MILSTD810F.pdf

NOT MEASUREMENT

SENSITIVE

MIL-STD-810F

1 January 2000

SUPERSEDING

MIL-STD-810E

14 JULY 1989

DEPARTMENT OF DEFENSE

TEST METHOD STANDARD

FOR

ENVIRONMENTAL ENGINEERING CONSIDERATIONS

AND LABORATORY TESTS

AMSC N/A AREA ENVR

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

MIL-STD-810F

1 January 2000

Part One-ii

FOREWORD

This test method standard is approved for use by all Departments and Agencies of the Department of Defense (DoD).

Although prepared specifically for DoD applications, this standard may be tailored for commercial applications as well. MIL-STD-810F is a significant revision of MIL-STD-810E. Much of the standard is rewritten completely to provide clearer direction. The primary emphases are still the same -- tailoring a materiel item's environmental design and test limits to the conditions that the specific materiel will experience throughout its service life, and establishing laboratory test methods that replicate the effects of environments on materiel rather than trying to reproduce the environments themselves. However, the "F" revision has been expanded significantly up front to explain how to implement the environmental tailoring process throughout the materiel acquisition cycle.

This revision recognizes that the environmental design and test tailoring process has expanded to involve a wide range of managerial and technical interests. Accordingly, this revision orients environmental design and test direction toward three basic types of users who have distinctly different, although closely associated, interests:

program managers who, among other responsibilities, ensure proposed concepts and systems are valid and functional in intended operational environments; environmental engineering specialists (EES), who enter the acquisition process early to assist combat and materiel developer tailoring efforts by preparing life cycle environmental profiles and drafting tailored design criteria and test programs, and the design, test, and evaluation community, whose analysts, engineers, and facility operators use tailored designs and tests to meet user needs.

The most visible difference in the "F" revision is that the overall document is in two parts.

Part One describes management, engineering, and technical roles in the environmental design and test tailoring process. It focuses on the process of tailoring materiel design and test criteria to the specific environmental conditions a materiel item is likely to encounter during its service life. New appendices support the succinctly presented text of Part One. Appendix A contains complete descriptions of environmental engineering tasks. These tasks, along with management information in Appendix B and EES guidance in Appendix C, will help to ensure the environmental design and test tailoring process is implemented and documented according to the disciplined, but flexible approach to materiel acquisition called for in Department of Defense (DoD) 5000-series documents (DoD 5000.1, A.4). Terms used in this standard relating to the materiel acquisition process are limited to terms used in the DoD 5000-series documents; to avoid confusion and promote simplicity, service-specific terms/processes are not used.

Part Two contains environmental laboratory test methods to be applied according to the general and specific test tailoring guidelines described in Part One. It is important to emphasize that these methods are not to be called out in blanket fashion nor applied as unalterable routines, but are to be selected and tailored to generate the most relevant test data possible.

To support the tailoring process described in Part One, each test method in Part Two contains some environmental data and references, and identifies tailoring opportunities for the particular method. Some methods afford a wide latitude for tailoring; some can be tailored up to established limits, and some have relatively few tailoring options.

Whenever possible, each method contains background rationale to help determine the appropriate level of tailoring.

Each test method supports the test engineer and test facility operator by describing preferred laboratory test facilities and methodologies. Any specific tailoring information and values contained in these test methods should be supplanted by more up-to-date or program-specific information when available.

When applied properly, the environmental management and engineering processes described in this standard can be of enormous value in generating confidence in the environmental worthiness and overall durability of materiel system design. However, it is important to recognize that there are limitations inherent in laboratory testing that make it imperative to use proper caution and engineering judgement when extrapolating these laboratory results to results that may be obtained under actual service conditions. In many cases, real-world environmental stresses (singularly or in combination) cannot be duplicated practically or reliably in test laboratories. Therefore, users

Part One-iii should not assume that a system or component that passes laboratory tests of this standard also would pass field/fleet verification trials.

The US Department of Defense would like to thank the following individuals for their contributions toward the development and publication of MIL-STD-810F:

Anderson, Andy – United Defense Merritt, Ron – US Navy, Naval Air Warfare Center

Bair, Jim – US Air Force, Wright-Patterson AFB Moriceau, Jacques – LRBA, France

Bell, Dwayne – US Air Force, Eglin AFB Moss, Ron – Ordnance Board, United Kingdom

Caruso, Hank – G’s and Degrees Sullivan, Jamie – US Army, Redstone Technical Test Center

Connon, Skip – US Army, Aberdeen Test Center Tanner, Steve – US Navy, Naval Air Warfare Center

Egbert, Herb – US Army Developmental Test Command

Walton, Scott – US Army, Aberdeen Test Center

Galloway, Judy – US Army, Aberdeen Test Center Weaver, Earl – US Air Force, Wright-Patterson AFB

Henry, Connie – US Air Force, Wright-Patterson

AFB

Williamson, Roger – US Army Test and Evaluation Command

MacMartin, Dave – National Defence Headquarters, Canada

Also, a special thank you to Herb Egbert, Chairman of the MIL-STD-810 revision committee for his leadership, dedication, and perseverance in revising this document.

This standard is intended to be a "living document" that will be updated as new concepts, technologies, and methodologies evolve. Address beneficial comments (recommended changes, additions, deletions) along with clear, supporting rationale and any pertinent data that may improve this document to: ASC/ENOI, Bldg. 560, 2530 Loop Road West, Wright-Patterson AFB OH 45433-7101. Use the Standardization Document Improvement Proposal (DD Form 1426) appearing at the end of this document or send a letter detailing the paragraph/page number, recommended wording, and reason/rationale for the recommendation.

