INTERNATIONAL SPACE STATION PTC Process Flows August 17, 2007 Robert D. Blum Payload Capability Training Lead

INTERNATIONAL SPACE STATION 2 Process Owner Product/ Outputs CustomerSchedule Template Process Documentation EO20/PTCIntegrated Systems Test MSFC Cadre, JSC Cadre, and International Partners On goingDRLI-25, DRLI- 70, SST-800 DRAFT, DRLI- 70, PTC Console Handbook Integrated Systems Test Process

INTERNATIONAL SPACE STATION 3 SSAT Phase 2 IST Prep IST K/O Integrated System Test (4 weeks) New (late) Content TR Fixes FELR DT Delivery Load Validation (3 weeks) Full ContentAll Cat 1 & 2 TRs Identified (DLVR -1 week) DLVR Fix & Checkout Critical TRs (3 weeks) Final TR corrections Final Test (3 days) Final Eval TRR Move to OPS (2 days) RFT Integrated Systems Test Process

INTERNATIONAL SPACE STATION 4 Process Owner Product/ Outputs CustomerSchedule Template Process Documentation EO20/PTCPayload Tool Development MSFC Cadre, JSC Cadre and International Partners On -goingDRLI-92, DRLI-25, DRLI-70, SST-800 DRAFT, PTC Console Handbook Generic Payload Tool Development Process

INTERNATIONAL SPACE STATION 5 Generic Payload Tool Development Process Identify Compatible Parts & Drivers Install hardware into PC Code G2 Interfaces Integrate into SSTF Write hardware interfaces Determine Requirements Integrate G2 & C Code Create Data Files C Programmer G2 Programmer Integrate/Ver ify Hardware Determine Design Concept Determine Hardware Interfaces Identify Parts & Drivers Install hardware into PC Hardware Engineer Integrate & Verify Hardware Software Engineer Determine Software Design Gather Model Data Write Model Procedures Test Model Code Integrate with External Facility Configuration Management Generic Payload Model

INTERNATIONAL SPACE STATION 6 Generic Payload Tool Development Process –Development has been separated into several distinct functions. The Hardware Engineer is responsible for the hardware design, installation, and testing. This includes ensuring connectivity within the SSTF and to any external facility required for the model simulation activities. The Software Engineer is responsible for the overall software design concept. Payload simulation data including interface and command and response definitions, system functions and configuration files that are gathered and analyzed. The software engineers also perform configuration management for the GPM software. This includes creating and updating model description documentation and identifying and controlling version releases. The C Programmer designs, codes, and tests the device interface processes and the G2 interface modules. The supported hardware interfaces include MIL-STD-1553B, signal conversion equipment (SCE), and TCP/IP. The G2 Programmer designs, codes, and tests the GPM models. The G2 model simulates the payload rack by modeling the rack thermal control system, electrical power system, and command and data responses. The model generates rack and payload health and status data as well as SSTF simulation data. Multiple payloads within a rack may be supported by a model. The GPM hardware and software engineers integrate the GPM model into the SSTF and with any required external facility like the POIC in MSFC or MCC at JSC. Integration activities include verifying data connectivity and flow.

INTERNATIONAL SPACE STATION 7 Generic Payload Tool Development Process Modify G2 Interfaces Integrate Modifications into SSTF Modify hardware interfaces Modify Data Files C Programmer G2 Programmer Support Test Sessions GPM Maintainer Identify Compatible Parts & rivers Install hardware into PC Hardware Engineer Integrate & Verify Hardware Software Engineers Modify Model Procedures Integrate Modifications with External Facility Debug Models Debug Interfaces Analyze Upgrade Needs Identify Upgrade Software Install Upgrade Software Configuration Management

