MIL-DTL-0083833B_Published_Copy_dated_12-DEC-2014.pdf

Comments, suggestions, or questions on this document should be addressed to:

AFLCMC/WNZED, Robins AFB GA 31098-1813 or email to SPEC99@us.af.mil . Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil .

AMSC N/A FSC 5430

DISTRIBUTION STATEMENT A. Approved for public release.

INCH-POUND

MIL-DTL-0083833B(84)

12 December 2014

USED IN LIEU OF

MIL-DTL-83833A

10 June 2014

DETAIL SPECIFICATION

3000 GALLON AERIAL BULK FUEL DELIVERY SYSTEM BLADDER

This specification is approved for interim use by the Air Force Life Cycle Management Center.

Other activities in the Department of Defense may use this interim revision or may continue using MIL-DTL-83833A.

1. SCOPE

1.1 Scope. This specification covers the general requirements and tests for a 3000 Gallon Aerial Bulk Fuel Delivery System (ABFDS) Bladder, used with the C-5, C-17, and C-130 aircraft.

2. APPLICABLE DOCUMENTS

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

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

MIL-DTL-0083833B

COMMERCIAL ITEM DESCRIPTIONS

A-A-52557 Fuel Oil, Diesel; for Posts, Camps and Stations A-A-59326/5 Coupling Half, Female by Internal Pipe Thread, Type V A-A-59326/10 Coupling Half, Cap, Dust, Type IX

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-6855 Rubber, Synthetic, Sheets, Strips, Molded or Extruded Shapes, General Specification for

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Identification Marking of U.S. Military Property MIL-STD-209 Lifting and Tiedown Provisions MIL-STD-810 Environmental Engineering Considerations and

Laboratory Tests MIL-STD-882 System Safety MIL-STD-1472 Human Engineering MIL-STD-1791 Designing for Internal Aerial Delivery in Fixed Wing

Aircraft

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

2.2.2 Other Government documents, drawings, and publications. This paragraph is not applicable to this specification.

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL (ASTM)

ASTM A276 Standard Specification for Stainless Steel Bars and Shapes ASTM B85/B85M Standard Specification for Aluminum Alloy Die Castings ASTM B221 Standard Specification for Aluminum and Aluminum

Alloy Extended Bars, Rods, Wire, Shapes and Tubes ASTM D1149 Standard Test Method for Rubber Deterioration-Surface

Ozone Cracking in a Chamber

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken PA 19428-2959 or online at http://www.astm.org )

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI-H35.1 Alloy and Temper Designation Systems for Aluminum

(Copies are available from the American National Standards Institute, 1899 L Street, NW, 11th Floor, Washington DC 20036 or online at http://www.ansi.org.)

SOCIETY OF AUTOMOTIVE ENGINEERS (ASME)

SAE-ARP1247 General Requirements for Aerospace Ground Support Equipment, Motorized and Nonmotorized

SAE-AS3578 Packing, Preformed - O-Ring Seal Ams7271 SAE-AS29513 Packing, Preformed, Hydrocarbon Fuel Resistant, O Ring

(Application for copies should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale PA 15096 or online at http://www.sae.org .)

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

3. REQUIREMENTS

3.1 First article inspection. When specified, a Bladder (or bladders) shall be subjected to first article inspection in accordance with 4.2.

3.1.1 Sample selection plan. Prior to initial production, the contractor shall produce a Sample Selection Plan. The plan shall be designed for use in the quality conformance testing of Section 4 and shall provide the Government a method of selecting production seams, bonded fittings, coated fabric, and handle samples for destructive testing. The samples shall be cut from a production Bladder selected at random in accordance with Section 4. The test samples shall be provided in sufficient quantity for testing as specified in the Sample Selection Plan. The Sample Selection Plan shall be made available, upon request, to the contracting officer or Government representative on the site of the manufacturer.

3.1.2 Bladders for testing. Bladders selected as testing samples are in addition to the quantity required for delivery and shall remain the property of the contractor after completion of testing.

All bladders selected as samples for destructive testing must be completed samples.

3.2 Materials. The materials and components shall conform to applicable specifications, standards, and patterns required herein. Unless otherwise specified, nonmetallic materials used in construction of the assembly shall not have been manufactured more than 24 months prior to the date of delivery, except for rubber products, which shall have a cure date more than 12 months prior to the delivery date. However, when a definite material is not specified, a material shall be used which will enable the bladders to meet the performance requirements of this specification. Recovered materials shall be used to the maximum extent possible.

3.2.1 Material deterioration, prevention, and control. The bladder shall be fabricated from compatible materials, inherently resistant or treated to provide protection against the various forms of deterioration that may be encountered in the operational and storage environments to which it may be exposed.

3.2.1.1 Dissimilar metals. Dissimilar Metals shall not be used in intimate contact with each other unless appropriately protected against galvanic corrosion.

3.2.1.2 Identification of materials and finishes. The contractor shall identify the specific material, material finish, or treatment for use with components and subcomponents, and shall make information available upon request to the Government.

3.2.2 Coated fabric. The coated fabric shall be free from blisters, holidays or pinholes, and shall show no signs of coating delamination. The coated fabric shall withstand the effects of all environmental elements stated herein without damage or deterioration of performance requirements.

3.2.2.1 Coating compounds. Compounds used for the formulation of Acrylonitrile-Butadiene coatings shall be suitable for use with hydrocarbon fuels containing up to 40 percent aromatics.

