DRAFT EFAS PD v14.pdf

DRAFT PD

INCH-POUND

DRAFT PD

CAGE 98748

26 Feb 2020

PURCHASE DESCRIPTION

EXPEDITIONARY FLUID ANALYSIS SYSTEM

1. SCOPE

1.1 Scope. This purchase description is for an engine oil analysis instrument that will allow for laboratory testing of engine oil and lubricating fluids from in service and depot aircraft. This real time capability is known as the Expeditionary Fluid Analysis System (EFAS). EFAS is a requirement of the Air Force’s Oil Analysis Program (AFOAP) that will help the USAF meet the

Conditioned Based Maintenance Plus (CBM+) initiatives outlined in DoDI 4151.22. The instrument will provide oil-monitoring capabilities that simplify oil testing for the field user, reduce maintenance costs by monitoring lubricant condition in real time and develop information to implement conditioned based maintenance, improve material readiness, reduce the demand for off-site laboratories, and reduce hazardous waste.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks listed below form a part of this specification to the extent specified herein. Unless otherwise specified herein, the issues of these documents shall be the latest revisions in effect at time of solicitation.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-5606 Performance Specification: Hydraulic Fluid, Petroleum

Base; Aircraft, Missile, and Ordnance

AMSC N/A FSC 6650

DISTRIBUTION STATEMENT A. Approved for public release.

Comments, suggestions, or questions on this document should be addressed to: AFLCMC/LPZ, 3001 Staff Dr., Ste. 2AC4-105A, Tinker AFB, OK 73145

MIL-PRF-7808 Performance Specification: Lubricating Oil, Aircraft

Turbine Engine, Synthetic Base MIL-PRF-28800 Performance Specification: Test Equipment for Use with Electrical and Electronic Equipment, General

Specification For MIL-PRF-23699 Performance Specification: Lubricating Oil, Aircraft

Turbine Engine, Synthetic Base

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-461 Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and

Equipment MIL-STD-810 Environmental Engineering Considerations and

Laboratory Tests MIL-STD-882 System Safety

MIL-STD-1472 Design Criteria Standard: Human Engineering

DEPARTMENT OF DEFENSE INSTRUCTIONS

DoDI 8500.01 Cybersecurity

DoDI 8510.01 Risk Management Framework (RMF) for DoD

Information Technology (IT)

(Copies of these documents are available online at http://quicksearch.dla.mil/.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications of the exact revision level shown form a part of this document to the extent specified herein.

AIR FORCE INSTRUCTION (AFI)

AFI 17-101 Risk Management Framework (RMF) for Air Force

Information Technology (IT) AFI 32-7086 Hazardous Materials Management

(Copies of these documents are available online at http://www.e-publishing.af.mil/.)

CODE OF FEDERAL REGULATIONS (CFR)

40CFR82 Protection of Stratospheric Ozone

(Copies of this document are available online at http://www.ecfr.gov/.)

COMMITTEE ON NATIONAL SECURITY SYSTEMS

http://quicksearch.dla.mil/ http://www.e-publishing.af.mil/ http://www.ecfr.gov/

CNSSI No. 1253 Security Categorization and Control Selection for

National Security Systems

(Copies of this document are available online at http://www.cnss.gov/CNSS/searchform.cfm)

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

Special Publication 800-37 Risk Management Framework for Information Systems and Organizations: A System Life Cycle Approach for

Security and Privacy Special Publication 800-53 Security and Privacy Controls for Federal Information

Systems and Organizations

(Copies of these documents are available online at https://csrc.nist.gov/publications/sp.)

2.3 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

ASTM INTERNATIONAL (ASTM)

ASTM-D6300 Standard Practice for Determination of Precision and Bias

Data for Use in Test Methods for Petroleum Products and

Lubricants ASTM-D8092 Standard Test Method for Field Determination of

Kinematic Viscosity Using a Microchannel Viscometer

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO

Box C700, West Conshohocken PA 19428-2959, http://www.astm.org/.)

SAE INTERNATIONAL

AMS-STD-595 Colors Used in Government Procurement

(Application for copies should be addressed to SAE International Customer Service, 400

Commonwealth Drive, Warrendale PA 15096, http://www.sae.org/.)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4406 Hydraulic Fluid Power – Fluids – Method for Coding the

Level of Contamination by Solid Particles

(Application for copies should be addressed to ISO Customer Service, Chemin de Blandonnet 8, CP 401, 1214 Vernier, Geneva, Switzerland, http://www.iso.org) http://www.cnss.gov/CNSS/searchform.cfm https://csrc.nist.gov/publications/sp http://www.astm.org/ http://www.sae.org/ http://www.iso.org/

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), three samples shall be subjected to first article inspection in accordance with 4.2.

3.2 EFAS description. EFAS is an oil analysis system for the Joint Oil Analysis Program (JOAP).

It shall be more easily deployable and rugged than current oil analysis systems. It shall be designed to detect larger wear metal particles that are typical of serious engine mechanical system failure modes such as subsurface fatigue failure in rolling element bearings. It shall not require a correlation program. It shall also have capability to analyze aircraft hydraulic fluids as well as a limited magnetic chip detector (MCD) debris analysis capability. It shall be compact, lightweight, and with the exception to operating and storage temperature, and meet specified Class 2 requirements of MIL-PRF-28800.

