Procedures and Guidelines (PG)

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DIRECTIVE NO.

549
-
PG
-
8072.1.1


APPROVED BY Signature:

Original signed by:

EFFECTIVE DATE:

07/07/2010


NAME:

Carmine Mattiello

EXPIRATION DATE:

07/07/2015


TITLE:

Branch Head


CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

Procedures and Guidelines (PG)



COMPLIANCE IS MANDATORY
Responsible Office:

Code
549/Environmental Test Engineering and integration Branch

Title:

Vibration Testing



P
REFACE


P.1

PURPOSE


The purpose of the procedure is to define the test process and controls for vibration testing using the
GSFC Building 07 Vibration Test Facility.


P.2

APPLICABILITY


This procedure covers the standard operating elements associated with

vibration testing of hardware
using the Vibration Test Facility.


P.3

AUTHORITY


N/A


P.4

REFERENCES


549
-
PG
-
8700.1.2

Structural Dynamic Test Engineering Section Process Managem
ent Plan

09PC
-
WI36

Vibration Facility Operating Procedure

09PC
-
WI84

Digital Data Acquisition System Operating Procedure


Multi
-
Mode

09PC
-
WI85

Digital Data Acquisition System Operating Procedure


Standalone

09PC
-
WI113

Accelerometer Calibration Procedure

1
4CA
-
WI02

Incident Reports at GSFC

09PC
-
WI37

Vibration Test Facility Maintenance Plan


P.5

CANCELLATION



09PC
-
PP02, Vibration Testing


P.6

SAFETY



NONE

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
2

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)


P.7

TRAINING



N/A


P.8

RECORDS



Record Title

Record Custodian

Retention

Test Folio consisting of test procedure,
report and data

Contractor Vibration Engineer or
Dynamic Testing Supervisor

*
5 Years

Maintenance Records

Maintenance Engineer or Maintenance
Manager

*5 Years

Accelerometer Calibration Records


Dynamic Testing Supervisor

*5 Years

* NRRS


NASA Records
Retention Schedule (
NPR 1441.1
)


P.9

ME
ASUREMENT/VERIFICATION



N/A


P
ROCEDURES


IN THIS DOCUMENT, A
REQUIREMENT IS IDENT
IFIED BY “SHALL,” A
GOOD PRACTICE
BY “SHOULD,” PERMISS
ION BY “MAY” OR “CAN
,” EXPECTATION BY
“WILL,” AND
DESCRIPTIVE MATERIAL

BY “IS.”



DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
3

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

Document Flow

Project Test Plan


Process Management
Plan








DUT Specific Test
Procedure


Vibration Test Facility
Process Operations Plan
09PC
-
PP02


Vibration Facility Operating
Procedure

09PC
-
WI36





Digit a l Dat a Acquisit io n Syst em
Operat ing Procedure

09PC
-
WI84/09PC
-
WI85

Test ing




Acceleromet er Calibrat io n
Procedure

09PC
-
WI113





Vibrat ion Test Facilit y
Maint enance Plan

09PC
-
WI37

Test Report s





Faci l i t y De s cri pt i on

Te s t Purpos e

The
obj ect ive of vibrat ion t est ing is t o subj ect spacecraft and spacecraft component s t o
t he sinusoidal, random, st eady st at e and shock vibrat ion levels experience during lift
-
off.

The vibrat ion t est ing pass/fail crit eria consist of a comparison of pre
-
t est f
unct ional
baseline t est result s t o post
-
t est funct ional t est result s t o det ermine t he ext ent of any
degradat ion incurred as a result of t he t est environme nt.

Faci l i ty De s cri pti on

The Vibrat ion Test Facilit y provides all necessary services and equipment t o

perform
vibrat io n t est ing of spacecraft and subsyst ems. Digit a l cont rol syst ems provide
sinusoida l, random, and t ransient waveform cont rol t o four separat e elect rodyna mi c
excit ers. Dat a acquisit io n syst ems condit ion and record dynami c t ransducer respon
ses,
includ i ng acceleomet ers, laser vibromet e rs, force gages, and st rain gages. A small
machine shop wit h drill press, mill i ng, and finis hi ng services are availab le for vibrat io n
fixt ure fabricat io n and alt erat io ns.


