Technical Services

Systems Reliability
Activities related to ensuring reliability of space systems through rigorous quality control, quality assurance and test and evaluation activities continued at all DOS centres. In order to give further thrust to systems reliability activities, a Directorate of Quality and Reliability (DOQR) has been set up at ISRO Headquarters to provide direction for the realisation of quality systems. Audit of work centres involved in space activities are being conducted to ensure adherence by work centres and industries to stringent quality norms.

The assembly, integration and check out of spacecraft subsystems for INSAT-4C and CARTOSAT-2 were carried out during the year. The activities covered test and evaluation of space hardware, ground support equipment, review of test procedures and methods, test data analysis and non-conformance management. Integrated spacecraft thermovac test for the satellites were also carried out during the year.

Quality Assurance support for various subsystems of GSLV-F-02 and PSLV-C7 missions were carried out. Uniform stage clearance practices were adopted for process/product realisation at different work centers. Reliability estimates and trend analysis of all systems/sub systems of PSLV-C7 and GSLV-F-02 were carried out.

The Failure Analysis Committee (FAC), which reviewed the performance of GSLV-F-02 that could not accomplish the mission, has identified the causes and steps to implement the recommendations of FAC have been initiated.
Active and passive electronic components were screened before use in the subsystems. Necessary software and hardware were developed to screen special and non-standard devices. Performance analysis of Hybrid Micro Circuits and other devices were also carried out.

A high-level Assurance Board for ISRO projects has been constituted and the recommendations of the board are being duly implemented.

Maintenance of certification to ISO-9000 quality systems were continued through close interaction with various divisions and groups at DOS centers. Activities were also initiated by other centers/units, which are yet to obtain ISO-9000 certification. Upgradation of
ISO-9000 for 2000 version were carried out.

Under the indigenisation of space components and materials, several electronic components and advanced materials were qualified during the year and are being used progressively in the ongoing projects. Significant progress was achieved in the indigenous development of C-band Travelling Wave Tubes. Efforts to qualify several critical components for indigenisation were also initiated during the year.

Safety Services

Use of fire-proof dress during propellant segment preparation

The space programme continued to be free from any major accidents during the year. The launch of GSLV-F02 from the Second Launch Pad at SDSC SHAR was carried out without any safety related incidents. The emergency preparedness plan was executed flawlessly resulting in no damage to personnel. Launch campaign activities involved handling of solid rocket motors, pyrotechnic materials, earth storable and cryogenic propellants and high-pressure gas servicing of GSLV-F02 stages as well as INSAT-4C. The transportation of propellants, liquid propulsion stages, rocket hardware were carried out under the umbrella of a well-coordinated safety net, all along the route.

The successful functioning of the safety systems during integrated filling of liquid oxygen and liquid hydrogen in auto mode, expulsion trials and short duration hot test of indigenously developed cryogenic upper stage (CUSP) was a significant achievement during the year. The other major safety activities like qualification trial of SRE-1 passivation system, structural test of cryogenic stage with LN2, testing of gas generator of C-20 cryogenic engine, vertical static test of one-meter diameter subscale motor for slag accumulation studies in connection with S-200 Motor, disposal of life expired rocket motors, recovery of L-40 stages from Bay of Bengal after the failure of GSLV-F02, qualification tests of AOCS, LAM and RCS were conducted under rigorous safety surveillance.

Safety surveillance was in place during fabrication, integration, thermo-vac test, vibration tests, and high-pressure tests of INSAT-4C, SRE-1 and CARTOSAT-2.Safety reviews and clearance were accorded for Deep Space Network Station, static test of RH-560 motor for dual mode RAMJET, assembly of PS-1 hardware for proof pressure test and gas generator exhaust disposal during hot test of cryogenic stage. Safety committees at DOS establishments reviewed and cleared locations, construction and commissioning of new facilities. Rigorous safety inspections and audits, surprise checks, drills at various hazardous areas, preparations of safety manuals and emergency preparedness plan and review of facilities before critical operations were undertaken by safety groups. The high-level Board of Safety met regularly and recommendations duly implemented.

Safety awareness and promotional activities have continued through celebration of national safety day, fire service day, issuing safety posters, organising safety training programme, etc. In view of increased complexity and magnitude of space activities, inter-centre workshops on safety were also organised to share experiences within safety professionals.

Liaison with statutory authorities such as Chief Controller of Explosives, Nagpur, State pollution control boards and Centre for Fire, Explosive and Environment Safety, Delhi was continued during the year in order to meet the statutory requirements for various hazardous installations.

Civil Engineering
The Civil Engineering Division (CED) of DOS carries out planning, designing and construction of all buildings and auxiliary facilities required for various centres and projects of DOS. During the year the major civil works that were completed include: Thermovac facility for ISRO Satellite Centre, Horizonal Integration Building for GSLV-Mk III, L-110 and C-25 stages for LPSC at Mahendragiri, Building for ISRO Training Complex at VSSC, Propellant mixing station, Magazine, NDT, Inhibition and Tilting facility, Propellant Trimming Facility, Curing facility and Hardware Insulation and Lining facility at SDSC SHAR. A hospital has been constructed for SDSC employees at Sullurpeta. Phase-II housing for DOS employees at Jalahalli in Bangalore was also completed.