Attachment_0007_PRM_FAT_plan.pdf

DEPARTMENT OF THE ARMY

PROGRAM EXECUTIVE OFFICE

COMBAT SUPPORT & COMBAT

SERVICE SUPPORT

6501 EAST ELEVEN MILE ROAD

WARREN MICHIGAN 48397-5000

REPLY TO

ATTENTION OF

SFAE-CSS-FP-P December 10, 2016

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

DETAILED TEST

PLAN FOR THE

FIRST ARTICLE TEST (FAT)

OF THE

MODULAR FUEL SYSTEM PUMP RACK

MODULE (MFS PRM)

BY

ERIC LE COLAS

DECEMBER 2016

DISCLAIMER STATEMENTS

The use of trade names or the name of a manufacturer or contractor in this document does not constitute an official endorsement or approval of the use of such commercial hardware or software or services. This document may not be cited for purpose of advertisement.

Yuma Test Center (YTC) will conduct this test in accordance with the test sponsor’s requirements. It may not relate to the independent evaluator’s issues. Therefore, additional tests may be required to provide test data for evaluation issues.

This document contains information EXEMPT FROM MANDATORY DISCLOSURE under the Freedom of Information Act. Exemption 5 (pre-decisional materials) applies.

DISTRIBUTION INSTRUCTION AND LIMITATION

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

TABLE OF CONTENTS

SECTION 1. INTRODUCTION

1.1 SYSTEM DESCRIPTION

SECTION 2. SUBTESTS

2.1 INITIAL INSPECTION

2.2 PHYSICAL CHARACTERISTICS

2.3 SAFETY AND HUMAN SYSTEM INTEGRATION (HSI)

2.4 RELIABILITY AND MAINTAINABILITY

2.5 PUMPING PERFORMANCE

2.6 FINAL INSPECTION

SECTION 3. APPENDICES

A. TEST CRITERIA

B. TEST SCHEDULE

C. REFERENCES

ABBREVIATIONS

SECTION 1. INTRODUCTION

1.1 SYSTEM DESCRIPTION

The Modular Fuel System (MFS) is a Palletized Loading System (PLS) and Heavy Expanded Mobility Tactical Truck (HEMTT) Load Handling System (LHS)-compatible petroleum storage, issue, and distribution system. The MFS is capable of receiving, storing, filtering, and issuing kerosene based fuels (i.e. Jet Propellant (JP)-5, JP-8, Jet-A, Jet-A1) and diesel fuel. The MFS is an International Organization for Standardization (ISO)-compatible system that has the ability to be transported using the HEMTT LHS truck, PLS truck, PLS trailer, or HEMTT Tanker as the prime mover, and can be emplaced, operated, maintained, and recovered by military personnel.

The MFS can be set up in many different configurations with the biggest configuration being a 17,500-gallon capacity fuel farm, consisting of 7 Tank Rack Modules (TRMs) and one Pump Rack Module (PRM).

The MFS provides the ability to rapidly establish a fuel distribution and storage capability at any location regardless of the availability of construction equipment or material handling equipment.

The MFS consists of two different modules; a PRM, and a TRM. The modules of the MFS can be recovered and moved by organic assets of the using unit. HEMTT LHS and PLS prime movers can recover the TRMs and PRMs, transport them to the new location, and emplace the system (ref figure 1.1-2). An empty, full, or partially loaded TRM can be readied for transport, uploaded, and moved in a fraction of the time required for a collapsible tank.

Figure 1.1-2. A PRM on a HEMTT, and a TRM on a PLS Trailer.

The PRM can be used with up to seven interconnected TRMs. The collapsible tank provides a way to increase the capacity for operations that are expected to last for extended periods.

Operations can continue in an uninterrupted fashion by replacing empty TRMs with full ones.

The TRMs can also be used for line haul of bulk fuel throughout the Theatre. A PLS or HEMTT LHS can transport two TRMs, one on the truck and one on the trailer, for a total of up to 5,000 gallons of bulk petroleum. The increased mobility and capability of the HEMTT LHS and the PLS allows direct delivery of bulk fuel to the brigade area. An analysis of alternatives indicates that this mission can be completed using fewer assets than the current 5,000-gallon tractor/trailer combination. The truck off-loads the full TRM in the required position and loads any empty TRM for transport back to the fuel re-supply point. The selected site does not require any preparation prior to deployment. The use of the HEMTT LHS as the prime mover results in increased cross-country mobility. This increased capability is critical to uninterrupted resupply of maneuver forces.