Address technical questions to the following offices:

Aeronautical Systems Center, ATTN: ASC/ENFS, 2530 Loop Road West, Wright-Patterson AFB OH 45433-7101;

Commercial Tel: (937) 255-8357/8596; DSN 785-8357/8596; Fax: (937) 476-4546.

Naval Air Warfare Center, Weapons Division, ATTN: Code 476400D, China Lake CA 93555-6100; Commercial Tel: (619) 939-4667; DSN 437-4667; Fax: (619) 939-1065.

US Army Developmental Test Command, 314 Longs Corner Road, ATTN: CSTE-DTC-TT-M, Aberdeen Proving Ground MD 21005-5055; Commercial Tel: (410) 278-1476; DSN 298-1476; Fax: (410) 278-4243/1475.

Part One-iv

THIS PAGE INTENTIONALLY BLANK

Part One-v

PART ONE -- ENVIRONMENTAL ENGINEERING PROGRAM GUIDELINES

TABLE OF CONTENTS

Paragraph Page

1. SCOPE

1.1 Purpose

1.2 Application

1.3 Limitations

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government Documents

2.2.1 Standards

2.2.2 Other government documents

2.3 Non-government Documents

2.4 Order of Precedence

3. TERMINOLOGY

4. GENERAL PROGRAM GUIDELINES

4.1 Program Managers

4.1.1 Roles of the program manager

4.1.2 Guidance for program managers

4.1.2.1 Mission Need Statement (MNS)

4.1.2.2 Operational Requirements Document (ORD)

4.1.2.3 Systems Engineering Management Plan (SEMP)

4.1.2.4 Test and Evaluation Master Plan (TEMP)

4.1.2.5 Cost and Operational Effectiveness Analysis (COEA)

4.2 Environmental Engineering Specialists (EES)

4.2.1 Roles of environmental engineering specialists

4.2.2 Environmental engineering tailoring tasks

4.2.2.1 General

4.2.2.2 Preparing an Environmental Engineering Management Plan (EEMP), Task 401

4.2.2.3 Developing an Environmental Test and Evaluation Master Plan (ETEMP)

4.2.2.3.1 Defining a Life Cycle Environmental Profile (LCEP), Task 402

4.2.2.3.2 Developing Operational Environment Documentation (OED), Task 403

4.2.2.3.3 Developing an Environmental Issues/Criteria List (EICL), Task 404

4.2.2.4 Preparing a Detailed Environmental Test Plan (DETP), Task 405

4.2.2.5 Preparing an Environmental Test Report (ETR), Task 406

4.3 Design and Test Engineers and Facility Operators

4.3.1 Roles of design engineers

4.3.2 Roles of test engineers/facility operators

4.3.3 Guidance for design and test engineers and test facility operators

4.3.3.1 Natural environment (field/fleet) testing

4.3.3.2 Laboratory testing

5. GENERAL LABORATORY TEST METHOD GUIDELINES

5.1 Standard Ambient Test Conditions

5.2 Tolerances for Test Conditions

Part One-vi

TABLE OF CONTENTS (CONT’D).

Paragraph Page

5.3 Test Instrumentation

5.3.1 Suitability for environment

5.3.2 Calibration

5.4 Stabilizing Test Temperature

5.4.1 Test item operating

5.4.2 Test item non-operating

5.5 Test Sequence

5.6 Test Level Derivation

5.7 Pretest Information for Facility Operators

5.8 Test Setup

5.8.1 Installing the test item in test facility

5.8.2 Test item operation

5.9 Pretest Baseline Data

5.10 Information During Test

5.11 Interrupted Tests

5.11.1 In-tolerance interruptions

5.11.2 Out-of-tolerance interruptions for methods 503, 506, 510, 511, 514, 515, 516, 517, 519, 522, and 523

5.11.3 Out-of-tolerance interruptions for methods 500, 501, 502, 504, 505, 507, 508, 509, 512, 513, 518, 520, and 521

5.12 Combined Tests

5.13 Post-test Data

5.14 Environmental Effects and Failure Criteria

5.15 Environmental Test Reports

5.16 Water Purity

5.17 Analysis of Results

5.18 Monitoring

5.18.1 Monitoring test chamber parameters

5.18.2 Monitoring the item under test

6. NOTES

6.1 Intended Use

6.2 Issue of DoDISS

6.3 Subject Term (key word) Listing (Also see, Subject Index, page Index –1)

6.4 International Standardization Agreement

6.5 Changes from Previous Issue

FIGURES

1-1 Environmental engineering program guide ................................................................................ viii 1-2 Roles of acquisition personnel in environmental design/test tailoring process 4-1 Environmental test program tailoring process 4-2a Generalized life cycle histories for military hardware 4-2b Generalized life cycle histories for military hardware 5-1 Interrupted test cycle logic, Method 503, 506, 510, 511, 514, 516, 517, 519, 522, and 523

Part One-vii

TABLE OF CONTENTS – Continued

APPENDIX Page A Environmental Management and Engineering Tasks ………………………………….. A-1 B Detailed Program Management Guidance }}}}}}}}}}}}}}}}…… B-1 C Environmental Tailoring Guidelines for Environmental Engineering

Specialists (EES) }}}}}}}}}}}}}}}}}}}}}}}}}}}…..

