Attachment_4_Program_Management_Plan-NWSS_Test_Assets.pdf

Program Management Plan

For

Development, Integration, and Execution of

AGM-86, Air Launched Cruise Missile

Aging & Surveillance Program

498th MSUG 7330 Sentry Blvd

Tinker AFB, OK 73145

July 7, 2009

ATTACHMENT IV: PROGRAM MANAGEMENT PLAN (PMP). FOR REFERENCE ONLY.

ii

TABLE OF CONTENTS

1 INTRODUCTION

1.1 Overview

1.2 Scope

2 REFERENCE DOCUMENTS

3 PROGRAM DEVELOPMENT & IMPLEMENTATION

3.1 Organization

3.2 Program Schedule

3.3 Technical Approach

3.3.1 Hardware Analysis Tasks

3.3.2 Implementation Tasks

4 AGE SENSITIVITY ITEM ANALYSIS (ASIA)

4.1 Test Candidates

4.2 Test Parameters

5 ENVIRONMENTAL TEST PLANS (ETPs)

6 TEST REQUIREMENTS DOCUMENTS (TRDs)

6.1 Test Configurations

6.2 A&S Test Classifications

6.3 A&S Test Types

6.3.1 Baseline “A” Tests

6.3.2 Interval “B” Tests

6.3.3 Comprehensive “C” Tests

7 SAMPLING

7.1 Test Frequency

7.2 Sample Size and Sample Source

7.2.1 WAD

7.2.1.1 Dedicated Samples

7.2.1.2 Field Return Samples

7.2.1.3 Contingency Spares

7.2.2 Impact Sensor

7.2.2.1 Dedicated Samples

7.2.2.2 Field Return Samples

7.2.2.3 Contingency Spares

7.2.3 Rotary Switch

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7.2.3.1 Dedicated Samples

7.2.3.2 Field Return Samples

7.2.3.3 Contingency Spares

7.3 Additional Set Aside Requirements

7.3.1 Installation and Checkout (I&CO) Samples

8 SAMPLE STORAGE ENVIRONMENTS

8.1 Warhead Arming Device Storage Environment

8.2 Impact Sensor Assembly Storage Environments

8.3 Rotary Switch Storage Environments

9 TEST SCHEDULES

9.1 Recommended/Planned Test Schedules

10 DATA ANALYSIS AND SERVICE LIFE ESTIMATE

10.1 Methodology

10.2 Statistical Analysis

10.3 Service Life Estimate

10.4 Reports

10.5 Data Backups

11 OPERATIONAL IMPLEMENTATION FLOW

11.1 Implementation Approach

11.2 Intermediate Level A&S Activities

11.3 Test Level Activities

11.4 Implementation Tasks

11.4.1 Program Office

11.4.2 Contractor

12 ACRONYMS

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LIST OF FIGURES

Figure 1. MOB Temperature Comparison Chart Figure 2. MOB Humidity Comparison Chart Figure 3. ALCM A&S Implementation Flow Figure 4. Test Level Activities Figure 5. Implementation Tasks

LIST OF TABLES

Table 1. ALCM 2010 A&S Program Milestone Schedule Table 2. Recommended/Planned WAD Test Program for the First 10 Test Cycles Table 3. Recommended/Planned Rotary Switch Test Program for the First 10 Test Cycles Table 4. Recommended/Planned Impact Sensor Assembly Test Program for the First 10 Test

Cycles Table 5. Test Equipment

LIST OF APPENDICIES

v

AGE SENSITIVITY ITEM ANALYSIS (ASIA) REPORTS

Appendix A: Warhead Arming Device * Appendix B: Impact Sensor Assembly * Appendix C: Rotary Switch *

ENVIRONMENTAL TEST PLANS (ETPs)

Appendix D: Warhead Arming Device * Appendix E: Impact Sensor Assembly * Appendix F: Rotary Switch *

TEST REQUIREMENTS DOCUMENTS (TRDs)

Appendix G: Warhead Arming Device * Appendix H: Impact Sensor Assembly * Appendix I: Rotary Switch *

MISCELLANEOUS DOCUMENTS

Appendix J: Sample Size Analysis Appendix K: Recommended Temperature and Humidity Excursion Cycles for Stored Rotary

Switches

* Separately Bound Documents

1 INTRODUCTION

1.1 Overview

Original planning for the Air Launched Cruise Missile (ALCM) included provisions for a 10-year program life. As with most Department of Defense Weapon Systems, the ALCM has remained in the active inventory for many years beyond the original planned life without a firm end of life definition. Currently, the projected system life is planned through the year 2030. The Cruise Missile Aging & Surveillance (A&S) Program outlined in this document provides an orderly approach to analyzing age sensitive electro-mechanical devices and delivering statistically significant trend assessments on related parametric data thus determining service life expectancies for the age sensitive hardware.