The coating compounds shall be resistant to fungus, weathering, ozone, hydrolytic attack, and temperatures up to 160 °F.

3.2.2.2 Nylon cloth. The nylon cloth of the coated fabric shall be high tenacity and heat and light resistant. The nylon cloth shall be free from any imperfections affecting strength, coating adhesion, or coating thickness.

3.2.2.3 Weathering resistance. When tested as specified in 4.5.7, the nylon cloth shall have a retained breaking strength that is not less than 45 percent of its initial breaking strength warp and fill pounds minimum.

3.2.4 Fill/evacuate and vent nozzle material. Alloy and temper designations of wrought aluminum shall be in accordance with ANSI-H35.1. Cast aluminum alloy shall conform to ASTM-B85/B85M. Mold and sand castings are permissible.

3.2.5 Fill/evacuate and vent flange material. Alloy and temper designations of wrought aluminum shall be in accordance with ANSI-H35.1. Cast aluminum alloy shall conform to ASTM-B85/B85M. Mold and sand castings are permissible.

3.2.6 "D" rings material. The "D" ring material shall be equivalent to ASTM-A276 Type 304L stainless steel rod, low carbon alloy steel that allows welding.

3.3 Design and construction. The design shall promote cost effective, life-cycle sustainability by addressing considerations such as incorporating open standards, reducing pollutant emissions and wastes, and increasing fuel economy, while satisfying system performance requirements.

The bladder shall be constructed in accordance with the design in Figures identified in Appendix A. It is a built-up assembly of a number of constituent parts. These parts shall be joined by a leak-proof bonding process, which results in a homogeneous bladder equipped with twenty-eight

(28) diagonal forward restraint straps, ten (10) lateral double "D" tie down rings, and eight (8) lift handles. The bladder shall also equipped with a vent assembly and fill/evacuate assembly.

Internal to the bladder shall be three (3) rows of fluid flow restrictors (synonymous with surge suppresser) which are tied to the internal bladder with nylon tie cord. The fill/evacuate assembly shall be fitted with a quick disconnect type pressure gauge.

3.3.1 Bladder and associated component design.

3.3.1.1 Basic bladder. The basic bladder shall consist of six (6) Sections joined by an adhesive bonding process. The composition of the basic bladder material shall be Acrylonitrile-Butadiene Rubber (NBR) and nylon fabric (MIL-PRF-6855) inter-layered to form a layered sandwich construction. The bladder shall be 100 inches wide, 235 inches long, and approximately four (4) inches high when collapsed. The bladder shall be 108 inches wide, 240 inches long, and approximately 36 inches high when filled to normal capacity.

3.3.1.2 Double “D” tie down rings. There shall be ten (10) double "D" tie down rings located on the upper bladder external surface. The rings shall be attached to the bladder's longitudinal centerline by means of a coated NBR nylon strap, which is bonded to a patch, which, in turn, is bonded to the bladder surface.

3.3.1.3 Lift handles. The bladder shall be equipped with eight (8) lift handles located below the natural fold line of the bladder. The handles shall be formed from two (2) individual straps of coated fabric wrapped together with a coating to enable shaping. The straps shall be bonded to a patch, which is, in turn, bonded to the external bladder surface.

3.3.1.4 Fill/evacuate assembly. The fill/evacuate assembly shall consist of two subassemblies, which are mated with twenty (20) mounting bolts utilizing an O-ring for the sealing medium:

a. Subassembly No. 1. Subassembly 1 shall be the fill/evacuate nozzle which allows the attachment to the bladder on one side and the cap sealing of the nozzle or hose attachment point on the other. The fill/evacuate nozzle shall contain a foot feature on the lower surface of the mounting plate. The foot feature shall consist of four (4) pedestals with a diagonal channel across two (2) of the four (4) pedestals. This feature enables the fill/evacuate nozzle to come into contact with the lower internal surface of the bladder during fuel evacuation without allowing the lower surface to be sucked up into the suction port.

b. Subassembly No. 2. Subassembly 2 shall be the fill/evacuate flange which is made integral with the bladder's surface by the use of adhesive bonding and coating to form a leak-proof attachment.

3.3.1.5 Vent assembly. The vent assembly shall consist of two (2) subassemblies, which are mated with ten (10) mounting bolts utilizing an O-ring for the sealing medium:

a. Subassembly No. 1. Subassembly 1 shall be the vent nozzle, which allows the attachment to the bladder on one side and the cap sealing of the nozzle or the attachment of the anti-siphoning valve on the other.

b. Subassembly No. 2. Subassembly 2 shall be the vent flange, which is made integral with the bladder's surface by the use of adhesive bonding and coating to form a leak-proof attachment.

3.3.1.6 Reed valve vapor eliminator. The bladder shall be equipped with an automatically actuated reed valve vapor eliminator. The vapor eliminator shall attach to the vent assembly. It shall be capable of venting vapor through a ¾ inch ID hose that is attached to the aircraft overboard vent while bladder is filled/evacuated at 600 gpm.

3.3.1.7 Fluid flow restrictors. The bladder shall be equipped with three (3) internal rows of fluid flow restrictors, which control fuel surge. These restrictors shall be trapezoidal sections of material, which are a sandwich design with a stiffener to allow them to stand away from the bladder's internal skin. There shall be twenty (20) Sections in each row arranged alternately to restrict flow in both longitudinal directions. Each section of material shall be tied to the bladder's internal surface by means of an interlaced nylon cord utilizing eyelet-protected openings for the lacing. The eyelets shall be present on the restrictor sections and mating ribs of bladder material, which enable a continuous ring of restrictors to be formed that completely encircle the interior of the bladder laterally. This design produces a 26: 1 ratio of input velocity to output velocity by transmitting fluid surge to the bladder skin. An alternate design approach may be selected to enable new technology approaches with Government approval.