INTERNATIONAL SPACE STATION 8 Equipment and Software Maintenance –Support activities: Debugging the GPM model Making the necessary corrections to C and/or G2 code Integrating modified hardware/software into the SSTF and any external facility Debugging hardware interface problems Analyzing the need for hardware and/or software upgrades If a hardware or software upgrade is required, performing the upgrade includes: –identifying required hardware, drivers, and software, –installing both the hardware and software components, and –making any necessary modifications to the C and/or G2 code to accommodate the upgraded hardware and/or software –Updating GPM model software as payload configurations and RIC software change Performing Configuration Management functions which include: –Updating GPM documentation to reflect code and/or configuration changes –Making controlled releases of modified GPM model software. –Providing backup copies of GPM software to the archival site. –Maintaining configuration control information about GPM hardware and software. Generic Payload Tool Development Process

INTERNATIONAL SPACE STATION 9 Take photos of payload Convert photos into usable BMP images Create unique BMP Images Create Active X Controls (switches, lights) Assign Line Numbers Create Active X Panel from Active X Controls Create Resource File from BMP images Graphics Artist Determine Requirements Create Rack from Active X Panels Determine New Active X Controls, Panels, Rack Model the Rack based on assigned Line Numbers Graphics Programmer Model Programmer GRT Development Generic Payload Tool Development Process

INTERNATIONAL SPACE STATION 10 GRT Programming Team –The Graphics Artist is responsible for creating the BMP images which will be utilized by the Graphics Programmer. These images may be created from scratch, or the BMP image may be created by modifying a photo taken by a digital camera. A digital camera and Adobe Photoshop are used to create the necessary images. –The Graphics Programmer is responsible for animating the images that the Graphics Artist created as well as changing the state of that component. These animations are compiled into individual components which can be reused. Basic Active X functions are provided so that dragging a toggle switch for example will cause the component to change state. Visual Java and Visual C++ are used to create this components. –The Model Programmer provides the logic behind the individual components that the Graphics Programmer created. Individual components are tied together such as a switch activating a light or setting a line number to a predefined value. Visual Basic is utilized in the modeling of the rack. Generic Payload Tool Development Process

INTERNATIONAL SPACE STATION 11 Test and debug load Create RIC Checklist Build Load Software Engineer Determine Requirements Submit RIC Checklist to CCB Create any DIS terms for Debug / Display Create/ modify SAMMI Displays If new Display, submit to DAWG for review Submit Display to USA Make code changes Test and debug load Create RIC Checklist Build Load Software Engineer / Development Determine Requirements Submit RIC Checklist to CCB Create any DIS terms for Debug / Display Create/ modify SAMMI Displays If new Display, submit to DAWG for review Submit Display to USA Make code changes Generic Payload Tool Development Process

INTERNATIONAL SPACE STATION 12 Model and Graphics Programming –Programming is primarily in Ada with a few modules in C. Includes the creation and modification of the required SAMMI displays as well as building the model behind the displays. This model may interact with other models and not require any displays at all. Generic Payload Tool Development Process

INTERNATIONAL SPACE STATION 13 Process Owner Product/ Outputs CustomerSchedule Template Process Documentation EO20/PTCTrainer Shipping MSFC Cadre, JSC Cadre, and International Partners Based on Customer Requirements JSC Trainer Shipping Process

INTERNATIONAL SPACE STATION 14 Trainer Shipping Process JSC Representative Contact the JSC Payload Representative (Sim Engineer or Logistics Coordinator), at least 4 weeks prior to shipment Task Performance Sheet JSC Payload Representative, will complete a Task Performance Sheet (TPS) prior to shipment date to meet JSC Quality requirements for controlled hardware DD Form 1149 JSC Payload Representative will prepare a DD Form 1149 to accompany the shipment and provide it to the PD along with the proper shipping address Shipping Company Selection PD will select a shipping company and ship the hardware. Shipping Documentation PD will FAX copies of all shipping documentation to the Payload Representative. JSC building 10 bond Hardware may also be hand-carried to JSC building 10 bond by the PD, PI, or an authorized representative. Bonded Storage The hardware is transported to bonded storage by government vehicle and authorized drivers. Upon completion of bond processing, the hardware is placed in storage until requested for training. JSC Transportation Inspection Upon receipt of the controlled hardware JSC Transportation inspects the shipping container for damage but does not open the container. Bonded storage is notified in order to arrange transportation of the hardware to that facility. Controlled Hardware