The Cruise Missile A&S Program was initially modeled after the A&S Program developed and successfully executed for the electro-mechanical devices that are contained in the Re-Entry Vehicles associated with the Inter-Continental Ballistic Missiles. The Cruise Missile A&S Program was initiated on the Nuclear Weapon Sub-System (NWSS) for the Advanced Cruise Missile beginning in 1999. That program included testing on the Arm Disarm Devices, Impact Sensors, Warhead Mounts and Separation Switches. Management plans have included incorporating tests for the NWSS components in the ALCM as well as other flight critical components used in the weapon system.

Current contract actions include testing of the ALCM NWSS components in A&S with provisions for including other components as funds are identified and requirements dictate.

The ALCM NWSS consists of three components (Warhead Arming Device, Rotary Switch, and Impact Sensor). Each of these components was designed with a Service Life Requirement (SLR) of 10 years. This design goal was satisfied through analysis and testing during the production of the hardware. As the system gets older, the electro-mechanical devices in the components will tend to age. This aging can be attributed to fair wear-and-tear, the materials used in manufacture, and/or the original manufacturing and assembly processes.

In those instances where age related degradation can impact the safety or reliability of the force, it becomes necessary to monitor the aging trends to allow timely retrofit actions. The Aging & Surveillance (A&S) Program is the depot test program that has been devised to monitor age sensitive parameters on electro-mechanical components.

The decision to conduct an A&S Program on the ALCM nuclear components was based on an orderly approach that addressed the following minimum requirements:

a) Component Sensitivity Analysis: A study was accomplished to determine the sensitivity to aging and the relative impact on mission performance for each sensitive parameter. This study is referred to as an Age Sensitivity Item Analysis (ASIA). The results of the study have been documented in an ASIA Report for each component.

b) Identification of Test Candidates: The results of the ASIA were used to determine which components were valid test candidates.

c) Definition of Environmental Test Levels: Typical A&S tests include subjecting the component under test to environments such as shock, vibration, high/low temperature, and acceleration profiles. The test levels for the ALCM NWSS components were determined based on functional requirements, Stockpile to Target Sequence limits, specifications, and programmatic limitations.

Environmental test levels were documented in Environmental Test Plans (ETPs) for each component.

d) Determination of Sample Size and Sample Source: Statistical considerations, coupled with the test conditions, number of test conditions, and cost effectiveness, provided the rational for determining the sampling size and test frequency. The source for samples was recommended based on the test conditions and logistic impacts.

e) Definition of the Test Requirements: The hardware test configuration, along with the component test parameters, was established and documented in a Test Requirements Document (TRD).

The overall viability of conducting an ALCM A&S Program has been established.

The test equipment has been designed and is currently being modified or fabricated. The database required to store the parameter measurements has been established and the data analysis techniques and engineering criteria for evaluating the Service Life Estimate have been developed and integrated.

1.2 Scope

In light of the current system life projection to the year 2030, the management team responsible for the ALCM A&S Program will likely see several changes in personnel. This plan has been designed to preserve the technical approach taken to define the program requirements, define the necessary implementation tasks (i.e., test equipment design, fabrication and installation), and outline the management requirements for successful execution of the program.

2 REFERENCE DOCUMENTS

The following documents are for reference and guidance in the development of the A&S Program:

1. MIL-STD-1543 Reliability Program Requirements for 15 July 1974 Space and Missile Systems

2. MIL-STD-785B Reliability Program for System and Equipment 15 September 1980 Development and Production

3 PROGRAM DEVELOPMENT & IMPLEMENTATION

3.1 Organization

The initial Cruise Missile A&S Program for ACM was developed and conducted under United States Air Force contract XXXXXX. Consulting agreements and subcontracting actions were established to acquire such specialties as “materials expertise and statistical sample size analyses.” During the development of the ACM A&S Program the contractor the contractor worked closely with the Nuclear Weapons Directorate located at Kelly AFB to design, develop and deliver a suite of equipment to assess the remaining life of the age sensitive components of ACM Nuclear Weapon Sub System (NWSS) components. The equipment included in this suite comprises a major test complex.

As a result of a 1995 Defense Base Closure and Realignment Commission (BRAC) decision, Kelly Air Force Base, Texas, was realigned and the San Antonio Air Logistics Center, including the Air Force maintenance depot, was closed. At that time the Nuclear Weapons Support workload transferred to Kirtland AFB NM, OO-ALC UT, and OC-ALC OK. Throughout the transfer of workload, a contractor maintained the ACM A&S Test Complex at the corporate headquarters facility in XXXXXXX. Testing at the facility continued on an annual basis to assess the remaining life of the age sensitive ACM NWSS components.

A contractor was awarded contract XXXXXXXX to establish and sustain effective and efficient managed life cycle support of the Cruise Missile Sustainment Squadron’s Air Launched Cruise Missile (ALCM) laboratory test programs necessary to support and sustain cruise missile weapon systems. One of its many tasks requires the contractor to develop service life estimates and service life extensions based on annual tests of component samples. Upon contract award, work began immediately to upgrade the A&S Test Complex to permit the testing and assessment of age sensitive ALCM NWSS components. The A&S Test Complex upgrade is complete. Base year testing is well under way and the first year option to contract XXXXXXXXX was exercised on June 26, 2009.

