Attach_B_-_FINAL_KC46_Palletized_Seating_TRD_13_Jul_16.pdf

Tanker Division (AMC) KC-46

WRIGHT-PATTERSON AIR FORCE BASE, OHIO 45433

Technical Requirements Document

For

KC-46 Palletized Seating

Contract No:

Date: 22 April 2016

APPROVED BY: _______________________________________________

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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 General Requirements

3.2 Support Systems

3.3 Test and Evaluation

3.4 Emergency Egress

3.5 Systems Engineering

4.0 VERIFICATION

4.1 Methods of Verification

4.1.1 Responsibility for Test Category

Test category responsibility shall be assigned as follows:

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 Acceptance Verification

1.0 SCOPE

This Technical Requirements Document (TRD) identifies the requirements for the implementation, and qualification of the Palletized Seating.

2.0 APPLICABLE DOCUMENTS

2.1 General

The following documents form a part of this TRD to the extent specifically imposed in Section 3 and subsequent. 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, and any referenced documents not specially imposed by the TRD in Section 3 and subsequent, shall be used for guidance.

REFERENCE TITLE DATE

MIL-HDBK-516C

Airworthiness Certification

Criteria 12/12/2014

SAE AS8049 Rev B

Performance Standard For

Seats in Civil Rotorcraft, Transport Aircraft, and

General Aviation Aircraft

01/2005

2.2 Order of Precedence

In the event of any inconsistency within this TRD, the Program Office Palletized Seating 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

3.1 General Requirements

3.1.1 Pallet: In accordance with MIL-STD-1791B, the seat pallet shall be compatible with existing KC-46 cargo restraint system and existing USAF Material Handling Equipment (MHE).

Seat pallet base, where it interfaces with both the USAF Material Handling Equipment (MHE) and

KC-46 cargo restraint system, shall be dimensionally identical to an HCU-6/E, 463L cargo pallet, 88 inches by 108 inches. Markings will be on the seat tracks to make it easy to install seats in the correct location for each configuration.

3.1.2 Forward Bridge Plate: Pallets shall have integrated forward bridge plate to bridge the gap between it and the pallet in front of it to prevent tripping hazard and aid in egress operations.

The bridge plate shall not interfere with KC-46 cargo handling equipment.

3.1.3 Seat Material: Seat cover material must be medium to dark gray or blue in color and must be rugged enough to withstand the harsh conditions of austere environments (e.g., Kevlar, Nomex, etc.) with the ability of being easily maintained, and meet the flammability and toxicity requirements of MIL-HDBK-516C, section 8.4.14, “Fire Resistance”. Additionally, each seat will have padded arm rests, reclining seats backs and tray tables.

3.1.4 Emergency Equipment: Each seat must meet standard floatation capability per MIL-

HDBK-516C, section 18.1.14, “Floatation Devices”. Each seat must have storage capability to store oxygen equipment such as an Emergency Passenger Oxygen System (EPOS). Each seat must have a single point release restraint system that meets MIL-HDBK-516C requirements per section

18.1.2, “Restraint System Release Point”.

3.1.5 Pallet Configurations: Pallet configurations to include a 108 inch bias capable of holding

10 forward facing seats and an 88 inch bias capable of holding 12 forward facing seats.

3.1.6 Palletized Seating Certification: Seat pallets must meet USAF air-worthiness certification requirements for KC-46 passenger movement operations to include crash load survivability per

MIL-HDBK-516C, sections: 9.7.1, “Seating System Load Capability”; 9.7.3, “Restraint Systems

Loads”; 9.7.4, “Occupant Strike Envelope”, and 18.1.1, “Passenger Seating and Restraint

Systems”.

3.1.7 KC-46 Loading: Pallets must be able to meet maximum pallet position loading on KC-46

(i.e., simultaneously load 12-seat pallets in pallet positions 1 through 8 (12-seat pallet in pallet position 4 reconfigured to 8 seats with 1 row of seats removed for cross isle egress requirements) and 10-seat pallets in pallet positions 9 & 10, and be USAF certified per MIL-HDBK-516C to fly as such while each pallet is fully occupied with passengers).

3.1.8 Pallet All-Weather Covering: Each pallet must come complete with a durable all-weather cover to protect it from environmental elements such as extreme cold, heat, humidity, and precipitation. The cover shall be pliable enough to fold up, and have its own bag for stowage.

Stowage bag and seat pallet cover shall be marked with seat pallet serial number, or other identifying number to match it up with the seat pallet.

3.1.9 KC-46 Pallet Weight and Center of Gravity: The fully loaded pallet (to include all passengers with a maximum weight of 250 pounds each, personal bags for each passenger weighing no more than 10 pounds, EPOS (emergency passenger oxygen system), floatation device, and bridge plate) cannot exceed a total weight of 3520 pounds on the 108" bias or 4320 pounds on the 88" bias. The fully loaded seat pallet cannot exceed a center of gravity (C.G.) height of 30.75 inches.

3.1.10 Passenger Hand Carried Baggage: Small hand carried personal baggage not to exceed

18 inches wide by 15 inches long by 8 inches tall, and ten (10) pounds, per person may be stored on the pallet underneath seats.

3.1.11 Palletized Seat System Restraint Capability: The palletized seat system shall have the capability of restraining a 250 pound passenger to the seat, and the seat and passenger to the pallet, when the pallet is secured by the aircraft cargo restraining system(s). It must be able to withstand static forces per SAE AS8049 Table 4 and dynamic forces per SAE AS8049 section

5.3. The pallet shall remain in one piece. Otherwise, permanent deformation is permitted. The palletized seats need not be serviceable after undergoing such a load.

