N6660417Q0245__ATTACHMENT_8_FACTORY_ACCEPTANCE_TEST_REQUIREMENTS_REVISED_1-24-17.pdf

Factory Acceptance Test for the Survivability Assessment Laboratory Electro-Dynamic Vibration System.

Naval Undersea Warfare Center Division Newport, Rhode Island 02841

Approved for public release; distribution is unlimited.

Abstract

This Plan summarizes the steps necessary to confirm the published requirements for the Electro-Dynamic Shaker procured for the Naval Undersea Warfare Center, Division Newport, Survivability Assessment Branch.

FACTORY ACCEPTANCE TEST FOR THE SURVIVABILITY ASSESSMENT

LABORATORY ELECTRO-DYNAMIC VIBRATION SYSTEM.

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TABLE OF CONTENTS

Contents

1.0 SCOPE

1.1. PURPOSE

2.0 APPLICABLE DOCUMENTS

2.1. MILITARY SPECIFICATIONS AND STANDARDS

2.2. COMMERCIAL SPECIFICATIONS

2.3. DRAWINGS

2.3.1. NAVSEA Drawings

3.0 TEST SPECIMENS

3.1. Vendor Supplied Test Mass

3.2. Structurally Integrated Enclosure

3.3. Cube Fixture

4.0 TEST SEQUENCE

4.1. Mil-STD-167-1A

4.1.1. Vertical Direction

4.1.2. Horizontal Direction

4.2. Vibration Endurance Test-Random

4.2.1. Vertical Direction

4.2.2. Horizontal Direction

4.3. Half-Sine Shock

4.3.1. Vertical Direction

4.3.2. Horizontal Direction

4.4. Requirements

5.0 TEST FACILITIES

6.0 PRE/POST TEST INSPECTIONS

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LIST OF ACRONYMS AND ABBREVIATIONS

degree Grms

Inch acceleration root mean squared

F Fahrenheit

FAT

g

Factory Acceptance Test acceleration

Hz hertz

IAW

ips

In Accordance With inches per second lbs pounds msec

NAVSEA

NUWCDIVNPT

PSD

SIE

UNC

milli-second Naval Sea Systems Command Naval Undersea Warfare Center Division, Newport Power Spectral Density Structurally Integrated Enclosure Unified National Coarse

1.0 SCOPE

This document is to be used to evaluate the electro-dynamic vibration system requirements.

1.1. PURPOSE

This document establishes the steps to ensure the mechanical and operational requirements are met at both the manufacturer’s facility and at the Naval Undersea Warfare Center Survivability Assessment Lab installation site.

2.0 APPLICABLE DOCUMENTS

2.1. MILITARY SPECIFICATIONS AND STANDARDS

Mil-Std-167-1A Mechanical Vibrations of Shipboard Equipment

(DISTRIBUTION STATEMENT A)

2.2. COMMERCIAL SPECIFICATIONS

Not Applicable

2.3. DRAWINGS

2.3.1. NAVSEA Drawings

53711-7108329 A3 Structurally Integrated Enclosure

(DISTRIBUTION STATEMENT D)

3.0 TEST SPECIMENS

3.1. VENDOR SUPPLIED TEST MASS

The vendor may substitute a dummy test mass in place of those fixtures listed to support on site testing at the manufacturer’s facility.

3.2. STRUCTURALLY INTEGRATED ENCLOSURE

The weighted Structurally Integrated Enclosure (SIE) shall be provided by

NUWCDIVNPT to support testing at the NUWCDIVNPT.

3.3. CUBE FIXTURE

The weighted Virginia Class Cube Fixture shall be provided by NUWCDIVNPT to support testing at NUWCDIVNPT.

4.0 TEST SEQUENCE

The vendor shall execute the following tests in the order most expedient to the test schedule.