1.2 HISTORY

a. U.S. Army Test and Evaluation Command (ATEC) issued a Test Planning Directive on 26 April 2010 to the U.S. Army Yuma Proving Ground (YPG), Yuma Test Center (YTC), through the Automated Decision Support System (ADSS), Project No. 2010-DT-YPG-MFSTX- E7755, to conduct testing on the PRM and collect data that determined the Reliability and Maintainability (R&M) and performance of the PRM.

b. The following background information is provided to explain the YTC testing history of the MFS:

(1) The MFS was tested as a system (PRMs and TRMs) at YTC from 2006 to 2007 as a Production Qualification Test (PQT). The results were documented in a report, ATEC Project No. 2006-DT-YPG-LMFFX-C8384, YPG Report No. 07-103 (Ref 1, App C). The PQT Report summarized the overall results of the PQT and showed that while many of the system requirements were met, many were not met or were only partially met. After the completion of testing, the U.S. Army decided not to field the system.

(2) Various design changes have been made to the PRM since completion of the PQT that were intended to improve the PRM’s reliability, maintainability, and overall capability. The design changes that were implemented to the PRM as of 23 November 2010. FAT of the modified PRM was completed in February 2013.

1.3 SUMMARY

a. The test sponsor will provide two PRMs (the evaluated test items), eleven TRMs to use as support equipment (including 1 TRM as a back-up), one HEMTT LHS or PLS truck and one M1076 PLS trailers to help support the test. YTC will provide one PLS truck and one M1076 PLS trailer for back-up purposes, as well as facilities, instrumentation, and support personnel to support this test. The contractor will provide one Field Service Representative (FSR) to operate the MFS at the test site during each of the two 10-hour shifts for technical support.

b. The subtests covered in this test plan and the associated objectives are listed in table 1.2-

1.

Table 1.2-1. MFS PRM Test Objectives Subtest Objective

2.1 Initial Inspection

To determine and document the physical condition of the PRM.

To ensure all support equipment are functionally and operationally ready for test.

2.2 Physical Characteristics To determine whether the physical and compatibility characteristics of the PRM meet the criteria in the ATPD 2336G (Ref 2, App C).

2.3 Safety and HSI

To determine if the PRM presents any safety hazards to personnel, equipment, or the environment.

To identify any potential HSI issues with the PRM based on guidance from MIL-STD-1472 (Ref 3, App C).

2.4 R&M

To determine the reliability of the PRM through:

a. A total of 350 miles of endurance operations over a transportation profile of 20-percent primary roads, 50-percent secondary roads, 15-percent trails, and 15-percent cross-country trails.

b. A total of 50 PRM pumping hours measured by the engine hours accumulated on the engine hour meter of each PRM.

NOTE: Two PRMs will be utilized for R&M testing to shorten the test schedule.

2.5 Pumping Performance To determine if the performance characteristics of the PRM meet the criteria in the ATPD 2336G.

2.6 Final Inspection To determine the condition of the test equipment after the completion of all testing, and to prepare the test items for shipment.

LEGEND:

ATPD – Automotive Tank Purchase Description HFE – Human Factors Engineering MIL-STD – Military Standard PRM – Pump Rack Module

Test data collected during test operations will be recorded on the test record sheets provided.

The test data documents all PRM problems, PRM failures, significant PRM or TRM observations, and PRM performance test results noted throughout the test period. All failed components will be tagged and stored until instructions for the release of parts is provided by the test sponsor. Additionally, all supporting data (e.g. instrumentation recordings, plots, photographs, etc.) shall be properly annotated to insure correlation to the appropriate test activity. The failed PRM, assembly, or component will be repaired before testing resumed. All documentation, photographs, and data will be available through the Versatile Information Systems Integrated On-line Nationwide (VISION) Digital Library System (VDLS) at https://vdls.atc.army.mil.