3.3 Design and construction. The design shall promote cost effective, life-cycle sustainability by addressing considerations such as incorporating open standards, reducing pollutant emissions and wastes, while satisfying system performance requirements. It shall be designed and constructed so that no parts will work loose in service, and to withstand the strains, jars, vibrations, and other conditions incident to shipping, storage, installation, and service. It shall be weatherproof and designed to prevent the intrusion of water, sand, and dust into critical operating components.

3.3.1 Materials, protective coatings, and finish.

3.3.1.1 Recycled, recovered, environmentally preferable, or biobased materials. Recycled, recovered, environmentally preferable, or biobased materials should be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs.

3.3.1.2 Exclusion of water. The design of the EFAS shall be such as to prevent water leaking into, or being driven into, any part of the EFAS interior when in the transit case. All transit case panels, covers, etc., shall be provided with sealing arrangements such that the entry of water is minimized when these items are correctly closed.

3.3.2 Markings. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130. Markings shall be applied with decals and shall be 1-inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible. Markings, Information/Caution shall be Lusterless Black, Color Number

37038 of SAE AMS-STD-595, and Markings, Warning/Danger shall be Lusterless Red, Color

Number 31136 of SAE AMS-STD-595.

3.3.3 Identification and information plates.

3.3.3.1 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the EFAS in a readily accessible location. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). The EFAS and any of its components for which the Government’s unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as Item

Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. UID information shall be included as both a 2D Data Matrix and human readable markings.

3.3.4 Environment, Safety, and Occupational Health (ESOH).

3.3.4.1 System safety. The design of the EFAS shall not contain any system safety mishap risk categories greater than medium as defined in MIL-STD-882.

3.3.4.2 Hazardous material. The design shall minimize and control hazards associated with the inclusion or use of hazardous or toxic materials and the generation of toxic or noxious gases. The

EFAS shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. Class I ODS and hazardous materials shall not be used in any system, component, or process. The EFAS shall not contain or use either hexavalent chromium or cadmium without written approval by the procuring activity. Hazardous materials are defined in

AFI 32-7086; Class I and Class II ODS are defined in 40CFR82.

3.3.4.3 Component protection. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard. All wires, cables, tubes, and hoses shall be supported and protected to minimize chafing and abrasion and shall be located so as to provide adequate clearance from moving parts and high operational temperatures. Grommets shall be provided wherever wires, cables, tubes, or hoses pass through bulkheads, partitions, or structural members.

3.3.4.4 Foreign object damage (FOD). All loose metal parts, such as pins or connector covers, shall be securely attached to the EFAS with wire ropes or chains. "Dog tag" style beaded chains shall not be provided. Removable panels, if provided, shall be attached with captive fasteners.

3.3.5 Electromagnetic interference (EMI). The EFAS shall be in accordance with the following requirements of MIL-STD-461: CE102, CS101, CS114, CS115, CS116, RE102, and RS103.

3.3.6 Human systems integration. The EFAS shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance.

3.3.7 Fastening devices. All screws, bolts, nuts, pins, and other fastening devices shall be properly designed, manufactured, and installed with adequate means of preventing loss of torque or adjustment. Cotter pins, lock washers, or nylon patches shall not be used for this purpose, except for the attachment of trim items or as provided in commercial components. Tapped threads shall have a minimum thread engagement in accordance with Table I.

TABLE I. Minimum thread engagement.

Material

Minimum Thread Engagement

Steel 1.0 times the nominal fastener diameter

Cast iron, brass, or bronze 1.5 times the nominal fastener diameter

Aluminum, zinc, or plastic 2.0 times the nominal fastener diameter

3.3.8 Welders and welding. Welding procedures shall be in accordance with a nationally recognized welding code. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings. Cast components, structural steel components with an ultimate tensile strength greater than 100,000 psi, and threaded fasteners (except for weld studs and weld nuts) shall not be welded. Heat treated components shall be in the annealed, normalized condition when welded.

3.3.9 Service life. The EFAS shall be designed for a minimum service life of 7 years.

3.3.10 Electrical power. The EFAS shall be capable of operation from a nominal 120/240 volt alternating current (VAC) root mean square (rms), single-phase, 50 Hertz (Hz) or 60Hz power source and be equipped with a battery back-up. The internal battery shall be rechargeable by a nominal 120/240VAC rms, single-phase, 50Hz or 60Hz power source and have a battery life indicator. Battery life shall be at least 4 hours of normal operation testing samples before recharging is required. Battery recharging time shall not exceed the operating time and equipment shall maintain ability to be operational while battery is charging.

3.4 Environmental conditions.

3.4.1 Operating temperature range. The EFAS shall be capable of operating in ambient temperatures ranging from 32° F to 104° F.

3.4.2 Storage temperature range. The EFAS shall be capable of being stored in ambient temperatures ranging from -40° F to 160° F.

3.4.3 Solar radiation. The EFAS operation shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments and high altitudes.

3.4.4 Fungus. The EFAS, while in its transit case, shall meet the fungus resistance requirement specified in 3.8.7 of MIL-PRF-28800.

3.4.5 Salt fog. The EFAS transit case shall meet the salt atmosphere exposure requirement specified in 3.8.8 of MIL-PRF-28800.

3.4.6 Sand and dust. The EFAS transit case shall be dust resistant as specified in 3.8.10 of MIL-

PRF-28800.

3.4.7 Bench handling. The EFAS shall meet the bench handling requirement specified in 3.8.5.3 of MIL-PRF-28800.

3.4.8 Transit drop. The EFAS, while in its transit case, shall meet the transit drop requirement specified in 3.8.5.2 of MIL-PRF-28800.

