, Inc., will provide:

Future X SPASE Mission PI

Future X SPASE mission oversight and engineering

SPASE spacecraft kernel

Future X SPASE mission EGSE

Future X SPASE mission software

Integrated SPASE analysis, including MCGD

SPASE Spacecraft environmental test parameters

Shipping of the Bitsy kernel to MSFC for integrated systems tests

SPASE integration direction/support

Spacecraft kernel environmental test reviewers/approvers

Provide for a ground control station (may be contracted)

Payload integration into the Hitchhiker Ejection System

MSFC/SD will provide:

MCGD Funding and Program oversight

MCGD Project Manager

MCGD Systems/ Lead Engineer and support engineering

MCGD design support/engineering

MCGD flight crystal growth hardware/canister

MCGD integration with the Bitsy kernel

Integrated systems environmental testing and test coordination

Shipping crate, as required, for return shipment of integrated
MCGD/SPASE

Shipping of the integrated SPASE to AA, post systems test

MSFC/QS (S&MA office) will provide:

Support to major MCGD reviews held at MSFC

#### Representation on MCGD CCB

Provide inspections as defined in this Project Plan

MSFC/TD will provide:

MSFC SPASE Project Manager

File form 1628 to NASA headquarters Code R for SPASE manifest

Representation of MCGD at all flight and ground safety reviews

GSFC/Shuttle Small Payloads Projects Office (SSPPO) will provide:

> SPASE Mission Manager
>
> Payload vibration test Marmon clamp (loaned from GSFC) per memo TD14
> (00-15) 5/25/2000
>
> Payload integration into the Hitchhiker canister
>
> Payload safety and hazard analysis oversight
>
> Payload presentation before the JSC STS Flight Safety Review Panel and
> KSC Ground Safety Review Panel

All MSFC/SSD efforts for the MCGD will be directly managed by the MCGD
Project Manager in SD21. Technology demonstration objectives for MCGD
will be documented in the Technology Demonstration Requirements Document
(TDRD). Engineering, technical and fabrication support for MCGD will be
provided by SD22. In-house fabrication will be provided through the SD
support contract with Sverdrup, NAS 8-40-836. Technical information will
be forwarded through the MCGD Systems Engineer to the AA SPASE Project
Manager or through the designated AA engineering representative. All
S&MA tasks for MCGD will be conducted by the SD MCGD team, with the
exception being: (1) inspection of those items specifically identified
as safety critical including fasteners and their installation, (2)
inspection of packaging prior to shipment, (3) inspection for sharp
edges, and (4) MSFC S&MA support to the MCGD Configuration Control
Board. S&MA will provide quality requirements for procurement of
critical fasteners as defined by the MCGD team. All safety critical
fasteners procured by MSFC will be procured as quality sensitive and
will be routed through S&MA for receiving inspection. Safety critical
items will be inspected by the appropriate S&MA office. Managerial
support for the MCGD efforts at MSFC may also be provided by the Science
Systems Department (SD20), however, MCGD project funds will be under the
direction of the MCGD Project Manager in SD21.

**6. TECHNICAL SUMMARY**

MCGD requirements will flow down from the SPASE Requirements Document
(2210-0002, AA-RQMT-TBD, and will be documented in the MCGD Systems
Requirements Document and the Bitsy to MCGD Interface Control Document
that will be produced in conjunction and cooperation with AeroAstro
personnel. MCGD Level 2 demonstration requirements will be documented in
the MCGD Technology Demonstration Requirements Document (TDRD). This
information that follows in this section provides a general technical
overview of the mission and a general description of the MCGD.

The Future X SPASE on-orbit mission lifetime is expected to be at least
6 months. The spacecraft kernel's design and orbital parameters are
intended to support low earth orbit (LEO). The prolonged microgravity
environmental conditions are expected to deliver optimal sucrose crystal
growth. The spacecraft kernel will have two general operational systems:
the spacecraft kernel system and a sucrose crystal growth demonstration
system. The primary goal of this mission (and the MCGD payload) is to
provide AA with the opportunity to demonstrate its miniature SPASE
spacecraft kernel. The MCGD will constitute the sole payload for this
demonstration flight, along with spacecraft kernel-to-payload interface
hardware.

The Future X SPASE spacecraft kernel will be launched as a STS
HitchHiker payload while integrated into a "top opening" Hitchhiker
canister. While on orbit the entire, sealed SPASE payload (to include
MCGD) will be released from the Hitchhiker canister as a free flyer
spacecraft. The Future X SPASE spacecraft kernel can accommodate launch
upon either the GAS beam, GAS bridge or other similar Hitchhiker
mounting platforms. The SPASE miniature spacecraft kernel (w/o payload)
measures approximately twelve (12.0 ) inches long, by twelve (12.0)
inches wide by three and one-half (3.5) inches high. The fully (double)
enclosed, MCGD sucrose crystal growth canister will have one end
permanently mounted to the SPASE spacecraft kernel. The other end of the
MCGD canister will be open, and may carry an extra solar panel. Orbital
deployment of the SPASE payload will be provided by the Hitchhiker
Ejection System (HES). The SPASE system will interface with a Marmon
clamp release mechanism and payload interface plate. (Refer to GSFC
Hitchhiker CARS 740-SPEC-008, 1999, pgs. 2-127-129). Note, that after
orbital release the Future X SPASE payload is not intended to be
recovered or retrieved.