Failures due to operator error shall be considered non-relevant and shall be noted. The test shall be rerun from the point of error or if testing is dependent on a sequence of tests, then the affected sequence shall be repeated.

1.4 UNIQUE TEST PERSONNEL REQUIREMENTS

There are no unique test personnel requirements for this test.

SECTION 2. SUBTESTS

2.1 INITIAL INSPECTION

2.1.1 Objectives

a. To determine and document the physical condition of the PRM.

b. To ensure all support equipment are functionally and operationally ready for test.

2.1.2 Criteria and Data Analysis

Test personnel will analyze the data gathered during this test as presented in table 2.1.2-1.

Table 2.1.2–1. Criteria and Data Analysis

Criteria (App A, Item No.) Remarks/Analysis

35/36 – Test Center Devised

This criterion will be considered met if:

a. The PRM is fully mission capable.

b. All the support equipment needed to conduct the FAT are functionally and operationally ready for test, to include the BII of the PRM and TRM to be used.

LEGEND:

BII – Basic Issue Items

TRM – Tank Rack Module

2.1.3 Test Procedures and Data Required

(1) Thoroughly clean the test items and test support equipment before entering the inspection.

(2) YTC personnel will perform a Limited Technical Inspection (LTI) on the PRM and test support equipment. Test personnel will replace or repair all worn, damaged, failed, or questionable components to return the test support equipment to serviceable condition. Test personnel will report all PRM discrepancies and maintenance actions and perform any PRM repairs based on the test sponsor’s direction. YTC personnel will perform the before, during and after Preventive Maintenance Checks and Services (PMCS) to ensure the equipment is fully mission capable.

(3) Inventory the Basic Issue Items (BII) of each test item and report any discrepancies on test record sheets. Test personnel will also inventory the BII of test support equipment and take care of any discrepancies to bring the test support equipment back to serviceable condition.

a. Table 2.1.3-1 presents the data required for this subtest.

Table 2.1.3-1. Data Required

Specific information on any items that appear to be worn or damaged BII and SSP inventory results Photographs of any discrepancies with the test items Maintenance actions or parts required TIRs for all PRM discrepancies

LEGEND:

BII – Basic Issue Items PRM – Pump Rack Module SSP – System Support Package TIR – Test Incident Report PMCS – Preventive Maintenance Checks and Services LTI - Limited Technical Inspection

2.2 PHYSICAL CHARACTERISTICS

2.2.1 Objective

To determine whether the physical and compatibility characteristics of the PRM meet the criteria in Automotive Tank Purchase Description (ATPD) 2336G.

2.2.2 Criteria and Data Analysis

Test personnel will analyze the data gathered during this test as presented in table 2.2.2-1.

Table 2.2.2–1. Criteria and Data Analysis

(App A, Item No.) Remarks/Analysis

5 – Weight

This criterion will be considered met if the maximum gross weight of the PRM and all associated components including the container frame, do not exceed the loading, unloading, and lifting capabilities of the HEMTT-LHS of 26,000 pounds. The CG limit for the 26,000-pound flatrack for transport by the HEMTT 1120 is 110.3 inches from the front of the flatrack, and 39.9 inches from the bottom of the flatrack.

7 – Pump Rack Module

This criterion will be considered met if:

a. The PRM is capable of refueling both ground vehicles and aircraft.

b. The PRM is capable of being transported by the HEMTT-LHS, PLS, and

PLS trailer.

c. The PRM contains secure storage as specified in paragraphs 3.5.5 and

3.5.5.1 of the ATPD 2336G for hoses, fittings, nozzles, fire extinguishers, petroleum test kit, fuel spill control kit, and other equipment necessary to perform refueling operations.

