SITT_TRD.docx
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Technical Requirements Document (TRD)
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| File | Type | Posted |
|---|---|---|
| FA8224-15-R-0026-0002.docx | DOCX document | |
| SITT_Preliminary_Design_Concept_-_Dec-2014.docx | DOCX document | |
| Preproposal_QA.docx | DOCX document | |
| Testing_Examples.pdf | ||
| RFP_QA.docx | DOCX document | |
| FA8224-16-R-0026.pdf | ||
| PROPOSED_CDRL_LIST_SITT_ver_7_(002).docx | DOCX document | |
| FA8224-16-R-0026-00001.pdf | ||
| Appendix_E_-_Acronyms.doc | DOC document | |
| Shock_Isolator_Test_Statement_of_Work_(SOW).docx | DOCX document | |
| Complete_CDRL_Package_SITT_13_Apr_16.pdf | ||
| SITT_TRD.docx | DOCX document | |
| Foundation_and_Footing_Information.pdf | ||
| Building_850_Electrical_Panels.pdf | ||
| Purchase_Specification_20160303.doc | DOC document | |
| Building_850_Shop_Layout.pdf | ||
| Appendix_C_SHOCK_ISOLATOR_TEST_TOWER.doc | DOC document | |
| Shock_Isolator_Test_Statement_of_Work_(SOW).docx | DOCX document | |
| Purchase_Specification_20160303.docx | DOCX document |
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Text version
Technical Requirements Document For Shock Isolator Test Tower
4 April 2016
POC: Jacob Jackson, Program Engineer
AFNWC/NIAA
DSN: 777-4361
DISTRIBUTION STATEMENT D: Distribution authorized to DoD and U.S. DoD contractors only for Administrative or Operational Use determined as of 15 October 2015. Other requests for this document shall be referred to ICBM Systems Directorate, Hill AFB, UT 84056-5816.
WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq.) or Export Administration Act of 1979, as amended, (Title 50 U.S.C., App 2401 et seq). Violation of these export- laws is subject to severe criminal penalties. Dissemination of this document is controlled under DOD Directive 5230.25.
DESTRUCTION NOTICE: For classified documents, follow the procedures in DoD 5220.22-M, National Industrial Security Operating Manual, Chapter 5, Section 7, or DoD 5200.1-R, Information Security Program Regulation, Chapter 6, Section 7. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.
Table of Contents
| 1. SCOPE | 8 |
| 1.1 Document Overview | 8 |
| 2 APPLICABLE DOCUMENTS | 8 |
| 2.1 Government Documents | 8 |
| 2.2 Non-Government Document | 9 |
| 2.2.1 Specifications | 9 |
| 2.2.2 Drawings | 9 |
| 3 REQUIREMENTS | 10 |
| 3.1 Definition | 10 |
| 3.1.1 System Diagrams | 10 |
| 3.1.2 Interface Definition | 12 |
| 3.1.2.1 MSS SI | 12 |
| 3.1.2.1.1 Hydraulic and Mechanical Interface | 12 |
| 3.1.2.2 LER SI | 12 |
| 3.1.2.2.1 Hydraulic and Mechanical Interface | 12 |
| 3.1.2.3 LCC SI | 12 |
| 3.1.2.3.1 Pneumatic and Mechanical Interface | 12 |
| 3.1.2.4 SITT External Interface Requirements | 12 |
| 3.1.3 Government Furnished Equipment | 12 |
| 3.1.4 Government Loaned Property List | 13 |
| 3.2 Characteristics | 13 |
| 3.2.1 Performance Characteristics | 13 |
| 3.2.1.1 Testing – General Characteristics | 13 |
| 3.2.1.1.1 SI Test Position | 13 |
| 3.2.1.1.2 Stroke | 13 |
| 3.2.1.1.3 Extend/Retract Rate | 13 |
| 3.2.1.1.4 Hold Position | 13 |
| 3.2.1.1.5 Max Forces, Scenario 1 | 13 |
| 3.2.1.1.6 Max Forces, Scenario 2 | 13 |
| 3.2.1.1.7 Linear Displacement Data Recording | 13 |
| 3.2.1.1.8 In-line Force Data Recording | 13 |
| 3.2.1.1.9 Pneumatic Pressure Data Recording | 13 |
| 3.2.1.1.10 Pneumatic Pressure | 14 |
| 3.2.1.2 Testing – Applied Forces | 14 |
| 3.2.1.2.1 LCC SI | 14 |
| 3.2.1.2.2 MSS SI | 14 |
| 3.2.1.2.3 LER SI | 14 |
| 3.2.2 Physical Characteristics | 14 |
| 3.2.2.1 Electro Static Discharge (ESD) | 14 |
| 3.2.3 Reliability | 14 |
| 3.2.3.1 Availability/Reliability | 14 |
| 3.2.3.2 Operating Life | 14 |
| 3.2.4 Maintainability | 14 |
| 3.2.4.1 Maintenance | 14 |
| 3.2.4.2 Mean Time To Repair | 15 |
| 3.2.4.3 Accessibility for Repair and Maintenance | 15 |
| 3.2.4.4 Accessibility for Adjustment/Calibration | 15 |
| 3.2.5 Environmental Conditions | 15 |
| 3.2.5.1 Operating | 15 |
| 3.2.5.1.1 Temperature | 15 |
| 3.2.5.1.2 Humidity | 15 |
| 3.2.5.1.3 Altitude | 15 |
| 3.2.5.1.4 Fungus | 15 |
| 3.2.5.1.5 Wind | 16 |
| 3.2.5.1.6 Rain | 16 |
| 3.2.5.1.7 Snow | 16 |
| 3.2.5.1.8 Hail | 16 |
| 3.2.5.1.9 Ice | 16 |
| 3.2.5.1.10 Salt | 16 |
