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NASA NTRS2019

Trends in Human Spaceflight: Failure Tolerance, High Reliability and Correlated Failure History

In a half century of human spaceflight, NASA has continuously refined agency safety and reliability requirements in response to mission demands, critical failures, and technology development. Early spacecraft, including Mercury, Gemini and Apollo vehicles, were highly reliant on dissimilar redundancy and demonstrated test margins. Later programs, such as the reusable Space Transportation System (STS) and International Space Station (ISS), introduced probabilistic studies and isolated two-failure tolerance to improve robustness at the expense of added complexity. More recently, the Orion Multi-Program Crew Vehicle (MPCV) program adopted universal single-failure tolerance with two categorical exceptions; Zero-Failure Tolerant (0FT) and Design for Minimum Risk (DFMR) hardware. Failure tolerance variances are defined and managed in accordance with agency human-rating requirements, and require concurrence from program Technical Authorities (TA) as well as the MPCV Safety and Mission Assurance Safety and Engineering Review Panel (MSERP). To understand and reaffirm standards applied to Apollo, Space Shuttle and Orion vehicles, Orion and Deep Space Gateway Safety and Mission Assurance (S&MA) representatives conducted accelerated research to compare unique safety and reliability criteria against ground and flight anomalies, based on information contained in post-mission reports and the Problem Reporting and Corrective Action (PRACA) database. In some cases, high-profile failures and narrow escapes have reinforced decisions to maintain or adapt safety requirements. In others, empirical trends have highlighted the need for vigilance and innovative safety guidelines. Given the inability to achieve absolute compliance with evolving safety and reliability requirements, the team conducted a targeted review of DFMR and 0FT propulsion elements within the framework of changing system design, inspection, materials and process developments to formulate conclusions on technological maturity, failure density, and net changes in safety risk. Based on the aggregate performance of high-reliability and failure-tolerant systems, the authors have attempted to establish best practices and guidelines to inform future program decisions. On a somewhat cautionary note, this study is not intended to direct a universal set of requirements for future missions based on prior lessons learned. Spacecraft safety is a multi-variable problem, and attempts to mitigate past failures will not guarantee future success. However, this assessment offers a retrospective review of policy changes, implementation and effectiveness. In the future, NASA, European Space Agency (ESA) and industry partners may benefit from a more robust correlation between requirements and performance, as space-faring nations work toward more challenging, complex and long-duration commercial and deep-space ventures.

Green, Carrie↗

DOE OSTI2022

Snowmass Computational Frontier: Topical Group Report on Experimental Algorithm Parallelization

The substantial increase in data volume and complexity expected from future experiments will require significant investment to prepare experimental algorithms. These algorithms include physics object reconstruction, calibrations, and processing of observational data. In addition, the changing computing architecture landscape, which will be primarily composed of heterogeneous resources, will continue to pose major challenges with regard to algorithmic migration. Portable tools need to be developed that can be shared among the frontiers (e.g., for code execution on different platforms) and opportunities, such as forums or cross-experimental working groups, need to be provided where experiences and lessons learned can be shared between experiments and frontiers. At the same time, individual experiments also need to invest considerable resources to develop algorithms unique to their needs (e.g., for facilities dedicated to the experiment), and ensure that their specific algorithms will be able to efficiently exploit external heterogeneous computing facilities. Common software tools represent a cost-effective solution, providing ready-to-use software solutions as well as a platform for R&D work. These are particularly important for small experiments which typically do not have dedicated resources needed to face the challenges imposed by the evolving computing technologies. Workforce development is a key concern across frontiers and experiments, and additional support is needed to provide career opportunities for researchers working in the field of experimental algorithm development. Finally, cross-discipline collaborations going beyond high-energy physics are a key ingredient to address the challenges ahead and more support for such collaborations needs to be created. This report targets future experiments, observations and experimental algorithm development for the next 10-15 years.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS2022

Pre-Installation Acceptance (PIA) Functional Performance of the Design Verification Test (DVT) Exploration Extra-vehicular Mobility Unit (xEMU)

