January 17, 20131

ACME Quarterly StatusJanuary 2013

Mark Hickman, Project Manager

Dennis Stocker, Project Scientist ACME

Paul Ferkul, Project Scientist BRE

Brian Borowski, Project Contractor Lead

January 17, 2013

Advanced Combustion via Microgravity Experiments (ACME)GRC Project Manager: MSI/J. Mark HickmanProject Chief Engineer: DT0/Alan LinneSafety Mission Assurance Lead: QE0/Scott DarpelDPMI: Jana Van Horn/QB0; Scheduler: Paul McMasters/QinetiQContractor Lead: Brian Borowski, ZIN Technologies, Inc.NASA Customer: HEOMD/SLPSRA

Project Mission Statement:• Investigate gaseous fuel combustion by studying:

– combustion structure and stability near flammability limits – soot inception, surface growth, and oxidation processes– emission reduction through nitrogen exchange– combustion stability enhancements via an electric field– ignition and flammability of solid spacecraft materials in

realistic atmospheric conditions using a gas analog

GRC Scope:• Requirements, Design, Development, Test, Evaluation, and Operations for Project

Project Life Cycle ScheduleMilestones SCR RDR PDR IDR BRE

RDRCDR Safety

(Phase-3)SAR FHA Launch Ops End Ops Final

Report

Actual/ Baseline 2/2008 5/2010

01/2011

6/2012 6/2013 11/2013 12/2015 8/2015 8/2015 12/2015 1/2016 11/2017 11/2018

The Combustion Integrated Rack. ACME Chamber Insert Assembly Concept.

2

Structure and Response of Spherical Diffusion Flames (s-Flame), PI: Prof. C. K. Law, Princeton U.; Co-Is: Prof. Stephen Tse, Rutgers U.; Dr. Kurt Sacksteder, NASA GRC

Flame Design, PI: Prof. Richard Axelbaum, Washington U., St. Louis; Co-Is: Prof. Beei-Huan Chao, U. Hawaii; Prof. Peter Sunderland, U. Maryland; Dr. David Urban, NASA GRC

Coflow Laminar Diffusion Flame (CLD Flame), PI: Prof. Marshall Long, Yale U.; Co-I: Prof. Mitchell Smooke, Yale U.

Electric-Field Effects on Laminar Diffusion Flames (E-FIELD Flames), PI: Prof. Derek Dunn-Rankin, UC Irvine; Co-Is: Prof. Felix Weinberg, Imperial College, London; Dr. Zeng-Guang Yuan, NCSER/GRC

Burning Rate Emulator (BRE), PI: Prof. James Quintiere, University of Maryland; Co-Is: Peter Sunderland, U. of Maryland

Project Scientists: Dennis Stocker, NASA GRC; Dr. Fumiaki Takahashi, NCSER/GRC; Paul Ferkul, NCSER/GRC

s-Flame(drop test)

E-FIELD Flames

(1g schlieren)

Flame Design

(drop test)

CLD Flame(aircraft test)

BRE(1g test)

January 17, 20133

ACME Engineering Schedule

January 17, 2013

ACME Schedule

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January 17, 2013

ACME Status

Project Manager: Mark Hickman Status

Variances• ZIN costing is low per Phasing Plan; early impact of low staffing ripples through schedule; purchasing lead time longer

due to new ZIN processes; efforts underway to bring schedule to left.

Cost Schedule Technical Mgmt.

Jan 2013 Y G G GOct 2012 Y G G G

WBS 401769.07.01.01.01

Key Issue/Concern Potential Impact Action Plan Resolution Date

Data transfer rates from IPSU to IOP too slow for data files

May reduce obtainable science or extend on-orbit time to years

Request FCF Sustaining Engineering to investigate methods of improving data transfer rates

Request made to FCF Mgr. for inclusion in DO-101 Sustaining Engineering SOW; full resolution likely in FY11. Ops changes by FCF have improved average transfer rates from 0.9 MB/s to 1.15 MB/s, a 20% improvement. Improvement to 1.80 MB/sec not realized as IOP-HP upgrade implementation results in rack lock-up. Sustaining Engineering looking into possibility of replacing IPSUs.

