ATTACH_0015_PRIME_ITEM_FABRICATION_SPEC.pdf

OES-DTL-0099A

7 December 2015

OES-DTL-0099

04 December 2007

CODE IDENT 10001

PRIME ITEM FABRICATION SPECIFICATION

SIGNAL, SMOKE AND ILLUMINATION

MK 124 MOD 1

1. SCOPE

1.1 Scope. This specification covers the manufacture, assembly, and preparation for delivery of the MK 124 MOD 1 Marine Smoke and Illumination Signal and the methods of examination and tests upon which product acceptance shall be based.

1.2 Definitions. The meaning of terms used in this specification shall be listed in 6.3.

2. APPLICABLE DOCUMENTS

2.1 Government Documents. The following documents of the issue in effect on date of invitation for bids or request for proposal form a part of the specification to the extent specified herein. In the event of conflict between the documents referenced herein and the contents of this specification, the contents of this specification shall be considered a superseding requirement.

STANDARDS

Military

MIL-STD-331C Fuze and Fuze Components, Environmental and

Performance Tests for

MIL-STD-1168 Ammunition Lot Numbering and Ammunition Data Card

DOD-STD-2101 Classification of Characteristics

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: Commander, Crane Division, Naval Surface Warfare Center, Code JXRT, Crane, Indiana 47522-5001.

FSC 1370

DRAWINGS

Naval Sea Systems Command

8324674 Package Shipping & Storage (For 36 Signal Smoke Illumination Marine MK 124 MOD 1)

8324647 Signal, Smoke and Illumination, Marine

MK 124 MOD 1

8324651 Pack, Shipping and Storage (For 18 Signal, Smoke and Illumination, Marine)

(Copies of specifications, standards, drawings, and publications required by suppliers in connection with specified procurement functions should be obtained from the contracting agency or as directed by the contracting officer.)

2.2 Other Publications. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of invitation for bids of request for proposal shall apply. In event of conflict between documents referenced herein and contents of this specification, the contents of this specification shall be considered a superseding requirement.

JOURNAL OF THE OPTICAL SOCIETY OF AMERICA

D.B. Judd The 1931 I.C.I Standard Observer and Coordinate System for Colorimetry (1933) (Vol. 23).

George C. Szikiai A Tristimulus Photometer (Vol. 41, No. 5 (1951)).

(Application for copies of the above should be addressed to American Institute of Physics, 335 East 45th Street, New York, New York 10017).

AMERICAN SOCIETY FOR TESTING MATERIALS

Symposium on Color Its specification and use in Evaluating the Appearance of Materials (1941).

(Application for copies of the above should be addressed to American Society for Testing Materials, 1916 Race Street, Philadelphia, PA 19103).

U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

Circular C-429 Photoelectric Tristimulus Colorimetry with Three Filters, R.S. Hunter (1942).

(Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, D.C. 20402).

3. REQUIREMENTS

3.1 Item Definition. This prime item is the MK 124 MOD 1 Marine Smoke and Illumination Signal. The signal is approximately 5.408 maximum inches long by 1.700 maximum inches in diameter. The signal weighs approximately 0.5 pounds. The signal consists of four (4) major subassemblies: the flare candle, smoke candle, flare igniter, and smoke igniter.

3.2 Classification of Requirements. The requirements for the signal are classified herein as follows:

REQUIREMENTS PARAGRAPH

First Article Sample 3.3 Design and Construction 3.4 Performance and Product Characteristics 3.5 Workmanship 3.6

3.3 First Article Sample. Unless otherwise specified in the contract (see 6.2), a First Article sample of the signals (see 4.3) shall be furnished by the contractor. The signals, including their components and all materials, shall be of a single type, grade, class, size and composition and shall comply with all applicable provisions of this document. The First Article sample shall be manufactured using the proposed full-production methods. If a change in any of the production processes or a change in any of the materials used for production occurs or production is discontinued for more than 90 consecutive days, a new First Article sample shall be submitted unless waived by the contracting officer.

