News

'Space is hard'

By Sue Major Holmes

Photography By Randy Montoya

Thursday, August 04, 2016

Looking from space for nuclear detonations

Looking from space for nuclear detonations

GLOBAL BURST DETECTOR — Researcher Rachel Trojahn prepares one of the boxes that makes up Sandia’s Global Burst Detector for a test in the Labs’ Flight Test Chamber.  The chamber exposes individual boxes and the fully assembled flight system to the vacuum and thermal environment they’ll experience in orbit. The box or full system will be worked as if on orbit while it’s under vacuum conditions. (Photo by Randy Montoya)

Sandia’s Jaime Gomez was too busy to celebrate the successful launch of the latest nuclear detonation detection system — he was already deep into the next generation.

The Global Burst Detection (GBD) system launched from Cape Canaveral aboard the 70th Global Positioning System (GPS) satellite. The GBD looks for nuclear detonations around the world, offering real-time information about potential activity to US policymakers.

As project lead, Jaime (5796) oversaw teams responsible for everything from development to post-launch testing. The launch Feb. 5 was the 12th and final of the Block IIF (GPSIIF) series of GPS satellites in medium Earth orbit.

Project manager Bridget McKenney (5796) says that even before the final GPSIIF launch, Sandia was producing and delivering another generation of GBDs for a new round of eight satellites, GPSIII, being built by Lockheed Martin.

Sandia is already looking ahead to detectors for the launch series after that, dubbed Prime.

“We work 10 years ahead, from the time we get a concept for what the next generation of improved technologies and sensing will be,” Bridget says. Each GBD program starts with the initial concept, followed by approvals, engineering development, an extensive and complex design cycle, and production. The work is funded by the NNSA.

Sandia has been in the business of nuclear detonation detection for more than 50 years, starting with the 1963 launch of the first of 12 US Vela satellites to detect ground or atmospheric nuclear testing and verify compliance with the Limited Test Ban Treaty of 1963 and subsequently the Threshold Test Ban Treaty of 1974. That marked the start of the US Nuclear Detonation Detection System that supports treaty monitoring.

GPSIII set to launch next year

Defense Support Program satellites followed, succeeded by GPS satellites in 1978. The first of the IIF series was launched in 2010. The first GPSIII is expected to launch in 2017.

From the start, GPS satellites were seen as an ideal platform to look for nuclear detonations. Jaime says the sheer numbers planned meant there would always be many GBD systems in space, a detection redundancy highly prized during the Cold War. Today, GPS satellites are important for treaty verification and countless civilian uses, including timing signals for communications networks, financial markets, and power grids, ship navigation, and even pinpointing where crops might need more water or fertilizer.

Sandia’s GBD mission is appealing to Jaime and the rest of the Sandia team because it deals with space. “I think we’re all fascinated by space,” says Jaime, deputy project manager for the generation to fly on GPSIII. “And the treaty verification work is meaningful to a lot of folks.”

Detection was a natural extension for the labs that designed the early stockpile. They understood the physics and engineering of the weapons and the detectable optical, electromagnetic pulse, and X-ray signals they produce. “Those are the three that make it to space and what the GBD tries to detect,” Jaime says. Sandia develops the optical sensors; Los Alamos National Laboratory is responsible for electromagnetic pulse and X-ray sensors.

It takes about two years to build, test, and integrate GBD hardware into a satellite system, Jaime says. Five subsystems — what the teams call “boxes” — of sensors and instruments make up a GBD: three from Sandia and two from Los Alamos.

SATELLITE — A GPSIIF satellite is shown in production at Boeing’s Satellite Development Center in El Segundo, California. Such satellites carried the most recent generation of Sandia National Laboratories’ Global Burst Detectors into space. (Photo courtesy of Boeing)

Sandia integrates system

Sandia integrates it all into an overall system and performs seemingly endless tests. When a satellite launches, everything aboard faces extreme temperatures, vibration, and shock. Sandia’s testing and computer models help determine how the rigors of launch and deployment will affect the GBD.

Teams assemble printed circuit boards, wiring harnesses, and other mechanical hardware, conducting electrical and thermal testing on individual modules and pieces before assembly into the box. They follow with integration, electrical, functional, thermal, and vibration tests for each box. The five boxes together become a GBD system or payload. The entire system is then subjected to integration, functional, electrical, thermal-vacuum, and other tests before it’s shipped to the space vehicle contractor. Further electrical testing is done at the contractor site.

“Teams that build the hardware here develop a test plan suited for their subsystem and do that testing. Then we integrate the payload as the five boxes and do additional testing,” Jaime says. “At every level of integration, whether it’s the box level or a whole system at the vehicle level, you add to the testing to make sure that at every integration point the payload is operating.”

That’s especially important because the hardware can’t be repaired in space.

‘A very good track record’

“Some things you can fix through software but you depend on building something that has high reliability,” Jaime says. Bridget adds, “We have a very good track record for that. I think we can say that our payloads have substantially exceeded their design life.”

About 30 satellites and their detectors, representing several generations, remain in operation, some well past their design life, Jaime and Bridget say. The satellite generation before IIF was designed for 7.5 years, IIF was designed for 12 years, and GPSIII and Prime will be designed for 15 years.

 “GPS drives us because we want our payload to last as long as the bird does,” Bridget says.

Sandia teams work where the payloads go as they move toward launch. Jaime described the process for IIF: Once testing showed the GBD met requirements, Sandia shipped its payload to the satellite contractor, Boeing in El Segundo, California, for more tests. Sandia employees at the Boeing site provided GBD components for Boeing to install. Then the satellite went through months of additional tests, aided by the on-site Sandia team. Some 60 to 90 days before launch, Boeing shipped the satellite to Cape Canaveral, where ground crews aided by Sandia also did tests. Days after launch, a Sandia team arrived at Schriever Air Force Base, Colorado, for about a month of early orbit testing before the system was handed over to the Air Force to operate.

Sandia also develops ground stations

Even that isn’t the end. “We have a group that examines telemetry coming down from our payloads so we can monitor the state of health,” Bridget says. Developers use that information to improve next-generation technology. Under an agreement with the Air Force, Sandia also develops ground station components that support the Nuclear Detonation Detection System and integrate data from all the satellites.

As project lead, Jaime worked with the program office headed by Bridget, subsystem managers, team leaders, and colleagues at Los Alamos to ensure GBD development and delivery stayed on schedule. “It’s very much about schedule because our payload is integrated on a satellite that the Air Force is paying a subcontractor to build,” he says. “We have equipment that bolts onto that satellite so we need to be there and we need to be there with a product that works.”

He smiled and quoted a 2015 tweet from astronaut Scott Kelly that’s been informally adopted by members of Sandia’s satellite group: “Space is hard.”