After successful deployment, the Future X SPASE spacecraft will achieve
a stable LEO and will function as a self sustaining, free flyer at the
disposal of the MCGD team. The spacecraft kernel will be capable of
executing up link commands and will down link scientific video and
low-bandwidth data concerning crystal growth status and limited
spacecraft kernel parameters, such as power generation and solar panel
sun exposure. The MCGD will provide in-flight on-board video that will
closely view the process/progress of sucrose crystallization and then
transmit these images back to the MCGD Ground Station at the University
of Alabama in Huntsville (UAH) for dissemination to the science
community via the internet. The MCGD Ground Station will be a simplistic
arrangement, and will be accomplished/established with the cooperation
of UAH staff and students. The MCGD team will disclose and distribute
data pertaining to sucrose crystal growth rate on a monthly basis
throughout the duration of the mission. This monthly status will include
a report on the performance of the technology demonstration, a brief
synopsis of spacecraft kernel health and a discussion of
accomplishment/determination of scientific milestones.

MSFC/SD will have no role in the SPASE spacecraft kernel design,
fabrication or management. To the extent that the technology
demonstration requirements can still be met, the MSFC/SD MCGD project
will be responsive to the direction of the AA SPASE Project Manager.

**7. SCHEDULES**

The MCGD project schedule is maintained by the MCGD PM and is done in
Primavera software. The MCGD schedule is a stand-alone, detailed entity
and is not included in this project plan to avoid continuous revisions
to this document. A copy of the current schedule is readily available
from the MCGD PM upon request. MCGD milestone target dates are as
follows:

MCGD SRR/PDR -- May 2000

MCGD CDR -- Aug 2000

MCGD pre-delivery FRR -- Feb 2001

MCGD delivery to AA -- Feb 2001

**8. RESOURCES**

MCGD is funded by MRPO for \$156K and 4 FTE's, for a development and
fabrication effort that is expected to take a few months less than two
calendar years from the Authority to Proceed (ATP) of the AA contract
for SPASE. The \$156K is consistent with MSFC/SD in house estimates for
this project. The original cost estimates are valid and are available
upon request from the MCGD PM. The specific man-loading for this project
meets the current requirements of the MSFC Collaborative Work
Commitments (CWC) budgeting process.

Resource allocation is expected to require \$56K during the remainder of
FY00 (development), with the remaining \$100K to be expended during FY01
(fabrication, testing and delivery). The funds provided do not include
any resources for mission operations and data analysis (MO&DA), which is
to be funded by MRPO. Mission Operations (to include data collection and
posting on a SPASE web site) are being conducted by the University of
Alabama in Huntsville (UAH), under the SPASE mission contract and are
not within the scope of this effort. It is estimated that the MO&DA
effort will be supported by 1/3 FTE of a graduate students time for 6
months (approx. \$8K). FTE allocation for MCGD development is not
expected to exceed the level of 4 civil service FTE's at any given time
throughout the development, fabrication and delivery of the MCGD. The
usage rate of the 4 FTE allocation is expected to require 2 FTE's in
FY00 and 2 FTE's in FY01. MCGD completion and delivery is expected to
require approximately 18 months.

**9. CONTROLS**

For the MSFC/SD effort to support the Future X SPASE mission, technical
(design) control is only applicable to those flight components of the
mission that are to be designed, modified, and/or fabricated by MSFC/SD.

Design Control: All such design work is intended to be completed "in
house", tailored in accordance with the latest revision of MPG 8060.1
and should be accomplished by Science Directorate (SD) personnel.
Typical stand-alone control plans (e.g. a configuration management plan,
a quality plan) will not be produced. As such, documentation will be
provided within the body and contents of this Project Plan (Note: test
plans will be produced separately). A Risk Identification Matrix has
been produced which identifies project risks and mitigation procedures.
The MCGD team will produce a MCGD Systems Requirements Document (SRD).
The MCGD SRD will be a living document and will serve as the quality
record for requirements, defining verification methodology and the
documentation of compliance verification for each requirement. The Bitsy
to MCGD Interface Control Document will be produced by TD with MCGD
input.

