ANNEXURE-II-Reliability and Quality Assurance Requirements ... · ANNEXURE-II-Reliability and Quality Assurance Requirements CRYSTAL BAND PASS FILTERS CPUR 2018005747

ANNEXURE-II-Reliability and Quality Assurance Requirements

CRYSTAL BAND PASS FILTERS

CPUR 2018005747

Annexure-II_4_(R&QA)-Hi Rel Crystal BPF-CPUR 2018 00 5747.docx Page 2 of 19

1 CONTENTS

RELIABILITY AND QUALITY ASSURANCE (R & QA) ....................................................................... 4

1 RELIABILITY ..................................................................................................................................... 4

1.1 LIFE ............................................................................................................................................. 4

1.2 RELIABILITY ANALYSIS ........................................................................................................ 4

2 ENVIRONMENTAL CONDITIONS .................................................................................................. 4

2.1 NON-OPERATING ENVIRONMENT ....................................................................................... 4

2.2 OPERATING ENVIRONMENT ................................................................................................. 4

2.3 VIBRATION ................................................................................................................................ 5

2.4 EMI / EMC SHIELDING ............................................................................................................. 5

3 PARTS AND MATERIALS ................................................................................................................ 5

3.1 PARTS ......................................................................................................................................... 5

3.1.1 DESIGN VERIFICATION MODEL PARTS ...................................................................... 5

3.1.2 FLIGHT MODEL PARTS ................................................................................................... 5

3.2 MATERIALS ............................................................................................................................... 6

4 PROCESSES ........................................................................................................................................ 6

5 MARKING AND IDENTIFICATION ................................................................................................ 7

6 TRANSPORTATION .......................................................................................................................... 8

7 SPACE HERITAGE AND DESIGN QUALIFICATION REQUIREMENTS.................................... 8

8 TEST PROGRAMME .......................................................................................................................... 9

8.1 PHASE-1: DESIGN VERIFICATION PROGRAMME .............................................................. 9

8.2 PHASE-2: SCREENING AND LOT ACCEPTANCE TEST (LAT) PROGRAMME ............... 9

8.3 LOT FORMATION ..................................................................................................................... 9

8.4 FINAL PRODUCTION TEST ..................................................................................................... 9

8.5 SCREENING TEST ..................................................................................................................... 9

8.6 LOT ACCEPTANCE TEST (LAT) ........................................................................................... 10

8.7 FAILURE CRITERIA ................................................................................................................ 10

9 TEST PLAN ....................................................................................................................................... 12

9.1 PHASE-1: DESIGN VERIFICATION MODEL ...................................................................... 12

9.2 PHASE-2: FLIGHT MODEL ................................................................................................... 12

9.3 PARAMETERS TO BE MEASURED AFTER ENVIRONMENTAL TESTS ........................ 12

9.4 TOLERANCES .......................................................................................................................... 12

9.4.1 TOLERANCE OVER OPERATING TEMPERATURE RANGE .................................... 12

9.4.2 TOLERANCE ON TEST CONDITIONS .......................................................................... 13

TABLE – 1: SCREENING AND LOT ACCEPTANCE TEST......................................................... 13

10 TESTS & TEST CONDITIONS .................................................................................................... 14

10.1 VISUAL INSPECTION ............................................................................................................. 14


10.2 PHYSICAL MEASUREMENT ................................................................................................. 14

10.3 INITIAL PERFORMANCE TEST ............................................................................................ 14

10.4 STABILISATION BAKE .......................................................................................................... 14

10.5 THERMAL SHOCK .................................................................................................................. 14

10.6 TEMPERATURE STORAGE ................................................................................................... 15

10.7 TEMPERATURE OPERATIONAL TEST ............................................................................... 15

10.8 VIBRATION .............................................................................................................................. 16

10.8.1 SINE VIBRATION ............................................................................................................ 16