The manufacturer provided Test Inspection Log Sheet shall include the following:

1. Accelerometer data

2. Supply water temperature vs. flow diagram

3. Test payload weight

4. Bolt torque and thread lubricant used (if any).

5. Physical inspection results for each of the tests

Table 1 provides a list of thread lubrication materials and acceptable decreased torque values for a Grade 5 bolt if a thread lubricant is used.

Lubricant

Torque (ft.lb.)

Torque Decrease (%) 1/2" - 13 Threads

ASTM A449/SAE Grade 5

No lube 75 0

Graphite 38.25 to 33.75 49-55

White Grease 48.75 to 41.25 35-45

SAE 30 oil 48.75 to 41.25 35-45

Table 1

4.1. MIL-STD-167-1A

4.1.1. Vertical Direction

1. Install the SIE weighing 4000 pounds, with a center of gravity 28 inches from the base, on the head expander using ½”-13 UNC bolts torqued to 75 foot-pounds dry (or lubricated equivalent shown in Table 1).

2. The vendor shall install the vertical reference accelerometer at a location selected by the vendor with the concurrence of the NUWC test engineer overseeing the testing.

3. Limit the flow of the cooling water to a maximum of 40 gallons per minute.

4. Conduct testing to the level shown in Table I of Mil-Std-167-1A in the vertical direction from 4Hz to 33Hz.

5. Exploratory displacement .020 inches peak to peak.

6. Variable amplitude in accordance with Table I of Mil-Std-167-1A

7. Endurance will be conducted for 2 hours at 33Hz.

8. Complete manufacturer provided Test Inspection Log Sheet.

4.1.2. Horizontal Direction

1. Install the SIE weighing 4000 pounds, with a center of gravity 28 inches from the base, on the slip plate using ½”-13 UNC bolts torqued to 75 foot-pounds dry (or lubricated equivalent shown in Table 1).

2. The vendor shall install the horizontal reference accelerometer at a location selected by the vendor with the concurrence of the NUWC test engineer overseeing the testing.

3. Limit the flow of the cooling water to a maximum of 40 gallons per minute.

4. Conduct testing to the level shown in Table I of Mil-Std-167-1A in the horizontal direction from 4Hz to 33Hz.

5. Exploratory displacement .020 inches peak to peak.

6. Variable amplitude in accordance to Table I of Mil-Std-167-1A

7. Endurance will be conducted for 2 hours at 33Hz.

8. Complete manufacturer provided Test Inspection Log Sheet.

4.2. VIBRATION ENDURANCE TEST-RANDOM

4.2.1. Vertical Direction

1. Install a dummy load mass of 500 pounds on the vertical head expander.

2. The vendor shall install the vertical reference accelerometer at a location selected by the vendor with the concurrence of the NUWC test engineer overseeing the testing.

3. Limit the flow of the cooling water to a maximum of 40 gallons per minute.

4. Conduct testing to the level Power Spectral Density Level (PSD) shown in Figure -

1 for the level indicated for NAVMAT +6dB = 12.1 Grms.

5. Test Duration is 2 hours.

6. Complete manufacturer provided Test Inspection Log Sheet.

Figure -1

4.2.2. Horizontal Direction

1. Install a dummy load mass of 500 pounds on the horizontal slip plate.

2. The vendor shall install the horizontal reference accelerometer at a location selected by the vendor with the concurrence of the NUWC test engineer overseeing the testing.

3. Limit the flow of the cooling water to a maximum of 40 gallons per minute.

4. Conduct testing to the level shown in Figure -1 for the level indicated for NAVMAT +12dB = 24.15 Grms.

5. Test Duration is 2 hours

6. Complete manufacturer provided Test Inspection Log Sheet.

4.3. HALF-SINE SHOCK

4.3.1. Vertical Direction

1. Install the Virginia Class Shock Cube weighing 1000 pounds, with a center of gravity 12 inches from the base, on the head expander.

2. The vendor shall install the vertical reference accelerometer at a location selected by the vendor with the concurrence of the NUWC test engineer overseeing the testing.

