September 6, 2007

EA4-07-012

TO: EA3/Trent Martin

> Alpha Magnetic Spectrometer (AMS) Project Manager

FROM: EA4/Michelle Rucker

SUBJECT: Technical Authority Report of AMS Integration Review

Thank you for the opportunity to participate in the Alpha Magnetic
Spectrometer Integration Review held in Geneva, Switzerland on July
26-27. Attached is a summary report of my observations from a Technical
Authority point of view. Please feel free to contact me at 281-244-5569
if you have any questions.

*Original initialed by*

*Michelle Rucker*

cc:

EA2/L. Bromley

EA3/S. Porter

EA4/I. Kaye

EA4/J. McManamen

EA4/C. Hansen

NT/W. Bostick

**Executive Summary**

The Alpha Magnetic Spectrometer (AMS) project conducted a technical
interchange meeting and Integration Review in Geneva, Switzerland on
July 23-27, 2007. A Technical Authority review was conducted by
assessing AMS integration processes, procedures, and plans with respect
to a select set of technical standards. Due to time and resource
limitations a more comprehensive assessment with respect to
discipline-specific technical standards was not possible; it is assumed
that adherence to discipline-specific standards was adequately assessed
at prior design reviews.

Although JPR 8080.5 is not strictly applicable to AMS, the payload
appears to comply with most of the design and procedural standards.
Several specific suggestions are provided to ensure project success.

Extent of NPR 7120.5D applicability is unclear; applicability should be
verified with the process owner. It is also recommended that all AMS
Deviation/Waivers be coordinated with the Technical Authority, in
accordance with both NPR 7120.5 and JSC 63722.

Extent of NPR 7123.1A applicability is unclear; applicability should be
verified with the process owner. It is recommended that AMS document
project acceptance of risks associated with beginning payload assembly
without a comprehensive end-to-end integration review. To mitigate those
risks, it is recommended that partial integration reviews be conducted
prior to each individual subsystem integration; this would lower the
risk of assembly error and costly rework.

**1. Background**

The Alpha Magnetic Spectrometer (AMS) payload is a state-of-the-art
particle physics detector containing a large, cryogenic superfluid
helium, superconducting magnet. The AMS payload will use the unique
environment of space to search for cosmic sources of antimatter, dark
matter, and dark energy. The AMS project is a collaboration of 17
nations, with contributions from over 50 individual educational
institutions and industry partners.

The AMS project conducted a technical interchange meeting and
Integration Review in Geneva, Switzerland on July 23-27, 2007.

The NASA Johnson Space Center's (JSC) Engineering Directorate provided a
Technical Authority representative to the AMS Integration Review, as
authorized per JSC 63722.

**2. Assumptions**

The following assumptions were used in preparing this report:

-   Scope of this Technical Authority review is limited to integration
    of the various subsystems together into a single payload

    -   Internal integration within each subsystem is the responsibility
        of the subsystem providers, and is out of scope for the NASA
        Technical Authority;

    -   Technical Authority for integration of the payload to the
        Shuttle and Space Station programs will be provided by those
        Program's Chief Engineers;

-   Prior design reviews have assessed the AMS design and determined
    that technical requirements are adequate to meet the payload's
    intended scientific purpose

    -   Adherence to discipline-specific standards (welding, soldering,
        etc.) was assessed by discipline experts at prior design
        reviews;

-   The AMS is classified as a non-NASA payload

    -   Therefore many Government Furnished Property (GFP) requirements
        are not strictly applicable;

**3. References and Definitions**

**3.1 Reference Documents**

EA-WI-023 Project Management of Government Furnished Equipment Flight
Projects

JSC 63722 JSC Engineering Technical Excellence and Technical Authority
Implementation Plan

JSC 27296 Project Plan for the Alpha Magnetic Spectrometer (AMS)

JPR 8080.5 JSC Design and Procedural Standards

NPR 7120.5 NASA Program and Project Management Processes and
Requirements

NPR 7123.1 NASA Systems Engineering Processes and Requirements

**3.2 Definitions**

*Technical Authority* -- is the authority delegated by the Administrator
to the heads of NASA offices and/or functions that are responsible and
accountable for supporting the Agency's programmatic functions.
Technical authorities are the "official voices" of their functional
areas; they are the Agency's subject matter experts and monitor who set,
modify, oversee, and ensure conformance to technical requirements.
Technical Authorities are independent of programs and projects
organizationally and financially

*Chief Engineer* -- subject matter expert in a specific discipline or
system or related family of systems who executes the Technical Authority
for the assigned program or project

**4. Approach**

This Technical Authority review was conducted by assessing AMS
integration processes, procedures, and plans with respect to a select
set of high-level standards and processes.