3.2 Program Schedule

Current funded and/or negotiated tasks include annual tests for the 3 ALCM NWSS components. Additional tests can be developed for other electro-mechanical devices in the weapon system as funds and requirements are aligned.

Those development efforts will be monitored on individual schedules, while subsequent test cycles for those components can be co-joined with the existing test program.

Table 1 shows the FY2010 ALCM A&S program milestone schedule.

Receive Field Return Test Samples July 09 Complete Impact Sensor Tests September 09 Complete Rotary Switch Tests November 09 Complete Warhead Arming Device Tests

February 10

Submit Tear Down Analysis (TDA) Plan

April 10

Submit TDA Report May 10 Deliver Final Report Jun 10

Table 1. ALCM 2010 A&S Program Milestone Schedule

3.3 Technical Approach

The technical approach to the development of the ALCM A&S Program for NWSS components consisted of predefined analysis tasks and implementation tasks. The analysis tasks resulted in the development of the Age Sensitivity Item Analysis Reports, the Environmental Test Plans, the Test Requirements Documents, a Final Report, and this Program Management Plan. The results of the analysis tasks were used to complete the implementation portion of the program. The major elements of these tasks are described in the following paragraphs.

3.3.1 Hardware Analysis Tasks

a. Analytical assessment through development of the Age Sensitivity Item Analysis to determine aging characteristics and mechanisms associated with the components.

b. Selection of candidates to be included in the A&S Program.

c. Establishment of the test requirements to include test parameters, test limits, test environments, sample source/size, and test schedules.

3.3.2 Implementation Tasks

a. Design, develop and fabricate new test equipment and support equipment, or modify existing/available equipment as required to implement the test requirements.

b. Perform Installation, Checkout and Demonstration (IC&D) of the new and/or modified equipment.

c. Conduct tests on components to validate and verify the capability.

d. Develop the database required to assess and predict the individual service life for each component.

4 AGE SENSITIVITY ITEM ANALYSIS (ASIA)

The approach outlined in section 3.3 used the results of the ASIA as the first step in establishing test candidates. The ASIA identified which components were considered likely to degrade over time. The A&S test program will measure the performance degradation of these components. The goal of the program is to detect degradation early enough to allow sufficient lead-time for retrofit/replacement actions prior to decreased safety or reliability of the weapon.

Appendices A, B, and C contain the ASIA Reports, which detail the analysis approach and the results of the analysis for the Warhead Arming Device, Rotary Switch and Impact Sensor.

4.1 Test Candidates

The Executive Summaries of each ASIA contain recommendations for including each of the three NWSS components in the A&S Program. An orderly approach for tracking each A&S candidate item has been established through the assignment of Major Unit Identification Numbers (MUINs). The ALCM MUIN assignment is as follows:

Warhead Arming Device MUIN 101 Impact Sensor Assembly MUIN 102 Rotary Switch MUIN 103

4.2 Test Parameters

Each ASIA Report contains a listing of the parameters recommended for inclusion in the A&S Program along with the rational for each recommendation.

Two types of test parameters are included in the A&S Program. Those types are defined as Critical and Non-Critical. Critical parameters include all age sensitive test parameters that could cause mission failure or injury to personnel due to age related degradation. Non-Critical parameters include test parameters that may affect mission performance, but will not cause mission failure or injury to personnel. Non-Critical parameters are captured to assist in troubleshooting anomalous conditions.

5 ENVIRONMENTAL TEST PLANS (ETPs)

ETPs document the test approach required for each component identified as age sensitive in the Age Sensitivity Item Analysis (ASIA). Detailed assessment of each failure mode has resulted in a comprehensive description of the test conditions and test level environments, along with a test description, for each critical parameter. The ETPs for the Warhead Arming Device, Rotary Switch and Impact Sensor are provided as Appendices D, E, and F.

6 TEST REQUIREMENTS DOCUMENTS (TRDs)

TRDs have been developed for each component identified as age sensitive in the Age Sensitivity Item Analysis Report. The TRDs document the test equipment requirements for the specific components selected for test in the A&S Program.

Combined, the ASIA and the Environmental Test Plan (ETP) detail the individual failure modes and test parameters associated with a given component. The individual TRD’s treat each test parameter separately, while the complete TRD contains a composite set of requirements from which the necessary test equipment and software can be specified. The TRDs for the Warhead Arming Device, Rotary Switch and Impact Sensor are provided as Appendices G, H, and I.

6.1 Test Configurations

The TRDs document the test item configuration requirements. Test conditions that call for levels of disassembly or intrusive maintenance actions have been detailed. Variances between the test configurations for the A&S tests and acceptance or functional tests have been identified.