3. Limit the flow of the cooling water to a maximum of 40 gallons per minute.

4. Conduct half sine shock pulse of 30g over 20 msec with a velocity shift of 150 inches per second.

5. Measure the acceleration time history. Using the data collected, plot the half-sine pulse with an amplitude of 30G and a nominal duration of 20ms, such that the integration of the test pulse yields a velocity change of 150 in/sec. Integration shall be from 0.4D before the pulse to 0.1D after the pulse, where D = pulse duration. The time reference points used to measure the velocity shift shall occur at 10 percent of the peak acceleration, both before and after the peak.

6. Demonstrate the g levels and pulse duration was achieved within +/- 10 percent.

7. Complete manufacturer provided Test Inspection Log Sheet.

4.3.2. Horizontal Direction

1. Install the Virginia Class Shock Cube weighing 1000 pounds, with a center of gravity 12 inches from the base, on the slip plate.

2. The vendor shall install the horizontal reference accelerometer at a location selected by the vendor with the concurrence of the NUWC test engineer overseeing the testing.

3. Limit the flow of the cooling water to a maximum of 40 gallons per minute.

4. Conduct half sine shock pulse of 30g over 20 msec with a velocity shift of 150 in/sec.

5. Measure the acceleration time history. Using the data collected, plot the half-sine pulse with an amplitude of 30G and a nominal duration of 20ms, such that the integration of the test pulse yields a velocity change of 150 in/sec. Integration shall be from 0.4D before the pulse to 0.1D after the pulse, where D = pulse duration. The time reference points used to measure the velocity shift shall occur at 10 percent of the peak acceleration, both before and after the peak.

6. Demonstrate the g levels and pulse duration was achieved within +/- 10 percent.

7. Complete manufacturer provided Test Inspection Log Sheet.

4.4. REQUIREMENTS

Demonstrate the following requirements:

Minimum Vibration Force (Sine and Random): 50,000 pounds Minimum Velocity (Half Sine Shock): 150 inches/seconds Minimum Displacement Vibration: 3" Minimum Displacement Shock: 3"

Frequency Range: 2 to 2000 Hz

Minimum Payload Capacity: 4000 pounds

Maximum for Continuous Operation Water Cooling Requirements @

70ºF 40 GPM

Minimum g Capability (Sine): 100 Minimum g Capability (Shock): 300 Half Sine Shock pulse with 1000 pound test item (12" center of gravity): 30g-20msec

Minimum Slip Plate Size: 60" x 60"

Bolt Pattern: 6" x 6"

Bolt Size: ½ -13 UNC

Half Sine Shock pulse with 1000 pound test item (12” center of gravity): 30g-20msec Minimum Slip Plate Over Turning Moment (Pitch): 835,000 in-lbs

Head Expander Size: 60" x 60"

Head Expander Frist Mode: Above 500 Hz

Minimum Payload Capacity: 4000 pounds

Bolt Pattern: 6” X 6”

Bolt Size: ½ - 13 UNC

Half Sine Shock Pulse with 1000 pound test item (12” center of gravity): 30g-20msec

5.0 TEST FACILITIES

The factory acceptance testing (FAT) will be conducted at the manufacturer’s facility prior to the installation at the Naval Undersea Warfare Center Division, Newport (NUWCDIVNPT), Newport RI, Building 114.

At the completion of the installation at NUWCDIVNPT, the FAT shall be conducted to ensure that the vibration system is capable of meeting the requirements.

6.0 PRE/POST TEST INSPECTIONS

Any damage found at the conclusion of testing shall be documented and repaired by the manufacturer. The portion of the testing where the damage or failure occurred shall be repeated without reoccurring damage or failure. The test will be considered a failure if mechanical distortion, cracking, or the system exhibits any other visible deterioration of such a nature or extent as to impair the performance of the vibration system.