C-1

D Terminology for Dynamic (Mechanical) Test Methods}}}}}}}}}}}}}. D-1

APPENDIX FIGURE

C-1 Areas of occurrence of climatic categories ...................................................................... C-5

APPENDIX TABLE

C-I Summary of climatic conditions and daily cycles of temperature, solar radiation, and relative humidity ......................................................................................................... C-6

Subject Index (for Part One) }}}}}}}}}}}}}}}}}}}}}}}}}}}}}… Index -1

PART TWO -- LABORATORY TEST METHODS Part Two-1

500.4 Low Pressure (Altitude) }}}}}}}}}}}}}}}}}}}}}.. 500.4-1 - 500.4-8

501.4 High Temperature }}}}}}}}}}}}}}}}}}}}}}}} 501.4-1 - 501.4-12

502.4 Low Temperature }}}}}}}}}}}}}}}}}}}}}}}} 502.4-1 - 502.4-10

503.4 Temperature Shock }}}}}}}}}}}}}}}}}}}}}}}. 503.4-1 - 503.4-10 504 Contamination by Fluids }}}}}}}}}}}}}}}}}}}}}. 504-1- 504A-2

505.4 Solar Radiation (Sunshine) }}}}}}}}}}}}}}}}}}}} 505.4-1 - 505.4A-8

506.4 Rain }}}}}}}}}}}}}}}}}}}}}}}}}}}}}... 506.4-1 - 506.4-12

507.4 Humidity }}}}}}}}}}}}}}}}}}}}}}}}}}}… 507.4-1 - 507.4A-2

508.5 Fungus }}}}}}}}}}}}}}}}}}}}}}}}}}}…. 508.5-1 - 508.5-12

509.4 Salt Fog }}}}}}}}}}}}}}}}}}}}}}}}}}}… 509.4-1 - 509.4-10

510.4 Sand and Dust }}}}}}}}}}}}}}}}}}}}}}}}…. 510.4-1 - 510.4-12

511.4 Explosive Atmosphere }}}}}}}}}}}}}}}}}}}}}… 511.4-1 - 511.4-6

512.4 Immersion }}}}}}}}}}}}}}}}}}}}}}}}}}…. 512.4-1 - 512.4-8

513.5 Acceleration }}}}}}}}}}}}}}}}}}}}}}}}}}. 513.5-1 - 513.5-14

514.5 Vibration }}}}}}}}}}}}}}}}}}}}}}}}}}}… 514.5-i - 514.5C-16

515.5 Acoustic Noise }}}}}}}}}}}}}}}}}}}}}}}}…. 515.5-i - 515.5B-2

516.5 Shock }}}}}}}}}}}}}}}}}}}}}}}}}}}}… 516.5-i - 516.5C-4

517 Pyroshock }}}}}}}}}}}}}}}}}}}}}}}}}}}. 517-1 - 517-24 518 Acidic Atmosphere }}}}}}}}}}}}}}}}}}}}}}}.. 518-1 - 518-6

519.5 Gunfire Vibration}}}}}}}}}}}}}}}}}}}}}}}}.. 519.5-i - 519.5D-10

520.2 Temperature, Humidity, Vibration, and Altitude }}}}}}}}}}}... 520.2-1 - 520.2A-10

521.2 Icing/Freezing Rain }}}}}}}}}}}}}}}}}}}}}}}.. 521.2-1 - 521.2-8 522 Ballistic Shock }}}}}}}}}}}}}}}}}}}}}}}}}.. 522-1 - 522-14

523.2 Vibro-Acoustic/Temperature }}}}}}}}}}}}}}}}}}}.. 523.2-1 – 523.2A-8

Part One-viii

EEMP LCEP OED EICL DETP ETR

tailoring simulation alternatives laboratory testing field/fleet testing

D E V EL O P E N V IR O N M E N TA L E N G IN E ER IN G

M A N A G EM EN T PL A N (E EM P).

(TA S K 4 01 , R EF PA R A GR AP H 4 .2 .2.2 )

S C H E D U L E TA S K S 4 02 -4 06 , P L U S TA S K S U P P O R T.

C O N S ID E R ALT E R N ATIVE S TO T E ST IN G H A R D W A R E.

P R E PA R E C O ST /B E N E F IT /R IS K AN ALYS IS F O R

A LT E R N AT IV E(S) TO TE ST IN G H A R D W AR E.

P R E PA R E LIF E C Y C LE

E N V IR O N M E N TA L P R O F ILE (L C E P).

(TA S K 4 02 , R EF PA R A GR AP H 4 .2 .2.3 .1)

P R E PA R E EN VIR O N M EN TAL

ISS U E S /C R IT E R IA L IST (E IC L ).

(TA S K 4 04 , R EF PA R A GR AP H 4 .2 .2.3 .3)

B AS E O N R ES U LT S F R O M TAS K S 4 02 & 4 03 .

L IS T A LL TA IL O R ED IS S U E S & C R IT E R IA .

P R O VID E R AT IO N AL E F O R T H EIR

D E R IVAT IO N S .

P R E PA R E D E TAIL ED E N V IR O N M E N TA L

T E S T P L AN (D E T P).

(TA S K 4 05 , R EF PA R A GR AP H 4 .2 .2.4 )

L AB O R ATO R Y T E S T PL A N S : U S E M E T H O D S IN T H IS

S TAN D A R D , SE L EC T ED & TA IL O R E D TO T H E

S PE C IF IC T E S T IT E M .

F IE LD /F L E ET T E S T PLA N S : D E V EL O PM E N T /

O PE R AT IO N A L T E S T A G E N C IE S U S E T H E IR O W N

P LA N R E Q U IR E M E N T S /F O R M AT S. TA IL O R E D

T O T H E S PE C IF IC T E S T IT E M .

A LT E R N AT IV E(S) : E X PL A IN M E T H O D O LO G Y.

P ER F O R M E N V IR O N M E N TA L T E ST S.

L AB O R ATO R Y T E S T S : U S E M E T H O D S IN T H IS

S TAN D A R D S EL E C T E D & TA ILO R E D T O T H E

S PE C IF IC T E S T IT E M .