3.4.9 Humidity. The EFAS shall meet the relative humidity requirement specified in 3.8.2.3.2 of

MIL-PRF-28800.

3.4.10 Altitude. The EFAS shall be capable of operation at any altitude from sea level to 10,000 feet without degradation in performance. The EFAS shall be capable of storage and/or transportation at any altitude from sea level to 40,000 feet and shall continue to function without degradation in performance after a return to sea level from 40,000 feet.

3.5 Weight and dimensions. Overall weight and dimensions of the EFAS when stored in the transit case shall not exceed:

Weight 75 pounds.

Length 20 inches.

Width 20 inches.

Height 10 inches.

3.6 Transportability.

3.6.1 Surface transportability. The EFAS, in its transit case, shall be transportable via all modes of surface shipment (highway, rail, and water) in accordance with MIL-STD-1366, and shall be capable of withstanding the mechanical shock and vibration characteristics of highway, rail, and water transport, except that design for rail impact testing (see paragraph 5.2.5 of MIL-STD-1366) is not required.

3.6.2 Air transportability. In the transit case, the EFAS shall be capable of withstanding, without loss of serviceability, 2.0 G up and 4.5 G down accelerations, and shall be capable of being withstanding, without loss of structural integrity, 3.0 G forward, 1.5 G aft, and 1.5 G lateral accelerations.

3.6.3 Transit case. The EFAS shall contain all test equipment and accessories in one hard transit case.

3.6.3.1 Transit case handles. The EFAS transit case shall be equipped with handles meeting the requirement specified in 3.7.3.1 of MIL-PRF-28800, except that the handles need not be metallic.

3.6.3.2 Transit case corners. The corners of the EFAS transit case shall meet the requirement specified in 3.7.5 of MIL-PRF-28800.

3.6.3.3 Transit case accessory stowage. The EFAS transit case shall meet the requirement for accessory stowage specified in 3.7.4 of MIL-PRF-28800.

3.6.3.4 Transit case pressure equalizing valve. The EFAS transit case shall meet the requirement for pressure equalizing valves specified in 3.7.6 of MIL-PRF-28800.

3.6.4 Continuous operation. The EFAS shall be capable of 4 hours of continuous operation in all operational environments specified herein.

3.7 Maintainability. The EFAS shall be designed for maintainability in accordance with 5.9 through 5.9.18 of MIL-STD-1472; forces shall not exceed those specified for both males and females.

3.7.1 Inspection and servicing provisions.

a. Pre-use inspections and servicing tasks shall not require tools.

b. Routine service and preventive maintenance shall not require special tools (see 6.3.2).

c. The EFAS shall be designed with maximum usage of sealed lifetime lubrication bearings.

3.7.2 Relative accessibility. Critical items that require rapid maintenance shall be most accessible.

When relative criticality is not a factor, items that require the most frequent access shall be most accessible. High failure rate items shall be accessible for replacement without moving non-failed items.

3.7.3 Error-proof design. The design of the EFAS shall incorporate error-proofing in equipment mounting, installing, interchanging, connecting, and operating.

a. Equipment shall include physical features (for example, supports, guides, size, or shape differences, fastener locations, and alignment pins) that prevent improper mounting. In the absence of physical features, equipment shall be labeled or coded to identify proper mounting and alignment.

b. Equipment that has the same form and function shall be interchangeable throughout a system and related systems. If equipment is not interchangeable functionally, it shall not be interchangeable physically.

c. Connectors serving the same or similar functions shall be designed to preclude mismating or misalignment.

d. Design, location, procedural guidance, and suitable warning labels shall be provided to prevent damage to equipment while it is being handled, installed, operated, or maintained.

3.7.4 Special tools. The design of the EFAS shall not require any special tools for maintenance of the unit.

3.7.5 Diagnostic software. A copy of any diagnostic software required or recommended for maintaining the EFAS shall be provided with each EFAS on CD-ROM or DVD-ROM. This software shall operate as specified on a computer with 64-bit Windows 10.

3.8 Software and interface requirements.

3.8.1 Controller. The EFAS shall be controlled by a PC-compatible computer using the USAF

Standard Desktop Configuration.

3.8.2 Data storage. The EFAS system shall be capable of reporting elemental analysis data in physical units of measure (parts per million ppm). The test results shall be displayed and output

(including to other devices) as discrete test results for each characteristic analysis. The capability to transfer all data linked to an individual sample to a data repository via Ethernet should also be an available option.

3.8.3 Fluid library. The EFAS shall be configurable to accommodate different fluids and component types. The EFAS software shall have a selectable on-board fluid library that contains common commercially available fluids. The library shall allow the user to define fluid characteristics and add additional fluids not already available in the library. The minimum capacity of the fluid library shall be at least 500 fluids. The EFAS shall contain an operating environment that allows users to develop, modify, and review the library and test data.

3.8.4 OAP-Ex. The EFAS shall be capable of transferring data to the OAP-Ex database in comma delineated Comma Separated Value (CSV) format. Data shall include the full range of elements identified in Table 2, the particle sizes, and particle counts.

3.8.5 EFAS software requirements.

3.8.5.1 User privileges. The EFAS software shall not require elevated user privileges for its operation.

3.8.5.2 External communication. The EFAS software shall not communicate with any system outside of the DoD network.

3.8.5.3 Freeware, shareware, and open source software. The EFAS software shall not use any freeware or shareware. The EFAS software shall avoid use of open source software. If open source software is used, it shall be supported with a Configuration Management Plan and Support

Plan.