3.4 Design and Construction.

3.4.1 Prime Item Documentation. The signal shall be manufactured, examined, tested and packed in accordance with the contract documents, drawing 8324647 and this specification.

3.4.2 Classification of Characteristics. Characteristics verified by the inspections and tests specified herein are classified as Critical, Major and Minor in accordance with DOD-STD-2101. Critical characteristics are identified by the symbol (C) and the Major characteristics by the symbol (M). The number following the classification symbol indicates the serial number of the characteristic. Characteristics that are not annotated by the classification code symbol are classified as Minor.

3.5 Performance and Physical Characteristics.

3.5.1 Performance.

3.5.1.1 Function. The signal shall meet the following requirements, when tested in accordance with 4.5.1.1:

a. Display color (C1): Produce red smoke and red flare display from the designated end.

b. Function (M101): Ignite and produce a display from both ends.

c. Delay (M102): Three (3) seconds maximum from initiation to generation of display. (Smoke display delayed by flaming is considered delay).

d. Display times (M103): The display time shall begin after the delay time ends and shall not include any output after generation of the display stops.

TEST REFERENCE OF TABLE I FLARE (SEC) SMOKE (SEC)

Min Max Min Max Five (5) Foot Drop (4.5.2.1) 16 23 12 25 Transportation Vibration (4.5.2.3) 16 23 12 25 Temperature and Humidity (4.5.2.4) 16 23 12 25 High Temperature (4.5.2.5) 16 23 11 25 Low Temperature (4.5.2.6) 16 23 12 25 Sealing (4.5.2.7) 16 23 12 25

e. Safety function (C2): Igniter shall not separate from the outer container as a result of functioning.

3.5.1.2 Flare Candlepower and Color (M104). Candlepower and color shall be determined from one (1) second after ignition and continue for 14 additional seconds.The flare end of the signal shall meet the requirements as follows, when tested in accordance with 4.5.1.2:

DISPLAY TIME CANDLEPOWER DOMINANT WAVE PERCENT PURITY

(Min Seconds) (Min Average) Length (Min) (Min)

16 3500 600 Nanometer 80

3.5.2 Durability and Environmental.

3.5.2.1 Five (5) Foot Drop (C3). The signal shall withstand five (5) foot drop without exploding or burning when tested in accordance with 4.5.2.1.

3.5.2.2 Forty Foot Drop (C4). The signal shall withstand forty foot drop without exploding or burning when tested in accordance with 4.5.2.2.

3.5.2.3 Transportation Vibration (C5). The packaged signal shall withstand transportation vibration without exploding or burning when tested in accordance with 4.5.2.3.

3.5.2.4 Temperature and Humidity (C6). The signal shall withstand temperature and humidity without exploding or burning when tested in accordance with 4.5.2.4.

3.5.2.5 High Temperature (C7). The signal shall withstand a temperature of +120°F ± 5°F for a minimum period of 16 hours without burning or exploding when tested in accordance with 4.5.2.5.

3.5.2.6 Low Temperature (C8). The signal shall withstand a temperature of -20°F ± 5°F for a minimum period of 16 hours without burning or exploding when tested in accordance with 4.5.2.6.

3.5.2.7 Sealing (M105). The signal shall withstand a vacuum of 6.0 ± 1.0 inches of mercury below atmospheric for a minimum period of 60 seconds without signs of leakage when tested in accordance with 4.5.2.7.

3.5.2.8 X-ray (M106). The signal shall show no evidence of missing components, extra components, displacement of components or foreign objects when tested in accordance with 4.5.2.8.

3.6 Workmanship. The product, in all stages of production, shall be processed under such inspection control as to assure uniformity in quality. All components shall be free of chips, dirt, grit, or other foreign material. The cleaning methods used shall not be injurious to any of the parts nor shall the parts be contaminated by the cleaning agents employed. There shall be no deteriorative effects as a result of the manufacturing process.