| 3.2.5.1.11 Dust | 16 |
| 3.2.5.1.12 Sunshine | 16 |
| 3.2.5.1.13 Vibration | 16 |
| 3.2.5.1.14 Shock | 16 |
| 3.2.5.2 Non-Operating | 16 |
| 3.2.5.2.1 Temperature | 16 |
| 3.2.5.2.2 Humidity | 16 |
| 3.2.5.2.3 Altitude | 17 |
| 3.2.5.2.4 Fungus | 17 |
| 3.2.5.2.5 Wind | 17 |
| 3.2.5.2.6 Rain | 17 |
| 3.2.5.2.7 Snow | 17 |
| 3.2.5.2.8 Hail | 17 |
| 3.2.5.2.9 Ice | 17 |
| 3.2.5.2.10 Salt | 17 |
| 3.2.5.2.11 Dust | 17 |
| 3.2.5.2.12 Sunshine | 17 |
| 3.2.5.2.13 Vibration | 17 |
| 3.2.5.2.14 Shock | 18 |
| 3.2.6 Transportability | 18 |
| 3.2.7 Implementation | 18 |
| 3.2.7.1 Firmware | 18 |
| 3.2.7.2 Test Set Operation | 18 |
| 3.2.7.3 Calibration | 18 |
| 3.2.7.4 Visual Displays | 18 |
| 3.3 Design and Construction | 18 |
| 3.3.1 Materials | 18 |
| 3.3.1.1 Materials, Processes, and Parts | 18 |
| 3.3.1.2 Toxic Products and Formulation | 18 |
| 3.3.1.3 Corrosion Prevention and Control | 19 |
| 3.3.1.4 Dissimilar Metals | 19 |
| 3.3.1.5 Electromagnetic Compatibility/Interference (EMC/EMI) | 19 |
| 3.3.1.6 Finish | 19 |
| 3.3.2 Nameplates and Product Markings | 19 |
| 3.3.2.1 Labels | 19 |
| 3.3.3 Workmanship | 20 |
| 3.3.3.1 Cleaning | 20 |
| 3.3.3.2 Threaded Parts | 20 |
| 3.3.3.3 Bearing Assemblies | 20 |
| 3.3.3.4 Cabling | 20 |
| 3.3.3.4.1 Wiring | 20 |
| 3.3.3.4.2 Shielding | 20 |
| 3.3.3.4.3 Containment | 20 |
| 3.3.3.4.4 Insulation | 20 |
| 3.3.3.4.5 Clearance | 21 |
| 3.3.3.4.6 Welding | 21 |
| 3.3.3.5 Fabrication | 21 |
| 3.3.4 Interchangeability | 21 |
| 3.3.5 Safety | 21 |
| 3.3.5.1 Personnel Safety | 21 |
| 3.3.5.2 Electrical Safety | 22 |
| 3.3.5.3 Electrical Connectors | 22 |
| 3.3.5.4 Mechanical | 22 |
| 3.3.5.5 Factors of Safety | 22 |
| 3.3.5.5.1 Yield | 22 |
| 3.3.5.5.2 Ultimate | 23 |
| 3.3.5.6 Environmental Compliance | 23 |
| 3.3.5.6.1 Environmental Compliance | 23 |
| 3.3.5.6.2 Hexavalent Chrome | 23 |
| 3.3.5.7 Toxic Product Safety | 23 |
| 3.3.6 Human Performance/Human Engineering | 23 |
| 3.3.6.1 Anthropometry | 23 |
| 3.3.6.2 Equipment Handling | 23 |
| 3.3.6.3 Labels | 23 |
| 4 QUALITY ASSURANCE PROVISIONS | 24 |
| 4.1 General | 24 |
| 4.1.1 Quality Conformance Definitions | 24 |
| 4.1.1.1 Inspection/Examination | 24 |
| 4.1.1.2 Analysis | 24 |
| 4.1.1.3 Demonstration | 24 |
| 4.1.1.4 Test | 24 |
| 5 PREPARATION FOR DELIVERY | 25 |
| 6 NOTES | 25 |
| 6.1 Intended Use | 25 |
| 6.2 Definitions | 26 |
| 6.3 Acronym list | 27 |
| 6.4 Tables | 28 |
| 3.2.1.1.7 Linear Displacement Sample Rate | 28 |
| 3.2.1.1.8 In-line Force Sample Rate | 28 |
| 3.2.1.1.9 Pneumatic Pressure Data Recording | 28 |
| 3.2.1.1.10 Pneumatic Pressure | 28 |
| 7 Reserved | 32 |
| 8 Reserved | 32 |
| 9 Reserved | 32 |
| 10 APPENDIX I | 32 |
TRD for SITT 4 April 2016
List of Figures
| Figure 1. LCC SI Testing Diagrams – Equilibrium and Differential (Left), Dynamic (Right) | 10 |
| Figure 2. MSS SI Testing Diagrams – Spring Rate and Friction (Left), Damping (Right) | 11 |
| Figure 3. LER SI Testing Diagram – Spring Rate and Friction | 11 |
| Figure 4. SI General Dimensions | 32 |
List of Tables
| Table 1. Definitions | 26 |
| Table 2 - Verification Requirement Compliance Matrix | 28 |
1. SCOPE
This document establishes the performance, design, development, and test requirements for the ICBM Shock Isolator Test Tower (SITT). The SITT provides means to mechanically validate Acceptance Test Procedure (ATP) procedures for new and refurbished Missile Suspension System (MSS), Launcher Equipment Room (LER), and Launch Control Center (LCC) shock isolators (SIs).
1.1 Document Overview
| Section 1 |
| General scope information, system overview, and defines the document contents and format. |
| Section 2 |
| Identifies applicable documents that are referenced in this specification. |
| Section 3 |
| Requirements for the system/subsystem. |
| Section 4 |
| Quality Assurance Provisions |
| Section 5 |
| N/A |
| Section 6 |
| Notes |
| Section 7 |
| Appendices |
2 APPLICABLE DOCUMENTS
The following documents of the exact revision and date shown form a part of this specification to the extent specified herein. In the event of conflict between the documents referenced herein and the contents of this specification, the contents of this specification shall be considered a superseding requirement.