3.8.5.4 High level vulnerabilities. The EFAS software shall not have any high level vulnerabilities as reported in the NIST National Vulnerability Database (https://nvd.nist.gov/vuln).

3.8.5.5 Internet Protocol. The EFAS shall support IPv4 and IPv6.

3.8.5.6 Current vendor support. The EFAS software and its dependencies shall have current vendor support.

3.8.5.7 Root directory. The EFAS software shall not write to the system root directory.

3.8.5.8 Adobe Flash. The EFAS software shall not use Adobe Flash.

3.8.5.9 Self-signed certificates. The EFAS software shall not use self-signed certificates.

3.8.5.10 Foreign software. The EFAS software shall not use foreign software of any kind.

3.9 Fluid analysis requirements.

3.9.1 Fluids. The EFAS shall analyze new and in-service fluids that conform to MIL-PRF-7808, MIL-PRF-23699, and MIL-PRF-5606 to determine oil condition and the presence and composition of wear metal particles.

3.9.2 Warm-up time. EFAS warm-up time shall not exceed 10 minutes from initiating startup to beginning an oil analysis.

3.9.3 Analysis time. EFAS time to complete an oil analysis shall not exceed 10 minutes per sample.

3.9.4 Sample volume. Sample volume should not exceed 30 milliliters for all testing.

3.9.5 Wear metal elements. The EFAS shall detect, at minimum, the following elements:

TABLE II. Elements to be detected.

Element Elemental Symbol

Aluminum Al

Chromium Cr

Cobalt Co

Copper Cu

Iron Fe

Lead Pb

Magnesium Mg

Molybdenum Mo

Nickel Ni https://nvd.nist.gov/vuln

Silicon Si

Silver Ag

Tin Sn

Titanium Ti

Tungsten W

Vanadium V

Zinc Zn

3.9.6 Limits of detection. 3σ limits of detection (LODs) for wear metal elements shall be no greater than that specified in Table III.

TABLE III. Limits of detection by element.

Elemental

Symbol

LOD

(ppm)

Repeatability

(at 1ppm)

Reproducibility

(at 1ppm)

Al 0.05 0.13 0.15

Cr 0.04 0.08 0.09

Co 0.07 0.09 0.10

Cu 0.07 0.09 0.10

Fe 0.02 0.08 0.09

Pb 0.15 0.17 0.19

Mg 0.15 0.16 0.20

Mo 0.05 0.08 0.09

Ni 0.03 0.09 0.12

Si 0.03 0.11 0.12

Ag 0.14 0.15 0.17

Sn 0.35 0.37 0.38

Ti 0.02 0.08 0.09

W 0.16 0.17 0.18

V 0.03 0.07 0.08

Zn 0.11 0.12 0.13

3.9.7 Particle size. The EFAS shall quantify the presence of debris particulates ranging from 4 μm to 1,000 μm in size.

3.9.8 Particle count detection. EFAS particle count detection shall meet or exceed ISO 4406 Code

16.

3.9.9 Analysis of magnetic chip detector debris. The EFAS shall analyze metal debris from magnetic chip detectors (MCDs) to determine the composition of metal debris captured by engine

MCDs. In addition to determining the bulk elemental composition, the EFAS shall be able to identify the presence of M50 steel alloy.

3.9.10 Repeatability and reproducibility of results. The EFAS shall achieve 3σ repeatability and reproducibility for wear metal elements no greater than that specified in Table III.

3.9.11 Standards. The EFAS shall be provided with non-expendable standards that can be used to test the EFAS and ensure that the accuracy of its wear metal results are within the requirements in

Table III.

3.9.12 Oil condition and contamination. The EFAS shall measure total acid number (TAN), water contamination, alien fluid contamination, and anti-oxidant depletion.

3.9.13 Oil condition and contamination limits of detection, repeatability, and reproducibility. The

EFAS shall meet the requirements for limits of detection, repeatability, and reproducibility in the ranges specified in Table IV.

TABLE IV. Oil condition and contamination requirements.

Property Range LOD Repeatability Reproducibility

TAN 0-5 mgKOH/g 0.6 ± 3% of value or 0.05 mgKOH/g whichever is larger

± 15% of value or 0.25 mgKOH/g whichever is larger

Water 0-2000 ppm 300 ± 3% of value or 100 ppm whichever is larger

± 5% of value or 300 ppm whichever is larger

Alien Fluid 0-100% 4.6 ± 5% of value or 0.4% whichever is larger

± 12% of value or 1.5% whichever is larger

3.9.14 Oil viscosity. The EFAS shall measure fluid viscosity with a repeatability and reproducibility no greater than that specified in ASTM D8092.

3.10 Workmanship. The EFAS, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of welding, painting, and riveting; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.10.1 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred.

Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.10.2 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the component.

3.10.3 Gear and lever assemblies. Gear and lever assemblies shall be properly aligned and meshed and shall be operable without interference, tight spots, loose spots, or other irregularities. Where required for accurate adjustment, gear assemblies shall be free of excessive backlash.

3.10.4 Cleaning. The EFAS shall be thoroughly cleaned. Loose, spattered, or excess solder;

welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3).

Requirements shall be verified in accordance with Table V.

TABLE V. Requirement verification matrix.

Section 3 Requirement Verification

Method

Section 4 Verification

3.1 First article. N/A

3.2 EFAS description. N/A

3.3 Design and construction. Examination 4.5.1 Examination of product.

3.3.1 Materials, protective coatings, and

finish.