9 – Filtration and Water Separation

System

This criterion will be considered met if:

a. The filtration and water separation system is capable of removing sediment and undissolved water from bulk fuel at the maximum rated flow of the pumping assembly.

b. The filtration and water separation system is capable of providing a direct reading of differential pressure across the filtration and water separation system without the manipulation of valves.

c. The differential pressure gauge has an accuracy of ±0.5 psi and does not require periodic calibration.

d. A means to prevent sediment from obstructing proper operation is provided.

e. The gauge or device is color-coded to indicate normal operating conditions, marginal operating condition, and immediate service required ranges according to the filter-coalescer element manufacturer’s recommendation.

f. The filtration and water separation system is provided with a device to manually or automatically vent trapped air from the top of the filtration and water separation system while minimizing release of fuel during venting.

g. The filtration and water separation system is provided with a device to manually drain the water from the sump under operating conditions.

h. The filtration and water separation system is provided with a sight gauge that clearly shows the level of collected water within the sump.

i. A mark on this sight gauge is provided to indicate when the water should be discharged before it reaches the bottom of the elements.

j. The drain removes water and inhibits discharge of fuel with the water.

k. The discharge outlet is equipped to control the discharge flow and directs it safely into an appropriate size and type receptacle.

l. A means to draw fuel samples from the center of fuel flow is provided at both the inlet and outlet of the filtration and water separation system.

m. A quick disconnect coupler with dust plug is provided at each sampling point.

n. The quick disconnect coupler can interface with Gammon Actuator Nipple, model GTP-722 (or equivalent) without binding or leaking during sampling.

11 – Control Panel

This criterion will be considered met if:

a. Each PRM is equipped with an integrated control panel containing all necessary controls required to operate the pump assembly including an engine-hour meter.

b. Sufficient indicators are provided to inform the user of operating status at all times, under both conditions of normal operation and activation of system shut-offs.

c. The control panel includes an indicator for monitoring system voltage.

d. The control panel has the capability of displaying volumetric flow rate and the differential pressure across the filtration system to an accuracy of ±2 percent.

e. All control panel components including circuit boards, switches, and LEDs are replaceable without special tools.

f. The control panel includes the power source’s diagnostic connector.

g. The diagnostic connector is attached to the panel for connecting to the

TMDE without damaging the connector or wiring.

h. The control panel is easily operable by soldiers wearing MOPP IV.

i. Controls, gauges, and indicators are readable in direct sunlight.

15 – Inspection and Clean-out

This criterion will be considered met if:

a. The design of the MFS piping system provides ease of cleaning of the manifold(s) without contamination of the system.

b. Valves are located such that the piping system can be completely drained.

LEGEND:

ATPD – Automotive Tank Purchase Description CG – Center of Gravity HEMTT – Heavy Expanded Mobility Tactical Truck LED – Light Emitting Diode LHS – Load Handling System MFS – Modular Fuel System MOPP – Mission Orientated Protective Posture PLS – Palletized Load System PRM – Pump Rack Module psi – pounds per square inch TMDE – Test, Measurement, and Diagnostic Equipment

2.2.3 Test Procedures and Data Required

a. The PRM will be prepared for the physical characteristic subtest as follows:

(1) The PRM will have all BII installed and secured IAW storage data plate and TM guidance. Auxiliary equipment will be placed in the stowed/transport position.

(2) The PRM will have all fluid levels at their respective full levels (i.e. fuel tank fuel level, oil, coolant, 5-gallon water cans, fire extinguishers, etc.).

(3) The PRM will be fully primed, to include having fuel in the filtration and water separation system, in the centrifugal pump, and in all the remaining pipes associated with post evacuation of the MFS distribution manifold.

(4) All PRM valves will be in the closed position to eliminate fuel movement and fuel leakage.

b. A data sheet will be prepared prior to the subtest to help capture all of the required principle dimensions and functional characteristics needing to be captured.

c. All physical dimensions will be measured with the test item positioned on a level paved surface. Pertinent physical dimensions will be determined using standard measuring instrumentation such as steel tape measures, plumb bobs, straightedges, and inclinometers.

d. Photographs of the PRM will be taken illustrating the front, both sides, rear, top, and three-quarter front and rear views.

• The individual corner weights of the PRM will also be measured using individual wheel scales placed under each corner casting. From these measurements, the lateral CG location will be calculated using the “Weight Method” as presented in section 4.4 of TOP 2-2-800. The vertical CG and longitudinal CG locations of the PRM will be measured using the “Suspension Method” as presented in section 4.2 of TOP 2-2-800.

