In order to maintain cleanliness during preparations for JWST’s OTIS (Optical Telescope Element-Integrated Science Instrument Module) Cryogenic Thermal Vacuum Test, a cleanroom was built that attached directly to the 60-year-old Chamber A. The cleanroom and chamber were outfitted with independent environmental control systems each providing ISO Class 71 air cleanliness. To maintain balanced, positive pressure in both the cleanroom and chamber volumes, a special control protocol was developed and successfully implemented. Dual back-up environmental control units (one each for the chamber and cleanroom) were installed just outside the building to provide environmental control redundancy due to a single source chilled water supply and weather threats. In addition, lack of a dedicated cleanroom airlock facilitating clean ingress and egress made it necessary to perform additional cleaning and packaging, as well as augment the uncontrolled truck lock space with small clean tents for pre-cleaning. Special procedures were developed to allow ingress of extra-large support equipment required for load testing of the cleanroom crane, installation of optical equipment in Chamber A and accommodation of the OTIS shipping container. A thorough bake-out and cleaning of Chamber A was also necessary to reduce volatiles from the shroud’s black thermal paint and to reduce particle fallout. Acrylic adhesive fracture discovered during early cryo-testing represented a significant challenge that was successfully mitigated prior to OTIS testing. A dedicated team of Contamination Control (CC) Technicians was specifically trained to clean support equipment and screen materials entering the cleanroom and chamber to ensure cleanliness and vacuum compatibility.
The James Webb Space Telescope (JWST) is a multi-national program with Instruments and hardware supplied by companies all over the world and numerous states in the United States. In order to transport larger assemblies, like the Optical Telescope Element / Integrated Science Instrument Module (OTIS), and ultimately JWST, the Space Telescope Transporter for Air, Road and Sea (STTARS) was designed and constructed. STTARS is a massive mobile cleanroom (longer than 2 semi-trailers) that provides an ISO class 7 payload environment while being transported by road, airborne and marine vehicles. Temperature, humidity and particle counts are controlled and continuously tracked, with fallout and NVR witness samples for confirmation. Instruments or sensitive hardware may be purged continuously during transport. STTARS has 5 main components: the upper tent frame, lower tent frame, pallet, strong back and lid. After transporting OTIS to Northrup Grumman (NG), STTARS was modified to increase its height to house the JWST Observatory on its voyage to French Guiana. This new configuration was designated Observatory STTARS (OSTTARS). OSTTARS was too tall to travel by C5 aircraft, so the trip to the launch site was made by ship. Through JWST’s land, air and sea transports, STTARS and OSTTARS kept JWST hardware exceptionally clean and safe.
The James Webb Space Telescope (JWST) program was supported by a unique team of Contamination Control Technicians (CCTs) who received Webb specific training from Webb Contamination Control Engineers (CCEs) and Lead CCTs. Webb’s design featured exposed optics and thermal control surfaces. These remained susceptible to damage or degraded performance from particulate and molecular contamination if a systematic approach to controlling contamination generating processes was not strictly enforced. Cleanroom maintenance is typically performed by janitorial services throughout the industry. However, Webb’s requirements necessitated a team who safely and effectively performed various tasks including daily facility cleaning to flight hardware handling. The CCT team performed daily cleanings of the processing facilities and effortlessly switched to inspecting and cleaning flight hardware, assisting CCEs with inspections, lab work, and performing on-demand cleaning of all items entering the cleanroom facilities. The versatility of the CCT team was on display as each CCT took on additional responsibilities and maintained ownership of subtasks such as Image Analysis and Ellipsometry, transportation, Self-Contained Atmospheric Protection Ensemble (SCAPE) suit support, inventory, and cleanroom garment laundering, while supporting the demanding launch campaign. The CCTs maintained a constant presence on the integration floor, allowing for quick resolution to CC issues and elevation of more serious problems that required further guidance. These dedicated CCTs broke new ground in efficient collaborative work with the integration and testing team while cultivating positive attitudes towards contamination control.
KEYWORDS: James Webb Space Telescope, Contamination, Picture Archiving and Communication System, Rockets, Mirrors, Inspection, Telescopes, Optical fibers, Observatories, Contamination control
Over the life of the James Webb Space Telescope (JWST), Integration & Test (I&T) has taken place in areas that needed considerable work to make the facility itself and/or the protocols used while working in the rooms suitable to meet JWST percent area coverage (PAC) and molecular accumulation requirements. In addition to normal particulate matter, JWST had a uniquely significant challenge: fibers! Fibers not only cause much higher PAC levels, but they also risk damaging the angstrom sized Near Infrared Spectrometer (NIRSpec) microshutter array (MSA), which is critical to NIRSpec instrument performance. The primary emphasis of this paper is to address particulate and fiber contamination. The success of the JWST mission required effective cleanrooms, protocols, and mitigations in non-cleanroom areas that were pressed into service to house contamination-sensitive optics and scientific instruments. Some presented profound challenges. These included: NASA’s 60-year-old Johnson Space Center (JSC) Chamber A, which had never been used for anything contamination-sensitive, and the European tropical launch facilities, which were designed to meet International Standard Organization (ISO) Class 8 processing for communication satellites. The final challenge for JWST, as if to stare us in the face and say, “I dare you to try and make me clean enough,” was preparing the 4 areas in the Centre Spatial Guyanais (CSG) Final Assembly Building (BAF) located in French Guiana, a building in which one entire side opens for Ariane 5 rocket ingress and egress. This paper will describe our initial evaluation processes and the actual work undertaken to transform even the most challenging areas into first class cleanrooms that met JWST particulate and fiber requirements.
The James Webb Space Telescope (JWST) launched from the Centre Spatial Guyanais (CSG) in December 2021. JWST’s requirements permitted processing in International Organization for Standardization (ISO) Class 7 or better facilities, but CSG was only equipped with ISO Class 8 facilities. To temporarily upgrade the air cleanliness in the Payload Processing Facility, Fueling Hall, and Final Assembly Building Encapsulation Hall, NASA provided two portable High Efficiency Particulate Air (HEPA) and carbon filter walls that were used in each location. The walls were comprised of stacks of two modules high and arranged in push-push configurations as shown to be most effective via Computational Fluid Dynamics simulations of expected floor layouts in each facility. After delivery to NASA’s Goddard Space Flight Center in 2020, the walls underwent initial verification measurements inside a cleanroom and validation testing in an uncontrolled area to quantify their improvement of air cleanliness and particle and molecular fallout. Validation testing showed improvements of 83-99% for airborne particle counts, 79-91% for particle fallout, and 50- 90% for molecular fallout. The particle improvements were applied to the contamination budget analysis that tracked current and predicted future cleanliness against End-of-Life requirements for JWST’s critical surfaces. At CSG, the walls successfully maintained an ISO Class 7 environment or better within their envelope in each location, despite their presence in ISO Class 8 facilities with dense integration operations.
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