6.2 A&S Test Classifications

Two basic environmental levels have been defined within the A&S Program, namely “ambient” and “hard”. The ambient level determines whether the aging environment (i.e., storage and periodic maintenance) affects the performance characteristics of the hardware. The hard environments include the application of vibration, shock, and/or temperature variation to determine if the hardware is capable of performing in a flight environment after being subjected to the aging environment. In some instances, a destructive tear down will be required. This destructive test is also classified as a hard environment. In the event an age out problem is detected, this dual level concept allows a comparison to determine if the problem is due to aging alone or if it is caused by the interactive effect of aging and the flight environment.

6.3 A&S Test Types

The two test classifications, namely ambient and hard, are further characterized by definition of the types of tests conducted within the classification. Five specific test types have been defined for the ALCM A&S Program. Baseline “A” Tests and Interval “B” Tests comprise the ambient classification, while three Comprehensive “C” Tests (C1, C2, and C3) fall within the hard environment classification.

6.3.1 Baseline “A” Tests

These tests are non-damaging tests that establish the health of each parameter of interest. The A Tests should be conducted at the earliest possible opportunity. In as much as the ALCM A&S Program development was started well after the production lines were shut down and the hardware was delivered to the Air Force, it is impossible to capture data at true time to (typically referred to as zero-time data). Therefore, the baseline should be established by testing the maximum number of samples available in the first test cycle. Section 7 discusses in detail the recommended sample size and source.

6.3.2 Interval “B” Tests

These tests are non-damaging tests that are made on dedicated A&S units.

Section 7 discusses in detail the recommended sample size, source, and test frequency. These dedicated units should be stored in a controlled environment that emulates the aging environment of the operational force. Section 8 details the recommended storage environments. A comparison of the cumulative B test data from year to year with the previously established baseline will determine if the aging environment is causing degradation.

6.3.3 Comprehensive “C” Tests

Comprehensive tests include pre-environment tests (C1), tests during environments (C2), and post-environment tests (C3). Comprehensive tests are designed to include the baseline parameters as well as functional performance parameters. The Environmental Test Plans for each component define the test environments for each parameter.

7 SAMPLING

In 1999, a sample size analysis for Advance Cruise Missile components determined that statistical “power” analysis could be used to determine the number of A&S samples that should be tested in order to predict forward 72 months with 90% confidence that less than 10% of the force would be affected by an aging problem. Although the sample size analysis was performed on the ACM NWSS components (i.e., A/DD, Separation Switch, and Impact Sensor), the results of the analysis remain fundamentally sound and can be applied to the ALCM NWSS components. Not only to the ALCM components serve equivalent functions as their ACM counterparts, but they also have similar reliability and service life requirements. WAD, Rotary Switch, and Impact Sensor A&S sample size have been derived directly from the ACM analysis. See the Sample Size Analysis Report for details (Appendix J). It is worth noting here that the basic results sample size analysis were directly in line with the sample size requirements levied on the Re-Entry Vehicle component A&S tests that were the original model for the Cruise Missile A&S tests.

Based on engineering judgement and past experience, the following recommendations are made with regard to initial sample sizes. In light of the fact that a programmatic decision has been made to conduct only non-destruct tests on the WAD, Impact Sensor, and Rotary Switch, the sample sizes identified here include quantities which would not support destructive testing.

7.1 Test Frequency

An annual test schedule is required to preserve the 72-month lead-time for preventive maintenance actions.

7.2 Sample Size and Sample Source

Based on engineering judgement, the contractor recommended that the sample sizes for each test type should reflect the recommendations outlined in the ETPs.

7.2.1 WAD

Three types of samples are recommended for the WAD, namely dedicated samples, field return samples, and contingency spares.

7.2.1.1 Dedicated Samples

A minimum of 6 dedicated WAD samples are required to meet the ETP requirements. The dedicated A&S samples were drawn from assets pulled from the deactivation stockpile and segregated for continued use in the A&S Program.

7.2.1.2 Field Return Samples

Four field return samples are required each year. Eight WADs were drawn from the deactivation stockpile and set aside for pipeline assets to meet the field return requirements. These 8 assets have been segregated into 2 sets of 4 each. The pipeline will allow for one set of samples to be in the current year test cycle and one set to be in the repair/re-qualification cycle following the preceding test cycle and to obtain 4 serviceable assets to be pre-positioned at OO-ALC to replace the samples selected for the next test cycle. This decision to use 8 pipeline assets was based on the fact that the turn around time for repair and re-qualification cycle should be minimal; therefore, those assets could be used to obtain the next year’s samples.

7.2.1.3 Contingency Spares

It is likely that during the course of conducting the A&S Program individual units will fail and become unsuitable for continued use. Setting aside contingency spares will prevent delays and distractions when failures are encountered. The contingency spares will be maintained in the same controlled environment recommended for the dedicated assets. The initial recommendation to draw 10

WADs from the deactivation stockpile and control them as contingency spares has been executed.

7.2.2 Impact Sensor

Three types of samples are recommended for the Impact Sensor, namely dedicated samples, field return samples, and contingency spares.