INTERNATIONAL SPACE STATION 15 Shipment to the Home Site This clears the hardware to be returned to the JSC bonded stores facility for return shipment to the home site. The original shipping documents must be presented to the JSC bond personnel in order for the hardware to be released for shipment. Bonded Storage Once controlled hardware is processed into bonded storage, it can only be moved between facilities by filling out a TPS and following the SRQA Requirements. JSC Training Facility When required for training the JSC Payload Representative will prepare a TPS and the hardware is transported to the JSC training facility via a government vehicle and authorized personnel QA Inspection Upon completion of training with controlled hardware, a functional checkout is performed under observation of JSC SRQA according to procedures (attached to the TPS) provided by the PD or PI. The QA will also inspect the hardware visibly for damage. If the hardware is functional and visibly free of physical degradation, SRQA will indicate this on the TPS form. Controlled Hardware Transfer Between Facilities Trainer Shipping Process

INTERNATIONAL SPACE STATION 16 JSC Payload Representative Contact the JSC Payload Representative (Sim Engineer or Logistics Coordinator), at least 2 weeks prior to shipment Shipping Company Selection PD will select a shipping company and ship the hardware at least 2 days before the need date. Documentation PD will FAX copies of all shipping documentation to the Payload Representative. Hand-Carried Hardware Hardware may also be hand-carried to JSC building 5S or 9 by the PD, PI, or an authorized representative. NASA Tagged and Shipped If the articles are NASA tagged and shipped by a NASA contractor, a DD Form 1149 must accompany the hardware Damaged Verification For hardware shipped to JSC that is not owned by NASA, JSC Transportation, will not perform a receiving inspection other than verification that the container arrived undamaged. Damage Inspection For NASA tagged hardware, JSC Transportation, will inspect the items per NASA/JSC receiving inspection policies Transportation Delivery JSC Transportation will deliver the hardware to building 5S or 9 within 1 day of arrival. The JSC Payload Representative may also pick up the hardware. Hardware Received The hardware is received into the building by the JSC Payload Representative and the building hardware manager and placed into inventory and secured storage. Shipment and Handling of Non-Controlled Hardware Trainer Shipping Process

INTERNATIONAL SPACE STATION 17 Hardware Responsibility The PD is responsible for the return shipment of his hardware. Training Completion JSC Payload Representative will contact the PD when training is complete and no longer required. Hardware Transportation The selected carrier will pick up the hardware at the Transportation dock. Shipping Company Selection PD will select a shipping company and provide the JSC Payload Representative the information required to ship the hardware. Shipping Documentation The JSC Payload Representative will fill out the appropriate shipping forms and either deliver the hardware to JSC Transportation or call them and arrange pickup Transportation to Pick Up The JSC Payload Representative will fill out a JSC Form 290 have it signed by either the OZ or DT Division Chief and arrange for transportation to pick up the hardware. NASA Tagged Hardware If the hardware is NASA tagged it is possible that NASA would be responsible for return shipping the item Hardware Identification JSC Transportation, will inspect the items per NASA/JSC receiving inspection policies. The JSC Payload Representative must be available to identify items for JSC Transportation Personnel. Return of Non-Controlled Hardware Trainer Shipping Process

INTERNATIONAL SPACE STATION 18 Hardware Responsibility The PD is responsible for the return shipment of his hardware. Training Completion JSC Payload Representative will contact the PD when training is complete and no longer required. Hardware Transportation The selected carrier will pick up the hardware at the Transportation dock. Shipping Company Selection PD will select a shipping company and provide the JSC Payload Representative the information required to ship the hardware. Shipping Documentation The JSC Payload Representative will fill out the appropriate shipping forms and either deliver the hardware to JSC Transportation or call them and arrange pickup Return of Non-Controlled Overseas Hardware Trainer Shipping Process Oversea shipments Oversea shipments through JSC require export control approval and item inspection which will be arranged by the JSC Payload Representative.