In an effort that began with technology investment by NASA in a few key components during the Constellation Program and then evolved to demonstrate a packaged Portable Life Support System (PLSS) as part of the Advanced Exploration Systems (AES) Program, the next evolution of the PLSS is now a key component of the Exploration Extra-vehicular Mobility Unit (xEMU) and is assembled as a Design Verification Test (DVT) unit. The xEMU has been detailed with respect to completing a demonstration on the International Space Station (ISS) with support of units for initial lunar capability. The xEMU completed the Preliminary Design Review (PDR) with subsequent Safety Review Panel (SRP) Phase I reviews in 2019-2020. The objectives for DVT are to validate requirements, train the team, learn how to fabricate the hardware with appropriate process controls, assemble the hardware, test the hardware, determine the failure mechanisms/limits of the hardware design and buy down the most risk possible for the qualification and flight phases of the development. With completion of the assembly and initial functional testing of the DVT PLSS in laboratory ambient conditions and vacuum conditions the xEMU has progressed significantly into the DVT objectives. A key part of the test sequences for DVT and all future phases is the Pre-Installation Acceptance (PIA) functional testing which validates the performance of integrated systems including: primary thermal control, auxiliary thermal control, suit ventilation, primary oxygen, secondary oxygen, power distribution, as well as caution and warning all with respect to the applied requirements. This discussion will include an overview of the assembly, summary of the PIA functional testing, lessons learned, and corrective actions implemented moving forward into the remainder of the DVT phase for xEMU.

Colin Campbell↗

NASA NTRS2002

Cost Estimation and Control for Flight Systems

Good program management practices, cost analysis, cost estimation, and cost control for aerospace flight systems are interrelated and depend upon each other. The best cost control process cannot overcome poor design or poor systems trades that lead to the wrong approach. The project needs robust Technical, Schedule, Cost, Risk, and Cost Risk practices before it can incorporate adequate Cost Control. Cost analysis both precedes and follows cost estimation -- the two are closely coupled with each other and with Risk analysis. Parametric cost estimating relationships and computerized models are most often used. NASA has learned some valuable lessons in controlling cost problems, and recommends use of a summary Project Manager's checklist as shown here.

Hammond, Walter E.↗

NASA NTRS2014

Lessons We Learned Designing and Building the Chandra Telescope

2014 marks the crystal (15th) anniversary of the launch of the Chandra X‐ray Observatory. This paper offers some of the major lessons learned by some of the key members of the Chandra Telescope team. We offer some of the lessons gleaned from our experiences developing, designing, building and testing the telescope and its subsystems, with 15 years of hindsight. Among the topics to be discussed are the early developmental tests, known as VETA‐I and VETA‐II, requirements derivation, the impact of late requirements and reflection on the conservatism in the design process.

Arenberg, Jonathan↗

NASA NTRSDate not supplied

Weather Guidance for UAS Urban Medical Transport Missions

Unmanned aircraft will revolutionize healthcare services by providing efficient and expeditious delivery of life-saving transplant organs and supplies to hospitals in urban environments, where road traffic and congestion can slow delivery times and endanger lives. Bell has developed the Autonomous Pod Transport (APT) vehicle to serve this market, with entry into service in mid-2020s. Adverse weather conditions can introduce risks and inefficiencies in urban environments leading to flight delays and cancellations. In 2018, National Aeronautics and Space Administration (NASA) and Bell entered into a cooperative agreement, under the Systems Integration and Operationalization (SIO) program to tackle key challenges to enable future commercial unmanned aircraft operations. The Center for Collaborative Adaptive Sensing of the Atmosphere (CASA) at the University of Massachusetts, Amherst, joined this team to demonstrate weather avoidance technologies for remotely piloted and autonomous vehicles. CASA has developed the ‘City Warn’ hazard alerting platform to gather weather information from various weather sensors and models, and based on user (or mission) preferences for alerting and on user (or unmanned aircraft) locations, the platform shares timely weather intelligence with users and the systems used by them for remote operations. This presentation discusses the weather avoidance solution developed during this project, leading up to the demonstration of the end-to-end system in Fall 2020. The presentation will cover the following topics: 1) goals related to weather avoidance 2) the design requirements process, including the results of pilot interviews, 3) weather observation and avoidance needs 4) selection of regional and national weather data sets 5) design of the weather graphical interface and 6) considerations for real-time weather alerting. The end-to-end system that was developed will be discussed, along with the results from the demonstration flight. The presentation will conclude with insights from the project team on lessons learned and best practices on weather avoidance technologies for the industry going ahead.