The MCGD Configuration Control Board (CCB) will ensure the baselining of
the MCGD design and will be responsible for MCGD configuration control
in accordance with this plan. The MCGD CCB will approve the issue of
standard drawing numbers. Any MCGD document or drawing that is issued a
number will then be considered to be a MCGD "controlled
document/drawing" and will thereafter be subject to change/redline
approval and signature of the MCGD CCB. MCGD working drawings will be
held by the responsible engineer, but paper copies of all final MCGD
fabrication drawings will be held by the MCGD PM, who will serve as the
project repository for all controlled drawings and documents. The MCGD
CCB will sign and date all controlled document/drawing
baselines/redlines. Should any drawing require a redline change, the
latest date of CCB signature will always indicate the controlling
iteration of that drawing. The MCGD CCB will also review the project
Engineering Parts List (EPL) which will document all flight materials
and all flight parts (COTS and otherwise). As a minimum, the MCGD CCB
will consist of the following members from within MSFC/SD and S&MA, and
will sign all controlled drawings and documents.

Chair: MCGD Project Manager: MSFC/SD20

MCGD Systems/Lead Engineer: MSFC/SD SD22

MCGD Design Engineer (for subject component): MSFC/SD SD22

S&MA Representative: MSFC/QS

Technical nonconformance reporting and disposition will be conducted
within the MCGD team and will be resolved by the members of the MCGD
CCB, as described above. The MCGD team will evaluate and the CCB members
will resolve all issues of potential impact upon mission safety and
performance. Should the circumstance require it, experts from outside
the MCGD team would be sought for further comment and opinion on a
gratis basis. A safety, interface, or AA requirement related
nonconformance would be reported to the SPASE PM at Aeroastro and
resolved according to the oversight and direction of the NASA center
responsible for the integration and acceptance of the SPASE/MCGD
Hitchhiker payload (GSFC). Final disposition for any and all such
changes, alterations, modifications, to include any required changes to
this plan, must be approved and documented by the MCGD CCB. Final
release of MCGD controlled drawings/documents will be derived from the
redline drawings/documents and will be signed/dated by the MCGD CCB. The
MCGD Project Manager will serve as the sole MCGD documentation
repository and will maintain copies of all quality records. Test
nonconformances will be documented on MSFC Form (3473) Discrepancy
Record (DR) and controlled and dispositioned by the MCGD CCB. Test
discrepancies upgraded to a DR will be dispositioned by a Material
Review Board (MRB) consisting of S&MA (chair), the MCGD Project Manager,
and the MCGD Systems/Lead Engineer. The CCB Chairman has final approval
authority for CCB actions.

Control of customer-supplied product will be implemented per the
Customer-Supplied Product Arrangement (CSPA), TD14-003.

**10. IMPLEMENTATION APPROACH**

The MCGD will be developed "in-house" within MSFC/SD, utilizing a team
approach to provide civil service management and civil service
engineering/design support. MSFC civil service design support,
engineering support and civil service environmental test support will be
sought outside of SD, while existing (on-site) SD support contractor
technicians will be used to perform MCGD flight hardware
production/fabrication work, as required. Collaborative Work Commitments
(CWC's) will be implemented where required, per the MCGD Work Breakdown
Structure (WBS).

The MCGD does not constitute program critical hardware. This is verified
by the 29FEB00 letter from TD14/SPASE Project Office to SD21/MCGD
Project Office. As such, MWI 6410.1 Packaging, Handling and Moving
Program Critical Hardware (PCH), para 5.15, does not apply. SD is not
required to follow the PCH transportation requirements for SPASE, MCGD
or parts thereof.

This project plan will not circumvent or reduce those procedures that
are consistent with good engineering practice for the production of
flight hardware. However, it is essential that all steps taken represent
the best value to the MCGD project. Therefore, certain MSFC support
organizations may not be called upon to perform tasks they traditionally
complete for larger, more complex, fully funded, projects. This does not
mean that those tasks will go undone. However, SD MCGD team personnel
will perform most of the quality inspection tasks required by this plan,
with the exception being inspection of those items determined to be
safety critical. Safety criticality for the SPASE hardware is being
determined by AA in conjunction with GSFC (the payload to spacecraft
integrator). Inspection of any MCGD items identified as safety critical
will be performed by the MSFC S&MA Office. MSFC S&MA will also approve
of fasteners and their installation and inspect for sharp edges. The
MSFC S&MA office is requested to support the MCGD Project as an
independent reviewer through their attendance and support of major MCGD
reviews held at MSFC as well as providing representation to the MCGD
Configuration Control Board.

The MSFC/SD MCGD tasking will require mechanical design, electrical
design and fabrication. There is no MCGD flight software. Each design
engineer will provide inputs and comments through the MCGD Systems
Engineer to ensure that all requirements are defined before designs are
finalized and fabrication is begun. Mission level design reviews (e.g.
PDR, CDR) are coordinated with the AA SPASE Project Manager. MSFC/SD
team personnel will participate in these reviews by telecon and/or in
person, as directed by the MCGD PM, and to the extent that travel
funding is available. The MCGD PM will also conduct in-house, weekly
MCGD/AA project team telecons. The weekly telecon between MSFC/SD and
AeroAstro, Inc., will ensure that MCGD design work is meeting system,
interface, and operational requirements and progressing as scheduled. As
a minimum, the MCGD Project Manager, the MCGD Systems Engineer and MCGD
design engineers will participate in these weekly telecons, along with
other MSFC support engineers/personnel, as appropriate. With regards to
the MCGD work package, MSFC/SD is essentially functioning as the
sub-contractor for delivery of this simple scientific payload.
Definition and design of the payload to Hitchhiker interface structure
lies with the AA SPASE Project Manager .