Getting BRE up to speed quickly enough that the design is not negatively impacted

May have to do some redesign to ACME

Working with BRE PS to get requirements in as early as possible.

RDR/PDR (Go/No Go Gate), March 2013

5

January 17, 2013

ACME Key Project Metrics WBS 401769.07.01.01.01

6

Accomplishments• Avionics Package (AVP)

• 89 drawings completed as of January and under configuration management• Awaiting boards and harness to continue AVP build

• Chamber Insert Assembly (CIA)• 191 drawings completed and under configuration management beginning from January 2012 • The CIA diagnostic subsystem designs and drawings are completed; this includes the

radiometer package and PMT package• Work is now underway on the Thin Filament Pyrometry (TFP) assembly along with the gas flow

system• Switching and Input manifolds, and concept burner interface are complete• Analog Camera Assembly design is complete, drawings are nearly complete

• Incorporating design changes required by structural analysis• Updating the mounting method of the LEDs so they aren’t attached to the mirror • Rotating the assembly a few degrees to completely remove the mirror from the HiBMS-1

field of view

• Color Camera Package (CCP)• 58 Camera Enclosure drawings approved and under configuration management• Camera electronics enclosure drawings in progress

January 17, 2013

ACME FY12 Milestone Summary

Next Milestone Risk• Next major milestone is BRE RDR/PDR in June. If BRE integration is delayed, there is a possibility that the

instrument may not be completed and flown.

Milestones (FY12) Baseline Projected Actual Comments/Schedule Variance

Phase 0/1 Safety Review Nov 2011 Feb 2012

Ignition subsystem build complete Dec 2011 Jan 2012

Stereo-Lith of 3 main subsystem packages (CIA, Camera, Avionics)

Jan 2012 Feb 2012 Vendor quote process taking longer than expected for all purchases

Complete Assembly of E-Field subsystem Feb 2012 May 2012 Delayed due to late epoxy arrival and some fixtures to complete mesh assembly. Completed 5/21/12.

BRE Interface Requirements Document Feb 2012 Jan 2012 Draft document completed

Procurement of EM Mass Flow Controllers Mar 2012 Mar 2012

Preliminary EMI testing of E-Field subsystem

Apr 2012 Jun 2012 EMI Test completed

Ignition subsystem test complete Apr 2012 April 2012

Card Cage Assembly Drawings complete May 2012 May 2012

Interim Design Review Jun 2012 Jun 2012

Avionics package structure design complete

Aug 2012 Aug 2012

BRE SCR Aug 2012 Aug 2012 Scheduled for Aug 28-29, 2012

Flow subsystem build complete Sep 2012 Aug 2013 Tasks reshuffled; this task to be complete Aug 2013

Project is less than 1 month behind plan Project is less than 2 months behind plan Project is greater than 2 months behind plan

Schedule Color Key

WBS 904211.04.02.30.14

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January 17, 2013

ACME FY13 Milestone Summary

Next Milestone Risk• Next major milestone is BRE RDR/PDR in June. If BRE integration is delayed, there is a possibility that the

instrument may not be completed and flown.

Milestones (FY12) Baseline Projected Actual Comments/Schedule Variance

Complete EM Camera Top Bracket Assembly

Oct 2012 Oct 2012

Phase 0/1 Safety TIM to sign ACME Hazard Reports

Nov 2012 Oct 2012 Completed on October 30. All open issues from Phase 0/1 FSR were addressed and closed at the TIM and the Hazard Reports are being delivered for signature.

Complete EM Cube Assembly Dec 2012 Dec 2012

Complete EM Mass Flow Controller Assemblies

Jan 2013 Jan 2013 In-work. Completion anticipated by end of month.