**5. Compliance with JPR 8080.5**

**5.1 JPR 8080.5 Applicability**

Although JSC 27296, Project Plan for the Alpha Magnetic Spectrometer,
does not specifically cite JPR 8080.5 as an applicable document, it does
cite EA-WI-023, which in turn cites JPR 8080.5 as applicable. However,
it should be noted that JPR 8080.5 guidelines are specifically intended
for *human spacecraft* design; because the AMS is a payload\--not a
spacecraft\--the recommendations in Section 5.3 below should be
considered prudent technical steps to enhance project success, rather
than strict requirements.

**5.2 Observations**

In general, AMS appears to comply with the intent of most JPR 8080.5
Revision A design and procedural standards. AMS team members answered
questions and provided requested information on general processes and
procedures, as well as fluid and electrical systems design and handling.

**5.3 Recommendations with respect to JPR 8080.5**

1.  Obtain JSC Materials & Processes concurrence on mitigation steps
    (conformal coating) taken for electrical components with pure tin
    internal plating.

> *Rationale: refer to JPR 8080.5 Standard E-7.*

2.  Verify that warm helium fittings are unique or clocked such that
    other fluids cannot be accidentally introduced.

> *Rational: refer to JPR 8080.5 Standard F-3.*

3.  Verify adequate strain relief, support, and chafing protection for
    plumbing and cable runs between subsystems to account for design
    loads, deflections, and thermal expansions/contractions. Analysis
    should take into account operational scenarios involving possible
    temperature differentials across the payload as fluids are moved or
    vented, and account for shims, brackets, and straps.

> *Rationale: refer to JPR 8080.5 Standards E-25, F-16 and G-25.*

4.  Communicate to collaboration hardware providers that caps/bags on
    tubing should meet flight cleanliness specifications. Use of plastic
    push-on caps which can generate particulate should be discouraged.

> *Rationale: Refer to JPR 8080.5 Standards F-7 and F-19.*

5.  If fluid quality is important for proper AMS sensor function, then
    Helium, Carbon Dioxide, and Xenon should be sampled prior to filling
    for flight, to verify vendor specifications.

> *Rationale: refer to JPR 8080.5 Standard F-27.*

6.  Consider replacing glued pins/clip washers on thermal blankets with
    grommet/lacing

> *Rationale: To mitigate Foreign Object Debris hazards posed by loose
> clip washers*. *Refer to JPR 8080.5 Standard G-5;* Note: this
> recommendation was captured as AMS action item #150.

7.  Include a step in the master integration procedure to check for
    duplicate part numbers as Acceptance Data Packages arrive, and
    assign an alternate number if duplicates are found.

> *Rationale: Because each collaboration partner is using their heritage
> part numbering system, there is potential for part number duplication
> between subsystems. This has the potential for confusion and possible
> human error. Refer to JPR 8080.5 Standards G-10 and G-22.*

**6. Compliance with NPR 7120.5 D**

**6.1 NPR 7120.5 Applicability**

Although JSC 27296, Project Plan for the Alpha Magnetic Spectrometer,
does not specifically cite NPR 7120.5 as an applicable document, it does
cite EA-WI-023, which in turn cites NPR 7120.5 as applicable. Para P2.b
of NPR 7120.5 Revision D states:

[]{.mark}

> This NPR applies to all current and future NASA space flight programs
> and projects (including spacecraft, launch vehicles, instruments
> developed for space flight programs and projects, research and
> technology developments funded by and to be incorporated into space
> flight programs and projects, critical technical facilities
> specifically developed or significantly modified for space flight
> systems, and ground systems that are in direct support of space flight
> operations). This NPR also applies to reimbursable space flight
> programs/projects performed for non-NASA sponsors. [For existing
> programs and projects, the requirements of this document are
> applicable to the program/project's extant phase as of the effective
> date of this NPR and to phases yet to be completed]{.mark}.

[]{.mark}

Although this verbiage implies applicability to AMS, it should be noted
that the AMS project baseline pre-dates key integration review verbiage
in this latest NPR revision. For this reason,
applicability---specifically System Integration Review
requirements---should be verified with the process owner.
Recommendations outlined in Section 6.3 below are based on a presumption
that Table 2-5 of NPR 7120.5 Revision D, which defines the System
Integration Review (SIR) project life cycle phase, is applicable:

> The SIR evaluates the readiness of the project to start flight system
> assembly, test, and launch operations. V&V plans, integration plans,
> and test plans are reviewed. Test articles hardware/software), test
> facilities, support personnel, and test procedures are ready for
> testing and data acquisition, reduction, and control.