3.3.2 Bladder assembly construction.

3.3.2.1 Basic bladder. The bladder shall be fabricated from single-ply coated fabric as specified herein. The configuration and dimensions of the bladder and the location of ports, fittings, handles, and restraint system shall be as shown in Appendix A, Figure 1. For both bladder interior and exterior, all coated fabric edges (seams, patches, and fabric flanges of fittings) shall be covered with coated fabric or coating compound used to fabricate the bladder. Coated fabric panels may be spliced together to make up the length of the bladder. All bladder seams between adjacent panels shall be constructed to prevent wicking through the nylon fabric.

3.3.2.2 Forward restraint harness. The Forward Restraint Harness shall be built into the forward section of the bladder as shown in Appendix A, Figure 1. The harness shall consist of fourteen

(14) each 24 foot long straps which are bonded together and bonded to the bladder. Each individual strap shall attach to a "D" Ring in fashion to enable the "D" to be an integral part of the forward restraint harness and bladder. This shall be accomplished on both ends of the strap.

The underside straps are attached to a fixed length strap (not part of the bladder) to the appropriate tiedown clevis on the platform utilized for transportation. The topside straps are attached to an adjustable length strap (not part of the bladder) to the appropriate tiedown clevis on the platform. The straps shall be positioned on the bladder such that they run diagonally across the Bladder, around the nose, and under the bladder. All fourteen (14) straps shall be equal in length and configured so that the longest length of strap on the top surface results in the shortest length of strap underneath and vice versa. This technique of diagonal straps and bonding results in the bladder being constrained by twenty-eight (28) attachments to the transportation platform.

3.3.2.3 Lift handles. The lift handles shall be 1.75 to 2.0 inches wide U-shaped straps, as shown in Appendix A, Figure 2, fabricated from nylon cloth that is coated with the same coating used externally on the bladder. They shall be fastened to a coated fabric patch similar to the Bladder material. The patch shall be bonded to the bladder below the peripheral fold line. The patch shall not be placed over the Bladder's seams. There shall be eight (8) lift handles on the bladder.

The lift handles shall be placed in accordance with Appendix A, Figure l.

3.3.2.4 Fill/evacuate and vent flanges. The fill/evacuate and vent flanges shall be bonded to the coated fabric of the bladder as shown in Appendix A, Figure 1. The manufacture shall be as shown in Appendix A, Figures 3 and 4. A patch-type procedure may be utilized. The fill/evacuate and vent flanges shall have protective coatings. The minimum coating thickness shall be 0.0004 inch for castings and 0.0007 inch for wrought aluminum. All aluminum parts exposed to view on the outside of the bladder shall have a dyed coating approximating the bladder exterior color and shall be non-reflective.

3.3.2.5 Closure plates - fill/evacuate and vent flange. The closure plates shall be bolted to the fill/evacuate and vent flanges prior to shipment. The manufacture shall be as shown in Appendix A, Figures 5 and 6. Closure Plates shall have protective coatings. The minimum coating thickness shall be 0.0004 inch for castings and 0.0007 inch for wrought aluminum. All aluminum parts exposed to view on the outside of the bladder shall have a dyed coating approximating the bladder exterior color and shall be non-reflective.

3.3.2.6 "D" rings (forward restraint harness) and double “D” rings. The double and single "D" Ring assemblies shall be capable of being shaped and welded to form one continuous ring as shown in Appendix A, Figures 7 and 8. Installation of double and single "D" Ring assemblies shall be as specified in 3.3.2.2.

3.3.2.7 Fill/evacuate nozzle. The fill/evacuate nozzle shall be bolted to the fill/evacuate flange utilizing a sealing medium. The nozzle shall be packaged/shipped with the bladder in the same container. It shall then be installed on the bladder fill/evacuate flange prior to use. The manufacture shall be in accordance with Appendix A, Figure 9. Aluminum alloy fill/evacuate nozzle shall have protective coatings. The minimum coating thickness shall be 0.0004 inch for castings and 0.0007 inch for wrought aluminum. All aluminum parts exposed to view on the outside of the bladder shall have a dyed coating approximately the bladder exterior color and shall be non-reflective.

3.3.2.8 Vent nozzle. The vent nozzle shall be bolted to the vent flange utilizing a sealing medium. The nozzle shall be packaged separately and shipped with the bladder in the same container. It shall then be installed on the bladder vent flange prior to use. The manufacture shall be in accordance with Appendix A, Figure 10. The aluminum alloy vent nozzle shall have protective coatings. The minimum coating thickness shall be 0.0004 inch for castings and

0.0007 inch for wrought aluminum. All aluminum parts exposed to view on the outside of the bladder shall have a dyed coating approximately the bladder exterior color and shall be non-reflective.