weather avoidance↗

NASA NTRS2021

Weather Guidance for UAS Urban Medical Transport Missions

weather avoidance↗

NASA NTRS2006

Near-Miss Evaluation Bias as an Obstacle to Organizational Learning: Lessons from NASA

After the Shuttle Columbia catastrophe, the investigation board (CAIB) stated that NASA needs to develop a "learning culture", meaning a capability to learn from past failures by understanding the technical and organizational causes of these mistakes (CAIB report, 2003). While many organizations learn from obvious failures, we argue that it is harder for organizations to learn from near-miss events (i.e., situations where a failure does not occur but nearly did), because these near-misses are processed as successes. For the shuttle program, prior debris problems could have caused a similar failure as on the Columbia mission except that the large pieces missed the highly sensitive portions of the orbiter. This acceptance of foam debris was adopted as a normal occurrence by the shuttle program managers similar to the problems at the time of the Challenger Disaster (detailed in Vaughan, 1996). We extend that work to show that an outcome bias influences people's evaluation of project managers, such that managers of failed missions were perceived more poorly than managers who made the same decisions but whose mission ended in either success or a near-miss. The similarity of ratings between the near-miss and success condition imply that even when a problem occurs that is clearly linked to prior managerial decisions, if the project is not harmed because of good luck, that manager is not held accountable for faculty decision making and neither the individual manager nor the organization learn from the experience potentially increasing the likelihood of a failure in the future.

Dillon, Robin L.↗

DOE OSTI2020

Building Interfaces with Echo Using R

The following report details the functionality that was developed to directly query the MongoDB and read in echo records from within R, and the ability to create a cinema database directly from echo records. Both of these efforts used the data collected under the MINOS project for development. The nuclear facility under consideration is the High-Flux Isotope Reactor (HFIR) and co-located Radiochemical Engineering Development Center (REDC) at Oak Ridge National Laboratory in Oak Ridge, TN. HFIR is an 85 MW research reactor and is used primarily for production of a medical radioisotopes, material irradiation experiments, neutron activation, and neutron scattering. Targets for the reactor are fabricated and processed and dissolved at REDC, in addition to other glove-box and hot-cell type activities. An overhead view of the facility is provided. The rest of the report is organized as follows: Section 2 describes how to query the MongoDB and load in echo records from within R, with background information on the database type, MongoDB, and the file format of echo records, hdf5, as well as lessons learned during the development phase. Section 3 details the functionality and usage of creating a cinema database directly from echo records within R. A series of appendixes display all the R code (Section 5), some example scripts where the code is used (Section 6), and useful links for further exploration (Section 7).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Design for Additive Manufacturing: Exploring Remelt Strategies to Tailor Density and Microstructure

The potential advantages of AM (e.g. weight reduction, novel geometries) are well understood within a systems context. However, adoption of AM at the system level has been slow due to the relative uncertainty in the final material properties, which leaves capabilities and/or performance gains unrealized. Utilizing remelt strategies it may be possible to expand the available process window to provide densities and microstructures beyond what is capable with standard scan strategies. This work explored remelting strategies for 316L stainless steel to tailor grain size and increase density. Twelve scan strategies were explored experimentally and computationally to understand the limitations of remelt strategies and the robustness of the current simulation package. Results show tailoring of grain size, density, and texture is achievable through remelting and several key lessons learned were made to improve the texture evaluation through simulation.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Development of a High-Efficiency Hybrid Dry Cooler System for sCO 2 Power Cycles in CSP Applications