The Build i ng 07 Room 036 and Room 040
Vibrat io n Test Cells are serviced by a 7.5 t on crane in
each Vibrat io n Test Cell. The Build i ng 07 Room 026 Vibrat ion Test Cell is serviced by 2.0
-
t on
monorai l crane. Forklift s, personnel lift s, et c. are also availabl e t o support t est set up and t est
it em
st aging operat ions.


Refer t o t he GSFC Facilit y Capabilit ies Manual for det ailed performance infor mat i o n on
facil it i es and equipment.



DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
4

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

Flowchart






5

Testing




2.

Test Procedure Development


5
.1 Emergency Procedures






2
.1 Cost Estimating and

Scheduling


5
.2 Test Authorization






2
.2 Inputs to Test Procedure


5
.3 Test Changes





2
.3 Test Procedure Development


5
.4 Test Monitoring








5
.5 Data Review













3.

Process Control


6
.

Corrective Actions






3.1

Design


6.1 Error Malfunction Reports






3.2 Stress Analysis


6.2 Incident Reports






3.3

Test Fixture
Fabrication


6.

3 Corrective Action





3.4 Test Fixture Acceptance







3.5 R & D Testing


7.

Post Test Activities






3.6

Facility Operations


7
.1 Post Test Review






3.7

Facility Data Systems


7
.2 Reports






3.8

Operational Readiness
Review



7
.3 Test Folio





4
.

Workmanship


8.

Facility Activities

4
.1 Facility Checkout


8
.1 Facility Maintenance






4
.2 Calibration


8
.2
Calibration Procedures















DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
5

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

1.


Responsibilities

1.1.

Product Design Lead



Provide Vibration Test Plan



Review Test Procedure



Conduct and monitor DUT operations



Approve fixture test procedure

1.2.

Process Owner



Schedule Vibration Test Facility



Approve
waivers



Determine need for facility readiness reviews prior to vibration test



Maintain Vibration Test Facility schedule

1.3.

Test Engineer



Advise PDL of Vibration Facility capabilities, limitations, and test practices



Review Vibration Test Plan



Obtain vibration

test specific information from PDL not included in test plan



Approve Test Procedure



Develop fixture test procedure

1.4.

Test Team

The test team receives direction from the Test Engineer through the Test Conductor.

1.4.1.

Test Conductor



Prepare cost estimate



Maintain

Test Folio



Approve Test Procedure including VCS operational parameters, DDAS operational
parameters



Perform Vibration Pre
-
Test Master Check List



Operates the Vibration Test Facility Console



Direct Vibration Testing Activities including VCS and DDAS Operat
or Personnel



Implement and Direct Emergency Actions



Generate Test Report

1.4.2.

Design Engineer



Design and perform stress analysis of Vibration Test Fixtures.



Facilitate fabrication of Vibration Test Fixtures.

1.4.3.

Data Acquisition System Operator



Setup and Operate DD
AS



Monitor Vibration input levels via independent Input Monitor Accelerometers

1.4.4.

Vibration Control System Operator



Setup and Operate VCS



Install Control Accelerometers

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
6

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

1.4.5.

Mechanical Support Technician



Install vibration test Fixturing



Install DUT or assist
Project in installation of DUT



Modify existing Vibration Facility Test Fixtures to mount DUT.

1.4.6.

Instrumentation Technician



Install instrumentation on DUT



Install and connect cabling to DDAS



Provide DDAS operator with instrumentation parameters.


2.

Test Procedu
re Development

2.1.

Cost Estimating and Scheduling

A cost estimate will be prepared and the facility scheduled in accordance with the Structural
Dynamic Test Engineering Section Process Management Plan
.

The cost estimate is based on
the test requirements state
d in the Test Plan.

2.2.

Inputs to Test Procedure

The PDL shall provide an approved test plan to the TE. The test plan shall contain, as a
minimum, specific vibration waveforms, levels, orientations and test durations. The test
procedure will contain all proj
ect specific information required for vibration testing such as
fixture requirements, hardware mounting specifications, contamination requirements, ESD
limitations, safety/hazard issues, handling restrictions and specific test operations. The TE
will revi
ew the test plan for completeness and request needed information or clarification
from the PDL. A complete test plan and the Vibration Facility Operating Procedure, 09PC
-
WI36 together will constitute the test procedure. The Operating Procedure specifies
the step
-
by
-
step facility hardware and documentation requirements for vibration testing.

2.3.