• An inventory list for the PRM BII will be obtained and used to verify that the PRM has all of the necessary equipment to satisfy all bulk and retail fueling operations. A visual presentation of all currently known bulk and retail fueling layouts, identifying hose quantities and sizes of each layout, will be provided by the test sponsor.

• The PRM will be inspected for secure storage, as specified in paragraphs 3.5.5 and

3.5.5.1 of the ATPD 2336G, for hoses, fittings, nozzles, fire extinguishers, a petroleum test kit, a fuel spill control kit, and all other equipment necessary to perform refueling operations.

• The filter and water separator will be inspected for the following capabilities/items:

(1) If the filtration and water separation system is capable of removing sediment and undissolved water from bulk fuel at the maximum rated flow of the pumping assembly.

(2) If the filtration and water separation system is capable of providing a direct reading of differential pressure across the filtration and water separation system without the manipulation of valves.

(3) If the differential pressure gauge has a minimum accuracy of ±0.5 pounds per square inch (psi) and does not require periodic calibration.

(4) If there is a means to prevent sediment from obstructing proper operation.

(5) If the gauge or device is color-coded to indicate normal operating conditions, marginal operating condition, and immediate service required ranges according to the filter-coalescer element manufacturer’s recommendation.

(6) If the filtration and water separation system is provided with a device to manually or automatically vent trapped air from the top of the filtration and water separation system while minimizing release of fuel during venting.

(7) If the filtration and water separation system is provided with a device to manually drain the water from the sump under operating conditions.

(8) If the filtration and water separation system is provided with a sight gauge that clearly shows the level of collected water within the sump.

(9) If there is a mark on the sight gauge to indicate when the water should be discharged before it reaches the bottom of the elements.

(10) If the drain removes water and inhibits discharge of fuel with the water.

(11) If the discharge outlet is equipped to control the discharge flow and directs it safely into an appropriate size and type receptacle.

(12) If there is a means to draw fuel samples from the center of fuel flow at both the inlet and outlet of the filtration and water separation system.

(13) If there is a quick disconnect coupler with dust plug at each sampling point.

(14) If the quick disconnect coupler can interface with Gammon Actuator Nipple, model GTP-722 (or equivalent) without binding or leaking during sampling.

(15) If the filtration and water separation system incorporates filter-coalescer elements fabricated and assembled to the form and dimensions shown in MIL-PRF-52308 Figure 1 and Figure 2 to insure proper interface and interchangeability with existing US Army filter/separator vessels.

j. The PRM control panel will be inspected for the following capabilities/items:

(1) If the PRM is equipped with an integrated control panel containing all the necessary controls required to operate the pump assembly including an engine-hour meter.

(2) If all control panel components including circuit boards, switches, and Light Emitting Diodes (LEDs) are replaceable without special tools.

l. Table 2.2.3-1 presents the data required for this subtest.

Table 2.2.3-1. Data Required BII inventory list and storage locations GVW configuration description PRM characteristic photographs PRM physical dimensions, weights, and CG All currently known bulk and retail fueling layouts Storage compartment BII fitment results Filter and water separator criteria compliance data Control panel criteria compliance data Tactical display control unit mockup photographs The remaining generalized criteria compliance data

LEGEND:

BII – Basic Issue Items CG – Center of Gravity GVW – Gross Vehicle Weight

2.3 SAFETY AND HUMAN SYSTEM INTEGRATION (HSI)

2.3.1 SAFETY AND HSI INSPECTIONS

2.3.1.1 Objectives

a. To determine if the PRM presents any safety hazards to personnel, equipment, or the environment.

b. To identify any potential HSI issues with the PRM based on guidance from MIL-STD- 1472.

2.3.1.2 Criteria and Data Analysis

Test personnel will analyze the data gathered during this test as presented in table 2.5.1.2-1.

Table 2.3.1.2–1. Criteria and Data Analysis

(App A, Item No.) Remarks/Analysis

13 – Emergency Shutoff

This criterion will be considered met if:

a. The PRM is equipped with a manual shutoff capability located at the operator’s position that stops the flow of fuel within 5 seconds after activation in the event of an emergency.

b. In addition to the manual shut-off, the PRM includes a reel-mounted "dead-man" switch that, when released, stops the flow of fuel from the filtration unit.