4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection. Unless otherwise specified in the contract, the supplier is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified in the contract, the supplier may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1 Inspection Requirements. The inspection requirements are specified by the classification of characteristics in this specification and on the referenced drawings and by the supplemental quality assurance provisions of the contract.

4.1.2 Inspection Review. Unless otherwise specified in the contract, the contractor and all test activities in the contract shall submit to the Technical Activity and Design Agent for review, a description of the proposed procedure and equipment to be used to perform all examinations and tests (see 6.2).

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. First Article Inspection (4.3).

b. Quality Conformance Inspection (4.4).

4.3 First Article Inspection. The contractor shall produce and deliver a sample of 180 signals to the destination specified (see 6.2) for examination, testing, evaluation and acceptance as in TABLE I. Any production of the item prior to procuring agency authorization shall be at the risk of the contractor. The sample shall be prepared for delivery as specified in Section 5.

4.4 Quality Conformance Inspection. An inspection lot shall consist of 3,201 to 10,368 signals offered for delivery at one time including test samples (see 6.2). Inspection lots shall be inspected as follows:

a. Any change in materials, suppliers or production methods shall be considered sufficient interruption for the beginning of a new inspection lot. Record reason for interruption on the Data Card (see 6.2).

b. Each lot shall be sampled as required for Plan A, TABLE I.

c. Upon failure of any lot to meet acceptance requirements of either Plan A or Plan B tests, the next lot shall be tested and accepted in accordance with Plan A, TABLE I.

d. No lot shall be accepted in accordance with Plan B, TABLE I, unless the preceding lot has met the test requirements of the applicable plan.

e. Each inspection lot shall contain only primers from one (1) lot produced by one (1) contractor.

f. Upon completion of a lot and selection of the sample, the Government shall be notified. The designated Government activity shall then notify the contractor which test plan shall apply (see 6.2).

g. Sampling, examination, testing, and acceptance of inspection lots shall be performed as specified in the steps given below:

Step 1. Upon starting production or delivery of an acceptance first article sample, as applicable, all inspection lots shall be examined, tested in sequence and accepted in conformance with TABLE I, Sampling Plan A, until two (2) consecutive lots have met acceptance requirements of TABLE I.

Step 2. Inspection lots other than those defined in Step 1 shall be examined, tested in sequence and accepted in conformance with TABLE I, Sampling Plan B, except that one (1) lot shall be randomly selected from each five (5) consecutive inspection lots and examined, tested in sequence and accepted in conformance with TABLE I, Plan A.

NOTES: 1. Although lots may be tested and accepted in accordance with Plan B tests, all lots must be capable of passing Plan A tests.

2. The Government reserves the right to perform any or all Plan A tests on any lot if deemed necessary to assure delivery of acceptable supplies.

3. Upon acceptance of a lot, the remaining signals containing no defects may be returned to the lot.

TABLE I

INSPECTION PLANS

EXAMINATIONS AND TESTS FIRST ARTICLE

SAMPLING PLAN

INSPECTION LOT

SAMPLING PLANS

Test Sequence 4/ Sample Size

Acceptance Criteria 1/

Plan 2/ Sample Size

Acceptance Criteria 1/ A B

Examinations and Workmanship (4.6) (3.6) 180

Signals

Critical Ac 0 Re 1

Major Ac 0 Re 1

Minor Ac 0 Re 1

X X Plan A

Signals Plan B

Signals

Critical Ac 0 Re 1

Major Ac 0 Re 1

Minor Ac 0 Re 1

X-Ray ( 4.5.2.8) 100% of Sample

Ac 0 Re 1 X X 100% of Sample

Ac 0 Re 1

Sealing (4.5.2.7) 100% of Sample

Ac 0 Re 1 X X 100% of Sample

Ac 0 Re 1

Five (5) Foot Drop (4.5.2.1)

Sealing (4.5.2.7)

Function (4.5.1.1)