The MCGD Project Manager will utilize redline drawings throughout the
MCGD design and layout processes as necessary. MSFC/SD MCGD CCB (see
section 9) will maintain the baselined and redlined MCGD
configuration/design drawings within SD. The MSFC/SD CCB will not
release finished drawings until the time for fabrication. MCGD drawings
will be baselined thru the MSFC release desk prior to shipment of the
MCGD to AA. A full set of MCGD as-built drawings and MCGD controlled
documents will be delivered to the AA SPASE Project Manager at the time
of hardware delivery. A second full (paper copy) set of MCGD as-built
drawings and controlled documents will be also held by the MCGD PM per
Section 23.

The MCGD Project Manager, working with an SD engineer serving as the
MCGD project purchasing agent, will have complete oversight for the
purchase, certification, locked storage, use and documentation of all
MCGD flight components (COTS or otherwise). All electrical parts will be
stored in anti-static bags. Vendor certification, receipts and component
traceability will be maintained as appropriate for all MCGD flight
materials and components. This team approach to the acquisition, locked
security and utilization of flight hardware components provides a
continual audit trail for MCGD flight hardware. This procedure
equivocates more stringent flight hardware acquisition approaches at a
greatly reduced cost, commensurate with the very limited funding for
this demonstration.

MSFC SD contractor personnel will be requested to inspect all MCGD
flight drawings prior to final flight hardware fabrication in order to
ensure that the provided MCGD drawings and notations conform with
industry drawing standards established for produceability. Given the
simplicity of and low funding for MCGD hardware, quality inspections for
MCGD drawings will not be conducted at every drawing level. This project
management plan will not request the quality organization to conduct
"build to print" inspections of MCGD piece parts. All parts, fabricated
or purchased, will be closely inspected by the MCGD CCB and MCGD design
engineers who have already built bench models of several MCGD
components. All parts inspections will be documented with the date and
CCB acceptance signatures verifying that all parts have been fitted and
tested. The MCGD project will not build an engineering model. All
components will be fabricated from flight material stock and flight
parts. The first "proto-flight" part produced may eventually be
designated by the MCGD CCB as the flight part if form, fit, function and
testing permits (as described below).

Wherever possible, MCGD system verification will be done by testing
instead of analysis. Separate test plans will be written and are not
included in this project management plan. Analysis may be utilized on a
limited basis, particularly to characterize the MCGD canister thermal
environment. All verification, validation and functional testing will be
conducted and documented by MCGD team personnel and MCGD CCB, with the
exception of vibration testing as described below. MCGD team personnel
are well equipped and experienced in verification testing for flight
hardware and software. The MCGD team is situated such that many
iterations of pertinent tests can be run to characterize/verify hardware
performance and response. Integrated environmental testing (to include
EMI/EMC testing, as required) on MCGD and the SPASE (aka "bitsy")
spacecraft kernel will be done within MSFC. MSFC/SD expects AA to
deliver the Future-X spacecraft kernel to MSFC for combined
environmental testing. Combined MCGD/bitsy (integrated payload) testing
is being done in an effort to save the overall mission the expense of
conducting separate tests for MCGD and for SPASE, then having to retest
upon integration. Therefore, the MCGD will conduct one extensive series
of combined, integrated payload environmental testing. The integrated
test requirements for SPASE/MCGD will be jointly developed by AA/MSFC
SD22 and documented in test plans separate from this document. The
combined Environmental Test Plans for the SPASE/MCGD will then be
compiled, written and produced by SD22 personnel and reviewed
by/concurred with by AA. AA will further provide to MSFC, in writing,
all Future-X SPASE pre-test/post-test functional testing requirements.
Integrated payload thermal-vac testing will be conducted within SD and
the results will be documented by the MSFC/SD MCGD team. Vibration
testing will be conducted and documented by MSFC/ED personnel. MSFC/ED
will provide the post-test summary report to the AA SPASE PM and the
MCGD PM for the vibration testing.

When environmental and functional testing are successfully completed,
the MCGD hardware (still integrated with the Future-X SPASE spacecraft
kernel) will be delivered (without exchange of title) by MSFC/SD
personnel, directly to the SPASE Project Manager at AeroAstro, Inc. A
Form 57 will be prepared and the MCGD will go thru MSFC shipping for
packaging. MSFC Quality shall approve packaging only. AA will be
required to provide a letter to the MCGD PM of acknowledgement and
acceptance, upon delivery. AA will implement delivery of the integrated
SPASE payload to GSFC and will observe Hitchhiker integration at GSFC
and observe payload integration into the STS launch vehicle at KSC. MCGD
will not require any KSC on-pad access prior to STS cargo bay closure.
The following provides the Level 2 MCGD Work Break Down Structure.