3.1.12 Seat-To-Track Connections Verification: Static test is required to verify the capability of seat to track connections. For assembly and/or its components not statically tested, structural analysis is required. Margins of safety must equal or exceed 0.05 with the exception for operational down load ultimate condition, a margin of safety of 0.25 is required. For any fittings including seat to track local attachments, a fitting factor of 1.15 or higher shall be used.

3.1.13 Preventing Pallet Movement: Pallets must be equipped with "anti-rattle" clamping devices to minimize pallet movement with a minimum slip force of 200 pounds.

3.1.14 Supplemental Restraints: Supplemental restraints, such as braces, struts, guy wires, or other “add-ons” are not permitted to enhance performance of palletized seats if emergency egress, loading/unloading, locking into the KC-46 cargo restraint system or proper use of existing USAF Material Handling Equipment (MHE) is hindered.

3.1.15 Clean Air Act: Ensure that new designs or modifications meet the requirement of Title VI of the Clean Air Act Amendments, Public Law 102-804, and AFI 32-7080. The Contractor shall design the system such that ODSs are not required in the manufacture, test, operation, and maintenance of the system, subsystem, item, or component. In case of conflict or disparity between this requirement and other contract requirements, the Contractor shall notify the cognizant IPT, who will promptly make a determination on the issue. When executing the PTP, the Contractor shall identify hazardous materials used on and planned for use on the system, including those used in manufacturing, testing, operation, and maintenance. The cognizant IPT shall be notified when hazardous materials are identified.

3.1.16 Repair: The seat pallet must be maintainable without requiring item specific tools and hardware, or specialized equipment, rather common tools with such exception as necessary for intricate metal working.

3.2 Support Systems

3.2.1 Technical Orders: Technical data to sustain the entire seat pallet organically (inspect, maintain, and repair) is required. All technical data will be digital format and must be viewable on DoD (specifically Air Force) standard desktop configuration (SDC) laptop and tablet devices.

Final product Technical Orders (TOs) will be in S1000D Issue 4.0.1 (MIL-STD-3048) IETM format for upload into ETIMS (Enhanced Technical Information Management System) or other

AMC approved T.O. distribution system. Technical data will include: Introduction: Descriptive

Overview of Seat Pallets; Preparation For Use, Storage And Shipment; System Operation; General

Maintenance To Include: Preventative Maintenance; Inspection And Cleaning, Troubleshooting

And Approved Repairs; Illustrated Parts Breakdown; Special Tools and Test Equipment Required;

and Schematic Diagrams And Drawings.

3.2.2 Illustrated Parts Breakdown: Technical data must include an illustrated parts break-down detailing parts with corresponding part numbers, which comports with current Air Force standard for technical data publication.

3.2.3 Parts Provisioning: Provide for spare parts to enable future sustainment as necessary.

3.2.4 Parts Cataloguing: Catalog spare parts to enable induction into Air Force logistics systems, which will allow for future organic material management/sustainment.

3.3 Test and Evaluation

3.3.1 Test Plan: A test plan shall be submitted to the Air Force for review if testing is required.

3.3.2 Fit Check: Perform fit check with at least one (2) 10-seat pallet and one (4) 12-seat pallet.

3.3.3 Anti-Movement Test: Evaluation and determination of minimizing relative movement between pallets and KC-46 floor locks to be part of fit check.

3.4 Emergency Egress

3.4.1 Passenger Aisle Flow Rates: Perform analysis/simulation of passenger aisle flow rates and emergency egress times for the two proposed palletized seating configurations.

3.4.2 Maximum Passenger Count: Perform analyses required to determine and verify maximum passenger count and palletized seating configurations in order to achieve 90-second emergency egress requirement.

3.4.3 Egress Through Half The Primary Exits: Demonstrate the ability to egress all crew members and passengers through half the primary exits. Determine maximum number able to egress within ninety (90) seconds or less, as well as time required to egress all crew members and passengers. For configurations with less than 25 passengers, demonstrate the ability to egress within 45 seconds or less through half the primary exits. MIL-HDBK-516C, section 9.1.2

3.5 Systems Engineering

3.5.1 Risk Management: Identify, analyze, document, and track program risks.

3.5.2 Requirements Management: Identify, analyze, and document program requirements.

3.5.3 Technical Interchange Meetings: Support design reviews and Technical Interchange

Meetings (TIMs).

4.0 VERIFICATION

Verification of the Palletized Seating 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

Palletized Seating System.

4.1 Methods of Verification

The palletized seating 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.

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 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, 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 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:

The contractor may utilize their 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 as specified in the contract.

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 contract 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, and 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 Palletized Seating

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 Palletized Seating System will be performed for any USAF airworthiness criterion that is non-compliant to the certification basis, 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 Palletized Seating System and examine failures or combination of system failures that affect the Palletized Seating System functions.

b) Hardware FMECA – The Hardware FMECA will identify single point failures or a combination of single point failures of Palletized Seating 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 Palletized Seating 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 Acceptance Verification

Acceptance is the method by which an item and/or system is verified to meet preproduction and production drawings and specifications. Each deliverable Palletized Seating System shall be subjected to acceptance verification prior to delivery of the system to the user. Appropriate documentation indicating compliance with this requirement shall accompany each delivery.

Every Palletized Seating system shall be checked dimensionally and examined visually to determine conformance to 1-4 Critical items, and 1-3 Minor items, below of 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 attached

3. Incorrect assembling or improper positioning of components

4. Any functioning part that works with difficulty

Minor

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

2. Material imperfections not serviceability

3. Surfaces rough, unclean or other flaws affecting appearance