Signals

Ac 0 Re 1 X

Signals

Ac 0 Re 1

Ac 0 Re 1 Ac 0 Re 1 (a&e)

Ac 0 Re 1 (b,c,&d)

Ac 1 Re 2

(a&e) Ac 0 Re 1 (b,c,&d)

Ac 1 Re 2 Forty (40) Foot Drop (4.5.2.2)

Signals

Ac 0 Re 1 None

Transportation Vibration (4.5.2.3)

Sealing (4.5.2.7)

Function (4.5.1.1)

Signals

Ac 0 Re 1 X

Ac 0 Re 1 Ac 0 Re 1 Ac 0 Re 1

(a&e) Ac 0 Re 1

(b) Ac 2 Re 3

(c&d) Ac 3 Re 4

(a&e) Ac 0 Re 1

(b) Ac 1 Re 2

(c&d) Ac 2 Re 3

Temperature and Humidity (4.5.2.4)

Function (4.5.1.1) 30

Ac 0 Re 1 X

Signals

Ac 0 Re 1 (a&e)

Ac 0 Re 1 (b)

Ac 2 Re 3 (c&d)

Ac 3 Re 4

(a&e) Ac 0 Re 1

(b) Ac 1 Re 2

(c&d) Ac 2 Re 3

High Temperature (4.5.2.5)

Ac 0 Re 1 X

Signals

Ac 0 Re 1

(a&e) Ac 0 Re 1

(b) Ac 2 Re 3

(c&d) Ac 3 Re 4

(a&e) Ac 0 Re 1

(b) Ac 1 Re 2

(c&d) Ac 2 Re 3

EXAMINATIONS AND TESTS FIRST ARTICLE

SAMPLING PLAN

INSPECTION LOT

SAMPLING PLANS

Test Sequence 4/ Sample Size

Acceptance Criteria 1/

Plan 2/ Sample Size

Acceptance Criteria 1/ A B

Low Temperature (4.5.2.6)

Ac 0 Re 1 X

Signals

Ac 0 Re 1 (a&e)

Ac 0 Re 1 (b)

Ac 2 Re 3 (c&d)

Ac 3 Re 4

(a&e) Ac 0 Re 1

(b) Ac 1 Re 2

(c&d) Ac 2 Re 3

Function (4.5.1.2)

Flare Candlepower and color (4.5.1.2)

(a&e) Ac 0 Re 1

(b) Ac 1 Re 2

(c&d) Ac 3 Re 4

(a&e) Ac 0 Re 1

(b) Ac 1 Re 2

Ac 3 Re 4

Ac 2 Re 3 Ac 2 Re 3

Group Data Acceptance 3/ 175 Signals

(b) Ac 5 Re 6

(c&d) Ac 10 Re 11

X 135 Signals

(b) Ac 3 Re 4

Ac 7 Re 8

Notes: 1/ Ac = Acceptance number for defectives of specified requirements of Section 3.

Re = Rejection number for defectives of specified requirements of Section 3.

2/ Test plans applicable to inspection lots.

3/ Grouped for Function Test.

4/ Test to be performed in order of indentured sequence within individual blocks.

4.5 Tests. Random samples shall be selected, tested, and accepted as specified in 4.3 or 4.4, as applicable.

4.5.1 Performance Tests.

4.5.1.1 Function Test. The signals, prior to testing, shall be immersed under a minimum six

(6) inch head of water at 68°F ± 5°F for a minimum period of 24 hours, except following test

4.5.2.5 and 4.5.2.6. The signals shall be function tested in accordance with the following procedure:

a. Verify applicable test temperature.

b. Remove the protective cap from end being tested.

c. Slide lever horizontally to fully extended position.

d. If the smoke end flames briefly, immerse in water and shake until extinguished.

e. WARNING. Prior to, during, and after ignition, hold the signal firmly with the arm fully extended overhead at an angle 45° degrees from the horizontal to prevent burns from hot drippings.

f. WARNING. Do not direct either end of the signal toward the user or other personnel.

g. WARNING. Prior to ignition, position finger below top end of signal. Do not look directly at flare flame.

h. Ignite signal by moving lever downward.

i. After testing one end, retain the signal for testing of other end.