10.8.2 RANDOM VIBRATION ................................................................................................... 16

10.9 LEAK TEST ............................................................................................................................... 16

10.9.1 FINE LEAK ....................................................................................................................... 16

10.9.2 GROSS LEAK ................................................................................................................... 16

10.10 THERMOVACUUM TEST ................................................................................................... 16

10.11 HUMIDITY TEST ................................................................................................................. 17

10.12 FINAL PERFORMANCE TEST ........................................................................................... 17

10.13 SOLDERABILITY ................................................................................................................ 17

10.14 TERMINAL STRENGTH...................................................................................................... 18

11 LIST OF DOCUMENTS TO ACCOMPANY THE QUOTE ........................................................ 18

11.1 LIST OF DOCUMENTS ALONG WITH THE TECHNICAL QUOTE .................................. 18

11.2 LIST OF DOCUMENTS REQUIRED AFTER AWARD OF CONTRACT ............................ 18

11.3 TEST DATA REPORTS ALONG WITH DELIVERABLES ................................................... 19

12 GENERAL ..................................................................................................................................... 19


RELIABILITY AND QUALITY ASSURANCE (R & QA)

Reliability and quality are important prerequisites of any space programme hardware. It is

therefore very essential for the vendor to understand and implement the R & QA requirements

judiciously. This section provides the details on R & QA requirements that shall be assured for

this programme.

1 RELIABILITY

1.1 LIFE

a) The unit shall meet all the design requirements for use onboard spacecraft with a minimum

life for 18 years.

b) The unit shall be capable of meeting all the functional requirements at various Spacecraft

assembly and storage as follows;

- 5 years in controlled environmental conditions. The vendor shall specify the exact

method of storage and retest criteria in case of longer storage.

- 3 years storage and life at various levels of spacecraft assembly.

1.2 RELIABILITY ANALYSIS

Manufacturer shall provide complete reliability analysis in terms of reliability estimation with

stress (derating) analysis, FMECA and worst-case drift and tolerance analysis. The Crystal filter

shall be designed and fabricated to achieve a failure rate of better than 0.08 x 10-06 per Hour at

the end of 15 years in orbit.

The reliability calculation shall be carried out as per MIL-HDBK-217F. The vendor should also

specify in analysis report, the methodology used in arriving the failure rate of Crystal Filters and

other components not mentioned in MIL-HDBK-217F. Vendor may propose any alternate

method for reliability analysis per standards for space parts.

2 ENVIRONMENTAL CONDITIONS

2.1 NON-OPERATING ENVIRONMENT

The units shall be capable of withstanding following environmental conditions.

a) TEMPERATURE RANGE : -50°C to +85°C

b) PRESSURE : Ambient to 10-10 torr

c) RELATIVE HUMIDITY : Up to 95% without condensation of

water at +40°C

2.2 OPERATING ENVIRONMENT

a) TEMPERATURE RANGE

Flight Model : -10°C to +60°C

Lot Acceptance Test : -15°C to +65°C


b) PRESSURE : Ambient, 10-10 torr

c) Relative Humidity : Up to 95% without condensation of water at 40°C

(Applicable for lab test only)

2.3 VIBRATION

The unit shall be designed and fabricated to meet the vibration (Sine and Random) requirements

as specified in this annexure.

2.4 EMI / EMC SHIELDING

The unit shall be designed for both magnetic and EMI shielding as per the requirements of MIL-

STD-461E.

3 PARTS AND MATERIALS

Parts and materials to be used in Units shall be selected from qualified parts and materials list

and through a qualified sub-vendor normally associated with long life satellite hardware.

Necessary certification showing compliance with this requirement shall be supplied along with

the units.