7.2.2.1 Dedicated Samples

A minimum of 6 dedicated Impact Sensor samples are required to meet the ETP

7.2.2.2 Field Return Samples

Four field return samples are required each year. Eight Impact Sensors were drawn from the deactivation stockpile and set aside for pipeline assets to meet the field return requirements. These 8 assets have been segregated into 2 sets of 4 each. The pipeline will allow for one set of samples to be in the current year test cycle and one set to be in the repair/re-qualification cycle following the preceding test cycle and to obtain 4 serviceable assets to be pre-positioned at OO-ALC to replace the samples selected for the next test cycle. This decision to use 8 pipeline assets was based on the fact that the turn around time for repair and re-qualification cycle should be minimal; therefore, those assets could be used to obtain the next year’s samples.

7.2.2.3 Contingency Spares

spares will prevent delays and distractions when failures are encountered. The contingency spares will be maintained in the same controlled environment recommended for the dedicated assets. The initial recommendation to draw 10 Impact Sensors from the deactivation stockpile and control them as contingency spares has been executed.

7.2.3 Rotary Switch

Three types of samples are recommended for the Rotary Switch, namely dedicated samples, field return samples, and contingency spares.

7.2.3.1 Dedicated Samples

A minimum of 12 dedicated Rotary Switch samples are required to meet the ETP

7.2.3.2 Field Return Samples

Four field return samples are required each year. Eight Rotary Switches were drawn from the deactivation stockpile and set aside for pipeline assets to meet the field return requirements. These 8 assets have been segregated into 2 sets of 4 each. The pipeline will allow for one set of samples to be in the current year test cycle and one set to be in the repair/re-qualification cycle following the preceding test cycle and to obtain 4 serviceable assets to be pre-positioned at OO-ALC to replace the samples selected for the next test cycle. This decision to use 8 pipeline assets was based on the fact that the turn around time for repair and re-qualification cycle should be minimal; therefore, those assets could be used to obtain the next year’s samples.

7.2.3.3 Contingency Spares

spares will prevent delays and distractions when failures are encountered. The contingency spares will be maintained in the same controlled environment recommended for the dedicated assets. The initial recommendation to draw 10 Rotary Switches from the deactivation stockpile and control them as contingency spares has been executed.

7.3 Additional Set Aside Requirements

In addition to the samples required for dedicated hardware, pipeline assets, and contingency spares several other considerations must be made to assure that all A&S Program requirements are satisfied.

7.3.1 Installation and Checkout (I&CO) Samples

During the A&S development effort, “golden” units were required as test beds for developing, validating, and verifying the automatic test equipment. These assets will be used throughout the A&S Program to perform system self tests and to aid in troubleshooting anomalies. A Program Office decision has resulted in a plan to set aside 4 of each type sample for I&CO use. This includes 4 each WADs, 4 each Impact Sensor Assemblies, and 4 each Rotary Switches. Many of these assets will be destructively tested and dissected to meet program goals and cannot therefore be returned to a serviceable condition.

8 SAMPLE STORAGE ENVIRONMENTS

The storage environments for the dedicated A&S samples differ from component to component. These variations are detailed in the Environmental Test Plans for each component. Appendices D through F contain the ETPs. The dedicated A&S samples should be maintained in a clean environment. A detailed historical record should be maintained documenting the number and types of tests conducted on each sample. The samples should be unpacked and neatly shelved.

The following paragraphs highlight the overall requirements for each component.

8.1 Warhead Arming Device Storage Environment

The recommended storage environment for the WADs represents approximations to the seasonal changes at the current Main Operating Bases (MOB 1 and MOB 2). That is, the recommended storage environment is 3 months at 70 degrees Fahrenheit, 3 months at 100 degrees Fahrenheit, 3 months at 70 degrees Fahrenheit, and 3 months at 0 degrees Fahrenheit. Since the missiles are desiccated and the WAD is contained within the desiccated compartment, a constant 20% relative humidity is recommended. The weather stations at the MOBs provided monthly averages for both the temperature and humidity patterns.

The following charts reflect the patterns for the MOBs.

Figure 1. MOB Temperature Comparison Chart

Figure 2. MOB Humidity Comparison Chart

Temperature Comparison

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

MOB 1

MOB 2

8.2 Impact Sensor Assembly Storage Environments

The samples should be stored identical to the storage specified for the WAD in paragraph 8.1.

8.3 Rotary Switch Storage Environments

The recommended storage environments for the rotary switch reflect the day to day changes in temperature and humidity at the operational bases. Rotary Switches are not housed in the desiccated compartment of the missile and are therefore susceptible to exposure to moisture and temperature changes.

Temperature fluctuations coupled with the relative humidity at the Main Operating Bases (MOBs) could force moisture past the o-ring seal on the switch actuation plunger and into the switch. Therefore a 360-day excursion cycle has been created. Appendix N contains a detailed explanation of the recommended cycle. Two configurations will be stored in the environments – one set with the detent pin removed and one set with the detent pin installed.