Test Procedure Development

The PDL shall provide all the test requirements, limitations and instructions to the TE
required to safely start vibration testing of the
test item. If the test plan is incomplete or
requires changes, the test plan may be redlined. In some cases, additional documents such as
Handling Requirements, ESD Requirements or Safety Notices may be taken together with
the test plan and Vibration Fac
ility Operating Procedure to constitute the test procedure. All
project specific documents will be approved by the PDL.

A copy of each project
-
supplied document that constitutes the test procedure shall be
stamped and signed by the PDL, TE and TC to creat
e an original test procedure quality
record.

When performing engineering tests on prototype or non
-
flight units a less formal test
procedure development process may be used. The Test Procedure is developed on
-
line using
the Vibration Controller System (VC
S). The on
-
line procedure is done in accordance with
Procedure 09PC
-
WI36.

The desired vibration levels are defined along with the system drive parameters. The VCS
Operator reviews the VCS parameters and provides a hard copy to the TC. The TC stamps
DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
7

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

the
VCS parameters hard copy as approval acknowledgement.

All project
-
supplied documents that constitute the Test Procedure are stamped and
"Approved" by the PDL and TE. The TC shall sign as "Reviewed" all documents to
acknowledge receipt of the test requirem
ents.

When the output of one or more triaxial response transducers is used as input to the VCS to
“limit” or “notch” test levels, all axes of the transducer shall be active as limits, unless
specifically waived by the PDL using the red
-
line procedures.

3.

Pro
cess Control

3.1.

Design

The Test Plan provides vibration test specifications, instrumentation locations and
requirements, fixture mounting requirements, and/or test configuration drawings.

If a Vibration Test Fixture is designed by Code 549 to mount the DUT
in the required
configuration(s), the fixtures must meet the safety factors provided in section 6.2.2, Stress
Analysis. The design will include the layout of the DUT in the test configuration. The design
also includes drawings and specifications sufficien
t to fabricate the fixtures. By definition, flat
plate vibration adapter plates do not require stress analysis.

Vibration Test Fixture drawings shall be reviewed and approved (signed
-
off) by the design
engineer and TE prior to use in the Vibration Test Fac
ility.

3.2.

Stress Analysis

Stress analysis is performed on Vibration Test Fixtures and related facility structure
modifications to ensure they are designed to meet the load factors specified in this section
6.2.4. This analysis provides an independent
verification of the design.

The analysis starts with an engineering review of the design criteria for stress analysis and
fixture design. All loads bearing test fixtures and related facility structures shall be designed
to a safety factor of 3 based on yie
ld strength and 5 based on ultimate strength.

The results of the stress analysis will be documented in a report and submitted for review and
approval by the TE and PO. Deviation from these standards requires a written waiver from the
Test Engineer with co
ncurrence by the PO. The results of stress analysis, approval, and/or
waiver are included in the test folio.

3.3.

Vibration Test Fixture Fabrication

The Test Engineer is responsible for facilitating the fabrication of Vibration Test Fixtures.

3.4.

Vibration Test Fi
xture Acceptance

Vibration testing of Vibration Test Fixtures supporting a DUT shall be performed. A vibration
fixture test procedure will be developed by the Test Engineer and approved by the PO. As a
minimum the vibration fixture testing shall include a
baseline test of the test fixture. This
consists of a sine survey over a frequency range encompassing the planned vibration test
frequency range for the DUT to characterize the resonant frequencies of the vibration test
fixture without the DUT mounted.

I
n addition, vibration testing shall include a set of vibration test runs encompassing the
vibration test runs specified in the Test Procedure on the vibration test fixture without the
DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
8

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

DUT mounted. The Test Engineer shall review the data acquired during vib
ration test fixture

acceptance vibration testing, and approve the vibration test fixture for use prior to mounting
the DUT.

All load
-
supporting fixtures shall be visually inspected

after proof load testing.

The Test Conductor may request a proof test waive
r based on an analysis test loads and
fixture design. The Design Engineer performs this analysis and submits this analysis and
request for proof testing waiver to the TE and PO for review and concurrence. The waiver,
analysis, and approval are filed in the

Test Folio.

3.5.

R&D Testing

R&D vibration testing may be performed in the Vibration Test Facility. This testing consists
of a series of vibration test runs determined by the Test Conductor just prior to operation of
the vibration exciter systems and without
a pre
-
determined test plan. R&D testing can not be
performed on flight hardware or high fidelity engineering models.

3.6.