3.1 PARTS

3.1.1 DESIGN VERIFICATION MODEL PARTS

The quality of parts proposed to be used shall be as follows:

a) Passive Parts : ESCC level C3 or with failure level "M" or better

b) Crystals : ESCC level C3 or as per MIL-C-3098

3.1.2 FLIGHT MODEL PARTS

For flight model, the component quality level shall be as follows:

a) Passive Parts : ESCC level B3 or with failure rate level "S" or better

b) Crystals : The following order of preference shall be followed.

First preference: Qualified to ESCC level B3 or MIL-C-3098 with group B testing

Second preference: Non-qualified crystal from QPL/QML vendor. In this case

crystal shall be subjected to Screening, Group A, B and C testing for S Level, as per

the requirements of MIL-PRF-3098.

In the case of passive electronic parts quality levels being lower than the requirements of Para

3.1.2, Parts only from MIL/ESA QPL/QML manufacturer or ISRO qualified manufacturer shall

be used. Such parts shall have sufficient space flight history and DPA and Verification of

Quality (VOQ) shall be performed along with appropriate up-screening. Vendors, in such cases,

shall submit the proposed parts usage list to ISRO for review.


The electronic parts used should not be of date code older than TWO years, at the time of

FILTER manufacturing. In the case, that devices with recent codes are not available, a

rescreening plan for these devices is to be submitted for review by ISRO and only after

completion of such rescreening tests, these devices may be used. Parts older than 5 years shall

not be used.

3.2 MATERIALS

Ferrous and non-ferrous materials used shall be corrosion resistance type or suitably treated to

resist corrosion, oxidation, tarnishing caused by atmospheric conditions existent in storage or

normal operational conditions. Non-magnetic materials shall be used for all parts except where

magnetic materials are essential. A uniform plating thickness, preferably nickel, shall be applied

all over the crystal BPF body. Plating thickness shall be minimum 1mil.

It is to be noted that Brass and Cadmium plated components and surfaces shall not be used at

any stage of FILTER fabrication. If any such material is proposed by Vendor(s), they shall

submit the proposed material list to ISRO for review and approval.

Materials that are nutrient for fungus shall not be used. Organic and inorganic materials shall be

stable under atmospheric and high vacuum conditions. These materials shall have Total Mass

Loss (TML) less than 1% and Collected Volatile Condensable Material (CVCM) of less than

0.1% when subjected to 125°C and 10-6 torr pressure for 24 hours as per ASTM-E-595. Only

space-qualified epoxies, potting materials, etc. shall be used within their shelf life and cure

schedule specified by the manufacturer. However, their use shall be restricted and failures due to

these shall be recorded and analysed as and when they are detected.

The selection and use of dissimilar materials shall be avoided, where it is impractical to avoid

dissimilar materials in direct contact with each other, suitable protection shall be provided by

space proven coating-plating etc.

4 PROCESSES

The unit shall be built to the standards normally associated with long life satellite hardware. All

the fabrication processes including surface treatment (like plating, painting etc) should be the

qualified processes for space applications. Vendors shall submit their most recent process

qualification status along with the proposal. No, non-qualified process shall be used for crystal

filter fabrication. Particular attention shall be paid, as a minimum, in respect to the following:

Neat clean, smooth and fully wetted homogeneous solder joints

Eliminate bubble entrapment in coatings / epoxies where ever used

All components including torroidal / bead inductors / coils shall be suitably supported on

PCB by suitable potting compound

Wherever wires are attached to casing for grounding etc., a higher melting point solder than

that used for lid soldering, shall be used


The input / output connections on pins from the PCB etc. shall also be made with high

melting point solder to avoid detachment of these connections while soldering the pins to

external system using SN 63 solder

The marking and plating etc. shall be permanent and should not get damaged during normal

cleaning process using isopropyl Alcohol and other cleaning solvents approved for the

fabrication of electronic hardware. Further, a list of recommended solvents may be provided

to ISRO.

All tolerances not specified shall be consistent with the best engineering practices. Units shall be

uniform in quality and free from blemishes and defects.