F IE LD /F L E ET T E S T S : D E V EL O PM E N T /

O PE R AT IO N A L T E S T A G E N C IE S U S E T H E IR O W N

M E T H O D S , SE L EC T ED & TA IL O R E D TO T H E

S PE C IF IC T E S T IT E M .

A LT E R N AT IV E(S) : E X EC U T E M E T H O D O LO G Y.

P R E PA R E EN VIR O N M EN TAL

T E S T R EP O R T S (E T R ).

(TA S K 4 06 , R EF PA R A GR AP H 4 .2 .2.5 )

L AB O R ATO R Y T E S T R E PO R T S : U S E T H E

F O R M AT IN TA SK 40 6.

F IE LD /F L E ET T E S T R E PO R T S :

D E V EL O PM EN T /O P E R AT IO N AL T ES T

A G E N C IE S U S E T H E IR O W N T E S T

R E P O R T R E Q U IR E M E N T S /F O R M AT S .

A LT E R N AT IV E(S) : A P PR O P R IAT E R EP O R T (S ).

E N V IR O N M E N TA L T E S T & E VA L U AT IO N M A S T E R PL A N (E T E M P )

(TA S KS 4 02 , & 40 4 R EF PAR AG R A P H 4.2 .2.3)

N O T E 1:

N O T E 2:

N O T E 3:

C O M P L ET E TA SK D E SC R IPT IO N S A R E IN

A PP E N D IX A .

IN C L U D E EE M P & E T E M P W IT H O T H E R

S YS T E M P LA N S & P R O P O S A LS TO

A LL O W R E A LIS T IC C O ST E S T IM AT IN G .

M A K E C O N T R A C T PR OV IS IO N S F O R T H E

E Q U IPM EN T S U P P LIE R TO U P D AT E E E M P &

E T E M P O N A PE R IO D IC B AS IS A S A D D IT IO N A L

IN F O R M AT IO N B EC O M ES AVA ILA BL E .

P R E PA R E O P E R AT IO N AL EN VIR O N M EN T

D O C U M E N TAT IO N (O E D ).

(TA S K 4 03 , R EF PA R A GR AP H 4 .2 .2.3 .2)

D O C U M E N T R E AL -W OR LD P L AT F O R M

C H A R A C T E R IS T IC S .

O BTAIN D ATA F R O M D ATAB A SE S , M O D EL S ,

S IM U L AT IO N S .

O BTAIN R E M A IN IN G D ATA B Y M EA S U R IN G

R E A LIS T IC PL AT F O R M E N V IR O N M E N T S .

T E S T H A R D W A R E/

P R O TO T Y P ES

? N O

Y ES

(S E E TA S K 4 01

R E F PA R A G R A PH S

4 .1 .2, 4 .2 .2.1 , &

A PP E N D IX B , PA R A . F )

A LT E R N AT IV ES .

S EL E C T ALT E R N AT IV E

(e .g., M O D E LIN G &

S IM U L AT IO N , C O U P O N

S AM PL E S, S IM ILA R IT Y,

O T H E R A N ALY SE S .)

S C H E D U L E A N D JU STIF Y

A LT E R N AT IV E(S) IN

TA SK 40 1 .

FIGURE 1-1. Environmental engineering program guide.

Part One-1

PART ONE -- ENVIRONMENTAL ENGINEERING PROGRAM GUIDELINES

1. SCOPE.

1.1 Purpose.

a. This standard contains materiel acquisition program planning and engineering direction for considering the influences that environmental stresses have on materiel throughout all phases of its service life. It is important to note that this document does not impose design or test specifications. Rather, it describes the environmental tailoring process that results in realistic materiel designs and test methods based on materiel system performance requirements. Figure 1-1 summarizes this direction.

b. This document supports the functions of three different groups of personnel involved in the materiel acquisition process. Each of these groups is critical to the goal of successfully incorporating environmental considerations into materiel design, test, and evaluation. Although each group has different tasks to perform, none of these tasks can be isolated from the others in a successful acquisition program. As shown on figure 1-2, this information is intended for the following:

(1) Materiel acquisition program managers among whose responsibilities is ensuring materiel will function as required in intended operational environments. (See paragraph 4.1 below.)

(2) Environmental engineering specialists (EES) who assist combat and materiel developers throughout the acquisition process to tailor their materiel designs and test designs to environmental stresses/constraints expected during the materiel's service life. (See paragraph 4.2 below.)

(3) Design, test, and evaluation community analysts, engineers, and facility operators who meet user needs by focusing on tailored designs and tests. (See paragraph 4.3 below, and Part Two of this standard.)

1.2 Application.

The tailoring process described in this standard (i.e., systematically considering detrimental effects that various environmental factors may have on a specific materiel system throughout its service life) applies throughout the materiel acquisition cycle to all materiel developed for military or commercial applications, including foreign and nondevelopment item (NDI) procurements.

a. Part One lays out a disciplined, tailored approach for acquiring systems that will withstand the stresses of climatic, shock and vibration environments that they expect to see in their service lives. The basic process for acquiring materiel that satisfies users' needs from this environmental engineering viewpoint is at figure 1-1.

b. Part Two also is an integral part of the environmental tailoring process. It contains tailoring information, environmental stress data, and laboratory test methods. The environmental data contained in the methods may help, but should not be used exclusively, to define environmental stresses that materiel will encounter throughout its service life. This will help engineers to tailor analyses and tests to specific materiel and its defined life cycle. It is not valid to call out all of the methods in this standard in a blanket fashion for a materiel system; nor is it valid, once a method is determined appropriate, to regard the environmental stress data, test criteria, and procedures in the method as unalterable.

c. Guidance and test methods of this standard are intended to:

(1) Define environmental stress sequences, durations, and levels of materiel life cycles.