![](media/image2.wmf)

**11. ACQUISITION SUMMARY**

The MCGD will be accomplished "in-house" and the procurement of
significant off-site support is not anticipated or expected. The most
likely off-site procurement would be minor machine shop work.

MCGD will use COTS flight hardware wherever possible. However, it is not
possible to use COTS hardware on components that are deemed to be safety
critical (e.g. per GSFC, all fasteners). All MGCD safety critical flight
certified parts and COTS components (that are within acceptable cost
parameters according to the FAR) will be procured by US Government
Credit Card. A partial list of typical MCGD COTS items for flight
includes aluminum stock, electronic parts, wiring, seals, insulation,
mylar, glass tubing and shrink tubing. Documentation of all parts
purchased, to include receipts and flight certifications (as
appropriate), will be maintained by the MCGD PM. All flight hardware
purchased with credit cards will be in accordance with MWI 5113.1.

12. **PROGRAM/PROJECT DEPENDENCIES**

MCGD and the SPASE mission has no external project dependencies other
than launch services which is being secured by AA.

**13. AGREEMENTS**

\(1\) MCGD funding letter signed by MRPO

\(2\) MSFC/SD letter of commitment to AA to provide the MCGD

\(3\) MSFC Future-X SPASE contract w/AA, released late July 14, 2000.

\(4\) Customer-Supplied Product Agreement w/AA

**14. PERFORMANCE ASSURANCE**

\(a\) GENERAL: The primary objective of the MCGD is to achieve a
successful technology demonstration while minimizing every aspect of
overhead costs, employing process innovations and not compromising
safety. Extensive quality control expenditures are not budgeted, nor
desirable given the limited scope and funding for this project. It is
the responsibility of the entire MCGD team, and the ultimate
responsibility of the MCGD project manager, to ensure the best possible
quality for this payload.

\(b\) RELIABILITY: Reliability will be demonstrated by repeated testing
wherever possible. Active systems will be minimized in the design phase
and all components and systems will be thoroughly tested in the lab.
MCGD will have no mechanisms and will be of robust structural design.
Final acceptance of product reliability will lie with the MCGD CCB. The
MCGD team will be responsible for all aspects of Reliability except as
specifically noted in this Plan

\(c\) QUALITY ASSURANCE: Determination of the quality of workmanship
lies with the MCGD team and especially with the MCGD CCB. The MCGD team
will perform post fabrication inspections on all piece parts to ensure
that they conform to the intended design specifications. The final
determination for quality of workmanship and function will be
demonstrated by an array of environmental and operational testing. Final
acceptance of the components and release of the MCGD product will be the
responsibility of the MCGD CCB. The MSFC S&MA Office responsibilities
for Quality Assurance are described in detail in other sections of this
document.

\(d\) PARTS: The MCGD is intended to demonstrate that selected COTS
parts can perform safely and acceptably in limited space flight
applications. This aspect of MCGD is a major facet of the rationale for
the low funding of the project. All selected COTS parts will be
inspected and tested to determine their suitability. Wherever allowed
within US Govt. costing regulations, government credit cards will be
utilized for parts/components purchases in an effort to streamline the
parts acquisition process. All parts will be inspected upon delivery,
labeled according to the MCGD Engineering Parts List (EPL) and stored in
a locked parts cabinet within a secure SD storage area. Anti-static
bagging will be provided for electrical parts. The parts will be held in
secure storage until required for use and the storage area key will be
held by a MCGD team member. The keeper of the key will also maintain a
parts log book for notation of parts received and removed. The MCGD PM
will be ultimately responsible to maintain all purchasing documentation
and component certifications per Section 23.

\(e\) MATERIALS and PROCESS CONTROL: MCGD materials will be tracked by
the MCGD team, throughout the fabrication process to ensure that only
approved/purchased project materials are used. Records of materials and
process will be maintained by the MCGD PM per Section 23. The MCGD PM
will conduct impromptu visits to the fabrication areas to observe
ongoing MCGD work. If testing, observation and/or analysis reveals that
changes in materials or components are required, then the MCGD CCB will
adhere to the change process as described in the Controls section of
this document.

\(f\) PERFORMANCE VERIFICATION: Pre-launch performance of the MCGD will
be verified by test, where practical, on all functional/operational
parameters. However, some aspects of performance cannot be fully
verified outside of the orbital and micro-gravity environments. It will
be particularly difficult to absolutely assure the performance of the
MCGD thermal stabilization system in other than orbital conditions since
the attitude control system is completely passive and the spacecraft
orbital attitude is inexact, although predictable. Likewise, the
performance of the growth cell could be somewhat altered by launch
dynamics, time delays and micro-gravity itself. For example, it is not
assured that the sucrose crystal will grow at the desired growth
location (i.e. the tip of the sting). Further, it is not assured that
the attitude control system (two magnetized steel stabilization bars)
will totally damp out all the extraneous effects (motion) due to
gravity. In any case, operational efforts will be taken to meet all the
scientific requirements, even if certain systems function at less than
an optimal or anticipated level.