5 MARKING AND IDENTIFICATION

The unit shall be identified by assigning unique serial number on the exterior surface by a

suitable process applicable for space use. Marking shall not degrade the performance of the unit.

In addition to functional marking like input/output, etc. following marking shall appear on each

unit:

a) Center Frequency

b) Part name : XTL Filter

c) Part Number

d) Specification Number/Contract Number

e) Serial Number

f) Name of the Manufacturer

g) Date Code (in YYWW format, where YY represents last two digits of

year and WW represents week number of manufacture of unit)

Suggested part no. : XTL aaa.aaaa MHz 02 SMT ccc.ccc kHz RFP

Where,

aaa.aaaa : CF of filter

bb : Type as defined in electrical spec.

ccc.ccc : 3 dB bandwidth in KHz

The permanency of the marking shall be sufficient to withstand the specified environmental

conditions and normal cleaning operations using isopropyl alcohol and other cleaning solvents.

The test method to demonstrate the same shall be specified by the vendor.

In case of space constraints for marking on units, the information may be put on primary

box/data documentation with cross references to build records.


6 TRANSPORTATION

Each unit shall be packaged in individual ESD protective package. This package shall protect the

unit from environmental conditions during transportation like heat, humidity dust. Each

individual container shall have a moisture absorbing material inside. This individual container

shall then be placed in a transportation container more than one individual unit packages may be

placed in transportation container. Transportation container shall protect the units from heat,

humidity, dust, mechanical shock & vibrations during transportation. The transportation

container shall conform to the applicable carrier rules and regulations and may be the

contractor's commercial practice. The shipping package shall contain all the necessary technical

documents as specified and the necessary commercial documents.

In addition to other mandatory shipping markings, the following additional marking shall appear

on the shipping packages in bold letters:

"HANDLE WITH CARE / HIGH-RELIABILITY COMPONENTS"

"To be opened under clean environment with ESD protection only"

"Store in a cool and dry place"

7 SPACE HERITAGE AND DESIGN QUALIFICATION

REQUIREMENTS

Vendor shall provide details of one (or more, if any) FILTER which is most similar to the

proposed design and is qualified for space use. Vendors should supply qualification report

summary which should necessarily include (apart from other details):

1. Electrical specifications including Centre frequency, BW & Rejection

2. Operating & non-operating temperature range

3. Vibration and shock test conditions etc.

4. Life Test details including test duration and temperature conditions

5. Product specific space flight history of the offered design

6. Name of program

It is to be noted that information required as in points (1) to (6) above is MANDATORY.

Vendor to clearly state all the details so that similarity of the proposed design with that of

qualified design could be assessed.

After review of the space flight heritage and the qualification report, ISRO shall decide

suitability of the proposed part for required application as well as requirement of the DVM

phase. Design verification phase may be required if proposed design has no space flight

heritage. Designs not qualified for space shall not be considered.

Quotes from vendors with no space heritage and/or no design qualified to space requirements

will not be considered.


8 TEST PROGRAMME

The total program has been divided in two phases:

a) DESIGN VERIFICATION PROGRAMME

b) SCREENING AND LOT ACCEPTANCE TEST (LAT) PROGRAMME

8.1 PHASE-1: DESIGN VERIFICATION PROGRAMME

DVM units and shall undergo the testing as specified in this annexure. These units should meet

all electrical and mechanical specifications and should be identical to the flight hardware in all

respect except for the quality of the parts used (refer Para 3.1: Parts). Go ahead, for Phase-2 shall

be given only after successful completion of Phase-1 (DVM programme), if applicable.

8.2 PHASE-2: SCREENING AND LOT ACCEPTANCE TEST (LAT)

PROGRAMME

All the units shall undergo Screening and Lot Acceptance Test Programme as given in flow

chart (Figure-1.0) before they are acceptable to ISRO.