**6.2 Observations**

The dedicated AMS integration facility at the European Organization of
Nuclear Research (CERN) appears to be well-designed and ready to support
integration. A master integration schedule has been developed to help
choreograph subsystem hardware deliveries, and individual hardware item
schedules are being closely monitored by the integration authority.
Hardware Acceptance Data Packages (ADP) are being prepared. A spot check
of one sample ADP (Helium tank provided by Hans Bieri Engineering)
revealed only one minor problem. Trained personnel supplied by the
hardware providers will receive and inspect their hardware at CERN, and
assist in integration. Training and certification of in-line quality
personnel is nearing completion. Ground support equipment and tool lists
are being developed and coordinated.

Although the general AMS Integration Plan is complete, detailed assembly
procedures and verification plans are not yet mature enough to complete
a comprehensive System Integration Review.

**6.3 Recommendations with respect to NPR 7120.5D**

6.3.1 Verify with the process owner the extent of NPR 7120.5 Revision D
applicability to AMS (for JSC, EA2/Engineering Services and Management
Integration Office serves as the process owner). Update JSC 27296 if
necessary to document any changes from the baseline project plan.

> *Rationale: Because the AMS project baseline pre-dates key integration
> review verbiage in the latest NPR revision, applicability may be
> subject to interpretation; documenting an agreement now may help avoid
> misunderstandings at the System Acceptance Review.*

6.3.2 Obtain Technical Authority concurrence on all AMS
deviations/waivers.

> *Rationale: Refer to NPR 7120.5 Revision D, para. 3.4.2.2, and JSC
> 63722.*

**7. Compliance with NPR 7123.1 Revision A**

**7.1 NPR 7123.1 Applicability**

Although JSC 27296, Project Plan for the Alpha Magnetic Spectrometer,
does not specifically cite NPR 7123.1 as an applicable document, it does
cite EA-WI-023, which cites NPR 7120.5, which in turn cites NPR 7123.1
as applicable. Para P2.d of NPR 7123.1 Revision A states:

> The requirements enumerated in this document are applicable to all new
> programs and projects, as well as to all programs and projects
> currently in Formulation phase as of the effective date of this
> document. (See NPR 7120.5 for definitions of program phases.) [This
> NPR also applies to programs and projects in their Implementation
> phase as of the effective date of this document.]{.mark} However, the
> technical team may request permission from the designated governing
> authority to be allowed to continue without complying with all or
> sections of this NPR.

Recommendations outlined in Section 7.3 below are based on a presumption
that Table G-10 of NPR 7123.1A, which outlines SIR entrance & success
criteria, is applicable:

+---------------------------------------+------------------------------+
| **System Integration Review (SIR)**   |                              |
+---------------------------------------+------------------------------+
| **Entrance Criteria**                 | **Success Criteria**         |
+---------------------------------------+------------------------------+
| 1.  Integration plans and procedures  | 1.  Adequate integration     |
|     have been completed and approved. |     plans and procedures are |
|                                       |     completed and approved   |
| 2.  Segments and/or components are    |     for the system to be     |
|     available for integration.        |     integrated.              |
|                                       |                              |
| 3.  Mechanical and electrical         | 2.  Previous component,      |
|     interfaces have been verified     |     subsystem, and system    |
|     against the interface control     |     test results form a      |
|     documentation.                    |     satisfactory basis for   |
|                                       |     proceeding to            |
| 4.  All applicable functional,        |     integration.             |
|     unit-level, subsystem, and        |                              |
|     qualification testing has been    | 3.  Risk level is identified |
|     conducted successfully.           |     and accepted by          |
|                                       |     program/project          |
| 5.  Integration facilities, including |     leadership, as required. |
|     clean rooms, ground support       |                              |
|     equipment, handling fixtures,     | 4.  The integration          |
|     overhead cranes, and electrical   |     procedures and work flow |
|     test equipment, are ready and     |     have been clearly        |
|     available.                        |     defined and documented.  |
|                                       |                              |
| 6.  Support personnel have been       | 5.  The review of the        |
|     adequately trained.               |     integration plans, as    |
|                                       |     well as the procedures,  |
| 7.  Handling and safety requirements  |     environment, and         |
|     have been documented.             |     configuration of the     |
|                                       |     items to be integrated,  |
| 8.  All known system discrepancies    |     provides a reasonable    |
|     have been identified and disposed |     expectation that the     |
|     in accordance with an agreed-upon |     integration will proceed |
|     plan.                             |     successfully.            |
|                                       |                              |
| 9.  All previous design review        | 6.  Integration personnel    |
|     success criteria and key issues   |     have received            |
|     have been satisfied in accordance |     appropriate training in  |
|     with an agreed-upon plan.         |     the integration and      |
|                                       |     safety procedures.       |
| 10. The quality control organization  |                              |
|     is ready to support the           |                              |
|     integration effort.               |                              |
+---------------------------------------+------------------------------+