2.1 Government Documents
| 309th document rev. 14 March 2016 |
| Purchase Specification Shock Isolator Test Tower |
| S-133-128D |
| Minuteman Weapons System Specification |
| S-133-10763 |
| Launcher Equipment Room Shock Isolated Floor |
| S-133-10764 |
| Support – Missile, Shock Isolation and Alignment |
| S-133-112-1-56 |
| Model Specification, Shock Isolator |
| DODI # 8320.04 |
| Item Unique Identification (IUID) Standards for Tangible Personal Property 3 September 2015 |
| MIL-HDBK-454B |
| Electronic Guidelines 15 April 2007 |
| MIL-STD-130N |
| Identification Marking of U.S. Military Property 16 November 2012 |
| MIL-STD-810G |
| Environmental Engineering Considerations and Laboratory Tests 15 April 2014 |
| MIL-STD-882E |
| Standard Practice for System Safety 11 May 2012 |
| MIL-STD-889B |
| Dissimilar Metals 17 May 1993 |
| MIL-STD-1472G |
| Human Engineering 11 January 2012 |
| MIL-STD-1568D |
| Materials and Processes for Corrosion Prevention and Control in Aerospace Weapon Systems 31 August 2015 |
| MIL-STD-1546B |
| Parts, Materials, and Processes Control Program for Space and Launch Vehicle 27 July 1992 |
| MIL-STD-3018 |
| Parts Management 2 June 2015 |
| MIL-STD-461F |
| Control of Electromagnetic Interference 10 December 2007 |
2.2 Non-Government Document
2.2.1 Specifications
| NFPA 70 |
| National Electric Code 1 January 2014 |
| 29 CFR PART 1910 |
| Occupational Safety and Health Standards 1 July 2015 |
| 48 CFR 223.73 |
| Minimizing the Use of Materials Containing Hexavalent Chromium 5 May 2011 |
2.2.2 Drawings
| 25-66751 |
| LER SI |
| 25-66608 |
| MSS SI |
| 1269B-2000 |
| LCC SI W3/5 |
| 25-37556 |
| LCC SI W1 |
3 REQUIREMENTS
3.1 Definition
The SITT validates the operating parameters of the MSS, LCC, and LER SIs in accordance with (IAW) their respective acceptance criteria.
3.1.1 System Diagrams
SITT test diagrams are provided for each unit under test (UUT) in Figure 1, Figure 2 and Figure 3.
Figure 1. LCC SI Testing Diagrams – Equilibrium and Differential (Left), Dynamic (Right)
Figure 2. MSS SI Testing Diagrams – Spring Rate and Friction (Left), Damping (Right)
Figure 3. LER SI Testing Diagram – Spring Rate and Friction
3.1.2 Interface Definition
3.1.2.1 MSS SI
3.1.2.1.1 Hydraulic and Mechanical Interface
a. The SITT shall mechanically interface with the MSS SI in a way representative of the installed configuration with the piston eyelet end on top.
b. The SITT shall provide means to interface the MSS SI with a hydraulic pump while installed in the test tower.
3.1.2.2 LER SI
3.1.2.2.1 Hydraulic and Mechanical Interface
a. The SITT shall mechanically interface with the LER SI in a way representative of the installed configuration with the piston eyelet end on top.
b. The SITT shall provide means to interface the LER SI with a hydraulic pump while installed in the test tower.
3.1.2.3 LCC SI
3.1.2.3.1 Pneumatic and Mechanical Interface
a. The SITT shall mechanically interface with the LCC SI in a way representative of the installed configuration with the piston eyelet end on top.
b. The SITT shall provide means to interface the LER SI with an air compressor while installed in the test tower.
3.1.2.4 SITT External Interface Requirements
For External Interface Requirements reference the Purchase Specification document.
3.1.3 Government Furnished Equipment
For Government Furnished Equipment reference the Purchase Specification document.
3.1.4 Government Loaned Property List
Reserved
3.2 Characteristics
3.2.1 Performance Characteristics
The following performance criteria are applicable to the SITT.
3.2.1.1 Testing – General Characteristics
3.2.1.1.1 SI Test Position
The SITT shall hold all SIs in vertical position with piston eyelet end on top.
3.2.1.1.2 Stroke
The SITT shall allow the piston rods a minimum of 54 inches travel.
3.2.1.1.3 Extend/Retract Rate
The SITT shall be able to extend/retract piston rods at a rate between 0.2 and 1.0 inches/sec.
3.2.1.1.4 Hold Position
The SITT shall be able to hold piston rods in place at any 1/4 inch maximum increment within the stroke lengths specified in S-133-10763, S-133-10764, and S-133-112-1-56.
3.2.1.1.5 Max Forces, Scenario 1
The SITT shall have the ability to support 19,000 ± 500 lb (static) and also use the LCC SI to arrest a 19,000 lb object accelerating, from stand-still, at 32ft/s2 for 2 inches.
3.2.1.1.6 Max Forces, Scenario 2
The SITT shall have the ability to support 41,000 ± 500 lb (static) and also use the MSS SI to arrest a 41,000 lb object accelerating, from stand-still, at 32ft/s2.
3.2.1.1.7 Linear Displacement Data Recording
The SITT shall record linear displacement of piston rods at minimum sample rate of 1 kHz for the entirety of the stroke with minimum resolution of ±0.03125in.
3.2.1.1.8 In-line Force Data Recording
The SITT shall record in-line force at minimum sample rate of 1 kHz for forces between 0 and 64,000 lbf with minimum resolution of ± 60 lbf.
3.2.1.1.9 Pneumatic Pressure Data Recording
The SITT shall independently record pneumatic pressure for the LCC SI tank and cylinder at minimum sample rate of 1 kHz for pressures between 0 and 600psig with a minimum resolution of ±0.5psig.