8.3 LOT FORMATION

The term Lot is defined to be consisting of each type of units manufactured from the same batch

of raw materials at the same time on the same production and assembly line, having all the

provisions for quality assurance. The unit shall satisfy all design, performance and

environmental requirements of the specifications.

8.4 FINAL PRODUCTION TEST

The Final Production Tests are part of tests carried out by the vendor before the units are finally

ready for screening tests. This shall include following as a minimum:

Pre cap visual inspection and Physical dimension measurements

Crystal Aging

The vendor shall specify and provide the details of Final Production Tests and assembly

sequence along with the response to this RFP.

8.5 SCREENING TEST

All the units in the lot formed shall undergo 100% Screening Test as per Table-1. Units not

meeting the specified limits shall be removed from the lot. Maximum of 5% failures are allowed

during screening.


8.6 LOT ACCEPTANCE TEST (LAT)

On successful completion of Screening Test as per Table 1, Lot Acceptance Test (LAT) shall be

carried out on 5% samples of the lot or minimum one unit randomly selected from screened lot,

as per Table-1. Depending on the center frequency specification, selection of filter types to be

subjected to LAT shall be decided. During Lot Acceptance Test, no failure shall be allowed.

8.7 FAILURE CRITERIA

The units fall-out during Screening Test shall be prepared and submitted to ISRO. This shall

state the number of times that each test parameter failed and quantity of units failed one or more

test parameter. This shall identify all catastrophic failures and failure modes observed.

For number of failures more than 5% of lot during screening, or any failure during LAT, the

entire lot will be rejected. However, vendor may carry out the failure analysis thoroughly and

submit the failure analysis report to ISRO. After review of the failure analysis report, ISRO may

consider accepting the lot with re-work and retest.


FIGURE-1.0: FLOW CHART FOR SCREENING / LAT PROGRAMME

No

No Yes

Yes

No

LOT ACCEPTANCE TEST AS PER TABLE-

1 ON 5 % (TBD) OF RANDOMLY

SELECTED SAMPLE

Failures observed?

SCREENING TESTS AS PER

TABLE-1

No. of failures

< 5% of lot?

DELIVERABLES

FABRICATION OF FM

UNITS

IN

A SINGLE LOT

DVM (if applicable)

Accepted by ISRO?

FABRICATION OF DVM

UNIT

Yes

Yes


9 TEST PLAN

9.1 PHASE-1: DESIGN VERIFICATION MODEL

Following tests, with details as per Para 10 in this annexure, shall be conducted on Design

Verification Model:

1) External Visual Inspection

2) Physical Measurement

3) Initial Performance

4) Temperature Operational test

5) Final Performance test

Vendor shall supply test fixture for the electrical testing of the filters along with the deliverables

(DVM).

9.2 PHASE-2: FLIGHT MODEL

The manufacturer shall submit the test plan for the functional and environmental tests to be

conducted on the units during the screening and Lot Acceptance Test programme. The test plan

shall include but not limited to the tests and specification in the sequence as indicated in Table1.

The test plan shall also include the procedure for conducting each test, the test equipment used

and their calibration, total uncertainty for each test set-up and parameter tolerance / limits for the

unit under test. Suitable buffer connections shall be provided during testing.

Vendor shall supply test fixture for the electrical testing of the filters along with the FM

deliverables, if Phase-1 (DVM) is not applicable.

9.3 PARAMETERS TO BE MEASURED AFTER ENVIRONMENTAL

TESTS

All electrical parameters as per electrical specifications.

9.4 TOLERANCES

9.4.1 TOLERANCE OVER OPERATING TEMPERATURE RANGE

Tolerance over operating temperature range shall be as defined in Electrical

Specifications for:

1) Insertion loss 2) Bandwidth 3) Rejection / Attenuation

Note: The above are related to the initial value at ambient. Absolute values shall comply with

the specifications.