N/A

3.3.1.1 Recycled, recovered, environmentally preferable, or biobased materials.

Examination

4.5.1 Examination of product.

3.3.1.5 Exclusion of water. Examination 4.5.1 Examination of product.

3.3.2 Markings. Examination 4.5.1 Examination of product.

3.3.3 Identification and information

plates.

3.3.3.1 Identification plate. Examination 4.5.1 Examination of product.

3.3.4. Environment, Safety, and

Occupational Health (ESOH).

3.3.4.1 System safety. Analysis

4.5.2 System safety hazard

analysis.

3.3.4.2 Hazardous material. Examination 4.5.1 Examination of product.

3.3.4.3 Component protection. Examination 4.5.1 Examination of product.

3.3.4.4 Foreign object damage (FOD). Examination 4.5.1 Examination of product.

3.3.5 Electromagnetic interference

(EMI).

Test

4.5.6 Electromagnetic interference

test.

3.3.6 Human systems integration.

Demonstration

4.5.1 Examination of product.

4.5.11.1 Preventive maintenance

demonstration.

3.3.7 Fastening devices. Examination 4.5.1 Examination of product.

3.3.8 Welders and welding. Examination 4.5.1 Examination of product.

3.3.9 Service life. Analysis 4.5.5 Service life analysis.

3.3.10 Electrical power. Demonstration 4.5.9.1 Functional demonstration.

3.4 Environmental conditions. N/A

3.4.1 Operating temperature range. Test

4.5.7.1 Temperature storage and

operation test.

3.4.2 Storage temperature range. Test

4.5.5.1 Temperature storage and

operation test.

3.4.3 Solar radiation. Examination 4.5.1 Examination of product.

3.4.4 Fungus resistance. Test 4.5.5.3 Fungus resistance test.

3.4.5 Salt fog. Test 4.5.5.4 Salt fog test.

3.4.6 Sand and dust. Test 4.5.5.5 Sand and dust test.

3.4.7 Bench handling. Test 4.5.5.6 Bench handling test.

3.4.8 Transit drop. Test 4.5.5.7 Transit drop test.

3.4.9 Humidity. Test 4.5.5.2 Humidity test.

3.4.10 Altitude. Test 4.5.5.8 Altitude test.

3.5 Weight and dimensions.

Test

4.5.8 Weight and dimension tests.

4.5.8.1 Weight test.

4.5.8.2 Dimension measurement.

3.6 Transportability. N/A

3.6.1 Surface transportability. Analysis

4.5.9.1.1 Surface transportability

analysis.

3.6.2 Air transportability. Analysis

4.5.9.2 Air transportability

analysis.

3.6.3 Transit case. Examination 4.5.1 Examination of product.

3.6.3.1 Transit case handles. Examination 4.5.1 Examination of product.

3.6.3.2 Transit case corners. Examination 4.5.1 Examination of product.

3.6.3.3 Transit case accessory stowage. Examination 4.5.1 Examination of product.

3.6.3.4 Transit case pressure equalizing

valve.

Examination 4.5.1 Examination of product.

3.6.4 Continuous operation. Demonstration 4.5.9.1 Functional demonstration.

3.7 Maintainability. Demonstration

4.5.11.1 Preventive maintenance

demonstration.

3.7.1 Inspection and servicing

provisions.

Demonstration

4.5.11.1 Preventive maintenance

demonstration.

3.7.2 Relative accessibility. Examination 4.5.1 Examination of product.

3.7.3 Error-proof design. Examination 4.5.1 Examination of product.

3.7.4 Special tools. Examination 4.5.1 Examination of product.

3.7.5 Diagnostic software. Examination 4.5.1 Examination of product.

3.8 Software and Interface. N/A

3.8.1 Controller. Examination 4.5.1 Examination of product.

3.8.2 Data storage. Demonstration 4.5.10 Software demonstration.

3.8.3 Fluid library. Demonstration 4.5.10 Software demonstration.

3.8.4 OAP-Ex database. Demonstration 4.5.10 Software demonstration.

3.8.5 EFAS software requirements. N/A

3.8.5.1 User privileges. Demonstration 4.5.10 Software demonstration.

3.8.5.2 External communication. Examination 4.5.1 Examination of product.

3.8.5.3 Freeware, shareware, and open

source software.

Examination 4.5.1 Examination of product.

3.8.5.4 High level vulnerabilities. Examination 4.5.1 Examination of product.

3.8.5.5 Internet protocol. Examination 4.5.1 Examination of product.

3.8.5.6 Current vendor support. Examination 4.5.1 Examination of product.

3.8.5.7 Root directory. Examination 4.5.1 Examination of product.

3.8.5.8 Adobe Flash. Examination 4.5.1 Examination of product.

3.8.5.9 Self-signed certificates. Examination 4.5.1 Examination of product.

3.8.5.10 Foreign software. Examination 4.5.1 Examination of product.

3.9 Fluid Analysis. N/A

3.9.1 Fluids. Demonstration

4.5.9.5 Fluid variation

demonstration

3.9.2 Warm-up time. Demonstration 4.5.9.1 Functional demonstration

3.9.3 Analysis time. Demonstration 4.5.9.1 Functional demonstration

3.9.4 Sample volume. Examination 4.5.1 Examination of product.

3.9.5 Wear metal elements. Demonstration 4.5.9.4 Particle size demonstration

3.9.6 Limits of detection. Demonstration

4.5.9.2 Limits of detection

demonstration

3.9.7 Particle size. Demonstration 4.5.9.4 Particle size demonstration

3.9.8 Particle count detection. Demonstration

4.5.9.6 Particle count

demonstration

3.9.9 Analysis of magnetic chip detector

debris.

