DRAFT_TRD_Rev_-C_April_8_2016.pdf

DRAFT

Tanker Division (AMC) KC-46A

WRIGHT-PATTERSON AIR FORCE BASE, OHIO 45433

Technical Requirements Document

For

KC-46A Thermal Curtain Protective System

Contract No:

Date: 10 May 2016

APPROVED BY: _______________________________________________

Scott Keen

Chief Engineer, KC-46

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Contents

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

2.1 General

2.2 Order of Precedence

3.0 REQUIREMENTS

3.1 System Requirements

3.2 Installation and Use

3.3 Storage

3.4 Identification

3.5 Light tightness

3.6 Service Life

4.0 VERIFICATION

4.1 Methods of Verification

4.1.1 Responsibility for Test Category

4.1.2 Special Tests and Examinations

4.1.3 Operation and Performance Checks

4.1.4 Test Opportunities for Qualification by Similarity

4.2 Quality Conformance Verification

4.2.1 Formal Qualification

4.2.2 System Safety Analysis

4.2.3 Reliability, Availability and Maintainability

4.3 Formal Qualification by Test

4.3.1 Hardware Environmental Testing

4.3.2 Environmental Testing

4.3.3 Acceptance Verification

1.0 SCOPE

This Technical Requirements Document (TRD) identifies the requirements for the design, development, implementation, and qualification of the Thermal Curtains.

2.0 APPLICABLE DOCUMENTS

2.1 General

The following documents form a part of this TRD. The most current version of each document, as of the date of this TRD, shall be used. Second tier references called out by the government documents listed in this section shall be used for guidance.

REFERENCE TITLE DATE

MIL-STD-810F w/Change

Notice 3

Department of Defense Test Method

Standard - Environmental Engineering

Considerations and Laboratory Tests

01/01/2000

05/05/2003

AMS-3673 Cloth, Glass, Aluminum Face, Silicon

Rubber Back

2011-06

MIL-STD-130N Identification Marking of U.S.

Military Property

16 November 2012

2.2 Order of Precedence

In the event of any inconsistency within this TRD, the Program Office Thermal Curtain Lead Engineer, through the Procuring Contracting Officer (PCO), is to be contacted for clarification.

In the event of conflict between the text of this document and any reference 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

3.0 REQUIREMENTS

Each requirement listed below

3.1 System Requirements

3.1.1 The cockpit thermal curtain protective system shall provide quick and positive protection to the aircrew members and their stations from the thermal radiation and luminous effects of nuclear weapon detonations. (D)

3.1.2 Materials shall conform to AMS 3673C. Materials which are not covered by applicable specifications or which are not specified herein shall be of the best quality, of the lightest practicable weight, and suitable for the purpose intended. (A)

3.1.3 The test program shall consist of sufficient tests to exhibit and insure satisfactory installation of the thermal protective system into parent aircraft and to exhibit and insure overall system performance, reliability, and maintainability. (T,D,A,I)

3.1.4 The material shall not have an odor and shall be free from toxic fumes within operating temperature ranges, -69.7 F to +180 F. (T)

3.1.5 The material shall be capable of being cleaned with a mild soap solution or an alcohol-water solution without adverse effect. (T)

3.1.6 The cockpit thermal curtain system shall include a pilot observation flap to enable the pilot to see outside the cockpit when thermal curtain is installed and the observation flap is in the opened position. Pilot observation flap shall be a minimum of 10 inches by 10 inches. (I)

3.1.7 The material shall exhibit no visible deterioration other than light non-toxic smoking when subjected to thermal radiation. (T)

3.1.8 Thermal curtain protective system to include storage container shall be tested to MIL-STD-

810G standards for contamination by fluids. Fluids tested shall be agreed upon with the KC-46A

Program Office. (T)

3.1.9 Thermal curtain protective system to include storage container shall be tested to MIL-STD-

810G standards for Fungus. (T)

3.1.10 Thermal curtain storage container shall be tested to MIL-STD-810G standards for sand and dust. (T)

3.1.11 All thermal protective system’s surface touch temperatures shall remain within required limits to maintain safety of flight operations of the air vehicle. (D)

3.2 Installation and Use

3.2.1 The thermal curtain protective system design shall require no impacts to current aircraft design and airworthiness certification. (D)

3.2.2 When installed, the thermal curtain protective system shall be able to remain in-place throughout the entire flight envelope, including all phases of flight certified for the KC-46A, without interference to the operation of the aircrew controls. (D)

3.2.3 The thermal curtain protective system’s pilot flap shall be capable of remaining securely open through the entire KC-46 flight envelope. (D)

3.2.4 The thermal curtain protective system retention system shall be capable of being operated in such a way that a simple motion is required to install/uninstall the thermal curtain protective system. (D)

3.2.5 The thermal curtain protective system shall be capable of being operated in such a way that a simple motion is required to release the pilot’s observation flap when operated between the open and closed positions. (D)

3.2.6 The thermal curtain protective system shall be designed to preclude inadvertent closure or opening during any phase of flight, including severe atmospheric turbulence, and crash landing.