3.2.1.1.10 Pneumatic Pressure
The SITT shall pneumatically pressurize and bleed pressure from LCC SI up to 500 psi using provided or included compressed air and have the ability to manipulate pressures independently between the cylinder and tank of the LCC SI.
3.2.1.2 Testing – Applied Forces
3.2.1.2.1 LCC SI
The SITT shall be able to apply a force equal to stopping a 19,000 ± 500lbm object accelerating at 32.2 ft/s2 after traveling 2.0 ± 0.1in prior to being arrested by the LCC SI.
3.2.1.2.2 MSS SI
The SITT shall be able to apply a force equal to stopping a 41,000 ± 500 lbm object accelerating from rest at 32.2 ft/s2 while being arrested by the MSS SI.
3.2.1.2.3 LER SI
The SITT shall be able to apply 12,000 ± 500lbf to the LER SI.
3.2.2 Physical Characteristics
3.2.2.1 Electro Static Discharge (ESD)
The test equipment containing electrical and/or electronic subsystems shall be evaluated for ESD by testing in accordance with the test method described in S-133-128D Appendix II Paragraph 20.4.
3.2.3 Reliability
3.2.3.1 Availability/Reliability
a. The Mean Time Between Failures of the SITT, in any combination and in any configuration of items necessary to comply with test, diagnosis, and alignment requirements stated herein, shall not be less than 2000 operating hours.
b. Operating hours for the SITT shall include the sum of all times the item is used for hookup, tests, diagnosis, alignments, and adjustments.
3.2.3.2 Operating Life
The SITT shall meet the requirements of section 3.2.1 (Performance Characteristics) with periodic preventive maintenance for not less than 20 years from the time of initial delivery.
3.2.4 Maintainability
3.2.4.1 Maintenance
a. The test equipment shall be designed to ensure that maintenance access can be accomplished utilizing ordinary tools.
b. The equipment shall be constructed so that no damage to any component occurs and no permanent distortion to any structural member is caused during maintenance and calibration.
3.2.4.2 Mean Time To Repair
Ninety-five percent of all required maintenance tasks shall have a Mean Time To Repair (MTTR) of less than eight hours.
3.2.4.3 Accessibility for Repair and Maintenance
All replaceable components shall be accessible for applicable maintenance actions.
3.2.4.4 Accessibility for Adjustment/Calibration
The equipment design shall permit adjustments and calibration to be made without removing any internal component or subassemblies.
3.2.5 Environmental Conditions
3.2.5.1 Operating
The SITT and its components shall meet the requirements of this TRD after exposure to operating environmental conditions specified in Appendix II of Specification S-133-128D, unless otherwise specified by the procurement agency.
3.2.5.1.1 Temperature
The SITT shall be operated in an indoor, controlled environment with a temperature range between +50 to +90 °F under normal conditions. However, the SITT shall also withstand operating temperatures in an indoor, uncontrolled environment of 0 to +100 °F.
3.2.5.1.2 Humidity
The SITT shall operate in an indoor, controlled environment that has a relative humidity (RH) range of 20% to 80% ± 5% with maximum dew point temperature of +65 °F non-condensing under normal conditions. The SITT shall also withstand operating in an indoor, uncontrolled environment with a RH range of 10% to 95% ± 5% with maximum dew point temperature of +65 °F condensing.
3.2.5.1.3 Altitude
The SITT shall operate at an altitude between sea level and 6500 feet, which is equivalent to 14.7 to 11.6 psia.
3.2.5.1.4 Fungus
An analysis of design documentation shall be performed to verify that the materials listed in MIL-STD-810 Method 508.6 Annex B, Group II are not used in the design of the test equipment. If the analysis does not show compliance, a test shall be performed in accordance with MIL-STD-810 Method 508.6, based on a cost benefit analysis decision by the ICBM Systems Directorate Chief Engineer.
3.2.5.1.5 Wind
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.6 Rain
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.7 Snow
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.8 Hail
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.9 Ice
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.10 Salt
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.11 Dust
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.12 Sunshine
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.13 Vibration
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.1.14 Shock
N/A. The SITT shall be operated in an indoor, controlled environment.
3.2.5.2 Non-Operating
Non-operational storage environment for the SITT shall be in an indoor, controlled environment.
3.2.5.2.1 Temperature
The SITT shall be stored non-operational in an indoor, controlled environment with a temperature range between +50 to +90 °F under normal conditions. However, the SITT shall also withstand non-operating temperatures in an indoor, uncontrolled environment of 0 to +100 °F.
3.2.5.2.2 Humidity
The SITT shall be stored non-operational in an indoor, controlled environment that has a RH range of 20% to 80% ± 5% with maximum dew point temperature of +65 °F non-condensing under normal conditions. The SITT shall also withstand non-operating humidity in an indoor, uncontrolled environment with a RH range of 10% to 95% ± 5% with maximum dew point temperature of +65 °F condensing.
3.2.5.2.3 Altitude
The non-operating altitude/pressure requirement is either subparagraph a. or b. below, depending on the SITT transportation method:
a. Sea level to 40,000 ft (14.7 to 2.7 psia) for all SE transported by non-pressurized aircraft.
b. Sea level to 15,000 ft (14.7 to 8.3 psia) for all SE transported by commercial cargo aircraft or ground transportation.
Commercial-Off-the-Shelf (COTS) vendors may provide evidence of shipping procedures which utilize commercial cargo aircraft to show compliance to subparagraph b.
3.2.5.2.4 Fungus
An analysis of design documentation shall be performed to verify that the materials listed in MIL-STD-810 Method 508.6 Annex B, Group II are not used in the design of the test equipment. If the analysis does not show compliance, a test shall be performed in accordance with MIL-STD-810 Method 508.6, based on a cost benefit analysis decision by the ICBM Systems Directorate Chief Engineer.