9.4.2 TOLERANCE ON TEST CONDITIONS

Maximum allowed tolerances on test conditions are as given below:

Temperature : ± 3°C

Atmospheric Pressure

Greater than 0.1 torr : ± 5%

Less than 0.1 torr : ± 50%

Relative Humidity : + 0%, -5%

Acceleration : ± 10%

Vibration Frequency : ± 2% above 25 Hz, 0.5 Hz below 25 Hz

Sinusoidal Amplitude : ± 10%

Random (g-rms) : ± 10%

PSD 20-300 Hz : ± 1.5 dB

300-2000 Hz : ± 3.0 dB

TABLE – 1: DVM, SCREENING AND LOT ACCEPTANCE TEST

Sr. No. TEST DVM

SCREENING LOT

ACCEPTANCE

1. VISUAL INSPECTION √ √ √

2. PHYSICAL

MEASUREMENTS

√ √ √

3. INITIAL PERFORMANCE

TEST

√ √ √

4. STABILISATION BAKE - √ -

5. THERMAL SHOCK - √ √

6. TEMPERATURE STORAGE - √ √

7. TEMPERATURE

OPERATIONAL

√ √ √

8.

VIBRATION

- Sine

- Random

-

-

√

√

√

9. LEAK TEST - √ √

10. THERMAL VACUUM - - √

11. HUMIDITY - - √

12. FINAL PERFORMANCE TEST √ √ √

13. SOLDERABILITY - - √

14. TERMINAL STRENGTH - - √


Note-1: "√" Mark against the test denotes applicability of test. Test details and conditions are

described in Para 10

Note-2: At the end of each environmental test, Electrical Performance checks as per Para 9 and

visual inspection as per Para 10 shall be carried out.

Note-3: The stage, at which solderability and terminal strength test will be performed, shall be

specified by the manufacturer. These tests could be performed either on electrically rejected or

empty packages from the same lot. The manufacturer shall demonstrate that solderability of the

leads does not degrade after completion of Screening and LAT testing.

10 TESTS & TEST CONDITIONS

10.1 VISUAL INSPECTION

Filters shall be visually inspected at 10X magnification minimum. Defects related to

Metallization, surface, finish, discolouration / oxidation, mechanical and workmanship are not

allowed. The defects accept / reject criteria shall be same as those followed for all Hi-Rel

programs. External visual inspection guide lines and accept / reject criteria per

ESA/MIL/NASA-GSFC shall be followed. It is suggested to follow visual inspection

requirements of MIL-STD-883, method 2009. However, the manufacturer shall specify further

details.

10.2 PHYSICAL MEASUREMENT

The mechanical dimension measurements shall be performed as per the agreed fabrication

drawings. Test details to be specified by the manufacturer.

10.3 INITIAL PERFORMANCE TEST

Performance shall be measured for all defined specifications, as per SAC approved test

procedure.

10.4 STABILISATION BAKE

The units shall be stored at maximum non-operating temperature for 48 hours.

10.5 THERMAL SHOCK

Thermal shock test shall be performed as per MIL-STD-202, Method 107, Condition 'A', with

temperature ranges as defined in ENVIRONMENTAL SPECIFICATIONS. The number of

cycles shall be as given below,

Screening : 10 cycles

Lot Acceptance Test : 25 cycles


At the end of the above sequence a visual inspection shall be conducted to observe any possible

physical degradation of finish/materials or evidence of process deterioration in quality after the

exposure to the high and low temperature conditions.

10.6 TEMPERATURE STORAGE

High and Low temperature storage test shall be performed as per the sequence given below:

Step-1: Stabilize at ambient and perform Functional Test.

Step-2: Store all units at lowest non-operating temperature for 6 hours.

Step-3: At end of 6 hours, stabilize the units at ambient for 1-hour minimum and not more than

24 hours maximum and perform Functional Test as per specifications

Step-4: Store all units at highest non-operating temperature for 6 hours.