(T)

3.2.7 The thermal curtain protective system shall be constructed in such a way that the system is installable and removable from the windows by the pilot and co-pilot during flight while in a seated restrained position. (D)

3.2.8 The thermal curtain protective system shall be able to be installed inflight on the six cockpit windows in less than five minutes. This timing includes the time required to pass control from the pilot to co-pilot to maintain safe aircraft flight. (D)

3.2.9 The thermal curtain protective system shall be able to be installed on the ground, on all aircraft windows, with the exception of the six (6) cockpit windows, in less than 15 minutes with two maintainers. (D)

3.2.10 When installed, the thermal protective system design shall not introduce hazards to the aircrew during the imposition of crash load conditions or other emergency situations. (A)

3.2.11 The thermal curtain protective system shall not compromise the emergency escape and survival provisions of the aircraft. (A)

3.2.12 The installation and handling of the thermal curtain protective system must be able to be accomplished by AFI 48-123 Flying Class I aircrew at Aircraft Commander and Pilot positions, and accommodate AFI 48-123 Flying Class III aircrew at all other flight deck positions. (D)

3.2.13 The installation and handling of the thermal curtain protective system shall accommodate the Joint Primary Aircraft Training System (JPATS) Multivariate Cases 1-Small, 5-Overall Large and 7 Overall Small. (D)

3.2.14 The thermal curtain protective system shall require no additional tools for installation and removal. (D)

3.3 Storage

3.3.1 The storage container shall incorporate all window shades and shall be negligible in both weight and size. (D)

3.3.2 The storage container shall protect the curtains from outside contamination in addition to maintaining the integrity of the curtain. (T)

3.3.3 The storage container shall be impermeable to fluids and other foreign particles. (T)

3.3.4 When not in use, the system shall stow out of the way so as to not restrict crew entrance and exit. (D)

3.3.5 The storage container and all of the thermal curtains including accessories shall be able to fit into a closet with the measurements of 32” X 50’ X 10” (L X W X H). (D)

3.4 Identification

3.4.1 Each thermal curtain protective system shall be marked with a unique identification in accordance with MIL-STD-130N. (I)

3.4.2 Each thermal curtain protective system shall be independently marked to identify window location and orientation for quick installation and to avoid incorrect assembly which would result in damage or malfunction to the overall system. (I)

3.5 Light tightness

3.5.1 Under incident light conditions of direct sunlight and with the thermal curtain protective closure installed, the maximum allowable level of illumination attributed to light transmission in any part of the cockpit enclosed for aircrew thermal protection shall not exceed 0.01 percent of the incident light intensity. (T)

3.5.2 Materials that are used in the thermal curtain protective system to assure light tightness shall be capable of withstanding the same thermal flux levels as the thermal curtain protective system as defined in AMS3673C, section 4.5.2 when exposed to thermal radiation and the exposure shall not cause toxic smoking of the materials. (T)

3.5.3 The thermal curtain protective system design shall cover the entire window and block out all external light. (T)

3.6 Service Life

3.6.1 The materials used in the thermal curtain protective system shall be capable of meeting the above specified radiation protective requirements after being subjected to a service life test of 1000 cycles in an environment of -40 to 140 degrees Fahrenheit. (T)

4.0 VERIFICATION

Verification of the thermal curtain protective system requirements shall be conducted by the contractor based on the methods and criteria described in this section. The verification processes defined in this section shall properly verify the system requirements stated in Section 3 of this document. When the verification method in this section is labeled “IAW Spec,” requirements contained in the referenced specification or ICD shall be verified in accordance with the methods outlined in Section 3 and Section 4 of that specification or ICD. All sections under Section 4 apply to the thermal curtain protective system.

4.1 Methods of Verification

The thermal curtain protective system shall be subject to verification in accordance with this section to demonstrate compliance with this TRD. All requirements contained in Section 3 of this

TRD shall be verified using any one or combination thereof of the following methods:

a) INSPECTION (I): Inspection shall be defined as visual examination of the data and physical features of an item, measurement of the item and comparison of the item with applicable drawings and specifications to determine the compliance with requirements.