33 – HSI

This criterion will be considered met if:

a. PRM components are designed and mounted for ease of removal and replacement.

b. Electrical components are not be soldered.

c. Terminal boards, switches, LEDs, and E-stops are a plug-and-play type part/component and are able to be removed and replaced in field conditions without the use of special tools or equipment (see 3.7.4.2 of ATPD 2336G).

34 – HFE

A portion of this criterion will be considered met if:

a. Maximum accessibility to the PRM components is maintained such that system operation, pre-operative checks, and routine operator maintenance can be accomplished as safely and efficiently as possible. MIL-STD-1472, or commercial equivalent standards, will be used for guidance regarding HFE consideration.

b. All system controls and equipment are easily accessible and operable per specified requirements in all climatic conditions.

c. Operation of one control while wearing protective clothing does not result in the accidental activation of another control.

Table 2.3.1.2–1. Criteria and Data Analysis

(App A, Item No.) Remarks/Analysis

LEGEND:

ATPD – Automotive Tank Purchase Description HFE – Human Factors Engineering HIS - Human System Integration LED – Light Emitting Diode MANPRINT – Manpower and Personnel Integration MFS – Modular Fuel System MIL-STD – Military Standard

2.3.1.3 Test Procedures and Data Required

a. Specific tests to determine test item safety, health, and human factors will not be performed separately, but during testing at its entirety. A complete safety and human factors analysis will be made prior to and during the course of testing by the YTC SSE and Human Factor Engineer and will utilize portions of MIL-STD-1472 as a general guideline. Throughout testing, observations will be made through visual examination and functional checks for compliance in design to personnel safety. During the course of testing, any potential hazard observations during operations or maintenance actions will be recorded in test record sheets.

b. The PRM will be inspected for the following capabilities/items:

(1) If the PRM is equipped with a manual emergency shutoff capability located at the operator’s position that stops the flow of fuel within 5 seconds after activation in the event of an emergency.

(2) If in addition to the manual emergency shut-off, the PRM includes a reel-mounted "dead-man" switch that, when released, stops the flow of fuel from the filtration unit.

(4) If the PRM components are designed and mounted for ease of removal and replacement.

(5) If there are no soldered electrical components (i.e. plug-and-play replacement items only during maintenance repair of the PRM).

(6) If the terminal boards, switches, LEDs, and E-stops are a plug-and-play type part/component and are able to be removed and replaced in field conditions without the use of special tools or equipment (see 3.7.4.2 of ATPD 2336G).

(7) If maximum accessibility to the PRM components is maintained such that system operation, pre-operative checks, and routine operator maintenance can be accomplished as safely and efficiently as possible.

(8) If all system controls and equipment are easily accessible and operable per specified requirements in all climatic conditions.

(9) If operation of one control while wearing protective clothing does not result in the accidental activation of another control.

Table 2.3.1.3-1 presents the data required for this subtest.

Table 2.3.1.3-1. Data Required

Photographs and data of any discrepancies found TIRs on any out-of-specification performance capabilities or discrepancies

LEGEND:

TIR – Test Incident Report

2.4 RELIABILITY AND MAINTAINABILITY

2.4.1 Objectives

The R&M objective is to demonstrate the capability of the PRM to function properly over its Operational Mode Summary/Mission Profile (OMS/MP) ratio without degraded operation.

2.4.2 Criterion and Data Analysis

Table 2.4.2-1 presents the criteria for the MFS PRM R&M subtest.

Table 2.4.2-1. MFS PRM R&M Criteria Criterion

(App A, Item No.) Analysis

1 - HEMTT

LHS/PLS and PLS trailer compatibility

If the PRM is compatible with the HEMTT-LHS, the PLS truck, and PLS trailer and a HEMTT-LHS or PLS truck, each coupled with a PLS trailer; is capable of transporting two PRMs over the terrain specified in the OMS/MP without limitations; and the current level of HEMTT- LHS, PLS truck, and PLS trailer mobility and stability is maintained, this criterion will be considered met.