Demonstration

4.5.9.7 Magnetic chip detector

debris analysis demonstration

3.9.10 Repeatability and reproducibility

of results.

Demonstration

4.5.9.3 Repeatability and

reproducibility demonstration

3.9.11 Standards. Demonstration

4.5.9.3 Repeatability and

reproducibility demonstration

3.9.12 Oil condition and contamination. Demonstration

4.5.9.8 Oil condition and

contamination demonstration.

3.9.13 Oil condition and contamination

limits of detection, repeatability, and reproducibility.

Demonstration

4.5.9.8 Oil condition and

contamination demonstration.

3.9.14 Oil viscosity. Demonstration

4.5.9.9 Oil viscosity

demonstration.

3.10 Workmanship. Examination 4.5.1 Examination of product.

3.10.1 Bolted connections. Examination 4.5.1 Examination of product.

3.10.2 Riveted connections. Examination 4.5.1 Examination of product.

3.10.3 Gear and lever assemblies. Examination 4.5.1 Examination of product.

3.10.4 Cleaning. Examination 4.5.1 Examination of product.

4.2 First article inspection. The first articles shall be subjected to the analyses, demonstrations, examinations, and tests described in 4.5.1 through 4.5.10. The contractor shall provide or arrange for all test equipment and facilities. Unless otherwise approved by the procuring activity, all first articles shall be in the same configuration at all times and configuration changes shall not be made during the first article inspection.

4.3 Conformance inspection. Each production EFAS shall be subjected to the examination described in 4.5.1.

4.4 Inspection requirements.

4.4.1 General inspection requirements. Apparatus used in conjunction with the inspections specified herein shall be laboratory precision type, calibrated at proper intervals to ensure laboratory accuracy.

4.4.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data or shorter intervals shall be provided as appropriate for any specific test.

a. Date.

b. Time started.

c. Time finished.

d. Ambient temperature.

e. Ambient humidity.

4.4.3 Test rejection criteria. Throughout all tests specified herein, the EFAS shall be closely observed for the following conditions, which shall be cause for rejection. Note that these conditions are not related to reliability failures.

a. Failure to conform to design or performance requirements specified herein.

b. Any spillage or leakage of any liquid, except as allowed herein.

c. Thermal or structural failure of any component, including permanent deformation, or evidence of impending failure.

d. Evidence of excessive wear. If excessive wear is suspected, the original equipment manufacturer’s (OEM’s) specifications or tolerances shall be utilized for making a determination.

e. Evidence of corrosion or deterioration.

f. Misalignment of components.

g. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

4.4.4 Failure reporting, analysis, and corrective action system (FRACAS). A closed loop system shall be used to collect data, analyze, and record timely corrective action for all potential failures that occur during the first article and operational tests. The contractor's existing FRACAS shall be utilized with the minimum changes necessary to conform to this specification. The system shall cover all test samples, interfaces between test samples, test instrumentation, test facilities, test procedures, test personnel, and the handling and operating instructions. The contractor shall establish and maintain a FRACAS database; all information shall be entered into the database.

Authorized procuring activity personnel shall have read-only access to the FRACAS database.

4.4.4.1 Problem and failure action. At the occurrence of a problem or potential failure that affects satisfactory operation of a test sample, entries shall be made in the appropriate data logs and the failed test sample shall be removed from test, with minimum interruption to the other test samples continuing on test.

4.4.4.1.1 Problem and failure reporting. A failure report shall be initiated at the occurrence of each problem or potential failure of the contractor hardware or software. The report shall contain the information required to permit determination of the origin and correction of the failure. The contractor’s existing failure report form may be used with minimum changes necessary to conform to the requirements of this specification. The failure report form shall include the information specified in a through c:

a. Descriptions of failure symptoms, conditions surrounding the failure, failed hardware identification, and operating time (or cycles) at the time of failure.

b. Information on each independent and dependent failure and the extent of confirmation of the failure symptoms, the identification of failure modes, and a description of all repair actions taken to return the test sample to operational readiness.

c. Information describing the results of the investigation, the analysis of all part failures, an analysis of the system design, and the corrective action taken to prevent failure recurrence. If no corrective action is taken, the rationale for this decision shall be recorded.

4.4.4.1.2 Identification and control of failed items. A failure tag shall be affixed to the failed part immediately upon the detection of any failure or suspected failure. The failure tag shall provide space for the failure report serial number and for other pertinent entries from the test sample failure record. All failed parts shall be marked conspicuously or tagged and controlled to ensure disposal in accordance with contract requirements. Failed parts shall not be handled in any manner which may obliterate facts which might be pertinent to the analysis. Failed parts shall be stored pending disposition by the authorized approval agency of the failure analysis.

4.4.4.1.3 Problem and failure investigations. An investigation and analysis of each reported failure shall be performed. Investigation and analysis shall be conducted to the level of hardware or software necessary to identify causes, mechanisms, and potential effects of the failure. Any applicable method (for example, test, microscopic analysis, applications study, dissection, X-ray analysis, spectrographic analysis) of investigation and analysis which may be needed to determine failure cause shall be used. When the removed part is not defective or the cause of failure is external to the part, the analysis shall be extended to include the circuit, higher hardware assembly, test procedures, and subsystem if necessary. Investigation and analysis of GFE failures shall be limited to verifying that the GFE failure was not the result of the contractor's hardware, software, or procedures. This determination shall be documented for notification of the procuring activity.