Complete EM Radiometer Assembly Feb 2013 Feb 2013

Complete EM Zoom Lens Assembly Mar 2013 Mar 2013

Complete EM Avionics Package Assembly Apr 2013 Apr 2013

Complete EM Camera Enclosure Ass’y May 2013 May 2013

BRE RDR/PDR Jun 2013 Jun 2013

Complete EM TPF Assembly Jul 2013 Jul 2013

Complete EM Flow System Assembly Aug 2013 Aug 2013

Complete EM Far Field Temperature Ass’y Sep 2013 Sep 2013

Project is less than 1 month behind plan Project is less than 2 months behind plan Project is greater than 2 months behind plan

Schedule Color Key

WBS 401769.07.01.01.01

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January 17, 2013

Project Manager’s Top Challenges

1. Integration of BRE into ACME (BRE SCR indicates that integration is highly feasible)

2. Insufficient on-orbit transfer rates to quickly telemeter data to ground (performed telemetry analysis to determine data volume and rates—rates still determined to be insufficient; IPSU replacement now DO-101 task)

3. Large number of Test Points to accomplish over mission life—approximately 250 primary test points for 5 experiments; however, PI’s would like more than 50 test points each

4. ZIN Vendor/subcontractor delivery process slower than expected; ZIN to address through their company

WBS 401769.07.01.01.01

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Prosilica Camera, Color Camera Package

(outside Chamber)

Hitachi Analog Camera, Operations Imaging

(inside Chamber)ACME E-Field Grid System

January 17, 2013

ACME Risk Assessment (Top 5 Risks)

Criticality L x C Trend

High Increasing (Worsening)

Decreasing (Improving)

Unchanged

(★) New since last month

Med

Low

Approaches: Mitigate, Watch, Accept, Research

Last update 09/18/12Next update 10/16/12

WBS 401769.07.01.01.01

Risk ID Risk Title Risk Statement L C Approach

ACME021

Mroczka04/2012

Inability to disassemble Mass Flow Controllers for Conformal Coat / Ruggedizing

Given that the Mass Flow Controllers cannot be fully taken apart to perform conformal coating and staking on the electronic boards; then there may be an incompatibility with elements of the chamber atmosphere including fuels, oxygen and diluent mixtures causing CIA electronics to fail.

4 4 Mitigate: This risk will be re-assessed after reviewing the results of the analysis scheduled to take place by September 2012. [ZIN M&P assessing.]Close: Oct 2012

ACME014

Rogers12/2010

IPSU to IOP image transfer rate

Given that the current data transfer rates from the IPSU to the IOP is severely limited, transfer of ACME data may take an unacceptable amount of time and may reduce obtainable science for the allotted operational time on-board ISS.

5 3 Mitigate: FCF Sustaining Engineering will investigate methods of improving data transfer rates. ACME requires 10 MB/s.Close: Dec 2013

ACME010

Mroczka06/2010

CIA electronics and fuel mixture compatibility

Given that the CIA electronics are exposed to chamber atmosphere; then there may be incompatibility with elements of the chamber atmosphere including fuels, oxygen and diluent mixtures causing the cube to fail.

3 5 Mitigate: Develop a test plan to determine what components and what surface treatments would mitigate this risk. This risk will be re-assessed after reviewing the results of the analysis scheduled to take place by September 2012. [ZIN M&P assessing.]Close: Dec 2012

ACME008

Gobeli12/2009

E-field emission exceedences

Given that there might be emission exceedences; then there is the possibility that the EMI requirement will not be met and ACME hardware would be adversely effected causing diminished science to occur.

2 3 Mitigate: Test integrated assembly for EMI interference. . [ACME Project Scientist is in discussions with the ACME team about requirement change or deviation.]Close: May 2013

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LIKELIHOOD

5 014

4 021

3 010

2 008

1

1 2 3 4 5

CONSEQUENCES

Closed -- Accepted

Closed -- Accepted

Closed -- Accepted

January 17, 201311

ACME Key Project Metrics — FY11

Released Drawings Measure of Performance

WBS 401769.07.01.01.01

• CIA drawings slightly behind arbitrary linear MOP• Color Camera and Avionics Package ahead of plan

January 17, 201312

ACME Science Report January 2013

Progress in last quarter (nominally Oct.-Dec. 2012)1. BRE – 40 exploratory 2.2s drop tests with gaseous fuel (CH4 & C2H4) and cup burner.2. BRE – prototype burner received from PI and preparations initiated for 5.2s testing.3. E-FIELD Flames – determined that planned power supply is unacceptably slow and verified

in 1g that the loaned alternate met response time req’ts, but loaner was +/-5 instead of +/-10kV.