(2) Be used to develop analysis and test criteria tailored to the materiel and its environmental life cycle.

(3) Evaluate materiel performance when exposed to a life cycle of environmental stresses.

(4) Identify deficiencies, shortcomings, and defects in materiel design, materials, manufacturing processes, packaging techniques, and maintenance methods.

Part One-2

(5) Demonstrate compliance with contractual requirements.

program manager environmental engineering specialists design engineers test engineers facility operators

MNS ORD STAR TEMP COEA EEMP LCEP OED DETP ETR

tailoring field/fleet testing laboratory testing

FIGURE 1-2. Roles of acquisition personnel in environmental design/test tailoring process.

1.3 Limitations.

Although environmental analysis, design analysis, and laboratory testing are valuable tools in the materiel acquisition process, there are inherent limitations in analysis and laboratory testing techniques that must be recognized. The methods in Part Two of this standard do not include many of the naturally-occurring forcing functions that may affect materiel performance or integrity in service use. Further, analytic and laboratory test methods are limited in their abilities to simulate synergistic or antagonistic stress combinations, dynamic (time sequence) stress applications, aging, and other potentially significant stress combinations present in natural field/fleet service environments. Use caution when defining and extrapolating analyses, test criteria, and results. Part Two test methods purposely do not address the following but may, in some cases, be applied:

a. Electromagnetic interference (EMI).

b. Lightning and magnetic effects.

c. Nuclear, biological, chemical weapons or their effects.

d. Certain aspects of munitions and pyrotechnics safety testing.

e. Piece parts such as bolts, wires, transistors and integrated circuits.

f. Packaging performance or design.

g. Suitability of clothing or fabric items that are described in specific specifications.

h. Environmental stress screening (ESS) methods and procedures.

i. Reliability testing.

j. Safety testing.

M ISS IO N NEE D STATE ME NT

O PER AT IO NAL REQ UIREM ENTS

DO CUM ENT

SYS TEM S ENG INEE RING

M ANAG EME NT P LAN

SYS TEM THREAT ASSESSM ENT

REPO RT

TE ST & EVALUATIO N MA STER

PLAN

CO ST & O P ERATIO NA L

EFFECT IVEN ESS ANALYS IS

ENVIRO NM ENTAL ENG INEERIN G

M ANAG EME NT P LAN

LIFE CYCLE ENVIRONM ENTAL PRO FILE

O PER AT IO NAL ENV IRO NM ENT

DO CUM ENTATIO N PLAN

TAILO RED ENVIRO NM ENTA L

DESIG N/TEST REQ UIRE MENTS

ENVIRONM ENTAL TE ST

PLANS/REPO RTS

ENG INEERIN G DESIG NS AND

SPE CIFICATIO NS

M IL-STD-810F, PART TW O

LABO RATO RY TEST M ETH OD S

NATURA L ENVIRONM ENT

FIELD /FLEET TES T FACIL IT IES

AND PRO CEDURE S

M IL-STD-810F

ENVIRO NM EN TAL D ESIGN/TEST

TAILORING G UIDANCE

ENVIRO NM EN TAL

ENGINEERING

SPEC IALISTS

DESIG N/TEST

ENGINEERS &

FACILITY O PERATORS

PROG RAM

M ANAG ER

Part One-3

2. APPLICABLE DOCUMENTS.

2.1 General.

The documents listed in this paragraph are referenced in Part TWO of this standard. There are other documents cited in Part TWO of this standard that are 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 should consider all specified requirements documents and tasks cited in paragraph 4 of this standard.

2.2 Government Documents.

2.2.1 Standards.

The following standard forms a part of this document to the extent specified herein. When applying a portion of this standard that contains one of these references, cite the particular edition of the document that is listed in the current Department of Defense Index of Specifications and Standards (DoDISS), or in the DoDISS that was in effect at the time of solicitation. Unless otherwise specified, the issues of these documents are those listed in the issue of the DoDISS and supplement thereto, cited in the solicitation (see paragraph 6.2).

STANDARD

MIL-STD-882 System Safety Program Requirements

HANDBOOKS

MIL-HDBK-310 Global Climatic Data for Developing Military Products

(Copies of the above documents are available from the Defense Automated Printing Service, Building 4/Section D, 700 Robbins Avenue, Philadelphia PA 19111-5098.)

2.2.2 Other government documents.

The following other Government documents and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

DIRECTIVES, INSTRUCTIONS, AND MANUALS.

DODD 5000.1 Defense Acquisition

DODD 5000.2 Mandatory Procedures for Major Defense Acquisition Programs (MDAP’s) and Major Automated Information System (MAIS) Acquisition Programs

DOD 5000.2M Defense Acquisition Management Documentation and Reports

(Copies of the above documents may be downloaded from the Washington HQ Services web site “http://web7.whs.osd.mil/corres.htm”.)

PUBLICATIONS

AR 70-38 Research, Development, Test and Evaluation of Materiel for Extreme Climatic Conditions

(Copies of the above document are available from the U.S. Army Publications Distribution Center, 1655 Woodson Rd., St Louis, MO 65104.)

2.3 Non-government Documents.

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents that are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation.

Unless otherwise specified, the issues of documents not listed in the DoDISS are the issues of the documents cited in the solicitation (see 6.2).