3.2.5.2.5 Wind
N/A per S-133-128D Appendix II
3.2.5.2.6 Rain
N/A per S-133-128D Appendix II
3.2.5.2.7 Snow
N/A per S-133-128D Appendix II
3.2.5.2.8 Hail
N/A per S-133-128D Appendix II
3.2.5.2.9 Ice
N/A per S-133-128D Appendix II
3.2.5.2.10 Salt
N/A per S-133-128D Appendix II
3.2.5.2.11 Dust
N/A per S-133-128D Appendix II
3.2.5.2.12 Sunshine
N/A per S-133-128D Appendix II
3.2.5.2.13 Vibration
N/A per S-133-128D Appendix II
3.2.5.2.14 Shock
N/A per S-133-128D Appendix II
3.2.6 Transportability
N/A. The SITT will be assembled on site.
3.2.7 Implementation
The following requirements are fabrication specifications only based on the current implementation and will only be demonstrated during acceptance.
3.2.7.1 Firmware
If the design includes firmware, the test set user interface shall provide the operator a means to confirm a CPIN number upon power up.
3.2.7.2 Test Set Operation
a. The test set shall allow the operator to set the date and time.
b. The test set shall utilize a single cable and a series of adapters to interface to the defined UUT.
c. The test set shall allow the operator to manually enter information and allow the operator to view the information entered via a display.
d. The test set shall allow the operator to adjust the intensity of the display backlight.
3.2.7.3 Calibration
The test set calibration shall only be performed by the contractor or PMEL.
3.2.7.4 Visual Displays
The test set display shall provide prompts to guide the operator through the various test set operations.
3.3 Design and Construction
3.3.1 Materials
3.3.1.1 Materials, Processes, and Parts
a. Materials and processes shall be selected in the order of precedence specified in MIL-STD-1546B.
b. Parts selection in accordance with MIL-STD-3018 unless otherwise specified herein or in an individual item specification.
c. Common Materials Specification (MS), Army/Navy (A/N), or National Aerospace Standard (NAS) mechanical parts shall be used in preference to similar commercial items.
3.3.1.2 Toxic Products and Formulation
Any toxic materials used shall be approved by the procuring activity.
3.3.1.3 Corrosion Prevention and Control
Corrosion prevention and control shall meet requirements in MIL-STD-1568. Commercial parts shall conform to selected manufacturers standard processes.
3.3.1.4 Dissimilar Metals
Contact between dissimilar metals, as defined in MIL-STD-889B, shall be avoided. Where unavoidable, contact surfaces shall be protected against galvanic corrosion as specified in MIL-STD-889B. Contacts between aluminum and copper or their alloys or any other deviations shall not be used without prior approval of the procuring activity.
3.3.1.5 Electromagnetic Compatibility/Interference (EMC/EMI)
N/A
3.3.1.6 Finish
The commercial components may have the as-purchased original finish and colors, provided that such finishes and colors will withstand the environments as specified herein. Commercial parts which must be refinished to withstand the specified environmental conditions shall be refinished to requirements of MIL-STD-1568.
3.3.2 Nameplates and Product Markings
a. Nameplates, product marking, serial and lot number marking, and all other identifying marking required for the system and its equipment and parts shall be in accordance with MIL-STD-130N.
b. The top assembly test equipment shall have a nameplate and product marking IAW MIL-STD-130N, Construct Two.
c. The labels shall be placed in an area that is easily viewable to the end user.
d. Any subassembly of the test equipment that meets the criteria of DODI #8320.04 paragraphs 5.3.1 through 5.3.4 shall also be marked IAW MIL-STD-130N, Construct Two. Parts within an assembly or a subassembly not normally subject to removal, replacement, or repair, need not be marked.
3.3.2.1 Labels
a. Information and warning labels that are not part of the equipment or unit shall be securely attached to prevent its loss, damage, slippage, or accidental or unauthorized removal IAW MIL-STD-130N.
b. The location of any information or warning label not part of the test equipment shall be attached to a structural member that is not removed during equipment servicing or routine maintenance IAW MIL-STD-130N.
c. All labels shall be mounted so as to minimize wear or obscuration by grease, grime, or dirt IAW MIL-STD-130N.
d. To meet the label requirements herein, the labels may be etched directly onto the test equipment IAW MIL-STD-130N.
e. The test equipment shall be appropriately and clearly labeled IAW MIL-STD-130N.
f. Special labels such as warning and instructions shall be prominently displayed in proximity to their intended use IAW MIL-STD-130N.
g. Weight, lifting points, test and service points shall be labeled per the label requirements herein.
3.3.3 Workmanship
3.3.3.1 Cleaning
After fabrication, parts and assembled equipment shall be cleaned of smudges, loose, spattered, or excess solder, weld metal, metal chips and mold release agents, or any other foreign material which might detract from the intended operation, function, or appearance of the equipment.
3.3.3.2 Threaded Parts
Screws, nuts, and bolts shall show no evidence of cross threading, mutilation, or detrimental or hazardous burrs, and have the proper torque per the specification drawing.
3.3.3.3 Bearing Assemblies
a. Bearing assemblies shall be free of rust, discoloration, and imperfections of ground, honed, or lapped surfaces.
b. Contacting surfaces shall be free of tool marks, gouge marks, nicks, or other surface type defects.
c. There shall be no detrimental interference, binding, or galling.
3.3.3.4 Cabling
All internal and external wire harness and cables used for the test equipment shall comply with the following as applicable:
3.3.3.4.1 Wiring
Wires and cables shall be positioned or protected to avoid contact with rough or irregular surfaces and sharp edges and to avoid damage to conductors or adjacent parts.
3.3.3.4.2 Shielding
a. Shielding on wires and cables shall be secured in a manner that will prevent it from contacting or shorting exposed current-carrying parts.
b. The ends of the shielding or braid shall be secured to prevent fraying.
3.3.3.4.3 Containment
a. The harness and cable from containment means shall be neat in appearance, uniformly applied, and positioned to retain critical form factors and breakout locations.
b. The containment means, (lacing, ties, tie down straps, etc.) shall not cause the wire or cable insulation to deform so that performance characteristics are adversely affected.