4.4.4.1.4 Failure verification. Reported failures shall be verified as actual failures or an acceptable explanation provided to the procuring activity for lack of failure verification. Failure verification is determined either by repeating the failure mode of the reported part or by physical or electrical evidence of failure (for example, leakage residue or damaged hardware). Lack of failure verification, by itself, is not sufficient rationale to conclude the absence of a failure.

4.4.4.1.5 Corrective action. When the cause of failure has been determined, a corrective action shall be developed to eliminate or reduce the recurrence of the failure. Repairs shall be made in accordance with normal field operating procedures and manuals. The procuring activity shall review the corrective actions at the scheduled test status review prior to implementation. In all cases the failure analysis and the resulting corrective actions shall be documented.

4.4.4.1.6 Problem and failure tracking and closeout. The closed loop failure reporting system shall include provisions for tracking problems, failures, analyses, and corrective actions. Status of corrective actions for all problems and failures shall be reviewed at scheduled test status reviews.

Problem and failure closeout shall be reviewed to assure their adequacy.

4.5 Test methods.

4.5.1 Examination of product. Each EFAS shall be examined to verify compliance with the requirements herein prior to accomplishing any other demonstrations or tests listed in 4.6. A contractor-generated, Government-approved checklist (part of the test procedure) shall be used to identify each requirement not verified by an analysis, certification, demonstration, or test, and shall be used to document the examination results. Particular attention shall be given to materials, workmanship, dimensions, welding, fastening, and markings. Proper operation of each EFAS function shall be verified. Certifications and analyses shall be provided in accordance with Table

VI. Each production EFAS shall be inspected to a Government-approved reduced version of the checklist.

TABLE VI. Certifications and analyses.

Paragraph

Required Certifications and Analyses

3.3.4.1 System safety. Contractor system safety hazard analysis (see

4.5.2).

3.3.9 Service life. Contractor analysis of the service life

requirement (see 4.5.3).

3.4.4 Solar radiation. Contractor certification that the EFAS performance is not adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments.

3.6.1 Surface transportability. Contractor surface transportability analysis

(see 4.5.7.1.1) and certification that the EFAS is transportable via all modes of surface shipment (highway, rail, and water) in accordance with MIL-STD-1366, and shall be capable of withstanding the mechanical shock and vibration characteristics of highway, rail, and water transport.

3.6.2 Air transportability. Contractor air transportability analysis (see

4.5.7.2).

3.8.5.2 External communication. Contractor certification that the software does not communicate with any external system.

3.8.5.3 Freeware, shareware, and open source

software.

Contractor certification that the software does not contain any freeware or shareware. If open source software is used, provision of

Configuration Management Plan and Support

Plan.

3.8.5.5 Internet Protocol. Contractor certification that the EFAS supports IPv4 and IPv6.

3.8.5.6 Current vendor support. Contractor certification that the software and its dependencies have current vendor support.

3.8.5.9 Self-signed certificates. Contractor certification that the software does not use self-signed certificates.

3.8.5.10 Foreign software. Contractor certification that the software does not contain any foreign software.

4.5.2 System safety hazard analysis. A system safety hazard analysis of the EFAS shall be conducted in accordance with 4.3.1 through 4.3.8 of MIL-STD-882 to demonstrate compliance with the mishap risk requirement of 3.3.4.1.

4.5.3 Service life analysis. An engineering analysis shall be performed to demonstrate compliance with the service life requirement of 3.3.9.

4.5.4 Electromagnetic interference test. A first article EFAS shall be tested in accordance with

MIL-STD-461: CE102, CS101, CS114, CS115, CS116, RE102 and RS103 to demonstrate compliance with 3.3.5.

4.5.5 Environmental testing.

4.5.5.1 Temperature storage and operation test. A first article EFAS shall be tested in accordance with 4.5.5.1.1.1 of MIL-PRF-28800 to demonstrate compliance with 3.4.1 and 3.4.2.

4.5.5.2 Humidity test. A first article EFAS shall be tested in accordance with 4.5.5.1.1.2 of MIL-

PRF-28800 to demonstrate compliance with 3.4.9.

4.5.5.3 Fungus resistance test. A first article EFAS shall be tested in accordance with 4.5.6.1 of

MIL-PRF-28800 to demonstrate compliance with 3.4.4.

4.5.5.4 Salt fog test. A first article EFAS shall be tested in accordance with 4.5.6.2.1 of MIL-PRF-

28800 to demonstrate compliance with 3.4.5.

4.5.5.5 Sand and dust test. A first article EFAS shall be tested in accordance with 4.5.6.4 of MIL-

PRF-28800 to demonstrate compliance with 3.4.6.

4.5.5.6 Bench handling test. A first article EFAS shall be tested in accordance with 4.5.5.4.3 of

MIL-PRF-28800 to demonstrate compliance with 3.4.7.

4.5.5.7 Transit drop test. A first article EFAS shall be tested in accordance with 4.5.5.4.2 of MIL-

PRF-28800 to demonstrate compliance with 3.4.8.

4.5.5.8 Altitude test. A first article EFAS shall be tested to demonstrate compliance with altitude requirements of 3.4.10.

4.5.6 Weight and dimension tests.

4.5.6.1 Weight test. The weight of a first article EFAS shall be measured to demonstrate compliance with the weight requirement of 3.5.