9 TEST SCHEDULES

The test schedules recommended in the Environmental Test Plans have been reviewed and deemed appropriate by the Program Office. There are no destruct tests planned. Section 9.1 outlines the ETP recommended and actual planned test schedules.

9.1 Recommended/Planned Test Schedules

Humidity Comparison

J a n

F e b

M a r

A p r

M a y

J u n

J u l

A u g

S e p

O c t

N o v

D e c

Month

R e la ti v e H u m id it y

MOB 2

MOB 1

Technical discussion with the program office during the development effort led to firm planning numbers for the sample sizes for each component. The actual planning numbers under consideration for the first 10 years are included in Tables 4 through 6.

Sample Size Test Cycle

Dedicated A&S

Samples

Contingency Spares

Pipeline Assets

Field Returned Samples

Total Number Samples

1 2 3 4 5 6 7 8 9 10

GROUP 1:

2 ea WADs

C A

B B B

GROUP 2:

A

B B B

GROUP 3:

A

B B B

10 ea 10 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

6 10 4 36 56 20 6 6 6 6 6 6 6 6 6

Table 2. Recommended/Planned WAD Test Program for the First 10 Test Cycles

A&S

Samples

Contingency Spares

Pipeline Assets

Field Returned Samples

Total Number Samples

1 2 3 4 5 6 7 8 9 10

4 ea Rotary Switches

4 A B B B

10 ea 10 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

12 10 4 36 62 34 8 8 8 8 8 8 8 8 8

Table 3. Recommended/Planned Rotary Switch Test Program for the First 10 Test Cycles

A&S

Samples

Contingency Spares

Pipeline Assets

Field Returned Samples

Total Number Samples

1 2 3 4 5 6 7 8 9 10

2 ea impact sensor assemblies

2 A B B B

10 ea 10 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

4 ea 4 C

9 10 4 36 56 31 7 7 7 7 7 7 7 7 7

Table 4. Recommended/Planned Impact Sensor Assembly Test Program for the First 10 Test Cycles

10 DATA ANALYSIS AND SERVICE LIFE ESTIMATE

Following each test cycle, the parametric data for each test parameter must be added to the assessment database for analysis and service life predictions. The database is integrated with a software program that was specified for use in performing the data analysis. The Cruise Missile A&S test station control computer is also used to provide long-term data storage. A Cruise Missile Data Analysis program has been developed by the contractor to conduct the post-test data analysis and trend analysis required to establish service life estimates.

10.1 Methodology

A&S data is captured by automated test equipment and/or manual data entry at the time the measurement is made. The Cruise Missile test station controller stores the data files to a pre-defined file structure that is used by the Data Analysis program. This is a convenient technique, as the transferred data files require no intermediate (manual) conversion steps. The methods and data formats for transfers were defined in conjunction with the original development of the Cruise Missile A&S automated test equipment.

A Major Unit Identification Number (MUIN) has been assigned for each NWSS component type in the A&S program. The A&S Program will take samples of each MUIN and perform the A&S measurements identified in the associated Test Requirements Document (TRD). This will provide measurement data that will be statistically analyzed in order to develop parameters used to look for aging trends and predict remaining service life.

A separate statistical analysis will be run for each A&S parameter to estimate MUIN service life based only on that single parameter. A curve will be fit to the measured data, then the curve will be compared to the limits specified for that measurement as identified in the TRD. The results of the analyses for individual measured parameters will be combined to establish a Service Life Estimate (SLE) for the MUIN.

Test data for each parameter identified in the TRD will be collected in the A&S database after each test. The measurement data will be entered in the A&S database with appropriate vendor codes, lot numbers, acceptance dates, and test-type codes. The additional test information and codes will be used to extract data sets to be used in the statistical analysis. The database includes measurement limits (upper and/or lower physical limits) per specifications noted in the TRD for each A&S parameter.

A relational database has been created to maintain the A&S measurement data that will be used for the statistical analysis. The database has been implemented for the 3 ALCM NWSS components and the measurements defined in the TRD. Flexibility has been designed in for future use of the database and Data Analysis software for changes in measurements data, additional components, other A&S programs, and enhancement of the analysis methods.

A&S image files (photographs, graphs, and similar historical data) will be maintained as separate files. File naming conventions for A&S data follow the names specified in the TRDs so that consistency is maintained. The image files will be archived on removable media.

10.2 Statistical Analysis

The standard sequence of A&S data analysis is as follows:

Select individual or grouped data sets from the database for analysis.

Establish validity and integrity of test data. Display plots of data points, linear regression line, confidence region limits, and parameter limits. Identify outlier data points that might be handled differently in the analysis (but not deleted from the database).

Perform hypothesis test for significance of slope of regression line or of correlation coefficient.

Perform goodness-of-fit test of regression, i.e., determine whether residuals are normally distributed with zero mean and homogeneous variance.

If necessary for the analysis, perform data transformations to correct lack of linear fit (e.g., logarithmic, exponential, or reciprocal).

Apply non-parametric U-Test when sample size is small (i.e., n1 or n2 is less than 30).