Defectives are signals failing to meet the requirements of 3.5.1.1

4.5.1.2 Flare Candlepower and Color Test. The signal with the flare igniter and sealant disc removed shall be mounted in the fireplace of the photometric tunnel, in a vertical position with the ignition end up and 6 ± 2 inches below the photometric axis. No down draft or forced air flow allowed. The signal shall be ignited with an electric match or squib inserted into one (1) of the nozzles of the signal flare primer holder, without obstructing the four (4) nozzles, tape the electric match or squib in place. The tunnel shall have nonreflecting surfaces. Light intensity and color shall be measured by the Tristimulus Photometer as described in the Journal of the Optical Society of America, Volume 41 (1951) pp 321-323, or equal. Calibration of the photometer shall be made using a projector lamp, calibrated for luminous intensity and color by the National Bureau of Standards, Washington, D.C. Using the Tristimulus Photometer, the luminous intensity, dominant wave length and the percent of purity of color produced by the burning signal shall be measured and calculated in accordance with I.C.I. (International Commission of Illumination) Tristimulus Color System, Journal of the Optical Society of America, Volume 23 (1933) p. 359; ASTM Symposium on Color (1941) and National Bureau of Standards Circular C-429. Defectives are signals failing to meet the requirements of 3.5.1.1.

4.5.2 Durability and Environmental Tests.

4.5.2.1 Five (5) Foot Drop Test. The signal shall be subjected to the five (5) foot drop test prescribed in Test A4 of MIL-STD-331C, except the signal shall be dropped free-fall without guidance system or associated equipment. Defectives are signals failing to meet the requirements of 3.5.2.1.

4.5.2.2 Forty Foot Drop Test. The signal shall be subjected to the forty foot drop test prescribed in Test A3 of MIL-STD-331C, except the signal shall be dropped free-fall without guidance system or associated equipment. Defectives are signals failing to meet the requirements of 3.5.2.2.

4.5.2.3 Transportation Vibration Test. The signal, as packaged in accordance with drawing 8324651, shall be subjected to the transportation vibration test prescribed in Test B1, section B1.6.3.2 (Procedure II) of MIL-STD-331C. Inert mock-up signals shall be used to complete the filling of the package for this test. Defectives are signals failing to meet the requirement of 3.5.2.3.

4.5.2.4 Temperature and Humidity Test. The signal shall be subjected to one (1) 14-day temperature and humidity cycle prescribed in Test C1 of MIL-STD-331C. Defectives are signals failing to meet the requirements of 3.5.2.4.

4.5.2.5 High Temperature Test. The signal shall be conditioned in a suitable chamber at +120°F ± 5°F for a minimum period of 16 hours and while at that temperature shall be subjected to the function test. Defectives are signals failing to meet the requirements of 3.5.2.5.

4.5.2.6 Low Temperature Test. The signal shall be conditioned in a suitable chamber at -20°F ± 5°F for a minimum period of 16 hours and while at that temperature shall be subjected to the function test. Defectives are signals failing to meet the requirements of 3.5.2.6.

4.5.2.7 Sealing Test. The signal, with protective caps removed, shall be tested in a water tank equipped for observation under vacuum. The water temperature shall be 60°F minimum to 75°F maximum.

CAUTION: The water tank should be equipped so that the signal must be raised above the water level while still under vacuum before releasing the vacuum and removing the signal.

The uppermost surface of the signal, when in a horizontal position, shall be submerged four (4) to six (6) inches below the water surface and subjected to a vacuum of 6.0 ± 1.0 inches of mercury for a minimum period of 60 seconds. Leakers are indicated by air bubbles issuing from the signal. Do not mistake the escape of occluded air for leakage.

Signals which are not defective may be used for further testing or returned to the lot.