3.3.3 Identification and information plates. The bladder shall be identified in accordance with MIL-STD-130 by means of an identification label. The label shall be made of coated fabric and bonded to the bladder in a readily accessible location. Additionally it shall be marked with an Item Unique Identification (IUID). UID information shall be included as both a bar code and human readable markings. The following information shall be molded, either recessed or in relief, using 0.50 inch lettering on the identification label:

BLADDER, FABRIC

3000 U.S. GALLONS FUEL

PART NUMBER: (Specify) NSN: (Specify) MANUFACTURER: (Specify) CAGE CODE: (Specify) DATE MANUFACTURED: (Specify month (3 letters) and year (4 numbers)) CONTRACT NO: (Specify) LOT & SERIAL NO: (Specify) WEIGHT EMPTY: (Specify approximate weight in pounds)

DATE OF WARRANTY EXPIRATION:

(Specify month (3 letters) and year (4 numbers)) SHELF LIFE: (Specify month (3 letters) and year (4 numbers))

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

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

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

The bladder shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. The bladder shall not contain or use hexavalent chromium. The bladder shall not contain or use cadmium without written approval by the procuring activity. For the purposes of this requirement, the Class I ODS and controlled substances identified in Chapter 4 of AFI 32-7086 shall not be used in any system, component, or process.

3.3.4.3 Component protection. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features, which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard.

All wires, cables, tubes, and hoses shall be supported and protected to minimize chafing and abrasion and shall be located to provide adequate clearance from moving parts and high operational temperatures. Grommets shall be provided wherever wires, cables, tubes, or hoses pass through bulkheads, partitions, or structural members.

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

3.3.4.5 Electrostatic discharge (ESD). The design of the bladder shall preclude equipment damage due to ESD, protect personnel from electrical shock due to static charging, and prevent ignition of explosive atmospheres due to sparking.

3.3.5 Human systems integration. The bladder shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including the use of arctic mittens and Mission-Oriented Protective Posture (MOPP) Level 4 Chemical Warfare Gear.

Chemical Warfare Gear is not required for preventive maintenance or major corrective maintenance.

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

TABLE I. Minimum thread engagement.

Material

Minimum Thread Engagement

Steel 1.0 times the nominal fastener diameter Cast iron, brass, or bronze 1.5 times the nominal fastener diameter Aluminum, zinc, or plastic 2.0 times the nominal fastener diameter

3.3.7 Service and Storage life.

3.3.7.1 Service life temperature range. The bladder and components shall be suitable for operational use for a minimum of one (1) year at ambient temperatures from -20 °F to 140 °F, when withdrawn from storage for operational use. The bladder, secured to a transportation platform in either the filled or the unfilled state, shall not leak under normal continued operational use when tested in accordance with 4.5.6.1 and 4.5.7.

3.3.7.2 Storage life temperature range. The bladder and associated components shall withstand folded storage in a shipping container for a minimum of five (5) years at ambient temperatures from -65 °F to 160 °F without damage or leakage, when subsequently filled with fuel and tested in accordance with 4.5.6.2 and 4.5.7.

3.3.7.3 Hydrocarbon fuel contact. The bladder shall be capable of use with continuous contact with hydrocarbon fuels with 40% aromatics, rainwater, and water associated with fuels when tested in accordance with 4.5.6.4.

3.3.7.4 Air leakage. The bladder shall be capable of withstanding an internal air pressure of 2.25 pounds per square inch gauge (psig) evidence of leakage when tested in accordance with 4.5.6.5.

3.3.7.5 Hydrostatic leakage. The bladder shall withstand a pressure, measured by gauge, of 150% (2.25 psig) of the normal pressure encountered during service for the duration of 15 minutes without evidence of leakage. The bladder shall not leak under normal transportation and use when tested in accordance with 4.5.6.6.

3.3.7.6 Surge damping. The bladder shall dampen the fluid surge and not allow self-amplification of the fluid surge during normal operational use when tested in accordance with 4.5.6.7.

3.3.7.7 Load stresses. In the filled condition, the bladder and its integral restraints shall withstand a forward stress load of 3.0 g's, an aft load of 1.5 g's, a vertical load of 2.0 g's, and a transverse load of 1.5 g's. The bladder shall withstand an 8.0 g forward stress (overload) condition when tested in accordance with 4.5.6.8.

3.3.7.8 Fill/vent rate. The bladder, with fill/evacuate nozzle and vent nozzle installed, shall permit fill/evacuate rates of 600 gallons per minute when tested in accordance with 4.5.6.9.

3.4 Environmental conditions.

3.4.1 Operating temperature range. The bladder shall be capable of operating in ambient temperatures ranging from -20 °F to 140 °F when tested in accordance with 4.5.7.1.

3.4.2 Storage temperature range. The bladder shall be capable of being stored in ambient temperatures ranging from -65 °F to 160 °F when tested in accordance with 4.5.7.1.

3.4.3 Humidity. The bladder shall show no degradation from humidity exposure either visually or hydrostatically when tested in accordance with 4.5.7.2.

3.4.4 Vibration. The shipping container shall show no breakage, loosening of skids, bolt distortion, nor any anomaly that may affect service or storage life. The bladder shall show no deformation, seam damage, cracking or peeling, separation of bonds, chafing, or any anomaly that may affect the mission or service life. Both these requirements shall be met when tested in accordance with 4.5.7.3.

3.4.5 Salt-fog. The bladder shall show no degradation from salt-fog exposure either visually in accordance with 4.5.1 or hydrostatically when tested in accordance with 4.5.7.4.

3.4.6 Fungus. All materials used in the bladder shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The bladder shall be suitable for operation and storage in conditions encountered in a tropical environment. The bladder shall show no ability to support spore growth when tested in accordance with 4.5.7.5.