**7.2 Observations**

7.2.1 Although a general AMS Integration Plan is complete, detailed
integration procedures are not yet completed or approved;

7.2.2 Some, but not all, components are available for integration;

7.2.3 Mechanical and electrical interfaces have not yet been verified
against the interface control documentation;

7.2.4 Functional, unit-level, and subsystem testing is in progress;

7.2.5 Integration facilities, including clean rooms, ground support
equipment, handling fixtures, overhead cranes, and electrical test
equipment, appear to be ready and available;

7.2.6 Support personnel training and certification is in progress;

7.2.7 Handling and safety requirements are being developed (hazard
reports are complete);

7.2.8 All known system discrepancies have been identified and are being
disposed in accordance with an agreed-upon plan;

7.2.9 Open design review issues have been moved to the Open Paper
Management Tool, and will be satisfied in accordance with an agreed-upon
plan;

7.2.10 The quality control organization is ready to support the
integration effort.

3.  **Recommendations with respect to NPR 7123.1**

7.3.1 Verify with the process owner the extent of NPR 7123.1 Revision A
applicability to AMS. Update JSC 27296 if necessary to document any
changes from the baseline project plan.

> *Rationale: Because the AMS project baseline pre-dates key integration
> review verbiage in the latest NPR revision, applicability may be
> subject to interpretation; documenting an agreement now will avoid
> misunderstandings later.*

7.3.2 Incorporate paper product (integration procedures, acceptance data
packages, etc.) required delivery dates & review times into the AMS
master integration schedule.

> *Rationale: Staggering integrated procedure review/approval cycles
> will help prevent a resource bottleneck. Seeing how the ADP review
> tasks fit into the overall work flow may also help collaboration
> partners understand the need for timely paper product deliveries.
> Note: this recommendation was captured during the Integration Review
> as Action Item #129.*

3.  Include all integration procedures and drawings in the master
    document list or tree. *Rationale: will help establish the order in
    which procedures must be available. Note: this recommendation was
    captured during the Integration Review as Action Item #129.*

4.  Document Project acceptance of the risk that integration will begin
    prior to a comprehensive, end-to-end integration review.

> *Rationale: Beginning hardware assembly without a comprehensive,
> end-to-end integration review poses a higher risk of assembly error,
> dimensional interferences, re-work, and potential integrated test
> problems. If this is an acceptable risk, it should be documented; if
> this is not an acceptable risk, hardware assembly should be postponed
> until integration review products are complete.*

5.  Prior to integrating any two subsystems together, complete all
    pertinent integration models, procedures, and analyses. Perform at
    least a partial SIR using NPR 7123.1A Table G-10 as a checklist for
    each subsystem integration.

> *Rationale: Even if it is not possible to complete an end-to-end
> integration review prior to beginning assembly, a detailed
> subsystem-to-subsystem integration review will mitigate the risk of
> assembly error and potential rework.*

6.  Close the one remaining open Critical Design Review Item Disposition
    (RID) prior to beginning micrometeoroid/orbital debris shield
    integration.

> *Rationale: RID 1-17 appears to have potential impacts to the
> integrated design.*

[]{.mark}

**8. Conclusions**

-   Although JPR 8080.5 is not strictly applicable to AMS, the payload
    appears to comply with most of the design and process standards.
    Section 5.3 of this report recommends several steps to enhance
    project success.

-   Extent of NPR 7120.5D applicability is unclear. Section 6.3 of this
    report recommends applicability be verified with the process owner;
    regardless of the extent of applicability, it is also recommended
    that all AMS Deviation/Waivers be coordinated with the Technical
    Authority, in compliance with JSC 63722.

[]{.mark}

-   Extent of NPR 7123.1A applicability is unclear. Section 7.3 of this
    report recommends applicability be verified with the process owner.
    It is recommended that AMS document project acceptance of risks
    associated with beginning payload assembly without a comprehensive
    end-to-end integration review. To mitigate those risks, it is
    recommended that partial integration reviews be conducted prior to
    each individual subsystem integration; this would lower the risk of
    assembly error and costly rework.