10.3 Service Life Estimate

The SLE is defined as the lesser of (1) the point in time that the 90% confidence bound intersects the individual parameter specification limit or (2) the Service Life Requirement

(SLR).

During the development of the ACM A&S program, it was determined that statistical “power” analysis was required to determine the number of A&S samples that should be tested in order to predict forward 72 months with 90% confidence that less than 10% of the force will be affected by an aging problem. Refer to the Sample Size Analysis Report for details (Appendix J). The issue was that the required A&S sample size could not be validated until sufficient measurement data has been collected to characterize the variation of the measurements. The power analysis could be performed for at least the first few years of the A&S program. This would coincide nicely with the need to gather at least three years worth of data prior to assessing the SLE. However, the sample sizes defined as the initial ACM requirements match exactly with the sample requirements defined for the program life for the Re-Entry Vehicle A&S Program. Therefore, the annual power analysis will be forgone and the sample size will remain constant.

The following types of engineering tasks will be included in the data analysis and reporting:

Determine SLR, where SLR is the age of the oldest component plus 72 months.

Investigate failures in A&S Program, Service STAR, and flight tests and field returns.

Screen parameters for correlation with age for linear SLE less than SLR.

Determine pooled, vendor, or lot grouping by physical differences in hardware or statistical differences in data.

Test screen parameters for compliance with linear requirements.

Make statistical adjustments as appropriate for specific non-compliance.

Determine the MUIN SLE.

10.4 Reports

The Data Analysis software program provides the following standard reports:

Hard copy of any graph Residuals analysis results Tabular hard copy of A&S parameter data

10.5 Data Backups

The Data Analysis system includes software and hardware to perform periodic back-up of the A&S database. Backups are made to removable disk media.

11 OPERATIONAL IMPLEMENTATION FLOW

As requirements are defined, additional ALCM flight critical hardware can be included in the Cruise Missile A&S Program for long-term assessment. Funding constraints can force the development of the additional A&S test capability into a multi-phased effort.

Due to this phased effort, an implementation approach has been designed which will allow for development to continue, as funding is available, while completing annual testing as the capability is delivered. The following paragraphs outline the implementation flow.

11.1 Implementation Approach

As a result of any further phased development, the implementation of the new A&S program will follow the flow outlined in Figure 3. Task orders will be issued to the contractor for program development as funds allow. The contractor will deliver the Data Analysis Capability per task order. The contractor will store and control the assets set aside for the A&S Program. As test capability is completed, The contractor will conduct annual tests, coordinating with OC-ALC and OO-ALC to pre-position replacement hardware and gather test samples.

The existing depot capability includes all of the technical data required to remove and replace the selected samples (returning the missile to operational status) and then package the samples for shipment. The likely source for sample selection is the Analytical Condition Inspection (ACI) Program. The A&S samples can be removed at the end of the ACI task (just prior to re-assembly and the outgoing Level I test).

The MOBs activities will not change using this approach. They will continue to process missiles for the normal ACI Program.

At the end of the A&S Program Development effort, a full operational test capability will be available.

11.2 Intermediate Level A&S Activities

With the implementation approach outlined above, the depot (OO-ALC) activities are the only intermediate level activities associated with the A&S Program. These activities are limited to removal and replacement of selected samples, and packaging the selected samples for shipment.

11.3 Test Level Activities

During the development period, the contractor will conduct the test level maintenance activities. (Note: The Program Office activities will be addressed in the next subsection.) Figure 4 shows the test level activities in the form of a block diagram.

At the conclusion of the development effort, the test level activities will remain the same regardless of who will be conducting the tests or where the tests will be conducted.

Figure 3. ALCM A&S Implementation Flow

Samples Set-Aside

~Initial Pipeline

~Dedicated "B Samples"

~Contingency Spares

~Storage/Control

(ESTI)

Conduct Annual Testing

Throughout Development

(ESTI)

A&S Samples Drawn from ACI Missiles

(OO-ALC)

MOB Ships

ACI Samples

(MOB)

Gather

Test

Samples

Develop A&S Program as Funding Permits

(ESTI)

Depot Capability

Established

(Factory)

Initial Force

Posturing

(Factory)

A&S Operational

Capability

(ESTI)

Conduct Data Analysis

~Data Analysis

~Data Storage

~Report Results

(OC-ALC)

Task Orders for Phased

Development

(OC-ALC)

Complete Test Capability

(per task order)

Pre-Position

Replacement

Assets

Deliver Data Analysis

Capability

Deliver Full

Capability

Pre-Position

Replacement

Assets

Gather Test

Samples

Figure 4. Test Level Activities

Inspect, Store & Maintain

~ Dedicated "B" Samples

~ Contingency Spares

Conduct A&S Tests

Receive & Inspect "C" Samples

Pre-Position Replacements

(Pipeline Assets)

Manage Pipeline Assets

1st Year Test to Establish

Baseline Data

Deliver Data & Status Reports

11.4 Implementation Tasks

11.4.1 Program Office

The Program Office involvement in implementing the Cruise Missile A&S Program is depicted in Figure 4. An Indefinite Delivery/Indefinite Quantity Task Order type contract will be established to route the task orders to the contractor for program development, for sample storage, and to conduct the annual tests. As shown in Figure 4, each of these lead into the test level activities block that was broken down in Figure 3.