INTERNATIONAL SPACE STATION 19 Process Owner Product/ Outputs CustomerSchedule Template Process Documentation EO20/PTCIntegrated Systems Test MSFC Cadre, JSC Cadre, and International Partners On goingDRLI-25, DRLI- 70, SST-800 DRAFT, DRLI- 70, PTC Console Handbook Back Up Integrated Systems Test Process

INTERNATIONAL SPACE STATION 20 Integrated Systems Test –Loads are delivered for each flight –Instructors from each discipline test load capabilities under the direction of the Station Training Lead –Integrated System Test process is lengthy and time consuming –Station Payload Instructor is most involved during the initial testing phase but also provides input as necessary during the other phases –ISTs are necessary for MSFC and JSC to conduct simulations Verify new training capabilities Fixes for old capabilities –Once load has been delivered, it can be used for Simulations –Some classes use SSTF loads to train ISS Crew (e.g. MELFI) Back Up Integrated Systems Test Process

INTERNATIONAL SPACE STATION 21 Back Up Integrated Systems Test Process Integrated Systems Test (continued) –Before a load can be used for training, it must first be tested to verify its stability and capability

INTERNATIONAL SPACE STATION 22 Sub-System Assessment Test (SSAT) Phase 2 –Conducted by Load Developer (USA) –USA determines what additional capabilities are to be included in load for each sub-system & what is needed to implement them MSFC Generic Sims Integrated System Test (IST) Prep –Conducted by DT & Load Developer –DT new content checklist –USA regression test checklist –Initialization Datastores definition Back Up Integrated Systems Test Process

INTERNATIONAL SPACE STATION 23 –Conducted by DT & Load Developer –Load Content –Schedule for missing content –Trouble Reports (TR) / Load limitations & Workarounds –TR Promise Dates (recovery plans) –Initialization Datastores IST Kick-Off IST 4 Weeks –Instructor Team thoroughly tests load for old and new content –Regression Testing – verifying capabilities from previous loads still work correctly –New Capability Testing – verify new content functions properly –Malfunction Testing – verify malfunctions fail correct systems Back Up Integrated Systems Test Process

INTERNATIONAL SPACE STATION 24 –Identify items that do not function correctly and submit TR –TRs are ranked into categories 1, 2, and 3 with 1 being the highest priority –TR fixes are incorporated and new Integration (Int) loads delivered for testing –Training team will receive several different integration loads for testing during this process –During this time loads can be extremely unstable with load crashes occurring often –Once load has achieved stability, integrated test sessions with MSFC / HOSC can be scheduled IST 4 Weeks (continued) Back Up Integrated Systems Test Process

INTERNATIONAL SPACE STATION 25 –Verify HOSC can be added as an asset to session –Verify correct S-band and Ku-band telemetry received at HOSC Frequently encounter telemetry format mismatches between SSTF and HOSC –Verify Generic Payload Models (GPM) add into session IP address problems between GPM and Host occur –Verify commanding to Payload racks using Flight Software (FSW) Problem with FSW having MELFI in the wrong place (P4 vs O4)! –Ensure PL MDM is delivered with the correct PEP version E.g. POIC Cadre need to be trained on PEP R5 vs PEP R4 prior to uplink on-orbit –POIC File Uplink troubleshooting Some Payload Specific IST Items Back Up Integrated Systems Test Process

INTERNATIONAL SPACE STATION 26 –conducted by DT & Load Developer –Regression Test results –Known limitations –Known Category 1 & 2 TRs –Deviations –DT Test Cases Full Evaluation Load Review (FELR) Delivery Load Validation Review (DLVR) –DT’s Test Results –Cat 1 & 2 TRs identified prior to this –Closure plans for TRs: Cat 1 & 2, with Cat 3 if time permits Back Up Integrated Systems Test Process

INTERNATIONAL SPACE STATION 27 –Verify load is ready to be used to conduct training –TR Corrections –Known limitations –Waivers Training Readiness Review (TRR) Ready For Training (RFT) –Declare the load Ready for Training –Load used for MSFC and JSC simulation –Load used for Crew Training Back up Integrated Systems Test Process