Step-5: At end of 6 hours. stabilize the units at Ambient for 1 hour minimum and not more than

24 hours maximum and perform Functional Test as per specifications.

10.7 TEMPERATURE OPERATIONAL TEST

The temperature operational tests shall be performed both during the Screening and LAT testing

for verifying the electrical performances at the specified High and Low operating temperature

limits.

The units shall be placed in a suitable thermal chamber, and connected to the external test set-up

through suitable interconnection. The test shall be conducted according to the following

sequence and conditions:

Step-1: Maintain the chamber temperature at 25 deg C for 1 hour; perform a functional

verification according to the applicable Screening /LAT Test Procedure.

Step-2: Decrease the chamber temperature down to the specified minimum operating limit and

maintain this condition for 1 hour after stabilization

Step-3: While in the above conditions perform a functional verification according to the

applicable Screening /LAT Test Procedure

Step-4: At the end, increase the chamber temperature up to the specified maximum operating

limit and maintain this condition for 1 hour after stabilization

Step-5: While in the above conditions perform a functional verification according to the

applicable Screening /LAT Test Procedure

Step-6: At the end, decrease the chamber temperature to ambient conditions and after 1 hour for

stabilization, perform a functional verification in accordance with the applicable

Screening /LAT Test Procedure.

All the inspection and tests results shall be recorded on the Test Data Record sheets and reported

in the Final Test Report.


10.8 VIBRATION

10.8.1 SINE VIBRATION

Sine vibration is applicable to LAT only. Sine vibration test shall be carried out as per MIL-

STD-202, Method 204, condition 'E', except the test level and sweep rate shall be as follows.

10 to 2000 Hz : 30 g peak

Sweep Rate : 2 Octave/Min.

No. of sweeps : FOUR (4), per axis (X, Y, Z)

10.8.2 RANDOM VIBRATION

Random vibration test shall be carried out as per MIL-STD-202, Method 214, following

conditions shall apply in all three axis:

Frequency (Hz) Units for Screening Units for LAT

Test level Test level

20-50 + 6 dB/Octave + 6 dB/Octave

50-1200 0.20 g2/Hz 0.45 g2/Hz

1200-2000 - 6 dB/Octave - 6 dB/Octave

Overall Level 18.2 g rms 27.2 g rms

Duration 1 minute/axis 4 minute/axis

10.9 LEAK TEST

The Leak test shall be carried out on all hermetically sealed units only.

10.9.1 FINE LEAK

The test shall be carried out as per MIL-STD-202, METHOD 112, condition C The maximum

leak rate shall not exceed 5 X 10-7 atm cc/sec.

10.9.2 GROSS LEAK

The gross leak test shall be carried out as per MIL-STD-202, METHOD 112, condition B or D.

10.10 THERMOVACUUM TEST

Thermal vacuum test is applicable to all units subjected to LAT testing and shall be conducted

under vacuum condition of 10-06 torr or better. The temperature limits shall be as specified in

Para 2. Thermo-vacuum test profile shall include FIVE cycles as per Fig.2. First cycle shall be

performed at non-operating temperature limits and no RF signal shall be applied during this

cycle. Remaining four cycles shall be performed at the operating temperature limits and the unit


shall continuously be ON (with nominal Power) during FOUR (4) cycles. The dwell time at

each temperature extreme shall be TWO (2) Hours minimum. The performance measurements,

with points marked as ‘cross-marks’ in Fig 2, shall be carried out during High and Low

temperature soak (dwell time). The duration of the soak may be extended for completion of

performance measurement tests.

FIG 2: THERMO VACUUM TEST PROFILE

10.11 HUMIDITY TEST

The test shall be carried out as per MIL-STD-202, Method 103, Condition 'A' for non-

hermetically sealed units. For hermetically sealed unit, the moisture resistance test as per MIL-

STD-202, Method 106 shall be carried out.