Instrumentation will be provided (e.g. thermal sensors) to return
orbital engineering feedback that might influence future designs for
similar payloads. On-orbit performance will be monitored and down-linked
in order to determine micro-gravity conditions, temperature oscillations
and crystal growth/quality. Solar cell performance will be monitored by
instrumentation internal to Bitsy and provided by AA. All crystal growth
information will be gathered and transmitted by video observation
(visual inspection). Regardless of the success or failure to grow
sucrose crystals, the availability of this on-orbit information from
MCGD will serve to broaden the knowledge base in design and fabrication
of future low budget, free flyer experiments.

\(g\) CONTAMINATION CONTROL: MCGD does not pose an external
contamination threat (e.g. to ground crews, the STS crew or to the STS
itself). MCGD will employ a simple, straightforward design and will
minimize and control the few possible sources for internal
contamination. Internal contamination mitigation can be anticipated in
three primary areas. For example, crystal growth data is to be captured
and transmitted by a miniature digital video camera. The lens of this
camera might be subject to coating and clouding if certain materials
(e.g. plastics) out-gas during the mission. The thermal vacuum
environment could precipitate out-gassing of hydrocarbons from
undesirable plastics which could cloud the lens over a short time.
Secondly, the field of view is subject to simply being obscured by
floating debris (e.g. loose insulation) that might drift toward and
lodge between the camera lens and the growth cell. The design will
shroud the lens in such a manner so as to preclude contact with floating
debris from any source. Contamination from leaking crystal growth medium
(4 mls of sugar water, or approximately 1/7 oz.) is not considered to be
a contamination risk although any such leakage would result in
scientific failure. Regardless, design steps will be taken to adequately
seal and contain the growth medium, as growth medium leakage constitutes
a single point failure.

\(h\) SOFTWARE ASSURANCE: MCGD has no flight software. Data handling as
well as all command and control functions are provided by the Bitsy
spacecraft kernel.

\(i\) MAINTAINABILITY: The MCGD will not be retrieved or serviced during
its operational life. As such, maintainability is not applicable to this
project/product. .

15. **RISK MANAGEMENT**

Risk, within this section, addresses technical risk only. Risk analysis
will be an on-going process and will be the general responsibility of
the MCGD CCB and the ultimate responsibility of the MCGD PM.

Technical risk has been numerically evaluated by subsystem comparison,
considering past engineering experience, flight history and technology
maturity. An assigned values risk map was built. The consensus result is
that the primary risk of MCGD lies in the limited ability of the MCGD
thermal control system to maintain the relatively narrow temperature
range required by the MCGD team in order to properly grow sucrose
crystals. MCGD can be heated, but no cooling loop can be provided due to
costs and complexity. Recognizing this risk, the crystal growth support
structure can be variably biased to provide an optimal rate of heat
transfer from the growth cell to the canister exterior. In addition,
thermal modeling and analysis is being iterated by multiple sources to
closely determine MCGD thermal profiles. Extensive laboratory testing is
planned to ensure that the final design delivers the best thermal
stability available within the budget of MCGD. However, since thermal
control is acknowledged to be difficult, it has been determined to
capture actual on-orbit thermal data, regardless of the crystal growth
success or failure. This will permit engineers to further refine thermal
models for future flights of similar experiment canisters. The MCGD
thermal data also serves to provide a secondary data source for
downlinking whereby "bitsy" can demonstrate proof of orbital
functionality.

The assigned values risk map (matrix) revealed that the second greatest
technical risk to MCGD came from the COTS solar panels. There is no
orbital flight history for "off the shelf" solar panels. Bids were
requested for typical "flight" solar panels and the cheapest of those
were far too costly for the MCGD budget. However, it is within the
charter of MCGD to seek out those opportunities to fly COTS hardware
that might result in future savings. There is no doubt that one of the
largest cost drivers to small free flyer missions relates directly to
solar panel costs. A successful flight of COTS solar panels could result
in significant future savings. In an effort to mitigate the perceived
technical risks of COTS solar panels, early environmental testing of the
selected terrestrial solar panels has been conducted at MSFC. That
series of tests, which was conducted entirely separate from and in
addition to the environmental testing of the actual flight COTS solar
panels, characterized the performance and true technical risks posed by
those COTS panels. The tests consisted of a rigorous series of thermal
vacuum tests, vibration tests and flash tests to determine efficiency
following each test sequence. The results of these tests were such that
the decision to fly COTS solar panels on this mission was made based on
the demonstrated capability of the COTS panels to withstand the rigors
of launch and repeated thermal cycling with no apparent loss of
efficiency.