Part One-4

STANAG 2895 Extreme Climatic Conditions and Derived Conditions for Use in Defining Design Test Criteria for NATO Forces Materiel

STANAG 4242 Vibration Tests for Munitions Carried in Tracked Vehicles

STANAG 4370 Environmental Testing

QSTAG 360 Climatic Environmental Conditions Affecting the Design of Military Materiel

AECTP 100 Allied Environmental Conditions and Test Publication (AECTP) 100, Environmental Guidelines for Defence Materiel (under STANAG 4370)

AECTP 200 Allied Environmental Conditions and Test Publication (AECTP) 200, Environmental Conditions (under STANAG 4370)

AECTP 300 Allied Environmental Conditions and Test Publication (AECTP) 300, Climatic Environmental Tests (under STANAG 4370)

AECTP 400 Allied Environmental Conditions and Test Publication (AECTP) 400, Mechanical Environmental Tests (under STANAG 4370)

(Copies of the above documents are available from the Defense Automated Printing Service, Building 4 / Section D, 700 Robbins Avenue, Philadelphia PA 19111-5098.)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI NCSL Z540-1 General Requirements for Calibration Laboratories and Measuring and Test Equipment

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) STANDARDS

ISO 10012-1 Quality Assurance Requirements for Measuring Equipment - Part I: Meteorological Confirmation System for Measuring Equipment First Edition

(Copies of the above documents are available from American National Standards Institute (ANSI), 11 West 42nd

Street, New York NY 10036-8002.)

2.4 Order of Precedence.

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. TERMINOLOGY.

This terminology section is meant to define the general terminology as it is used in this standard. In certain cases the terminology use may be somewhat different from its use in the general engineering community. No attempt has been made to be complete, therefore limiting the glossary to such terms as are found in the standard and that are important to the application of the standard. Terminology unique to a particular method is defined, as appropriate, in that method.

NOTE: A continuation of this terminology section that contains terminology more closely related to the dynamic (mechanical) test methods such as vibration, shock, gunfire vibration, etc., is in Appendix D.

a. Accelerated test. A test designed to shorten the controlled environmental test time with respect to the service use time by increasing the frequency of occurrence, amplitude, duration, or any combination of these of environmental stresses that would be expected to occur during service use.

b. Aggravated test. A test in which one or more conditions are set at a more stressful level than the materiel will encounter during service use.

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c. Ambient environment. The conditions, either outdoor or confined (e.g., temperature and humidity), that characterize the air or other medium that surrounds materiel.

d. Climatic categories. Specific types of world climates which materiel is designed to withstand during operation, storage, and transit. See Part One, Appendix C, table C-I and figure C-1.

e. Combat developer. Military specialist concerned with training, doctrine, and materiel needs documentation.

f. Critical threshold value. The level of an environment forcing function that degrades the capability of materiel significantly or requires degradation prevention measures be taken.

g. Cumulative effects. The collective consequences of environmental stresses during the life cycle of materiel.

h. Engineering judgement. Expert opinion based on engineering education and experience, especially in the area in which the judgement is made.

i. Environmental analysis. Technical activity covering an analytical description of the effects that various environments have on materiel, subsystems, and component effectiveness.

j. Environmental conditions. (See Forcing function (environment).)

k. Environmental engineering. The discipline of applying engineering practices to the effects that various environments have on materiel effectiveness.

l. Environmental engineering specialist (EES). A person or group of people skilled in one or more environmental engineering areas. Areas include, but are not necessarily limited to: natural and induced environments and their effects on materiel; expertise in measuring and analyzing in-service environmental conditions; formulating environmental test criteria; determining when environmental laboratory tests are appropriate/valid substitutes for natural in-service environmental tests; and evaluating the effects of specific environments on materiel. (See paragraph 4.2.)

m. Environmental test. A structured procedure to help determine the effects of natural or induced environments on materiel.

n. Environmental worthiness. The capability of materiel, subsystem, or component to perform its full array of intended functions in intended environments.

o. Equipment. For purposes of this standard, equipment includes the instrumentation, facilities, and support apparatus used to conduct or monitor tests. This does not include the test item itself or the materiel of which the test item is a sample or a part.

p. Forcing function (environment). A natural or induced physical environmental stress condition on materiel that may affect its ability to function as intended or to withstand transit or storage during its service life. (Also referred to as an environmental condition or an environmental stress.)

q. Hermetic seal. A permanent, air-tight seal.

r. Induced environment. An environmental condition that is predominantly man-made or generated by the materiel platform. Also, refers to any condition internal to materiel that results from the combination of natural environmental forcing functions and the physical/chemical characteristics of the materiel itself.

s. In-service use. The anticipated use of materiel during its intended service use life.

t. Integrated Product Team (IPT). A group of individuals from different professional disciplines and organizations (government and industry) who work together on a product from concept through production stages. Individuals who cover a discipline may change from stage to stage, but the discipline is covered, and the information pertinent to that discipline is passed to the succeeding team member(s) in that discipline.

u. Life cycle profile. A time history of events and conditions associated with materiel from its release from manufacturing to its removal from service, including demilitarization. The life cycle should include the

Part One-6 various phases materiel will encounter in its life, such as: packaging, handling, shipping, and storage prior to use; mission profiles while in use; phases between missions such as stand-by or storage, transfer to and from repair sites and alternate locations; and geographical locations of expected deployment.

v. Materiel. A commodity or set of commodities. A generic class of hardware designed to perform a specific function.

w. Materiel developer. An agency or group of individuals involved in designing, testing, or evaluating materiel to meet developer performance requirements.

x. Mission profile. That portion of the life cycle profile associated with a specific operational mission.

y. Operational worthiness. The capability of materiel, a subsystem, or component to perform its full array of intended functions.

z. Parameter. Any quantity that represents a descriptive generalization of a certain characteristic physical property of a system that has a certain value at a particular time.

aa. Parameter level. The value of a physical property that documents the degree, extent, or level at which a parameter exists at a given location at a given point in time, or the value to which a variable test control is set (see test level).