3.3.3.4.4 Insulation
There shall be no evidence of burns, abrading, or pinch marks in the insulation that could cause short circuits or leakage.
3.3.3.4.5 Clearance
The clearance between wires or cables and heat generating parts shall be sufficient to minimize deterioration of the wires or cables.
3.3.3.4.6 Welding
All welds shall be free of defects, having uniform and smooth fillets, no burn-through, and no damage to adjacent parts resulting from the welding.
3.3.3.5 Fabrication
a. The test equipment shall be fabricated and finished skillfully using standard shop practices and procedures.
b. Particular attention shall be given to: freedom from blemishes, defects, burrs, and sharp edges, marking of parts, appearance of soldering, broaching, welding, riveting, painting and wiring, alignment of parts, and tightness of threaded fasteners.
3.3.4 Interchangeability
a. Design tolerances shall permit parts, subassemblies, and assemblies to be used in their parent assemblies without regard to the source of supply or manufacturer.
b. Parts, subassemblies, and assemblies having the full range of dimensions and characteristics permitted by the specification governing the part, subassembly, or assembly shall be usable as replacement items without selection and without departure from the specified performance guidelines of the parent items.
c. During the standard design review cycle as identified by the respective design authority, all non-military standard parts shall be identified to the customer.
3.3.5 Safety
3.3.5.1 Personnel Safety
The test equipment design and operation shall follow the order of precedence established in MIL-STD-882E, section 4.4, for mitigating system hazards.
a. The test equipment shall comply with MIL-STD-1472G section 4.8, Safety.
b. The test equipment shall comply with MIL-STD-1472G, sections 5.5.3.1.11, Display Lighting, and5.5.4.4, Hazardous Noise.
c. The test equipment shall comply with MIL-STD-1472G, section 5.7 Warnings, Hazards and Safety.
d. The test equipment should comply with MIL-STD-1472G, Section 5.1.2 Control-display integration.
e. Use MIL-STD-1472G as a guide with particular emphasis in the following paragraphs and their sub-paragraphs:
a. Section 5.2 Visual displays.
b. Section 5.4 Controls.
c. Section 5.9 Maintenance Accessibility.
f. Electrical design guidelines for personnel safety are in Guideline 1 of MIL-HDBK-454B and should be applied where feasible.
g. As applicable, guidelines for safety markings are provided in section 4.8 of Guideline 1 of MIL-HDBK-454B and should be applied where feasible.
3.3.5.2 Electrical Safety
a. The test equipment should meet the applicable requirements of the National Electrical Code NFPA 70 and 29 CFR 1910 - Subpart S - Electrical.
b. All electrical conductors shall be protected against condensate by location or insulation.
c. Uninsulated energized connections shall be located or covered so that accidental contact or grounding is prevented.
d. All metallic surfaces shall be bonded together such that the ground terminal of the AC power plug provides grounding of all conductive structural parts and enclosures.
e. All other external components shall be at ground potential.
3.3.5.3 Electrical Connectors
a. Electrical connectors shall be selected or arranged so that it is physically possible to connect only the correct electrical cable and prevent improper connection.
b. This physical means to prevent improper connection shall be accomplished by providing keys or aligning pins, or size, location, or type differences, or equivalent means.
c. All electrical connectors shall be clearly labeled at least once such that the labels are on the cable near the connector or on the connector itself.
3.3.5.4 Mechanical
a. Glass fiber materials shall not be used as outer covering on cables, wires, or other components where they may cause skin irritation to personnel.
b. Hinged devices with hazardous characteristics shall be avoided.
3.3.5.5 Factors of Safety
All hardware which forms a part of the unit structure shall be designed for the following minimum factors of safety:
3.3.5.5.1 Yield
All hardware that forms a part shall be designed for simultaneous application of the limit load, times the yield factor of safety specified herein, and the accompanying environments for each design condition without experiencing detrimental deformation or stress above the structural material yield strength.
a. The minimum yield factor of safety for long-term static and maintenance loads shall be 1.65.
b. The minimum yield factor of safety for lifting loads shall be 3.0.
c. The minimum yield factor of safety for pressure vessels and lines that experience operating pressure surges shall be 1.65.
3.3.5.5.2 Ultimate
All hardware that forms a part shall be designed for simultaneous application of the limit load, times the ultimate factor of safety specified herein, and the accompanying environments for each design condition without experiencing stress above the material ultimate strength.
a. The minimum ultimate factor of safety for long-term static and maintenance loads shall be 2.0.
b. The minimum ultimate factor of safety for lifting loads shall be 5.0.
c. The minimum ultimate factor of safety for pressure vessels and lines that experience operating pressure surges shall be 5.0.
3.3.5.6 Environmental Compliance
3.3.5.6.1 Environmental Compliance
The production, design, and maintenance of the end item shall not require the use of Class I or II Ozone Depleting Substances (ODS), Polychlorinated Biphenyls (PCB), or asbestos; and shall minimize the use of hazardous materials including Environmental Protection Agency (EPA) 17 materials and Hazardous Air Pollutants. The production, design, and maintenance must be in compliance with federal, state, and local environmental laws and regulations.
3.3.5.6.2 Hexavalent Chrome
The use of Hexavalent Chrome (Cr6+), unless excluded by 48 CFR 223 or approved by the Program Executive Officer ALC/CC, shall be prohibited in the design and maintenance of the end item.
3.3.5.7 Toxic Product Safety
a. Test equipment materials shall not liberate gases which alone, or when combined with the atmosphere, result in corrosive fumes which would be detrimental to the test equipment the UUT, or to the health of personnel.
b. The hazmat program shall identify toxic or carcinogenic materials in the test set designs using the EPA-17 screening list.
3.3.6 Human Performance/Human Engineering
3.3.6.1 Anthropometry
Maintenance access and workspace should be in accordance with MIL-STD-1472G, sections 5.9.9 for access openings and cover designs and 5.7.1.3 and 5.7.2 for workspace design.