The risk values map revealed that the third greatest technical risk to
MCGD was the potential for leakage of the crystal growth medium (sugar
water) primarily due to freezing during the interim period between
launch and full power availability (approx. one week). While the leakage
of such a small volume (4 mls or approximately 1/7 oz.) of sugar water
poses no safety risk, such leakage would represent technical failure of
the crystal growth demonstration. The fluid growth medium leakage is a
single point failure and the limited MCGD budget cannot provide
redundancy. Extensive testing will be done, including freezer tests.
Design efforts will focus on the shape and mounting of the growth cell
to provide a strong acceptable design.

The other MCGD subsystems and components were determined to pose a
relatively low level of technical risk. The risk analysis for the
Future-X SPASE "bitsy" spacecraft kernel is the responsibility of AA.

**16. ENVIRONMENTAL IMPACT**

MCGD is designed to completely burn up in the earth's atmosphere during
re-entry and it is built entirely of light weight, non-hazardous
materials. Given its benign nature, it qualifies for a Categorical
Exclusion from any EPA requirement to submit an Environmental Assessment
or an Environmental Impact Statement. It poses no threat to the
environment either assembled or in part. The growth medium is organic
(sugar water) and could be safely ingested.

**17. SAFETY**

MCGD is a non-mission critical Hitchhiker payload and will be entirely
double contained within its structural canister, in addition to being
fully contained within a Hitchhiker payload canister. The MCGD is a
benign payload and poses no injury or illness hazard to ground support
personnel, ground support systems, the STS, the overall STS mission or
the flight crew. It has no mechanisms, no hazardous chemicals and
generates no significant levels of electrical charge. AeroAstro will
perform all hazard analyses required to verify MCGD conformance to
Agency safety requirements. MCGD will provide inputs to AeroAstro who
will inturn provide the appropriate safety data input into the SPASE
mission safety data package. MCGD safety data will be reviewed at all
SPASE and internal MCGD milestone design reviews. MCGD personnel will
support all SPASE flight and ground safety reviews. The SPASE Project
will represent MCGD in all flight and ground safety reviews in
accordance with the plan presented in FXP-EXP-SPASE-PLAN-001, Figure 13,
"Flight Safety Process". This representation will extend to Flight
Readiness Reviews, Prelaunch Assessment Reviews, and the MSFC Payload
Safety Readiness Review Board process. No System Safety support from
MSFC S&MA is requested, with the exception of support to major MCGD
design reviews to be held at MSFC.

MCGD Safety compliance data will be included in the SPASE Mission Safety
Data Packages. MCGD will support all SPASE flight and ground safety
reviews. SPASE Project Manager will represent MCGD in all flight and
ground safety reviews in accordance with the plan presented in
FXP-EXP-SPASE-PLAN-001, Figure 13, "Flight Safety Process".

**18. TECHNOLOGY ASSESSMENT**

MCGD does not represent a technology push from a science perspective,
but it does advance space flight technology in several ways. As the sole
payload for the SPASE spacecraft kernel ("bitsy"), the MCGD will provide
the means by which SPASE can prove itself as an orbital resource for
rapid and relatively inexpensive access to space. If data downlink is
successful, MCGD will constitute the first instance wherein a flight
crystal growth apparatus was designed and flown such that all data was
gathered in an microgravity environment of long duration without payload
recovery.

MCGD is intended to maximize the use of COTS items and should expand the
list of low cost items that could be safely and reliably used in
subsequent flight systems of similar design and mission. MCGD will also
seek to expand the knowledge base of thermal modeling for small free
flyer spacecraft by providing on-orbit thermal data for direct
comparison to the thermal models developed by AA and/or MSFC. While the
mission life goal is only six months, MCGD will also be watched closely
to ascertain which COTS items fail to complete or perhaps surpass their
expected mission life. The largest contribution to future missions would
seem to lie in the ability of MCGD to obtain adequate performance and
power generation from the size limited COTS solar panels.

**19. COMMERCIALIZATION**

While the MCGD does not constitute a commercially appealing entity, a
successful flight may indirectly lead to greater interest in space
flight by commercial interests. The SPASE/MCGD demonstration of a
streamlined process and cheaper access to space could serve to encourage
space flight by small businesses and commercial entities that heretofore
had felt it was simply too cumbersome and too expensive to attempt R&D
in space. As a pathfinder for low cost entry into space, MCGD could have
a significant impact as an educational outreach tool, serving to
encourage low budget space flight by universities and other educational
organizations. For this reason, it is imperative to seek all
opportunities to reduce the MCGD hardware/mission preparation process
while not jeopardizing safety. The more straightforward the process, the
more follow-on interest it may create.