10.12 FINAL PERFORMANCE TEST

Performance shall be measured for all defined specifications, as per SAC approved test

procedure. Also, this shall confirm no degradations are observed after environmental tests.

10.13 SOLDERABILITY

Solderability test shall be carried out as per MIL-STD-202, method 208.

25

-50

85

-15

65

-15

65

-15

65

-15

65

-15

25

-60

-50

-40

-30

-20

-10

0

10

20

30

40

50

60

70

80

90

FIG 2: THERMOVACUUM TEST PROFILE

TEMP (DEG C) MEASUREMENT POINT

2 Hrs


10.14 TERMINAL STRENGTH

Terminal strength test shall be carried as per MIL-STD-202, Method 211. The manufacturer

shall specify the test conditions. This test may be carried out on electrically reject unit/identical

dummy unit.

11 LIST OF DOCUMENTS TO ACCOMPANY THE QUOTE

11.1 LIST OF DOCUMENTS ALONG WITH THE TECHNICAL QUOTE

The following documents shall accompany the quotes. These are necessary in order to evaluate

the offer. Without these details, the quote from the vendor is liable to be rejected.

1) Point by Point Compliance to Electrical & mechanical specifications and each section of

R & QA Requirements with specific details and offered specifications

2) Space History/Space Program to which similar design items have been supplied.

3) Qualification report summary for similar design units listing device specifications, Test

plan, test conditions and results.

4) Detailed technical data sheet indicating electrical, mechanical (including Specification

control drawing (SCD)/Interface control drawing), package outline details with

dimensions, environmental specifications and ordering information.

5) Quotes from manufacturer having space heritage of product with similar design will only

be considered.

6) All the technical information to be supplied additionally as soft copy on CD/DVD (along

with the hard copies). It is to be noted that cost information should not be included in

this soft copy.

7) List of all parts and materials proposed to be used for this programme. Quality levels,

Qualification status of the parts and outgassing details of the materials proposed to be

used for flight model units.

8) Typical Failure rate value

9) Screening/Qualification Plans (if other than proposed R & QA requirement in this

document)

10) Quality Control Plan

11) Non-conformance Control Plan

12) Configuration change control Plan

11.2 LIST OF DOCUMENTS REQUIRED AFTER AWARD OF

CONTRACT

Apart from the documents required along with technical offer, vendor shall supply the reports as

mentioned below, but not limited to, at appropriate stages after the award of contract. This list is

tentative and will be finalised during purchase order placement. These have to be full reports

(not the summary reports):


1) List of parts, materials, their quality levels, derating criteria followed, traceability data,

purchase history etc.

2) Documents containing test procedures, test and calibration facilities, environmental

facilities and relevant operation details

3) Reliability Analysis Report

4) Non-conformance (parts and materials) test reports

5) [FOR FAILURES REPORTED, IF ANY] Failure reports (for catastrophic failures),

mechanical or handling failures, malfunctioning or operative deviations from the

specifications along with corrective actions

6) Thermal design analysis report

7) Mechanical design analysis report

11.3 TEST DATA REPORTS ALONG WITH DELIVERABLES

1) Certificate of compliance (CoC)

2) Test data reports of Screening & LAT, as soft copies

12 GENERAL

1) The deliverables shall consist of:

(i) Certificate of Conformance

(ii) DVM Units (if applicable)

(iii) FM units

(iv) LAT units

(v) Test data package of FM and LAT units

(vi) Two sets of Test fixture for electrical testing of filters (at DVM /FM stage, as

applicable)

2) The cost of each test is to be indicated separately in the proposal. Based on the quality,

previous qualification and space flight history details from the supplier in the proposal,

SAC may remove any test or group of tests in the final order. Vendor shall quote for test

fixtures as a separate item.

3) All the data/drawings should be provided on a Microsoft Windows compatible CD/DVD

along with a hardcopy. The drawings / ICD, preferably, should be in AUTOCAD and

test data in Microsoft Office.