bb. Platform. Any vehicle, surface, or medium that carries the materiel. For example, an aircraft is the carrying platform for installed avionics items or transported or externally mounted stores. The land is the platform for a ground radar set, for example, and a person for a man-portable radio.

cc. Platform environment. The environmental conditions materiel experiences as a result of being attached to or loaded onto a platform. The platform environment is influenced by forcing functions induced or modified by the platform and any platform environmental control systems.

dd. Program manager. The (Government) official who is in charge of the acquisition process for the materiel.

ee. Service life. Period of time from the release of materiel from the manufacturer through retirement and final disposition.

ff. Tailoring. The process of choosing design characteristics/tolerances and test environments, methods, procedures, sequences and conditions, and altering critical design and test values, conditions of failure, etc., to take into account the effects of the particular environmental forcing functions to which materiel normally would be subjected during its life cycle. The tailoring process also includes preparing or reviewing engineering task, planning, test, and evaluation documents to help ensure realistic weather, climate, and other physical environmental conditions are given proper consideration throughout the acquisition cycle.

gg. Test item. Specific materiel, a subsystem, or component being tested, including its container and packaging materials, that is representative of the materiel being developed. A representative sample of materiel that is used for test purposes.

hh. Test level. The value at which a test condition is set or recorded. (Also, see parameter level.)

ii. Test method. The criteria and procedures used to formulate an environmental test. Laboratory test methods are identified by the environment (or combinations of environments) in Part Two of this document.

jj. Test plan. A document that may include test procedures and test levels, failure criteria, test schedules, and operational and storage requirements.

kk. Test procedure. A sequence of actions that prescribes the exposure of a test item to a particular environmental forcing function or combination of environmental forcing functions, as well as inspections, possible operational checks, etc.

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ll. Virtual proving ground. Suite of tools, techniques, and procedures by which the tester will verify, validate, test, and evaluate systems, simulators, and models by exposing them to a synthetic rendition of the ground truth. “Ground truth data” are data collected from real-world tests or experiences.

4. GENERAL PROGRAM GUIDELINES.

4.1 Program Managers.

4.1.1 Roles of the program manager.

In the context of this standard, the program manager's primary role is to ensure environmental engineering considerations are addressed systematically, thoroughly, and effectively at appropriate times throughout the materiel acquisition process. The process for accomplishing this integration is diagrammed on figure 1-1. An associated role is to ensure environmental effects information is documented, available, and communicated from one program phase to another.

4.1.2 Guidance for program managers.

a. DoD 5000-series documents call for a systems engineering process that considers all life cycle needs, including storage, transport, and operation in natural environments, considering for example climatic, terrain, and oceanographic factors (DoDD 5000.2-R, paragraph 4.3). The environmental tailoring process shown on figure 4-1 occurs throughout the materiel acquisition cycle, helping to ensure system design and test criteria are tailored to environmental conditions within which materiel is to operate.

b. As indicated on figure 1-1, there may be times that the program manager has valid alternatives to testing actual hardware or hardware prototypes when conducting laboratory, development, or operational tests.

These alternatives include, but are not necessarily limited to, using simulation to reduce the costs involved in producing and testing hardware prototypes, using coupon samples instead of entire systems when specific materials are the central acquisition issue, and using analytical procedures such as verification by similarity to systems already tested and approved. An environmental engineering specialist (EES) can aid program managers to establish an engineering basis for selecting such alternatives. When these alternatives are selected, Task 401, Environmental Engineering Management Plan, must contain the rationale for their selection, including an explanation of expected cost savings, other benefits and risks to system effectiveness/safety. (See Part One, Appendix A, Task 401, and Appendix B, paragraph F.)

c. The following paragraphs, organized by major acquisition documents, capsulize environmental effects information for program managers and serve as background information for design engineers, test engineers, and environmental engineering specialists. Appendix B provides detailed direction for program managers.

Part One-8 requirements documents tailoring platform environment natural environment forcing functions induced

FIGURE 4-1. Environmental test program tailoring process.

4.1.2.1 Mission Need Statement (MNS).

The MNS identifies environments that may constrain the operation or survivability of materiel, including natural, induced (e.g., temperature and vibration during transportation), and special operational threat environments (e.g., electronic emissions during battle) in which the mission is to be accomplished. The MNS defines the desired levels of mission capability in these environments. An EES can assist the program manager in formulating this environmental effects input to the MNS.

4.1.2.2 Operational Requirements Document (ORD).

The ORD identifies materiel performance parameters that will meet the need described in the MNS. In identifying required capabilities and critical system characteristics, the ORD describes mission, storage, handling, and transport scenarios that the materiel will experience throughout its service life as shown on figure 4-2. In so doing, broad performance requirements (e.g., design for worldwide deployment) that may conflict with tailored issues can be avoided. This input to the ORD, covering natural and man-made environments and expected mission capabilities in those environments, is derived from the fundamental aspects of a Life Cycle Environmental Profile (LCEP). The LCEP, prepared through the assistance of an EES as described in Task 402 in Appendix A, supports development of not only the ORD, but also the Test and Evaluation Master Plan (TEMP) and the Cost and Operational Effectiveness Analysis (COEA) as described below, and the System Threat Analysis Report (STAR).

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4.1.2.3 Systems Engineering Management Plan (SEMP).

Program managers integrate environmental technical considerations (effects of various environments on system performance and reliability) into the SEMP. The mechanism for accomplishing this integration is provided in Task 401 in the form of an Environmental Engineering Management Plan (EEMP) prepared through the assistance of an EES. The EEMP basically lays out a schedule for implementing the remaining environmental engineering tasks, Tasks 402 through 406.

