Appendix_N.2_-_Example_Certification_Test_Report.pdf

CERTIFICATION TEST Report for

F-108-CF-100 Main Engine Control on

MAIN ENGINE CONTROL TEST STANDS

PN: 3C3972G05-OC002

3C3972G05-OC003

LOCATION: BUILDING 3902

REPORT DATE: 14 OCTOBER 2010

Appendix N.2

F-108-CF-100 Main Engine Control Certification Test Report

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Introduction

This document describes the certification test plan to qualify the General Electric (GE) Main Engine Control Test Stand 3C3972G05-OC002 and 3C3972G05-OC003, located in Building 3902, to perform and meet the production testing requirements of the F108-CF-100 Main Engine Control per T.O. 6J3-4- 113-3.

Background

The GE Main Engine Control Test Stand 3C3972G05-OC002 was modified under contract # FA8101-04- D-008, to replace the obsolete, proprietary, GE Microflo system with modern, commercial off the shelf (COTS), PLC/PC data acquisition and control system components. These modifications were performed to replace obsolete and unsupportable components and software. In addition, this modification will increase future parts availability and technical support and increase stand availability for production while reducing overall operating costs.

System Overview

Modifications performed on test stand 3C3972G05-OC002 replaced obsolete system components with modern COTS PLC/PC based data acquisition and control system components. All mechanical systems including pumps, piping, control valves and connection ports remain in the original GE configuration to maintain the original testing intent and specifications.

System Calibration and Accuracies

Test Stand calibration was performed and certified by Tinker PMEL Technicians IAW T.O. 00-20-14.

Calibration accuracies meet the requirements listed in 6J3-4-113-3 and the original test equipment referenced in this technical order.

Part Number For Correlation Testing

The Part Number listed in TABLE 1 was utilized for the correlation and single run comparsion study.

TABLE 1 Part Number Used For Correlation Testing Part Number

SN

Noun T.O.

Test Stand P/N

Test Method

9278M96P10 WYG47615 F-108-CF-100 Main Engine Control 6J3-4-113-3 3C3972G05-C002 5 run correlation 9278M96P10 WYG47615 F-108-CF-100 Main Engine Control 6J3-4-113-3 3C3972G05-C002 Single Run

Comparsion

Five Run Correlation Process

1. A serviceable fuel control listed in TABLE 1 was run five times on the Master Test Stand (3C3965G05) to obtain baseline correlation data. The control was then run five times on the Modified Test Stand (3C3972G05-OC002) and data recorded.

2. Data results were checked for outliers utilizing the Weisberg t-Test (See Attachment B – Statistical Correlation and Validation Method). If an outlier was flagged by the t-Test an additional run was made and replaced the outlier. If an outlier was still indicated after replacing the suspected outlier data point, it was considered normal data scatter and all six runs were used in developing the 95% confidence interval analysis. In cases, where the outlier was flagged but the means of the two data sets were within the test stand accuracy tolerance, the outlier was not considered significant with regards to the correlation analysis.

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3. The results from the correlation methods were documented in Attachment A – F-108 -Correlation Test Data for 3C3972G05-OC002.PDF

4. Correlation between the two data sets was accomplished utilizing the MOSI Method with a confidence interval of 95%. (See Attachment B – Statistical Correlation and Validation Method).

Single Run Comparison Method

This test method will be used for all identical test stands to the original correlation test stand. The single run comparison method will utilize the correlation data from both the Master Test Stand and modified correlation test stand. The 5 runs from both test stands will be averaged to provide a mean. The calculation; (mean times the Critical T ±Standard Deviation ± measurement device accuracy) was used to develop the allowable limits for the single data run comparison.

The results from the single run comparison method is provided in Attachment C F-108 MEC Single Run Comparison For 3C3972G05-OC003.PDF

Signature Sheet

Based on the contents of this report, the undersigned certify the GE Main Engine Control Test Stand Part Numbers 3C3972G05-OC002 and 3C3972G05-OC003 meet all test requirements of Technical Order 6J3-4-113-3.

X

76 CMXG/ENE

X

OC-ALC/GKGBAB

LANE.JACK.

R.1239575150

Digitally signed by LANE.JACK.R.1239575150 DN: cn=LANE.JACK.R.1239575150, c=US, o=U.S. Government, ou=DoD Date: 2010.10.14 17:56:29 -05'00'

1135822589C Rectangle

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Attachments:

Attachment A - F-108 -Correlation Test Data for 3C3972G05-OC002.PDF Attachment B - Statistical Correlation and Validation Method.PDF Attachment C F-108 MEC Single Run Comparison For 3C3972G05-OC003.PDF