4. E-FIELD Flames – 8 preliminary 2.2s drop tests with +/-5kV high-voltage amplifier.5. General – entire 2.2s video system upgraded for ACME - but is a new facility capability.6. General – initial evaluation of flight-like cameras in 2.2s testing (i.e., with 0g flames).

Plans for this quarter (Jan.-March 2013)1. BRE – 5.2s drop tests with PI-provided prototype burner(s).2. BRE – procure and evaluate smaller heat flux sensors, e.g., for use with 25-mm burner.3. BRE – update science requirements in preparation for June RDR.4. BRE – make initial arrangements for June RDR (e.g., science panel participation).5. E-FIELD Flames – prepare for 2.2s evaluation of alternate +/-10kV amplifier.6. General – 2.2s drop test evaluation of flight-like GigE camera for pyrometry.7. General – 2.2s drop test evaluation of flight-like radiometers and/or PMT modules.8. General – implement hardware to enable GigE camera evaluation in 5.2s drop tests.

Issues and Concerns (upcoming milestones)1. BRE - weak/unstable flames observed in some 2.2s drop tests.2. BRE - potential need for thermal control of burner’s heat flux transducers.3. BRE - RDR, including go/no-go decision, in June.4. E-FIELD Flames - unacceptable response time for planned high-voltage power supply.5. General - science loss for BRE and Flame Design if testing is restricted to 30% oxygen in the

chamber.

January 17, 201313

ACME Grant Status January 2013

All FY13 payments for PI funding have been made• FY13 is a skip year for PI funding, where the only PI funding is for Quintiere (U. Maryland). • With the exception of Quintiere, all ACME PIs were forward funded since the project’s

inception as a unified program (2006), e.g., with FY12 dollars for FY13 work. PI funding will next be added at the beginning of FY14. PI funding currently totals $0.5M /year for 5 experiments, i.e., $100k/year/experiment.

PI nameGrant

Inception Date

Grant End date

Date current funding runs out

Budget amount / current FY

PR commitment status

paid/owed

Long 01/01/2011 12/31/2014 12/31/2013 $0/ FY13 $0/$0

Dunn-Rankin

10/01/2011 09/30/2014 09/30/2013 $0/ FY13 $0/$0

Axelbaum 10/01/2009 09/30/2014 09/30/2013 $0/ FY13 $0/$0

Chao 10/01/2011 09/30/2014 09/30/2013 $0/ FY13 $0/$0

Sunderland 10/01/2009 09/30/2014 09/30/2013 $0/ FY13 $0/$0

Law 10/01/2009 09/30/2014 09/30/2013 $0/ FY13 $0/$0

Tse 10/01/2011 09/30/2014 09/30/2013 $0/ FY13 $0/$0

Quintiere 01/01/2010 12/31/2014 12/31/2013 $100k/FY13 $100k/$0

January 17, 2013

Backup Charts

14

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E-Field Power Supply

Cooling Plate

Thin Fiber Pyrometry (TFP) Motor

Motor Drivers

Burner

Far Field TCs

Mass Flow Controllers

Input ManifoldAnalog Camera

Cube

E-Field Mesh

PMTs

Igniter Motor

Igniter notes – The model shows the igniter armIn both deployed and stowed positions, and shows

the igniter tip in two different places

January 17, 2013

ACME Detectors WBS 401769.07.01.01.01

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Hamamatsu Photomultiplier Tube

Dexter Thermopile Detector,Radiometer with Board

Breadboard Igniter Arm Assembly

Digital Camera

Zoom Lens

Filter Barrel

Mirror

Camera Control Assembly

ACME Camera Assembly

ACME Engineering Model Avionics Package Frame

January 17, 2013

ACME Science Team Locations

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1. C.K. Law, Princeton University

2. Stephen Tse, Rutgers University

3. Richard Axelbaum, Washington University, St. Louis

4. Beei-Huan Chao, University of Hawaii

5. James Quintiere, Peter Sunderland, University of Maryland

6. Marshall Long, Mitchell Smooke, Yale University

7. Derek Dunn-Rankin, UC Irvine

8. Zeng-Guan Yuan, NCSER, Kurt Sacksteder, GRC, David Urban, GRC

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