3.4.7 Ozone resistance. The bladder shall show no evidence of cracking or checking after exposure to an ozone environment when tested is accordance with 4.5.7.6.

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

3.5 Component Requirements.

3.5.1 Lift handle. When inspected in accordance with 4.5.8.1, the bonds between each handle patch and the bladder fabric shall be capable of withstanding perpendicular loads of 1000 pounds.

3.5.2 Forward restraint harness. When inspected in accordance with 4.5.8.2, the restraint harness with the attached "D" ring shall be capable of withstanding a 10,000-pound tensile load without breakage of the nylon weave or wraparound attachment of the "D" ring. The stitching of the sewn areas for the harness-to-harness overlay attachments shall show no evidence of degradation. Total elongation of the harness under the tensile load shall not exceed 25% nor 10% when load is relaxed.

3.5.3 Nylon tie cord. When inspected in accordance with 4.5.8.3, the nylon tie cord shall be capable of withstanding a 450-pound tensile load without breakage of external woven overlay or seven (7) internal cords. Elongation shall not exceed 25% under tensile load or 10% when load is relaxed.

3.5.4 Fluid flow restrictor tie-down. When inspected in accordance with 4.5.8.4, the fluid flow restrictor tie down shall be subjected to a tensile load of 1500 pounds through the eyelets.

There shall be no degradation of the bond and no eyelet tearing through the cloth member.

Distortion of the eyelet is permissible where cable contact is made.

3.5.5 Bladder material - tensile load. When inspected in accordance with 4.5.8.5, the bladder material sample shall be subjected to a 3000-pound tensile load. The sample shall not show evidence of degradation in the form of tearing or breaking of the fabric weave, no separation of weave to coating, and no cracks or tears in the coating. The sample elongation shall not exceed 25% under load nor 10% when load is relaxed.

3.5.6 Bonded seam-in-line tensile load. When inspected in accordance with 4.5.8.6, the seam shall show no evidence of degradation in the form of bonding, cracking, fabric tear, sealing or separation of weave or coating on either side of the bladder.

3.5.7 Bonded seam-across-seam tensile load. When inspected in accordance with 4.5.8.7, the seam shall show no evidence of degradation in the form of bonding, cracking, fabric tear, sealing or separation of weave or coating on either side of the bladder.

3.5.8 Bonded fittings (vent-fill/evacuate flanges). When inspected in accordance with 4.5.8.8, the fittings shall show no evidence of separation of the bond between the flange and the bladder skin.

3.5.9 "D" rings - tensile load. When inspected in accordance with 4.5.8.9, the "D" rings shall have a 10,000 tensile load applied in the direction from the base to the nose. After this load has been relaxed, the "D" rings shall show no evidence of breakage or distortion.

3.5.10 "D" rings - metallurgy. When inspected in accordance with 4.5.8.10, the inspection results shall indicate that the material is equivalent to ASTM-A276 Type 304L Stainless Steel.

3.5.11 Nozzle assemblies - metallurgy. When inspected in accordance with 4.5.8.11, the inspection results shall indicate that the material is equivalent to ASTM-B221 Type 6061-T6 Aluminum.

3.5.12 Vent and fill/evacuate flanges - metallurgy. When inspected in accordance with 4.5.8.12, the inspection results shall indicate that the material is equivalent to ASTM-B221 Type 6061-T6 Aluminum.

3.6 Workmanship. Workmanship shall be the highest quality and shall permit no defects adversely affecting the strength or serviceability of the finished bladder. The reinforced flange type fittings shall contain no voids or cracks that could adversely affect the strength of the assembly. All metal parts shall be free of sand, dirt, and scale. Surfaces shall be smooth with edges rounded or beveled. The inside and the outside of the bladder shall be clean and free of all foreign material. Any necessary repair and rework shall restore the reworked area to its full strength and shall meet all the applicable requirements of this specification. The bonded surfaces of all seamed areas, fitting flanges, and patch-type repairs shall affect a bond that will result in the strength of the bonded area not less than the strength of the adjacent bladder fabric.

3.6.1 Repair and rework of bladders. Any repair and rework of any bladder shall be performed prior to quality conformance inspection with the exception of air leakage. Repair and rework of a seam shall not exceed 10% percent of the length of the seam. Repair and rework of panels shall be limited to areas of damage not greater than six (6) inches in length, six (6) inches in width, or two (2) inches in diameter. All repair and rework procedures shall be in accordance with the Repair and Rework Plan.

3.6.2 Repair and rework plan. The contractor shall prepare a Repair and Rework Plan. The plan shall include a specific description of methods and procedures for the repairs and/or rework of anomalies, which might occur during the manufacturing or assembly of the bladder. The plan shall include documented work instructions which shall be used by the contractor to ensure that repaired and reworked areas have structural integrity equal to or greater than seams or panels that have not been reworked. No part of this plan shall conflict with or take precedence over the requirements of this specification. The plan shall be made available, upon request, to the Government.

3.6.3 Special tools. The design of the bladder shall minimize the requirement for special tools (see 6.4.11). All special tools shall be provided with, and stored with, the bladder.

4. VERIFICATION

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

a. First article inspection (see 4.2)

b. Conformance inspection (see 4.3)

Requirements shall be verified in accordance with Table II.

TABLE II. Requirement verification matrix.