Facility Operation

Refer to Vibration Test Facility Operating Procedure, 09PC
-
WI36.

3.7.

Facility Data Systems

Refer to Data Acquisition System
(DDAS) Operating Procedure, Multi
-
Unit Mode, 09PC
-
WI84 or DDAS Operating Procedure, Standalone Mode, 09PC
-
WI85 depending on response
data channel count.

3.8.

Operational Readiness Review

The PO determines the need for a facility ORR. The results of the

ORR are
documented by
the Test
Conductor and stored in the Test Folio. An ORR will address the following:



Fixturing



Systems Verification Testing



Documentation and approvals



Safety



Overview of test instrumentation and applied vibration environment



Outstanding
Issues

4.

Workmanship

4.1.

Facility Checkout

A facility checkout test will be conducted to ensure that all vibration exciter, control systems,
and data acquisition systems are functional. This facility checkout is conducted prior to
mounting the DUT, and when appl
icable after mounting the DUT and prior to applying the
specification vibration environment. The Test Conductor can request a facility checkout
waiver based on the previous facility activity. This request for waiver is submitted to the TE
and PO for review

and approval. The request for waiver and approval is filed in the test folio.

4.2.

Calibration

The measurement and test equipment associated with the Vibration Test Facility shall be
within the calibration interval specified on the calibration label.

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
9

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

The equi
pment requiring periodic calibration in the Vibration Test Facility includes the
control and response accelerometers, charge amplifiers, digital voltage meters (DVM’s), and
oscilloscopes. The GSFC calibration support contractor calibrates the charge amplif
iers,
digital voltage meters (DVM’s), frequency counters, and oscilloscopes. The GSFC
calibration support contractor maintains the calibration periodicity and procedures.

Control accelerometers and response accelerometers are calibrated in accordance wi
th 09PC
-
WI113. The Test Conductor will ensure that the equipment is within the calibration period
prior to testing.

Force transducers are specified in some tests by the PDL as a vibration control limit. These
transducers are calibrated end
-
to
-
end, in plac
e, using a known weight during the vibration
system checkout without the test item mounted. The known weight normally consists of the
vibration plate used to mount the test item to the shaker for vibration testing. The vibration
plate is first weighed and
then mounted in the test configuration with the force transducers. A
sine dwell of fixed amplitude and low frequency (usually 5.0Gpk @ 20 Hz) is applied to the
shaker system. The in
-
axis force sum reading of the charge amplifier monitor display is made
by
the Test Conductor. The sensitivity of the force sum is corrected at the charge amplifier to
provide the correct force sum based on the equation:

Force = Mass x Acceleration

where Mass = weight of the vibration plate.

Using this method, the calibration
is only valid in the direction in which the system has been
calibrated.

Strain gage transducers are also specified in some tests by the PDL as a vibration response. A
shunt calibration is performed on all strain gages prior to the start of vibration testin
g. First,
the offset is adjusted to zero the strain gage channel. Next, the shunt calibration is performed
with a known resistor value, and the strain gage conditioning system gain adjusted to yield the
required micro
-
strain/volt output.

The measurement an
d test equipment associated with the data collection system that require
calibration consist of response accelerometers, low voltage mode power supplies, filtering,
and analog to digital converters. An end
-
to
-
end instrumentation verification occurs during
vibration testing (first vibration test run of each vibration test axis) typically consisting of
either a 0.10 or 0.25gpk 20 Hz sine shaker excitation.

The DDAS measures and records the accelerometer response data. The DDAS Operator
reviews the data during

acquisition using the DDAS real
-
time time history graphic display and
reports to the Test Conductor any anomalous conditions. Anomalous conditions include data
channels not working, in
-
axis channels displaying higher than expected vibration levels, and
da
ta channels displaying higher than expected noise.

The DDAS Operator reports to the Test Conductor that the in
-
axis channels are displaying
approximately the correct vibration levels based on the real
-
time time history graphic display.
The DDAS performs a

“Data Evaluation” after completion of data acquisition. The Data
Evaluation consists of a DDAS automated command procedure that generates a spreadsheet
listing of the maximum, minimum, average, rms, ac rms, and calculated peak levels for each
channel.

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
10

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

The

DDAS Operator reviews the Data Evaluation and provides the TC with a hard copy for
review. The TC reviews the Data Evaluation and retains the hard copy in the Test Folio. The
Data Evaluation is required for the Instrumentation Check vibration test run, an
d may also be
performed for other vibration test runs at the discretion of the Test Conductor.