In addition to managing the task orders, the Program Office will be responsible for the data analysis and Service Life Estimates. This requirement was covered in detail in Section 10 of this plan.

The Environmental Test Plans (ETPs) detail the test and support equipment required to conduct all recommended tests, to include both destructive and non-destructive tests. A decision was made to include all non-destructive tests for all components, but only the destructive disbond test for the warhead mount in the A&S Program. Based on this decision, a revised list of the equipment required is provided in Table 7.

11.4.2 Contractor

As defined by specific task orders, the contractor will develop the necessary test capabilities, provide for sample storage, conduct annual tests, and participate in failure analysis/refurbishment of samples.

Throughout the development effort, the contractor will be conducting the annual tests, therefore contractor format test procedures are considered both adequate for use and less expensive to develop and maintain. These procedures will be adapted to technical orders at a later date, if deemed necessary.

During the conduct of the annual testing, anomalies will likely occur that will interfere with the program. These anomalies may be anything from a short delay due to equipment malfunction to a catastrophic failure of the test sample. An Anomaly Reporting and Failure Analysis Tracking System will be established to mitigate the impacts of the delays. Formal records will be established to document anomalous conditions, resolutions, and authorized deviations from established procedures.

Establish Task Order

Contract Issue Task Order to

Store Hardware

Deliver Assets to AES

~"B" Samples

~Contingency Spares

~Pipeline Samples

Establish Program

Development Task

Deliver Data Analysis

Capability

(per task order)

Deliver Test Capability

(per task order)

Test Level Activities

(See Figure 3)

Establish Task Order to Test

(per completed phase)

Figure 5. Implementation Tasks

Equipment Item Suggested Mfg. and P/N or Description

WAD

Used For

Rotary Switch

Used For

Impact Sensor

Used For

Milliohmmeter Hewlett-Packard 4338B Contact resistance tests

Contact resistance tests

Contact resistance tests

Test lead kit Hewlett-Packard 16338A Contact resistance tests

Contact resistance tests

Contact resistance tests

High-potential tester Associated Research 7550DT Leakage current tests

Leakage current and insulation resistance

Leakage current and insulation resistance

Digital storage oscilloscope Hewlett-Packard 54600A Motor current tests; A4/B4 timing tests

Switch transfer time

Digital multimeter Hewlett-Packard 3458A Various electrical tests

LCR (Capacitance) meter Hewlett-Packard 4278A Capacitor and EMI filter tests

Power supply, variable Hewlett-Packard 6626A Relay tests;

Motor tests;

Wet tantalum leakage current

Force Measurement System with Linear Positioning Axis

Mecmesin Detent pin push and pull force verification

Shaker table Ling Electronics

Functional test Shock test Impact Test

Shaker table controller Spectral Dynamics

Functional test Shock test Impact Test

Table 5. Test Equipment

Equipment Item Suggested Mfg. and P/N or Description

WAD

Used For

Rotary Switch

Used For

Impact Sensor

Used For

Accelerometer with cable 10 mV/G, 200G minimum;

PCB Piezotronics

Dynamic test Dynamic test Dynamic test

Environmental chamber, AGREE type

Thermotron or other Functional test under environment

Environmental chamber, small

Thermotron or other Dedicated A&S Samples

Environmental chamber, medium

Thermotron or other Dedicated A&S Samples

Dedicated A&S Samples

Environmental chamber, large

Thermotron or other

Computer and related hardware/software

(test controller) ATE controller ATE controller

Printer Hewlett-Package Laserjet ATE reports ATE reports ATE reports Helium leak tester Varian 959 Housing seal integrity test

Nitrogen compressed gas bottle instrument grade inert gas Housing seal integrity test

Hand tools Test Fixture (custom) Various Shaker table mounting fixtures for functional tests; fixtures for helium leak test

Detent pin push and pull force verification

Shaker table mounting fixture for impact test

Table 7. Test Equipment (cont.)

12 ACRONYMS

A&S Aging & Surveillance ACI Analytical Condition Inspection ACM Advanced Cruise Missile ALCM Air Launch Cruise Missile WAD Warhead Arming Device ASIA Age Sensitivity Item Analysis ER Event Report ETP Environmental Test Plan IC&D Installation Checkout & Demonstration MOB Main Operating Base MUIN Major Unit Identification Number NucWeapSEP Nuclear Weapon System Evaluation Program NW Directorate of Nuclear Weapons NWSS Nuclear Weapon Sub-System OC-ALC Oklahoma City Air Logistic Center OO-ALC Ogden Air Logistic Center SLE Service Life Estimate SLR Service Life Requirement TRD Test Requirements Document UML Unified Measurements List