Replace protective caps after test. Defectives are signals failing to meet the requirements of 3.5.2.7.

4.5.2.8 X-ray Test. The signal shall be subjected to a radiographic examination using standard equipment and procedures to obtain legible images. Defectives are signals failing to meet the requirements of 3.5.2.8.

4.6 Examinations.

4.6.1 Signal Examination. Examination shall be made to assure that the signal meets the requirements of drawing 8324647. Only signals containing no defects shall be used for further testing or returned to the lot.

4.6.2 Packing and Marking Examinations. The packing and marking shall be as specified in the applicable drawings as listed in Section 5. Only packs containing no defects shall be returned to the lot.

5. PACKAGING

5.1 Packaging and Marking.

5.1.1 Level A.

5.1.1.1 Thirty six (36) signals shall be packed and marked in accordance with drawing 8324674.

5.2 Ammunition Data Card. Data cards shall be prepared in accordance with MIL-STD-1168 (see 6.2).

5.3 Ammunition Lot Numbers. Ammunition lot numbers shall be in accordance with

MIL- STD-1168.

5.4 Batch Numbers. The composition batches shall be identified by batch numbers identifying the composition (Flare composition – F, Ignition composition – A, Starter mixture – C and Smoke composition – S,), year (last two (2) digits) and month (Jan – A, Feb

– B, Mar – C, Apr – D, May – E, Jun – F, Jul – G, Aug – H, Sep – J, Oct – K, Nov – L, Dec

– M) of production and commencing with number B00001 and continuing in sequence until production of the contract is complete. The composition batch number shall be assigned after acceptance for Pressing (i.e., after any cross blending). The batch numbers used in each lot shall be listed in block 24 of the Ammunition Data Card (see 5.2).

6. NOTES

6.1 Intended Use. The signal is used by aircraft personnel down at sea for day (red smoke) or night (red flare) signaling.

6.2 Ordering Data. Procurement documents should specify:

6.2.1 Procurement Requirements.

a. Title, number, and date of this specification.

b. Quantity being ordered.

c. First article samples, if applicable, and test facility where sample is to be shipped for evaluation.

d. Government activity coordinating surveillance.

e. Inspection lot size if different than 4.4.

f. Inspection review when applicable (4.1.2).

g. Government activity that will designate individual lot test plan.

6.2.2 Data Requirements. When this specification is used in a procurement which incorporates a DD Form 1423 and invokes the provisions of 227. 405-70 of the Defense Federal Acquisition Regulation Supplement (DFARS), the data requirements identified below will be developed as specified by an approved Data Item Description (DD Form 1664) and delivered in accordance with the approved Contract Data Requirements List (DD Form 1423) incorporated into the contract. When the provisions of DFARS 227.405-70 are not invoked, the data specified below will be delivered by the contractor in accordance with the contract requirements. Deliverable data required by this specification is cited in the following paragraphs:

PARAGRAPH DATA REQUIREMENT APPLICABLE DID

5.2 Ammunition Data Card DI-MISC-80043

4.5.1 Reports, Test/Inspection DI-NDTI-80809

Test reports with individual data will be forwarded to the Technical Activity and Design Agent.

(Copies of data item descriptions required by the contractors in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer.)

6.3 Definitions.

6.3.1 Signal. The term “signal” means Signal, Smoke and Illumination, Marine MK 124 MOD 1, as depicted on drawing 8324647.

6.4 Conflicting Requirements. Refer in writing to the procuring agency for clarification, any conflicting requirements arising between this specification or publication listed herein.

6.5 Safety Precautions. Observe the safety precautions specified in DOD 4145.26M during loading, assembly, testing and handling operations. The use of this manual is not to be construed as to relieve the contractor or manufacturer of responsibility for the safety of their operations. The observation of these safety precautions is mandatory at Government plants.

NOTE: When this specification is used as part of the description of work to be accomplished by a Government activity, the safety precaution requirements of, “Ammunition and Explosives Safety Ashore” (OP 5) should be applicable.