This project addressed a major gap in supercritical CO 2 (sCO 2 ) power cycle research by focusing on the pre-cooler, a component that had received little attention despite its significant impact on cycle efficiency and plant economics. The team developed a compact dry cooler using brazed/diffusion-bonded microchannel passages paired with formed air-side fins, advancing the technology from TRL-2 toward commercial readiness. Compared to conventional fin-tube coolers, the design cuts installation footprint by roughly half for 10+ MWth systems while achieving better heat transfer and lower approach temperatures, translating into a projected LCOE reduction from 6.04 ¢/kWh to between 5.85 and 5.94 ¢/kWh. While fabrication of an aluminum MW-scale prototype revealed brazing and sealing challenges at larger scales, lessons learned informed a subsequent 1 MWth unit that was successfully built and delivered for integration into Sandia's Gen3 Particle Pilot Plant, advancing the technology to TRL-7 with a path toward TRL-8 pending successful testing.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

ExaFEL: extreme-scale real-time data processing for X-ray free electron laser science

ExaFEL is an HPC-capable X-ray Free Electron Laser (XFEL) data analysis software suite for both Serial Femtosecond Crystallography (SFX) and Single Particle Imaging (SPI) developed in collaboration with the Linac Coherent Lightsource (LCLS), Lawrence Berkeley National Laboratory (LBNL) and Los Alamos National Laboratory. ExaFEL supports real-time data analysis via a cross-facility workflow spanning LCLS and HPC centers such as NERSC and OLCF. Our work therefore constitutes initial path-finding for the US Department of Energy's (DOE) Integrated Research Infrastructure (IRI) program. We present the ExaFEL team's 7 years of experience in developing real-time XFEL data analysis software for the DOE's exascale supercomputers. We present our experiences and lessons learned with the Perlmutter and Frontier supercomputers. Furthermore we outline essential data center services (and the implications for institutional policy) required for real-time data analysis. Finally we summarize our software and performance engineering approaches and our experiences with NERSC's Perlmutter and OLCF's Frontier systems. This work is intended to be a practical blueprint for similar efforts in integrating exascale compute resources into other cross-facility workflows.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2010

SSME Engine Controller Development and Evolution

The SSME engine controller is a redundant, micro-processor based control unit. The controller along with its embedded software provides closed loop control of the engine s thrust and mixture ratio during flight as well as configuring the engine state and operations during non-flight activities such as checkouts, and pre-start engine conditioning. It processes orbiter commands into engine actions and provides engine state and health information to the orbiter for immediate action, telemetry and recording. In addition the controller includes functions which continually monitor and manage engine health, and can activate a variety of fault mitigation actions to insure safe engine operation. The objective of this paper is to provide a description of the SSME engine controller as well as its developmental history and lessons learned

Abrams, Russ↗

NASA NTRS2016

Preparations for Integrating Space-Based Total Lightning Observations into Forecast Operations

NASA's Short-term Prediction Research and Transition (SPoRT) Center has been a leader in collaborating with the United States National Weather Service (NWS) offices to integrate ground-based total lightning (intra-cloud and cloud-to-ground) observations into the real-time operational environment. For much of these collaborations, the emphasis has been on training, dissemination of data to the NWS AWIPS system, and focusing on the utility of these data in the warning decision support process. A shift away from this paradigm has occurred more recently for several reasons. For one, SPoRT's collaborations have expanded to new partners, including emergency managers and the aviation community. Additionally, and most importantly, is the impending launch of the GOES-R Geostationary Lightning Mapper (GLM). This has led to collaborative efforts to focus on additional forecast needs, new data displays, develop training for GLM uses based on the lessons learned from ground-based lightning mapping arrays, and ways to better relate total lightning data to other meteorological parameters. This presentation will focus on these efforts to prepare the operational end user community for GLM with an eye towards sharing lessons learned as EUMETSAT prepares for the Meteosat Third Generation Lightning Imager. This will focus on both software and training needs. In particular, SPoRT has worked closely with the Meteorological Development Laboratory to create the total lightning tracking tool. This software allows for NWS forecasters to manually track storms of interest and display a time series trend of observations. This tool also has been expanded to work on any gridded data set allowing for easy visual comparisons of multiple parameters in addition to total lightning. A new web display has been developed for the ground-based observations that can be easily extended to satellite observations. This paves the way for new collaborations outside of the NWS, both domestically and internationally, as the web display will be functional on PCs and mobile devices. Furthermore, SPoRT has helped developed the software plug-in to visualize GLM data. Examples using the official GLM proxy product will be used to provide a glimpse as to what real-time GLM and likely MTG-LI data will be in the near future.

