Attachment_2_-_FA-FAT_Testing_Requirements.pdf

Attachment 2 First Article and Factory Acceptance Testing Requirements N00024-15-R-6401

First Article Requirements

Component/

Assembly

Part/ Drawing

Number

Applicable C2-b/

CIPS

Factory Acceptance

Tests Performed by

Contractor

FAT Details Required Test Equipment/Solutions for

FAT

First Article Requirements

Verified by the GOV

During the POM Phase

Afterbody and

Tailcone Unit

8243663 6935288 6935288: Figure 1

To be completed only after successful FAT of lower level assemblies.

Figure 1 details:

4.2 Dimensional and Material Inspection

4.2.4.3.1 Insulation Resistance

4.2.4.3.2 Electrical Isolation

4.2.4.3.3 Fin Deflection

4.2.4.3.4.1 External Pressure Test by Contractor

4.2.4.3.5 Hydraulic System Leakage

4.2.4.3.6 Operational Test (air spin)

4.2.4.3.7 VSS Test

4.2 COTS

4.2.4.3.1 CTR

4.2.4.3.2 CTR

4.2.4.3.3 CTR

4.2.4.3.4.1 CTR Pressure Test & GFE

Vacuum Test Stand (MK5 Hydraulic Filling

Unit)

4.2.4.3.5 CTR

4.2.4.3.6 GFE Air Spin Test Tools and

Vacuum Test Stand

4.2.4.3.7 GFE VSS Testing Tools

6935288: Figure 3

Engine Assembly 7052739 6935289 SW-513-EO-PRO-050

Job Sheet 3-81 Engine assembly verification tests

3-81-6 Engine shaft Displacement Test

3-81-8 Piston Head Clearance test

3-81-6 GFE: Engine Assembly Cart (P/N

7052521)

3-81-8 GFE Engine Cart and Tools

6935289: Figure 4

Lube Oil Pump

Assembly

2074259 5893761 5893761: Figure 1 Figure 1:

4.2 Dimensional and Material Inspection

4.2.4.1 Self Priming Test

4.2.4.2 Flow and Pressure Low Speed

4.2 COTS

4.2.4.1 CTR Test Stand*

4.2.4.2 CTR Test Stand*

(*GFF Test Stand available)

5893761: Figure 3

Coolant Pump

Assembly

6935010 6935197 6935197: Figure 2 Figure 2:

4.2 Dimensional and Material Inspection

4.2.4.3.3.1 Valve cycle test

4.2.4.3.3.2 Valve Leak Test

4.2.4.3.3.3 Valve Operational Test

4.2.4.3.2 External Leakage

4.2.4.3.1 Flow and Pressure

4.2 COTS

4.2.4.3.3.1 CTR Test

4.2.4.3.3.2 CTR Test

4.2.4.3.3.3 CTR Test

4.2.4.3.2 CTR Test Stand

4.2.4.3.1 CTR Test Stand

6935197: Figure 4

Hydraulic Pump

Assembly

6558186 5893762 5893762: Source

Controlled Drawing, FAT Verified by Source

Contractor before delivery to Prime

FAT level test performed during top level FAT N/A: Source already has required equipment

N/A

Speed Control

Valve

5905689 5894150 ST890-BM-MMD-020

J/S 4-2

Must meet all testing requirements per J/S 4-2 GFE: MK 707 Speed Control Valve Test Set 5894150: Figure 5

Factory Acceptance Test Requirements

For Official Use Only

SOURCE SELECTION SENSITIVE INFORMATION – SEE FAR 2.101 and 3.104 Page 1 of 3

Deployable Water

Inlet Valve (DWIV)

6935142 6935196 5893750: Figure 1 Figure 1:

4.2 Physical Inspection

4.2.4.2.1 Cycling Test

4.2.4.2.2.1 Outlet Port Test

4.2.4.2.2.2 Inlet Port Test

4.2.4.2.3 Operating Pressure Test

4.2.4.2.4 Pilot Proof-Pressure Test

4.2.4.2.5 Opening Time Test

4.2.4.2.6 Closing Time Test

4.2 COTS

4.2.4.2.1 CTR

4.2.4.2.2.1 CTR

4.2.4.2.2.2 CTR

4.2.4.2.3 CTR

4.2.4.2.4 CTR

4.2.4.2.5 CTR

4.2.4.2.6 CTR

5893750: Figure 3

Velocity Sensor

Switch

6935175 6935194 6935194: Figure 4 and

SW-513-EO-PRO-040

Job Sheet 3-41

Velocity Sensor Switch test

Figure 4:

4.2 Performance Verification

4.2.4.1 Hydrostatic Pressure (one cycle)

4.2.4.2 Electrical Performance

4.2.4.3 Maximum Force

3-41 Velocity Sensor Switch Test

4.2 COTS

4.2.4.1 CTR

4.2.4.2 CTR*

4.2.4.3 CTR

3-41 CTR*

(*GFE VSS tester provided can be utilized for these tests)

6935194: Figure 6

Type II Cables: 5W1 (5893725)

5W2 (5893727)

5W2 (5893729)

5W7 (5893731)

5W8 (5893733)

5W9 (5893735)

5W13 (5893737)

5W14 (5893739)

5W15

(6105293)

5W16

(6105298)

5894148 5894148: Figure 1 Figure 1:

4.2 & 4.2.4.4 Dimensional, Material, Weight and

Workmanship Inspection only*

4.2.4.1 Pressure/Temp Operating

4.2.4.2 Electrical Performance

4.2.4.3 Cable Transition

(*Sub paragraphs of 4.2 not specifically called out are not part of FAT requirement)

4.2&4.2.4.4 COTS

4.2.4.1 CTR

4.2.4.2 CTR

4.2.4.3 CTR

5894148: Figure 3

Slide Valve 2507318 6724953 6724953: Figure 1 Figure 1:

4.2 Dimensional and Material Inspection

4.2.4.2.1 Connector Mating

4.2.4.2.2 Coil Resistance

4.2.4.2.3 Insulation Resistance

4.2.4.2.4 Continuity Loop

4.2.4.3 Operational Performance

4.2 COTS

4.2.4.2.1 CTR

4.2.4.2.2 CTR

4.2.4.2.3 CTR

4.2.4.2.4 CTR

4.2.4.3 CTR

6724953: Figure 3

SOURCE SELECTION SENSITIVE INFORMATION – SEE FAR 2.101 and 3.104 Page 2 of 3

Tailcone Assembly, Shock Hardened

8243661 N/A SW-513-EO-PRO-050

Job Sheet 3-104

Pass all testing required per job sheet 3-104. GFE: MK 659 Factory Steering Assembly

Test Set (FSATS)

N/A

Fuel Delivery

Assembly (FDA)

6935014 6935190 SW-513-EO-PRO-040

Job Sheet 3-42

Pass all testing required per job sheet 3-42. GFE: MK 658 Fuel Delivery Assembly Test

Set (FDATS)

6935190: Figure 2

Fuel Pump Valve 6935093 6935193 N/A All 6935193 FAT tests satisfied at FDA level N/A 6935193: Figure 5

Fuel Pump 6935015 6935195 N/A All 5894152 FAT tests satisfied at FDA level N/A N/A

EPS Regulator

Assembly

5894200 5893756 AEPS test per

Attachment 3

5893756: Figure 13

AEPS: All tests Passed

Perform only these tests from Figure 13:

4.2.4.1.1 Vacuum

AEPS: Contractor Designed Auto Electrical

Power System (AEPS) Test Equipment (CLIN

0x03)

4.2.4.1.1 GFE Vacuum Test Stand

5893756: Figures 11 & 15

Alternator

Assembly

6935009 5893755 AEPS test per

Attachment 3

5893755: Figure 13

AEPS: All tests Passed

Perform only these tests from Figure 13:

4.2 Dimensional and Material inspection

4.1.2.1 Run-In

4.2.4.17 Vacuum

AEPS: Contractor Designed Auto Electrical

Power System (AEPS) Test Equipment (CLIN

0x03)

4.2 COTS

4.1.2.1 CTR

4.2.4.17 GFE Vacuum Test Stand

5893755 Figures 10 & 11

Isolated Rotor

Assembly

7053477 7053456 7053456: 4.2.1 4.2.1 Axial Load Testing 4.2.1 CTR 7053456: 3.5 Performance per 6934934 requirements

COTS = commercial tools utilized by Contractor

GFE = test equipment provided by government per Attachment 7

CTR = test set or solution developed by Contractor

SOURCE SELECTION SENSITIVE INFORMATION – SEE FAR 2.101 and 3.104 Page 3 of 3