Examination consists of investigation, without the use of special laboratory appliances or procedures, to determine compliance with requirements. Inspection is generally nondestructive and includes (but is not limited to) visual inspection, simple physical manipulation, gauging, and measurement. Computer Software Configuration Item (CSCI) qualification by inspection may include comparison of requirements or mechanization equations to program source listings or program flows for verification.

b) ANALYSIS (A): Analysis shall be defined as using recognized analytical techniques, including computer models, to interpret or explain systems, equipment, personnel behavior, or reduced and representative data. Review of previous test data and any theoretical analysis that may be required. This includes all theoretical analyses and test data that were used to formally substantiate FAA, military or government certification/qualification. Analysis (including CSCI qualification by analysis) may take the form of the technical evaluation of accumulated results and conclusions (equations, data, and charts) intended to provide proof that verification of requirements has been accomplished. The analytical results may consist of a compilation or interpretation of existing information, or may be derived from lower-level inspections, tests, demonstrations, or analyses.

c) SIMILARITY (S): Similarity shall be a method of verification (a form of Analysis) where the requirement has been verified by inspection, analysis, demonstration, or test on a similar design and can be shown, without doubt, that the development item will also meet the requirement.

d) DEMONSTRATION (D): Demonstration shall be used when quantitative assurance is not required for verification. Demonstration, including CSCI qualification, is limited to readily observable functional operation to determine compliance with requirements. Generally, demonstration does not require the use of special or sophisticated instrumentation.

Reliability and Maintainability verification shall be performed using in-service data (where available), supplier data, and calculated reliability data to formally demonstrate compliance with the quantitative reliability and maintainability requirements of this TRD. This includes qualitative demonstrations of compliance with qualitative maintainability requirements and BIT adequacy and assessment verifications.

e) TEST (T): Test shall be defined as performing an operation to provide data of the properties and characteristics of the element under test, under the appropriate conditions and in accordance with approved test procedures. Examination consists of trial operation of an item under specific conditions requiring quantitative measurements and evaluations of the item and its environment. Test employs technical means, including (but not limited to) the evaluation of functional operation by use of special or sophisticated instrumentation, simulation techniques, and the application of established principles and procedures to determine compliance with TRD requirements. The analysis of data will be accomplished after test conduct. Tests are conducted when an acceptable level of confidence cannot be established by other methods, or, if testing can be shown to be the most cost-effective method.

4.1.1 Responsibility for Test Category

Test category responsibility shall be assigned as follows:

Category I – This testing shall be conducted by the contractor with USAF participation as required.

a) All of Section 3 of this TRD will be tested by the contractor with the exception of requirements listed under Category II.

Category II – This testing will be conducted by the USAF and shall have contractor support as required. The following requirements will be conducted by the USAF:

a) The Air Force Nuclear Weapons Center (AFNWC) will conduct thermal flash testing of the thermal curtain protective system attached to the KC-46 window as it is attached in the aircraft. This testing will be performed at the National Solar Thermal Test Facility at Kirtland Air Force Base, New Mexico. The purpose of this testing is: 1) to verify that the thermal curtain protective system can withstand the thermal radiation resistance levels as defined in AMS3673C, section 4.5.2; and 2) to determine the response of the system at other thermal radiation levels that may be encountered in a mission.

The contractor may utilize his own facilities or any other inspection facilities and services acceptable to the Government. Records of the examinations and tests shall be kept complete and available to the Government.

4.1.2 Special Tests and Examinations

In the event any special tests and examinations are performed by the contractor, and the results of such tests and examinations are intended to demonstrate compliance with requirements of this

TRD, the USAF Procuring Activity and the Local Government Inspector shall be notified prior to performance of the special tests and examinations, or immediately upon any change of the scheduled event. The USAF Procuring Activity reserves the right for an appointed government representative to witness any required inspection, demonstration, and test performed by the contractor or subcontractor. The USAF Procuring Activity also reserves the right to invite government and/or non-government personnel that may be associated with the overall program to observe any required inspection, demonstration, and test performed by the contractor or subcontractor. Special tests do not include the following: ETE, CSCI FQT, SIL, Ground or Flight testing.

4.1.3 Operation and Performance Checks

When operation and performance checks are required before, during, or after any part of a test specified herein, the operation and any performance checks made shall be of sufficient frequency, scope, and duration to adequately demonstrate that the set (or unit) meets the operation and performance requirements.