GLM↗

NASA NTRS2016

Application of Model-Based Systems Engineering for the Development of the Asteroid Redirect Robotic Mission

Model-Based Systems Engineering (MBSE) can augment existing Systems Engineering (SE) processes to more efficiently deliver enhanced products over the project life cycle. Using a multi-user accessible System Model, MBSE has been successfully deployed for the conceptual and preliminary design development of the Asteroid Redirect Robotic Mission (ARRM). The paper provides an overview and examples of the targeted MBSE deployment for development of the mission operational concept, system description, and functional requirements. The paper also includes description of the challenges and lessons learned.

Sindiy, Oleg V.↗

NASA NTRS2006

Cassini distributed instrument operations – what we’ve learned since Saturn orbit insertion

The Cassini mission to Saturn is complex with 12 science teams conducting distributed operations across the United States and Europe. Each Team includes scientists from around the world who actively participate in operations, including observation design, instrument commanding, downlink processing, and archiving. This represents a change in how JPL complex deep-space missions have been operated. Since Saturn Orbit Insertion (SOI), the Cassini Project has spent 17 months conducting science operations and has gained realworld experience that has tested the assumptions and rationale for this approach. We have learned that many of the expected benefits have been realized, but there were numerous unexpected challenges as well. This paper will discuss the lessons learned from the Cassini Tour experience to date. It will revisit the assumptions and rationale behind the distributed instrument operations design and will describe the results, good and bad, of implementing this method of operations. We will describe how Instrument Teams are structured, their roles and responsibilities, what challenges they faced going into orbital operations (the “tour”) and what creative solutions were proposed when funding limitations and schedule milestones prevented optimum solutions. We will also discuss the problems that have been encountered both on the ground and with the instruments, how these problems and anomalies were overcome, and what was learned along the way about the characteristics of distributed instrument operations.

Woncik, Pam↗

NASA NTRS1993

Publication of science data on CD-ROM: A guide and example

CD-ROM (Compact Disk-Read Only Memory) is becoming the standard media not only in audio recording, but also in the publication of data and information accessible on many computer platforms. Little has been written about the complicated process involved in creating easy-to-use, high quality, and useful CD-ROM's containing scientific data. This document is a manual designed to aid those who are responsible for the publication of scientific data on CD-ROM. All aspects and steps of the procedure are covered, from feasibility assessment through disk design, data preparation, disc mastering, and CD-ROM distribution. General advice and actual examples are based on lessons learned from the publication of scientific data for an interdisciplinary field experiment. Appendices include actual files from a CD-ROM, a purchase request for CD-ROM mastering services, and the disk art for the first disk published for the project.

Angelici, Gary↗

NASA NTRS2001

The Integration, Testing and Flight of the EO-1 GPS

The Global Positioning System has long been hailed as the wave of the future for autonomous on-board navigation of low Earth orbiting spacecraft despite the fact that relatively few spacecraft have actually employed it for this purpose. While several missions operated out of the Goddard Space Flight Center have flown GPS receivers on board, the New Millenium Program (NMP) Earth Orbiting-1 (EO-1) spacecraft is the first to employ GPS for active, autonomous on-board navigation. Since EO-1 was designed to employ GPS as its primary source of the navigation ephemeris, special care had to be taken during the integration phase of spacecraft construction to assure proper performance. This paper is a discussion of that process: a brief overview of how the GPS works, how it fits into the design of the EO-1 Attitude Control System (ACS), the steps taken to integrate the system into the EO-1 spacecraft, the ultimate on-orbit performance during launch and early operations of the EO-1 mission and the performance of the on-board GPS ephemeris versus the ground based ephemeris. Conclusions will include a discussion of the lessons learned.

Quinn, David A.↗