Section 3 Requirement Verification

Method

Section 4 Verification

3.1 First article inspection.

Not Applicable

(N/A)

3.1.1 Sample selection plan. N/A

3.1.2 Bladders for testing. Examination 4.5.1 Examination of product.

3.2 Materials. N/A

3.2.1 Material deterioration, prevention, and controls.

Examination 4.5.1 Examination of product.

3.2.1.1 Dissimilar metals. Examination 4.5.1 Examination of product.

3.2.1.2 Identification of materials

and finishes.

Examination 4.5.1 Examination of product.

3.2.2 Coated fabric. Examination 4.5.1 Examination of product.

3.2.2.1 Coating compounds. Examination 4.5.1 Examination of product.

3.2.2.2 Nylon cloth. Examination 4.5.1 Examination of product.

3.2.2.3 Weathering resistance. Examination 4.5.1 Examination of product.

3.2.4 Fill/evacuate and vent nozzle

material.

Examination 4.5.1 Examination of product.

TABLE II. Requirement verification matrix – Continued.

Method Section 4 Verification

3.2.5 Fill/evacuate and vent flange

material.

Examination 4.5.1 Examination of product.

3.2.6 "D" rings material. Examination 4.5.1 Examination of product.

3.3 Design and construction. Examination 4.5.1 Examination of product.

3.3.1 Bladder and associated

component design.

Examination

4.5.1 Examination of product.

3.3.1.1. Basic bladder. Examination

4.5.1 Examination of product.

4.5.2.1 Basic bladder.

3.3.1.2 Double “D” tie down rings. Examination 4.5.1 Examination of product.

3.3.1.3 Lift handles. Examination 4.5.1 Examination of product.

3.3.1.4 Fill/evacuate assembly. Examination 4.5.1 Examination of product.

3.3.1.5 Vent assembly. Examination 4.5.1 Examination of product.

3.3.1.6 Reed valve vapor

eliminator.

Examination Test

4.5.1 Examination of product.

4.5.6.9 Fill/Vent Rate.

3.3.1.7 Fluid flow restrictors. Examination 4.5.1 Examination of product.

3.3.2 Bladder assembly construction. N/A

3.3.2.1 Basic bladder. Examination

4.5.1 Examination of product.

4.5.2.1.1 Basic bladder.

3.3.2.2 Forward restraint harness. Examination

4.5.1 Examination of product.

4.5.2.1.2 Forward restraint harness.

3.3.2.3 Lift handles. Examination

4.5.1 Examination of product.

4.5.2.1.3 Lift handles.

3.3.2.4 Fill/evacuate and vent

flanges.

Examination

4.5.1 Examination of product.

4.5.2.1.4 Fill/evacuate and vent

flanges.

3.3.2.5 Closure plates - fill/evacuate

and vent flange.

Examination

4.5.1 Examination of product.

4.5.2.1.5 Closure plate -

fill/evacuate and vent flange.

3.3.2.6 "D" rings (forward restraint harness) and double “D” rings.

Examination

4.5.1 Examination of product.

4.5.2.1.7 Double “D" tie down

rings.

4.5.2.7 "D" rings (forward restraint harness) and double “D” rings.

3.3.2.7 Fill/evacuate nozzle. Examination

4.5.1 Examination of product.

4.5.2.1.8 Fill/evacuate nozzle.

3.3.2.8 Vent nozzle. Examination

4.5.1 Examination of product.

4.5.2.1.9 Vent nozzle assembly.

3.3.3 Identification and information

plates.

Examination 4.5.1 Examination of product.

3.3.4 Environment, Safety, and

Occupational Health (ESOH).

N/A

3.3.4.1 System safety. Analysis

4.5.3 System safety hazard

analysis.

3.3.4.2 Hazardous material. Examination 4.5.1 Examination of product.

3.3.4.3 Component protection. Examination 4.5.1 Examination of product.

3.3.4.4 Foreign object damage

(FOD).

Examination 4.5.1 Examination of product.

3.3.4.5 Electrostatic discharge

(ESD).

Analysis

4.5.4 Electrostatic discharge

analysis.

3.3.5 Human systems integration. Demonstration 4.5.1 Examination of product.

3.3.6 Fastening devices. Examination 4.5.1 Examination of product.

3.3.7 Service and storage life. N/A

3.3.7.1 Service life temperature

range.

Analysis Test

4.5.5.1 Service life analysis.

4.5.6.1 Service life.

3.3.7.2 Storage life temperature

range.

Analysis Test Test

4.5.5.2 Storage life analysis.

4.5.6.2 Storage life.

4.5.6.3 Storage life temperature.

3.3.7.3 Hydrocarbon fuel contact. Test 4.5.6.4 Hydrocarbon fuel contact.

3.3.7.4 Air leakage. Test 4.5.6.5 Air leakage.

3.3.7.5 Hydrostatic leakage. Test 4.5.6.6 Hydrostatic leakage test.

3.3.7.6 Surge damping. Analysis 4.5.6.7 Surge damping.

3.3.7.7 Load stresses. Analysis 4.5.6.8 Load stresses.

3.3.7.8 Fill/vent rate. Test 4.5.6.9 Fill/vent rate.

3.4 Environmental conditions. N/A 4.5.7 Environmental testing.

3.4.1 Operating temperature range. Test

4.5.7.1 Operating and storage

temperature tests.

3.4.2 Storage temperature range. Test

4.5.7.1 Operating and storage

temperature tests.