4.1.4 Test Opportunities for Qualification by Similarity

The Contractor may propose the qualification by SIMILARITY (as defined above) for any requirement specified in Section 3 herein during the course of the development as a means to eliminate the duplication of any effort (demonstration or test) subject to the USAF Procuring

Activity approval in writing. Otherwise, the Contractor shall be performing the qualification in accordance with this section to demonstrate compliance with this Technical Requirements

Document.

4.2 Quality Conformance Verification

The objective of Quality Conformance Verification is to ensure that the contractor has met all of the requirements of the applicable specifications. Verification that all of the requirements have been met can be achieved during Engineering Test & Evaluation, Formal Qualification phases of the program.

a) ENGINEERING TEST & EVALUATION. This is the phase in the program where verifications are performed to acquire data to develop the production designs or retrofit designs. These verifications will generally be conducted using preliminary models and prototype parts or assemblies.

b) FORMAL QUALIFICATION. This phase of the program is where the item or system is formally deemed to meet all of the requirements of the applicable specifications through inspection, analysis, demonstration or test of the item and/or system. It comprises, but is not limited to, design verification tests, environmental qualification tests, reliability tests, reliability and maintainability demonstrations, hardware and software validation, failure analysis and simulation.

c) ACCEPTANCE. This phase of the program is where the entire system is verified to meet all applicable drawings and specifications through inspection, demonstration or test, or any combination thereof, as a quality control measure prior to delivery to the user. It comprises, but is not limited to, item and/or system performance tests and any other test, inspection, or demonstration required to evaluate performance, workmanship, finish, dimensions, weight, interchangeability, marking and identification.

4.2.1 Formal Qualification

Formal qualification is the method by which the contractor demonstrates the Thermal Curtain

Protection system meets all of the applicable specification requirements. The qualification shall include as applicable any of the verifications outlined below and any additional verification necessary to fully verify compliance with applicable requirements.

4.2.2 System Safety Analysis

A System Safety Analysis of the Thermal Curtain Protective System will be performed and will be documented in the System Safety Assessment (SSA) Report. The SSA Report will integrate and summarize the following analyses:

a) Functional Hazard Analysis (FHA) – The FHA is a qualitative assessment that will identify failure conditions associated with the Thermal Curtain Protective System and examine failures or combination of system failures that affect the Thermal Curtain Protective

System functions.

b) Hardware FMECA – The Hardware FMECA will identify single point failures or a combination of single point failures of Thermal Curtain Protective System hardware that will affect the system

c) Fault Tree Analysis (FTA) – The FTA is a top-down, deductive analysis in graphical format performed for each identified failure mode listed in the FHA. It identifies events or a combination of events that could result in an undesired condition.

4.2.3 Reliability, Availability and Maintainability

Reliability, Availability, and Maintainability (RAM) calculations for Thermal Curtain Protective

System components will be performed and documented in the formal test report. RAM Analysis shall be conducted in accordance with the contractor’s RAM process, using MIL-HDBK-217F and

MIL-HDBK-472 as guides. The contractor shall use analysis only when test is not practical.

4.3 Formal Qualification by Test

4.3.1 Hardware Environmental Testing

Environmental testing of the Thermal Curtain Protective System shall be conducted against the profiles dictated in this section in order to demonstrate proper functioning in the intended operational environment. All hardware shall be inspected for quality control prior to testing.

4.3.2 Environmental Testing

Environmental testing of Thermal Curtain Protective Systems shall be conducted accordance with

MIL-STD-810.

4.3.3 Acceptance Verification

Acceptance is the method by which an item and/or system is verified to meet preproduction and production drawings and specifications.

In addition, to the acceptance testing that must be accomplished per the AMS-3673 specification, each deliverable Thermal Curtain Protective System shall be subjected to acceptance verification prior to delivery of the system to the user. Appropriate documentation indicating compliance with these requirements shall accompany each delivery.

Every thermal curtain protective system shall be checked dimensionally and examined visually to determine conformance the critical and minor items outlined below in this specification and applicable manufacturing drawings. The following classification defects shall be used to classify the defects found.

Critical

1. Any component missing, malformed, or otherwise damaged

2. Any component loose or otherwise not securely retained affecting

3. Incorrect assembling or improper positioning of components

4. Any functioning part that works with difficulty

5. Not being able to lock the closure in the closed position

6. Materials exposed which cannot withstand the thermal radiation or thermal flux specified for testing.

7. Any visible separations in the closure which would admit light

Minor

1. Marking - missing, insufficient incorrect, illegible, or not permanent.

2. Material imperfections not serviceability or thermal resistance

3. Surfaces rough, unclean or other flaws affecting appearance