**20. REVIEWS**

As travel funds permit, the MCGD Project Manager will attend all major
reviews scheduled by the AA SPASE Project Manager. Technical Interchange
Meetings (TIM) required by the Goddard Space Flight Center (GSFC)
Hitchhiker Payload Office will be attended. GSFC has held only one such
TIM thus far, and GSFC has agreed to limit the number of such required
meetings in a cooperative effort to hold down project costs. The
schedule and content of these GSFC reviews are yet to be determined. In
addition, the MCGD PM will conduct three major internal reviews; a
project level System Requirements Review/ Preliminary Design Review (May
2000), a project level Critical Design Review (September 2000), and a
project level pre-delivery/post test Flight Readiness Review (February
2001). These internal reviews will be conducted in accordance with MPG
8060.1. In addition, weekly intra-team product reviews will be conducted
to ascertain/coordinate team progress. There will also be formal monthly
project reviews with SD20. MCGD team reviews, in conjunction with the
MCGD CCB, will cover all applicable aspects of design progress,
fabrication status, assembly, test readiness and test results. Design
review minutes/results will be maintained by the MCGD PM as a quality
record per Section 23. The MCGD PM and the entire project team will be
available to provide MSFC/SD management with further information, as
requested. Given that the MCGD is funded as a demonstration, no science
community peer reviews, non-advocate reviews, Independent Assessments
(IA) or Independent Annual Reviews (IAR) will be required for MCGD.

The FRR Board will include the SD20 Manager (chairman), SD21 Group Lead,
SD22 Group Lead, a SMO representative, a S&MA representative, and a MRPO
representative. The SD20 Manager will author the certificate of flight
readiness to be provided to the SPASE Project Office.

## 21. EXPORT CONTROL

MCGD will follow all US laws and regulations regarding export control
per MSFC procedures. There are no expected Export Control issues since
SPASE involves only US participants.

**22. TAILORING**

**All tailored items listed below are discussed in greater detail in the
appropriate section of this document.**

The stated objective of MCGD is to provide a demonstrative payload for
the SPASE ("bitsy") spacecraft kernel. MCGD is striving for
cost/schedule/process innovation in several areas, while intending to
achieve the self-appointed science objectives in a safe manner. To
succeed within the limitations of the present MCGD budget and schedule
it is necessary to limit, delegate and modify certain typical aspects of
project management/oversight/support process that would be nominal in a
larger space flight project with a larger budget.

All supporting activities and services have been judged in the light of
whether they constitute a faster schedule, a better product or a cheaper
way to accomplish the stated goals of this project. This approach does
not seek to eliminate required tasking or control, but reserves the
right of the MCGD PM to determine who will accomplish this tasking.
Generally, the MSFC/SD MCGD team will conduct all manner of design,
control, purchasing, testing, inspection and transportation. Otherwise,
the team will complete the entire flight task and meet all requirements
in conjunction with the customer (the AA SPASE Project Manager). The
only absolute exception to this internal approach will be with regards
to flight safety requirements, which will be dictated by safety
personnel at the integrating NASA facility (GSFC) and observed by safety
personnel at MSFC.

This project will minimize cost and overhead while maintaining
quality/safety and meeting the technology demonstration objectives of
the MCGD.

This project will conduct internal quality inspections and establish
internal metrics to assure that a quality/safe product is being produced
and delivered.

MCGD flight hardware will utilize both certified flight hardware and
"off the shelf" commercial components as a special demonstration. The
MCGD Project Team and CCB will determine which components will be
purchased as "commercial" items and which will be "flight" certified
items. SD certified flight spares from former missions, which are not in
secure storage, may be utilized as form, fit, function, shelf life and
costs permit/dictate. Regardless, all MCGD safety critical items will be
from flight certified and controlled stocks.

All flight hardware, commercial or otherwise will be purchased directly
on US Government Credit Cards, where the dollar value of the purchase
falls within existing US government purchasing regulations and if the
purchasing of these items in this manner is in the best interest of the
government. Credit cards enable timely purchases of materials for US
government use. MCGD intends to maximize the flexibility and capability
for rapid acquisition that is provided by having such a credit card. It
should be noted that the expedience with which an item is purchased is
in no way a reflection upon the quality of the item itself. All
components that are used to assemble the flight MCGD will be certified
and documented to be of the desired level of quality. All the necessary
documentation will be maintained by the MCGD PM to provide an audit
trail of purchase/source.

Flight hardware drawings will be released through/to the MSFC Drawing
Repository before delivery. MCGD is a unique product and AA will
simultaneously take delivery of the MCGD hardware and a full set of
drawings/documents. The MCGD PM will serve as the MSFC drawing
repository for MCGD drawings and documentation per Section 23.

The MCGD will be delivered to AA without an exchange of title. It will
be built as and remain a NASA owned flight project throughout the
duration of the SPASE integration, launch and mission operations phase.

**23. DOCUMENTATION RETENTION**

The MCGD Project Manager is responsible for maintaining a complete and
current file of Quality Records in accordance with MPG 1440.2, MSFC
Records Management Program. Quality Records will be retained for a
period of 2 years after project or task completion. At the conclusion of
the 2 year retention period, the Project Manager shall disposition the
Quality Records in accordance with NPG 1441.1.