4.5.6.2 Dimension measurement. A first article EFAS shall be measured to demonstrate compliance with the dimensional requirements of 3.5.

4.5.7 Transportability verification.

4.5.7.1 Surface transportability verification.

4.5.7.1.1 Surface transportability analysis. An engineering analysis shall be performed to demonstrate compliance with 3.6.1. The engineering analysis shall utilize the data for road transportation in accordance with MIL-STD-810, Method 514.7, Table 514.7C-II.

4.5.7.2 Air transportability analysis. An engineering analysis shall be performed to demonstrate compliance with the air transportability requirements of 3.6.2. The analysis shall include all major components and their ability to withstand the accelerations specified in 3.6.2.

4.5.8 Maintainability analysis and demonstration.

4.5.8.1 Preventive maintenance demonstration. All recommended preventive maintenance tasks shall be performed and the task times shall be recorded. It shall be demonstrated that the forces required do not exceed those allowed in MIL-STD-1472.

4.5.9 Fluid analysis demonstration.

4.5.9.1 Functional demonstration. During all testing in section 4.5.9, the first article EFAS units shall be monitored for compliance with 3.9.2, and 3.9.3. Any instance of non-compliance shall be considered a failure. Sufficient testing shall be completed on internal battery power to demonstrate compliance with 3.3.10.

4.5.9.2 Limits of detection demonstration. The limits of detection demonstration shall be performed to demonstrate compliance with 3.9.6. Each first article EFAS shall analyze seven blank

(no wear metals) samples of MIL-PRF-7808 oil. The 3σ limits of detection shall be computed from the average of the 3σ limits of detection for all first articles.

4.5.9.3 Repeatability and reproducibility demonstration. The repeatability and reproducibility demonstration shall be performed to demonstrate compliance with 3.9.10. Each first article EFAS shall analyze the standards required by 3.9.11 seven times. Repeatability and reproducibility shall be computed to 3σ per 3.9.10.

4.5.9.4 Particle size demonstration. The particle size demonstration shall be performed to demonstrate compliance with 3.9.7. Each first article EFAS shall analyze MIL-PRF-7808 oil samples to be supplied by the Government containing 1, 5, and 10 ppm of each element at particle sizes of 5, 10, 20, and 40 μm, for a total of 12 samples of each element identified in Table II. All sample results shall be within the repeatability required in 3.9.10. If any single sample is outside of the required repeatability, it may be retested once. Continued non-compliance shall be considered a failure.

4.5.9.5 Fluid variation demonstration. The fluid variation demonstration shall be performed to demonstrate compliance with 3.9.1. The Government shall supply four additional oil samples made with MIL-PRF-23699, with particle sizes and concentrations randomly selected from the samples required for 4.5.9.4. All sample results shall be within the repeatability required in 3.9.10. If any single sample is outside of the required repeatability, it may be retested once. Continued non-compliance shall be considered a failure. Successful completion of 4.5.9.6 shall demonstrate compliance with the requirement to analyze MIL-PRF-5606 hydraulic fluid.

4.5.9.6 Particle count demonstration. The particle count demonstration shall be performed to demonstrate compliance with 3.9.8. Each first article EFAS shall analyze 10 samples of MIL-

PRF-5606 hydraulic fluid with 0, 0.22, 1.1, 3.3, 7.35, and 14.7 mg/L concentrations of NIST 8631a medium test dust, for a total of 60 samples per first article EFAS. The repeatability of the EFAS computed per ASTM D6300 shall be no greater than specified in Table VII.

TABLE VII. Repeatability at nominal concentration.

ISO Code Nominal Concentration

(p/mL > 4μm)

Repeatability

(p/mL > 4μm)

16 500 320

17 1000 560

18 3500 1600

19 7500 3000

20 15000 5350

21 30000 9500

4.5.9.7 Magnetic chip detector debris analysis demonstration. The magnetic chip detector debris analysis demonstration shall be completed to demonstrate compliance with 3.9.9. Each first article

EFAS shall analyze 1 gram samples of M50 powder with nominal particle sizes of 250, 500, 750, and 1000 μm. The analyses shall meet the repeatability and reproducibility requirement per 3.9.10, and the EFAS shall correctly identify the alloy present as M50 in all four cases.

4.5.9.8 Oil condition and contamination demonstration. The oil condition and contamination demonstration shall be completed to demonstrate compliance with 3.9.12 and 3.9.13. Each first article EFAS shall analyze the samples listed in Table VIII. Limits of detection, 3σ repeatability, and 3σ reproducibility shall meet the requirements listed in 3.9.13.

TABLE VIII. Test samples for oil condition and contamination demonstration.

Property Samples

TAN Three each samples of MIL-PRF-7808 with 0,1,2,3,4, and 5 mgKOH/g TAN (total 18 samples)

Water Three each samples of MIL-PRF-7808 with 0,500,1000,1500, and

2000 ppm of water (total 18 samples)

Alien Fluid Three each samples of MIL-PRF-7808 with 0,10,20,30,40, and

50% MIL-PRF-5606 (total 18 samples)

4.5.9.9 Oil viscosity demonstration. The oil viscosity demonstration shall be completed to demonstrate compliance with 3.9.14. Each first article EFAS shall analyze six samples of MIL-

PRF-7808 Grade 3 oil and shall meet the requirements for repeatability and reproducibility in

ASTM D8092.

4.5.10 Software demonstration. The software demonstration shall be performed to demonstrate compliance with 3.8.4, 3.8.5…