3.3.6.2 Equipment Handling
The test equipment shall have a means for grasping, handling and carrying in accordance with weight requirements within MIL-STD-1472G section 5.9.11.3 and 5.9.11.5.1.
3.3.6.3 Labels
The SITT and its components shall be appropriately and clearly labeled where required. Labels shall include weight, lift points, test and service points. Special labels such as warnings and instructions shall be prominently displayed in close proximity to their intended use.
4 QUALITY ASSURANCE PROVISIONS
4.1 General
Inspections which consist of examinations, demonstrations, tests, and analyses shall be conducted during the design and development of the SITT to provide the Air Force with assurance of compliance with the requirements of this specification.
The contractor shall be responsible for the performance of all inspections for the SITT produced in accordance with this specification. The procuring activity reserves the right to perform any of the specified inspections at the contractor’s or other facilities.
Qualification of the SITT to assure compliance with the requirements of Section 3 shall be by examinations, demonstrations, tests, or analyses, defined as follows:
4.1.1 Quality Conformance Definitions
4.1.1.1 Inspection/Examination
Inspection, sometimes referred to as Examination, consists of visual inspection, physical manipulation, weighing and/or measurements to verify that a configuration item conforms to the design requirements. This verification method also includes a review of the documentation that controls the configuration.
4.1.1.2 Analysis
Analysis is defined as a computational method using test data or modeling to verify the performance. Analysis is a technical evaluation of equations, graphs, reduced data, and/or representative data. All analysis methods should be standardized or industry recognized methods. Analysis tools need to be under configuration control and approved by the quality organization. Verification by analysis is used when it is not feasible to perform tests to obtain the required data. Analysis is also used where testing is not warranted for verification of requirements.
4.1.1.3 Demonstration
Demonstration is a simple, uninstrumented, buyer-witnessed test where success is determined by a "GO" or "NO-GO" result. These verifications will not generally involve any significant use of analysis or test equipment. In addition, these are verifications that are generally done only once. An example might be the requirement that a radar target of a certain type have a diamond shape displayed in red on the cockpit display. This could be demonstrated on a system bench using a target generator. Once visually confirmed, this requirement is satisfied and would in all probability not be repeated.
4.1.1.4 Test
In the context of a verification method, test implies a formal process. Test is the verification that a requirement is met by a thorough exercising of the system/subsystem/item. This includes actual measurement of unit performance with calculations/analysis as required and under a controlled and/or recorded environment.
5 PREPARATION FOR DELIVERY
N/A
6 NOTES
6.1 Intended Use
The SITT will be used to verify adherence to respective SI acceptance testing.
6.2 Definitions
Table 1. Definitions
| Yield Strength |
| Yield strength (stress) is the stress at which a structural material exhibits a 0.2 percent permanent deformation. |
| Ultimate strength |
| Ultimate strength (stress) is the maximum stress, which a structural material exhibits prior to material rupture or other failure mechanism of the material. |
| Factor of safety |
| The factor of safety is an arbitrary factor intended to account for slight variations from item to item in fabrication quality and details, internal load distribution within the structure, and possible degradation in strength that may result from the actual history of treatment of each structural item in service. |
| Operating environments |
| Operating environments are those environments to which equipment is exposed while performing its operational functions or while in a state of readiness for performing those functions. |
| Non-operating environments |
| Non-operating environments are those environments other than operating environments, including shipping, handling and storage. |
6.3 Acronym list
| Acronym | Definition | |
| ± | plus/minus | |
| °C | Degrees Celsius | |
| °F | Degrees Fahrenheit | |
| AF | Air Force | |
| AFB | Air Force Base | |
| AFI | Air Force Instruction | |
| ANSI | American National Standards Institute | |
| ATP | Acceptance Test Procedure | |
| ATR | Acceptance Test Report | |
| COTS | Commercial Off The Shelf | |
| CPIN | Computer Program Identification Number | |
| dB | Decibel | |
| DoD | Department of Defense | |
| DoDD | Department of Defense Directive | |
| EMI | Electromagnetic Interference | |
| ESD | Electro Static Discharge | |
| EPA | Environmental Protection Agency | |
| FCA | Functional Configuration Audit | |