2 - Operation

If the operator is capable of performing all PRM loading, unloading, and dispensing operations while the TRM is mounted on the HEMTT, LHS/PLS truck and while sitting on the ground, this criterion will be considered met.

4 - Failsafe structure.

If all the PRM bases and frames protect components of the PRMs from damage caused by loading and unloading onto their prime mover, transport, and normal use, and components on the PRM bases and frames are protected from accidental contact and damage by foreign objects on the ground, this criterion will be considered met.

6 - Component housings and storage boxes

If all housings and boxes protect components from damage, reduce noise signature, and store equipment; and all components contained in housings and boxes are easily identified and accessible; and are removable or allow sufficient interior access to permit performance of all inspections, unscheduled maintenance actions, and scheduled maintenance actions including the removal of all major components contained within, this criterion will be considered met.

10 - Power source If the power source on all PRMs is capable of starting and operating in all environmental conditions and is capable of operating on JP-8 at rated system capacity without damage, this criterion will be considered met.

14 - Fuel supply If the PRM has an integral fuel supply capacity sufficient to allow no less than 4 hours of operation, this criterion will be considered met.

16 - Battery.

If all batteries on the PRMs are readily accessible for service and inspection and are of sufficient quantity and type to comply with the starting, lighting, normal and surge electrical loads, reserve electrical power capacity, and maintenance requirements, this criterion will be considered met.

(App A, Item No.) Analysis

18 - Filtered fuel recirculation

If the PRM has the ability to recirculate fuel (filter the fuel) within the same storage tank or any other storage tank within the system, and has the capability to bypass any component/assembly that may be removed as not required due to mission requirements, this criterion will be considered met.

22 - Highway transport

If the PRM, when mounted on the HEMTT-LHS truck, PLS truck, and PLS trailer, is capable of unrestricted highway transport in the CONUS, this criterion will be considered met.

23 - Safety

If all electrical wiring, rotating, and reciprocating parts on the PRM are electrically and physically safe, and are guarded so as to not be a hazard to operating personnel and to minimize the hazard of fire in the event of a fuel spillage or leakage from hoses and connections, all electrical terminals and wiring are completely enclosed or insulated to prevent inadvertent contact by personnel or equipment, and danger or caution signs, labels, and markings are used to warn of potential or specific hazards, this criterion will be considered met.

24 - Workmanship.

If the PRMs are constructed with the safety of the operator and maintainer in mind and sharp edges, sharp points, “head bangers”, “shin bangers” and pinch points are avoided, this criterion will be considered met.

25 - Reliability.

If the PRMs have a mean time between hardware essential function failures (MTBHEFF) of not less than 350 hours, this criterion will be considered met.

26 - Maintainability.

If the PRM has lubrication fittings that are accessible without removal of major components, has electrical fittings that are waterproof, corrosion resistant, and resistant to disconnection due to vibration, the engine oil is drainable without flowing onto other components, and the total maintenance ratio does not exceed 0.07 maintenance man-hours/operating hours, this criterion will be considered met.

27 - Time to repair If the PRM has a MedTTR that does not exceed 1 hour and a MAXTTR for 90 percent of all EUMD that does not exceed 1.5 hours, this criterion will be considered met.

28 - Servicing, operation, and maintenance

If the PRM support concept uses two-level organic maintenance, is designed to reduce or eliminate as many tools, special tools, and test equipment as possible, all tools, specials tools, and test equipment required to the support the PRM are designed and provided by the contractor as part of each PRM to assemble, disassemble, maintain, and repair by designated PRM operators and maintainers, and DoD and US Army tools are utilized to the maximum extent possible, this criterion will be considered met.

29 - Operator If the PRM provides all tools, special tools, and test equipment required to perform operator-level PMCS which includes assemble, disassemble, adjust, maintain, diagnose, and repair or report the condition of the PRM

(App A, Item No.) Analysis during the required PRM service life, along with the required stowage space, this criterion will be considered met.