3.4.3 Humidity. Test 4.5.7.2 Humidity test.

3.4.4 Vibration. Test 4.5.7.3 Vibration test.

3.4.5 Salt-fog. Test 4.5.7.8 Salt-fog test.

3.4.6 Fungus. Test 4.5.7.9 Fungus test.

3.4.7 Ozone resistance. Test 4.5.7.10 Ozone resistance test.

3.4.8 Solar radiation. Examination 4.5.1 Examination of product.

3.5 Component requirements. N/A

3.5.1 Lift handle. Test 4.5.8.1 Lift handle.

3.5.2 Forward restraint harness. Test 4.5.8.2 Forward restraint harness.

3.5.3 Nylon tie cord. Test 4.5.8.3 Nylon tie cord.

3.5.4 Fluid flow restrictor tie-down.

Test

4.5.8.4 Fluid flow restrictor tie-

down.

3.5.5 Bladder material - tensile

load.

Test

4.5.8.5 Bladder material-tensile

load.

3.5.6 Bonded seam-in-line tensile

load.

Test

4.5.8.6 Bonded seam - in-line

tensile load.

3.5.7 Bonded seam-across-seam

tensile load.

Test

4.5.8.7 Bonded seam - across seam

tensile load.

3.5.8 Bonded fittings (vent-

fill/evacuate flanges).

Test

4.5.8.8 Bonded fittings (vent-

fill/evacuate flanges).

3.5.9 "D" rings - tensile load. Test 4.5.8.9 "D" rings - tensile load.

3.5.10 "D" rings - metallurgy. Test 4.5.8.10 "D" rings - metallurgy.

3.5.11 Nozzle assemblies -

metallurgy.

Test

4.5.8.11 Nozzle assemblies -

metallurgy.

3.5.12 Vent and fill/evacuate

flanges - metallurgy.

Test

4.5.8.12 Vent and fill/evacuate

flanges - metallurgy.

3.6 Workmanship. Examination 4.5.1 Examination of product.

3.6.1 Repair and rework of bladders. Examination 4.5.1 Examination of product.

3.6.2 Repair and rework plan. Examination 4.5.1 Examination of product.

3.6.3 Special tools. Examination 4.5.1 Examination of product.

4.2 First article inspection. The first article bladder shall be subjected to the analyses, demonstrations, and examinations of 4.5, and tests described in 4.5.6 through 4.5.8. Presence of one or more defects shall be cause for rejection. The contractor shall provide or arrange for all test equipment and facilities. Unless otherwise approved by the procuring activity all first article bladders shall be in the same configuration at all times and configuration changes shall not be made during the first article bladder inspection. A first article inspection shall be performed on one (1) bladder when a first article sample is required (see 3.1 and 6.2).

4.3 Conformance inspection. Each production bladder shall be subjected to the examination described in 4.5.1. Conformance inspection shall ensure that production items meet specification requirements prior to acceptance by the Government. Each bladder shall be inspected for compliance with the requirements specified in 3.3.2 through 3.3.6. Any redesign or modification of the product to comply with specified requirements, or any necessary redesign or modification following failure to meet the specified requirements shall receive particular attention to adequacy and suitability. This element of inspection shall encompass all visual, dimensional, and performance requirements. Noncompliance with any specified requirement or presence of one or more defects preventing or lessening maximum efficiency shall constitute cause for rejection.

4.3.1 Examinations.

4.3.2 Production lot testing. Unless otherwise specified, the production lot testing shall be performed by the contractor. The lot size shall be a quantity of bladders manufactured successively from one continuous lot of material. The assigned Government representative shall randomly select a tank assembly for conformance inspection. Acceptance of one tested bladder shall not exclude the remaining bladders from meeting all the requirements of the specification.

Failure to meet any requirement of this specification shall constitute failure of the production lot.

4.3.3 Completed bladder testing. Each completed bladder shall be examined as specified in 4.4.

Any non-conformance revealed by the examination or failure of the test shall be cause for rejection of the bladder.

4.3.4 Sampling for destructive testing. Selection of bladders for destructive testing shall be in accordance with the Sample Selection Plan (see 3.1.1), and shall be subjected to tests in 4.5.

Lift handle, Forward restraint harness, Nylon tie cord, fluid flow restrictor tie-down, bladder material-tensile load, Bonded seam, Bonded fittings (vent-fill/evacuate flanges), “D” rings, and Nozzle assemblies.

4.3.5 Vent-fill/evacuate flanges shall be tested. The frequency for random selection shall be one

(1) per lot. The bladder used for destructive testing shall remain the property of the contractor.

Failure to meet any requirement of destructive testing shall constitute failure of the production lot (see 3.5).

4.4 Inspection requirements.

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

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

a. Date.

b. Time started.

c. Time finished.

d. Ambient temperature.

e. Ambient humidity.

Test rejection criteria. Throughout all tests specified herein, the bladder shall be closely observed for the following conditions, which shall be cause for rejection.

a. Failure to conform to design or performance requirements specified herein or in the contractor's technical proposal.

b. Any spillage or leakage of any liquid, including fuel, coolant, lubricant, or hydraulic fluid, under any condition, except as allowed herein.

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

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

e. Evidence of corrosion or deterioration.

f. Misalignment of components.