4.1.2.4 Test and Evaluation Master Plan (TEMP).

The TEMP includes plans for testing in natural (field/fleet) environments, simulated (laboratory) environments and virtual proving ground (synthetic) environments. An EES assists the program manager in preparing the TEMP by developing an Environmental Test and Evaluation Master Plan (ETEMP), the preparation of which may be merged into the Integrated Test Program Schedule. Appendix C provides information on the balance of field/fleet tests, laboratory tests, and modeling/simulation, and on the values chosen as design criteria or test criteria. Part Two of this standard provides details for developing laboratory test procedures. Component parts of the ETEMP are Tasks 402 through 404. Thus, the ETEMP contains the following:

a. Life Cycle Environmental Profile (LCEP) displaying the series of events, and environmental conditions derived from those events that materiel is expected to experience from manufacturing release to the end of its useful life. Include in TEMP the system description. (See Task 402.)

b. Operational Environment Documentation Plan (OEDP) outlining plans for obtaining specific natural or platform environment data to be used in developing tailored environmental test criteria. The OEDP does not have to be included in the TEMP, but is a necessary subtask within the ETEMP for creating a valid basis for environmental test criteria. (See Task 403.)

c. Environmental Issues and Criteria List (EICL) containing fundamental environmental design and test criteria derived from the tailoring process. Include criteria in the required technical and operational characteristics of the TEMP. Include related critical issues in the TT&E or OT&E outline of the TEMP.

(See Task 404.)

4.1.2.5 Cost and Operational Effectiveness Analysis (COEA).

Operational environmental evaluations are integral parts of COEA's. Natural and threat environmental factors are critical in evaluating how well materiel will operate in regions where it is expected to be employed. Therefore, it is important to identify appropriate values for materiel design and test criteria related to environmental factors. An EES supports COEA preparation by preparing an LCEP and identifying realistic environmental parameters and materiel-specific parameter levels associated with environment-related issues and criteria.

4.2 Environmental Engineering Specialists (EES).

EES are government or industry professionals in the acquisition process whose experience allows them to support program managers by helping to perform the tasks in Appendix A. Their backgrounds may span many scientific/engineering disciplines. They already exist in Government and contractor agencies involved in the acquisition process (e.g., serving as design, test, and reliability engineers/scientists). Several EES of different backgrounds may work on an integrated product team (IPT) at one time or in sequence throughout the program, employed by or on contract to agencies of the services as appropriate at the time. Their work is documented and passed on through the products of each successive task.

4.2.1 Roles of environmental engineering specialists.

EES from agencies within and on contract to government agencies support program managers throughout the acquisition cycle. EES are assigned by agencies that are responsible for performing the tasks outlined on figure 1-1 and explained in detail in Part One, Appendix A. EES should be involved early in the acquisition process, serving as critical sources of environmental effects expertise and as technical facilitators throughout the entire acquisition process as part of an IPT. As shown on figure 1-2, EES form facilitating bridges among design and test needs of program managers and technical procedures used by testers. The primary mechanisms for accomplishing environmental engineering goals are the tailoring tasks described below.

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4.2.2 Environmental engineering tailoring tasks.

4.2.2.1 General.

a. Environmental engineering tailoring tasks are the basic strategy and structure for integrating environmental considerations into acquisition programs. The task sequence outlined on figure 1-1 is designed to meet the environmental effects integration called for in the DoD 5000-series documents. To accomplish this integration, EES personnel working for government or contractor staffs throughout the acquisition process help to perform these environmental engineering tasks to help create a scientifically sound, cost effective design and test program in the area of environmental effects. This process, including the hardware test alternatives indicated on figure 1-1, applies to all materiel developed for or intended to be used by the military or industry. Detailed task descriptions are in Appendix A.

b. As indicated in paragraph 4.1 above, the primary benefits of performing these tasks come from the technical information and structure they provide for the MNS, ORD, SEMP, TEMP, and COEA. This information covers natural and induced environmental conditions. The structure provides an orderly means of uncovering potentially significant environmentally related storage, transit, and operational effects on fielded materiel.

4.2.2.2 Preparing an Environmental Engineering Management Plan (EEMP), Task 401.

The EEMP is the basic management schedule used to integrate environmental effects considerations into the SEMP.

This integration helps to ensure materiel will be prepared for all environmental conditions to which it will be subjected during its life cycle. The EEMP identifies manpower, dollar estimates, timing and points of contact necessary to complete the remaining tasks (402 through 406). As indicated on figure 1-1, paragraph 4.1.2 and Appendix B, paragraph F, there may be times that the program manager has valid alternatives, such as modeling and simulation or other analytic techniques, to testing actual materiel or working prototypes. These alternatives are scheduled and justified in the EEMP. The EEMP is described in Part One, Appendix A, Task 401.

4.2.2.3 Developing an Environmental Test and Evaluation Master Plan (ETEMP).

This plan is not a formal document, but is comprised of the products from three separate tasks (Tasks 402, 403, and 404). Early in the acquisition process, initial work on these tasks helps build materiel need and performance requirements documents by identifying basic environments in which the materiel will operate, and fundamental issues to be addressed during the remainder of the acquisition process. These three tasks contribute to the TEMP when they are completed. See figure 1-1. The ETEMP contains basic guidance/background information not to be confused with detailed test planning documents explained in Task 405.

4.2.2.3.1 Defining a Life Cycle Environmental Profile (LCEP), Task 402.

The LCEP describes service-related events and environmental conditions that materiel will experience from its release from manufacturing to the end of its useful life. The scope and structure are shown on figure 4-2.

Fundamental progress is required on this task early in the acquisition process to influence the MNS and the ORD.

The completed LCEP is needed later in the process to help system designers and evaluators build the TEMP.