| fpm | Feet per minute | |
| fps | Feet per second | |
| ft | Feet | |
| GFP | Government Furnished Property | |
| GTP | General Test Plan | |
| HAFB | Hill Air Force Base | |
| Hz | Hertz | |
| IAW | In Accordance With | |
| ICBM | Intercontinental Ballistic Missile | |
| lb | Pounds | |
| lbf | Pounds force | |
| LCC | Launch Control Center | |
| LER | Launcher Equipment Room | |
| m | Meter | |
| ms | Milliseconds | |
| MSE | Maintenance Support Equipment | |
| MSS | Missile Suspension System | |
| ODS | Ozone Depleting Substances | |
| PCA | Physical Configuration Audit | |
| psig | Pounds per square inch, gauge | |
| QTP | Qualification Test Procedure | |
| RH | Relative Humidity | |
| SAE | Society of Automotive Engineers | |
| SI | Shock Isolator | |
| SITT | Shock Isolator Test Tower | |
| TBD | To be Determined | |
| U.S. | United States | |
| UUT | Unit Under Test | |
| USAF | United States Air Force |
6.4 Tables
Table 2 - Verification Requirement Compliance Matrix
| Paragraph |
| Conformance and Verification |
Methods
| Not Applicable |
| Examination |
| Demonstration |
| Test |
| Analysis |
| Qualification |
| Acceptance |
| 3.1.2 Interface Definition |
| X |
| 3.1.2.1 MSS SI |
| X |
3.1.2.1.1 Hydraulic and Mechanical Interface
X
| X |
| X |
| 3.1.2.2 LER SI |
| X |
3.1.2.2.1 Hydraulic and Mechanical Interface
X
| X |
| X |
| 3.1.2.3 LCC SI |
| X |
3.1.2.3.1 Pneumatic and Mechanical Interface
X
| X |
| X |
| 3.1.2.4 SITT External Interface Requirements |
| X |
| 3.2.1 Performance Characteristics |
| X |
| 3.2.1.1 Testing – General Characteristics |
| X |
3.2.1.1.1 SI Test Position
X
X
3.2.1.1.2 Stroke
X
X
3.2.1.1.3 Extend/Retract Rate
X
X
3.2.1.1.4 Hold Position
X
X
3.2.1.1.5 Max Forces, Scenario 1
X
X
3.2.1.1.6 Max Forces, Scenario 2
X
X
3.2.1.1.7 Linear Displacement Sample Rate
X
X
3.2.1.1.8 In-line Force Sample Rate
X
X
3.2.1.1.9 Pneumatic Pressure Data Recording
X
X
3.2.1.1.10 Pneumatic Pressure
X
X
| 3.2.1.2 Testing – Applied Forces |
| X |
3.2.1.2.1 LCC SI
X
X
3.2.1.2.2 MSS SI
X
X
3.2.1.2.3 LER SI
X
X
| 3.2.2 Physical Characteristics |
| X |
3.2.2.1 ESD
X
X
| 3.2.3 Reliability |
| X |
3.2.3.1 Availability/Reliability
| X |
| X |
| X |
3.2.3.2 Operating Life
| X |
| X |
| X |
| 3.2.4 Maintainability |
| X |
3.2.4.1 Maintenance
X
X
3.2.4.2 Mean time to repair
| X |
| X |
| X |
3.2.4.3 Accessibility for repair and maintenance
X
X
3.2.4.4 Accessibility for adjustment/calibration
X
X
| 3.2.5 Environmental Conditions |
| X |
| 3.2.5.1 Operating |
| X |
3.2.5.1.1 Temperature
| X |
| X |
3.2.5.1.2 Humidity
| X |
| X |
3.2.5.1.3 Altitude
| X |
| X |
3.2.5.1.4 Fungus
| X |
| X |
| 3.2.5.1.5 Wind |
| X |
| 3.2.5.1.6 Rain |
| X |
| 3.2.5.1.7 Snow |
| X |
| 3.2.5.1.8 Hail |
| X |
| 3.2.5.1.9 Ice |
| X |
| 3.2.5.1.10 Salt |
| X |
| 3.2.5.1.11 Dust |
| X |
| 3.2.5.1.12 Sunshine |
| X |
| 3.2.5.1.13 Vibration |
| X |
| 3.2.5.1.14 Shock |
| X |
| 3.2.5.2 Non-Operating |
| X |
3.2.5.2.1 Temperature
| X |
| X |
3.2.5.2.2 Humidity
| X |
| X |
3.2.5.2.3 Altitude
| X |
| X |
3.2.5.2.4 Fungus
| X |
| X |
| 3.2.5.2.5 Wind |
| X |
| 3.2.5.2.6 Rain |
| X |
| 3.2.5.2.7 Snow |
| X |
| 3.2.5.2.8 Hail |
| X |
| 3.2.5.2.9 Ice |
| X |
| 3.2.5.2.10 Salt |
| X |
| 3.2.5.2.11 Dust |
| X |
| 3.2.5.2.12 Sunshine |
| X |
| 3.2.5.2.13 Vibration |
| X |
| 3.2.5.2.14 Shock |
| X |
| 3.2.6 Transportability |
| X |
| 3.2.7 Implementation |
| X |
3.2.7.1 Firmware
X
| X |
| X |
3.2.7.2 Test Set Operation
X
X
3.2.7.3 Calibration
X
X
3.2.7.4 Visual Displays
X
X
| 3.3 Design and Construction |
| X |
| 3.3.1 Materials |
| X |
3.3.1.1 Materials, Processes, and Parts
X
X
3.3.1.2 Toxic Products and Formulation
| X |
| X |
3.3.1.3 Corrosion Prevention and Control
X
X
3.3.1.4 Dissimilar Metals
X
X
| 3.3.1.5 Electromagnetic Interference Characteristics |
| X |
3.3.1.6 Finish
X
X
3.3.2 Nameplates and Product Markings
X
X
3.3.2.1 Labels
X
X
| 3.3.3 Workmanship |
| X |
3.3.3.1 Cleaning
X
| X |
| X |
3.3.3.2 Threaded Parts
X
X
3.3.3.3 Bearing Assemblies
X
X
| 3.3.3.4 Cabling |
| X |
3.3.3.4.1 Wiring
X
X
3.3.3.4.2 Shielding
X
X
3.3.3.4.3 Containment
X
X
3.3.3.4.4 Insulation
X
X
3.3.3.4.5 Clearance
X
X
3.3.3.4.6 Welding
X
X
3.3.3.5 Fabrication
X
X
3.3.4 Interchangeability
| X |
| X |
| 3.3.5 Safety |
| X |
3.3.5.1 Personnel Safety
X
X
3.3.5.2 Electrical Safety
X
X
3.3.5.3 Electrical Connectors
X
X
3.3.5.4 Mechanical
X
X
| 3.3.5.5 Factors of Safety |
| X |
3.3.5.5.1 Yield
| X |
| X |
3.3.5.5.2 Ultimate
| X |
| X |
| 3.3.5.6 Environmental Compliance |
| X |
3.3.5.6.1 Environmental Compliance
X
X
3.3.5.6.2 Hexavalent Chrome
X
X
3.3.5.7 Toxic Product Safety
X
X
| 3.3.6 Human Performance/Human Engineering |
| X |
3.3.6.1 Anthropometry
X
X
3.3.6.2 Equipment Handling
X
X
3.3.6.3 Labels
X
X
LCC SI Old Tower Comparison Test
X
X
LER SI Old Tower Comparison Test
X
X
MSS SI Old Tower Comparison Test
X
X
7 Reserved 8 Reserved 9 Reserved
10 APPENDIX I
Figure 4. SI General Dimensions image1.png image2.png image3.png image4.png image5.png
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