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

4.5 Test methods.

4.5.1 Examination of product. Each bladder shall be examined to verify compliance with the requirements herein prior to accomplishing any other demonstrations or tests listed in 4.5. A contractor-generated, Government-approved checklist (part of the test procedure) shall be used to identify each requirement not verified by an analysis, certification, demonstration, or test, and shall be used to document the examination results. Particular attention shall be given to materials, workmanship, dimensions, surface finishes, protective coatings and sealants and their application, welding, fastening, and markings. Proper operation of each bladder function shall be verified. Certifications and analyses shall be provided in accordance with Table III. Each production bladder shall be inspected to a Government-approved reduced version of the checklist.

TABLE III. Certifications and analyses.

Paragraph

Required Certifications and Analyses

3.3.4.1 System safety. Contractor system safety hazard analysis (see

4.5.3).

3.3.4.5 Electrostatic discharge. Contractor analysis of the electrostatic discharge requirement (see 4.5.4).

TABLE III. Certifications and analyses – Continued.

Paragraph

Required Certifications and Analyses

3.3.7.1 Service life temperature range. Contractor analysis of the service life requirement (see 4.5.5.1).

3.3.7.2 Storage life temperature range. Contractor analysis of the service life requirement (see 4.5.5.2).

3.3.7.6 Surge damping. Contractor analysis of the surge damping requirement (see 4.5.6.7)

3.3.7.7 Load stresses. Contractor analysis of the load stresses (see

4.5.6.8).

3.4.6 Fungus. Contractor certification that the materials used in construction of the bladder are fungus resistant or suitably treated to resist fungus.

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

4.5.1.1 Examination setup. The bladder shall be laid out flat in an inspection area that allows access from all sides. The area shall be large enough for the bladder to be pulled from one end back over itself enabling the bladder to be turned upside down. The minimum required floor space of the inspection area is 12 feet wide by 40 feet long.

4.5.1.2 Examination procedure. The following visual examinations shall be performed and the results thereof recorded on the appropriate data sheets produced by contractor.

4.5.1.2.1 Bladder assembly. The entire external surface shall be visually examined for continuity, uniformity, surface texture, bonding of seams, patches, workmanship, appearance, and any anomaly that may affect service use. In addition, lift handle location and count shall be made along with the location and total of lateral tie down Double "D" Rings. The Double "D" Rings shall be located on the transverse center-line longitudinally along the top side of the bladder.

4.5.1.2.2 Harness layout and attachment configuration. The forward restraint harness layout and attachment configuration on top of the bladder shall be uniform and equal on both lateral sides of the bladder. The forward attachment technique and patch shall be conformable and uniform across the forward end of the bladder. The Bottom Harness Configuration shall not be bonded to the bladder behind the forward attachment point (see 3.3.2.2).

4.5.1.2.3 Lift handles. The lift handles shall be visually examined for uniformity of casting or machining, workmanship, freedom from burrs and sharp edges, cracks, protective coating, and any anomaly that may affect service use (see 3.3.2.3).

4.5.1.2.4 Fill/evacuate and vent flanges. The fill/evacuate and vent flanges shall be visually examined for uniformity of casting or machining, workmanship, freedom from burrs and sharp edges, cracks, protective coating, and any anomaly that may affect service use (see 3.3.2.4).

4.5.1.2.5 Fill/evacuate and vent flange material. The closure plates shall be visually examined for uniformity of casting or machining, workmanship, freedom from burrs and sharp edges, cracks, protective coating, and any anomaly that may affect service use (see 3.3.2.5).

4.5.1.2.6 "D" rings material. The "D" rings and double "D" rings shall be visually examined for uniformity of casting or machining, workmanship, cracks, freedom from burrs and sharp edges, and any anomaly that may affect service use (see 3.3.2.6).

4.5.1.2.7 Fill/evacuate and vent nozzle material. The fill/evacuate nozzle shall be visually examined for uniformity of casting or machining, workmanship, cracks, protective coating, freedom from burrs and sharp edges, and any anomaly that may affect service use (see 3.3.2.7).

4.5.1.2.8 Vent nozzle. The vent nozzle shall be visually examined for uniformity of casting or machining, workmanship, cracks, protective coating, freedom from burrs and sharp edges, and any anomaly that may affect service use (see 3.3.2.8).

4.5.2 Dimensional inspection. The following items shall be dimensionally examined in accordance with Appendix A, and the appropriate figures of this specification, to ensure compatibility with the existing system, drawing package compliance, and product assurance.

The results of this inspection showing dimensions greater than allowable specified tolerances shall be considered a failure of the test

4.5.2.1 Test procedure. The following dimensional examinations shall be performed and the results thereof recorded. Traceable measurement instrumentation shall be utilized and recorded.

4.5.2.1.1 Basic bladder. Prior to sectioning the bladder, the length, width, and average height shall be measured and recorded with the bladder collapsed. The location of the lateral tie downs (Double "D" Rings), fill/evacuate and vent flanges shall be measured and recorded in accordance with Appendix A, Figure 1 (see 3.3.2.1).

4.5.2.1.2 Forward restraint harness. The forward restraint harness shall be measured for total length, width, and thickness in the assembled position. All individual harnesses shall be measured and recorded in accordance with Appendix A, Figure 1. All individual straps shall be equal to the specified length plus 2 inches minus 0 inches. The fold back of harness through "D" Ring shall be 12 inches plus 1.2 inches minus 0 inches minimum (3.3.2.2).

4.5.2.1.3 Lift handles. The lift handle shall be dimensionally examined to verify compliance with Appendix A, Figure 2. Verify lift handle location, count, shape, and bonding technique. Two (2) lift handles shall be examined (3.3.2.3).

4.5.2.1.4 Fill/evacuate…