The following Table defines the calibration responsibilities:

Instrument

Calibration Procedure

Responsibility

Control
Accelerometers

Calibrated annually per
procedure 09PC
-
WI113.

Test Conductor

Charge Amplifiers

Calibrated annually by GSFC Center
Contractor.

GSFC Center
Contractor

Response

Accelerometers

Calibrated annually per procedure 09PC
-
WI113. Verified with end
-
to
-
end
instrumentation checkout during
vibration
testing (first vibration test run of each
vibration test axis) per 09PC
-
WI36.

Test Conductor

Vibration Test
Facility DVM’s,
lscill潳c潰osⰠ an搠
cre煵ency
C潵nters

Cali扲ate搠annually 批 dpcC⁃enter
C潮tract潲

dpcC⁃enter
C潮tract潲

5.

Testing

5.1.

Emergency Procedures

The Test Conductor shall take immediate action in accordance with approved safe
-
hold and
shutdown procedures in the event of an emergency situation. Safe
-
hold and shutdown
procedures are defined in the Vibration Facility Operating Proc
edure, 09PC
-
WI36. An
emergency situation consists when there is immediate danger of injury to personnel, damage to
flight hardware, or damage to the facility. The Test Conductor shall immediately notify the
Supervisor and TE of emergency actions. The Test
Conductor shall assess the situation and
inform the Function Manager and the Project Manager of the occurrence and the action taken.
The Function Manager shall inform the Code 549 Branch Head.

5.2.

Test Authorization

The Test Conductor shall accept technical
direction only from TE

or designated alternates. The
Test Conductor is the single point of contact for information concerning facility status. He will
respond directly to any inquiries concerning facility
-
operating parameters, state of readiness,
and malfu
nctions.

5.3.

Test Changes

The approved Test Procedure shall be followed explicitly. The Test Conductor may red
-
line the
approved Test Procedure. The Test Conductor will accept changes through the TE. The
procedure change shall be marked at the appropriate
location in the approved Test procedure
and the change signed by the PDL and TE.

The approved Test Procedure containing red
-
line changes shall be kept in the Test Folio. In the
event the original approved Test Procedure containing red
-
line changes must be

given to the
DIRECTIVE NO.

549
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PG
-
8072.1.1

Page
11

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

PDL, a copy of the approved Test Procedure with the “Completed As Run” red
-
line shall be
reconstituted as the test procedure quality record by stamping and resigning per section 6.1.3.

5.4.

Test Monitoring

System end
-
to
-
end testing will be perfor
med prior to testing in accordance with the Test
Procedure. The testing will ensure that the vibration exciter and vibration control systems are
functional. System end
-
to
-
end testing consists of a series of facility checkout tests that
encompass the requir
ed test specifications contained in the Test Plan to ensure that all vibration
exciter, control systems, and data acquisition systems are functional. This facility checkout is
conducted prior to mounting the DUT, and when applicable after mounting the DUT
and prior
to applying the specification vibration environment.

The Vibration Test Facility vibration acceleration levels will be monitored continuously during
testing by the TC by observing the charge amplifier read out meters, the vibration control
system

monitor, the oscilloscopes traces, and the data acquisition system monitor. The Test
Conductor shall abort the test run if any of the following conditions exist:

The VCS stops updating the control graph or timer display;

One of the control accelerometer f
ails as displayed on the VCS, oscilloscope, or charge
amplifier;

Any of the in
-
axis control charge amplifier displays indicate acceleration levels greater than
50% higher than the specified test level;

The PDL or TE notice a structural anomaly and order a
test abort;

A response accelerometer deeming critical to the successful completion of the test objective
fails. These accelerometers, other than control accelerometers, are identified prior to the start of
vibration testing and continuously monitor during
the test. The control accelerometers are by
definition deemed critical to the successful completion of the test objective.

Vibration test abort is normally under vibration control system control with an independent
Vibration Test Article Monitor/Limiter as

a backup.

At each vibration test level, the actual vibration is monitored and compared to the target
vibration specification. This is done by comparing the expected vibration at a given level to the
actual vibration acceleration levels measured by the charge amplif
iers and vibration control
system. The PDL and TE will monitor the response data from the DUT. If they observe a
condition unsafe to the DUT or undesirable to the test they will request the Test Conductor to
stop the test.

5.5.

Data Review

The DUT data collect
ed will be reviewed subsequent to the test and the validity of the data will
be determined. The data will be reviewed for any signs of unreliable or incorrect data. This will
be determined from past experience, e.g. an accelerometer that failed during test
ing but was not
flagged or was not critical to successfully completing the vibration test objects stated in the Test
Plan.

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
12

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

6.

Corrective Actions

6.1.

Error Malfunction Reports

Error Malfunction Reports will be generated to document facility problems that do not st
op a
test and require corrective actions after the test is completed. A memo addressing the
completion of said work will be sent to the PO.

6.2.

Incident Reports

The Test Conductor shall prepare a draft of an Engineering Services Division Incident Report
for an
y test operations event that has the potential to or results in injury to personnel, damage to
flight hardware or damage to facility.

This draft report shall be prepared immediately following the incident and submitted to the
Facility Operations Section S
upervisor for disposition. Incidence Reports will be generated in
accordance with Incident Reports at GSFC A14CA
-
WI02. A copy shall be distributed and a
copy shall be given to the Simulation Test Engineering Section Head.

6.3.

Corrective Action

Required correc
tive action will be documented in the incident or problem reports.

7.

Post Test Activities

7.1.

Post Test Review

The PO will determine if a Post Test Review will be conducted and what the content of the
review will include.

7.2.

Reports

Reports are generated within tw
o weeks of completion of testing. Reports typically include the
vibration test objective, facility description, test article description, test log, vibration control
system test data and setup parameters, response instrumentation parameters and locations,

and a
discussion of any anomalies or other aspects of the test which warrant attention.

7.3.

Test Folio

For each vibration test project, a folder is created and labeled with the WD number, test date(s),
and brief project identifier. This folder is designated
as the Test Folio. These folders are kept in
the Vibration Test Facility Engineering Office located in GSFC Building 07 Room 030. The
folders contain the following items as a minimum:



Work Directive



Test Report



Test procedure and Facility Checklist



Test
Run Log



Data Acquisition Log



Instrumentation Data Sheets with Transducer locations, sensitivities, and gain settings



Waivers if required



ORR if required by PO

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
13

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

8.

Facility Activities

8.1.

Facility Maintenance

The Vibration Test Facility Maintenance Plan, 09PC
-
WI37
, controls Facility maintenance. The
PO approves this plan.

The QNA Re
-
Certification Group maintains the schedule and performs the certification of the
Vibration Test Facility hydraulic systems.

8.2.

Calibration Procedures

Accelerometer calibration is in acco
rdance with procedure 09PC
-
WI113.

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
14

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

Appendix A



Definitions

Emergency Situation

Where there is immediate danger of injury to personnel, damage to flight
hardware, or damage to the facility

Test Plan

Procedure that defines the unique test conditions
required for a specific test
article or DUT

Test Conductor

Engineer responsible for directing the test team. Test Conductor may act as
Test Engineer & Test Conductor at discretion of PO or TE.

Test Engineer

Engineer designated by the PO to execute the te
st process. Test Engineer may
act as Test Engineer & Test Conductor at discretion of PO.

Test Folio

File of test related documentation maintained by the Test Conductor

Vibration Adapter Plate

Interface plate(s) with bolt hole patterns for Vibration Facil
ity Shakers
and DUT mounting designed to provide interface from DUT and
Vibration Test Facility. Typically, 1” to 3” thick. Does not require stress
analysis and vibration characterization.

Vibration Test Fixture

Test specific structure designed to mount
DUT to adapter plate.
Requires stress analysis and vibration characterization prior to use.


DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
15

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

Appendix B


A
cronyms

DDAS

Digital Data Acquisition System

DUT

Device Under Test

Gpk

Acceleration ref. Gravity
-

peak

Grms

Acceleration ref. Gravity


root
mean square

ORR

Operational Readiness Review

PDL

Product Design Lead


The project manager or leader responsible for the test
article.

PO

Process Owner
-

Code 549 Test Engineering Branch Head

VCS

Vibration Control System

WD

Work Directive

DIRECTIVE NO.

549
-
PG
-
8072.1.1

Page
16

of
16

EFFECTIVE DATE:

07/07/2010




EXPIRATION DATE:

07/07/2015










CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov

TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

GSFC 3
-
18 (11/09)

CHANGE
HISTORY LOG


Revision

Effective Date

Description of Changes

Baseline


07/07/2010

Initial Release