30 - Field and sustainment maintenance

If all tools, special tools, and test equipment required to adjust, maintain, and repair the PRM that are not already available to the upper level echelon repair organization that would normally provide these services to the using unit during the required PRM service life requirement, are provided in the quantities specified in Section 6.2 of ATPD 2336D (Ref 10, App D), this criterion will be considered met.

31 - Environmental hazard prevention

If the PRM is designed to prevent inadvertent product discharge or leakage during operation, storage, and maintenance, this criterion will be considered met.

32 - Fuel Spill Control Kit

If each PRM includes supplies and equipment to allow the containment and cleanup of up to a 50-gallon fuel spill, is equipped with a minimum of ten portable drip pans for use at hose connection points to capture any residual fuel remaining in the system, each drip pan has a capacity of a minimum of five gallons and does not impede the ability of the operator to install, operate, and recover the modules, the PRM has the provisions to securely store and transport the drip pans and fuel spill control kit, the drip pans and the fuel spill control kit are easily accessible to personnel, the drip pans have non-collapsible walls and are capable of capturing and retaining residual fuel remaining in the system while supporting the hose assemblies at the hose connection point, and the pans provide a method to drain any fuel captured in the pans, this criterion will be considered met.

33 - Human systems integration

(HSI).

If the PRM can accommodate the central 90 percent fully encumbered male, this criterion will be considered met.

34 - Human factors engineering (HFE)

If each PRM’s components maintain maximum accessibility such that system operation, pre-operative checks, and routine operator maintenance can be accomplished as safely and efficiently as possible, each PRM contains controls and indicators that are easy to read, understand, and use during day/night operations and which are readable and operable by personnel standing on the ground, and all equipment storage boxes and hardware requiring set-up for the conduct of fuel dispensing operations are accessible by personnel standing on the ground, this criterion will be considered met.

LEGEND:

ATDP – Automotive Tank Purchase Description CONUS – Continental United States DoD – Department of Defense EUMD – Essential Unscheduled Maintenance Demands HEMTT – Heavy Expanded Mobility Tactical Truck JP – Jet Propellant

(App A, Item No.) Analysis LHS – Load Handling System MAXTTR – Maximum Time to Repair MedTTR – Median Time to Repair MTBHEFF – Mean Time Between Hardware Essential Function Failure OMS/MP – Operational Mode Summary/Mission Profile PLS – Palletized Loading System PMCS – Preventative Maintenance Checks and Services

2.4.3 Test Procedures and Data Required

a. Test personnel will utilize TOP 2-2-506, Endurance Testing of Tracked and Wheeled Vehicles (Ref 6, App D) as a guideline to conduct this subtest.

b. Test personnel will utilize two PRMs and eight TRMs to construct two PRM pumping sites as shown in Figure 2.4.3-2. To conduct R&M testing, test personnel will:

(1) Accumulate mileage utilizing one HEMTT LHS or one PLS LHS, and one M1076 trailers. Test miles will be accumulated with one PRM configured on a trailer and one PRM loaded on a Prime Mover.

(2) Perform 350 miles of transport on each PRM over the terrain profile specified in the OMS/MP (20-percent primary, 50-percent secondary, 15-percent trails, and 15-percent cross-country). Table 2.4.3-1 presents a detailed mileage breakdown for the reliability testing. In addition, test personnel will perform 50 pumping hours on each PRM for a total of 100 pump engine hours.

Table 2.4.3-1. MFS PRM Mileage Accumulation Breakdown

Terrain Percent Course Mileage

On HEMTT or

PLS

Mileage On M1076 Trailer Total

Primary 20 HWTC 35 35 70

Secondary

26 KLG 45 45 90

12 PHG 21 21 42

12 PLG 21 21 42

Trails

5 LLT-W 9 9 18

5 LHT 9 9 18

5 PLT 9 9 18

Cross-country 15 DM 26 26 52

Table 2.4.3-1. MFS PRM Mileage Accumulation Breakdown

Terrain Percent Course Mileage

On HEMTT or

PLS

Mileage On M1076 Trailer Total

Totals 100 350 350 700

LEGEND:

DM – Desert March HEMTT – Heavy Expanded Mobility Tactical Truck HWTC – Hot Weather Test Complex KLG – Kofa Level Gravel LHT – Laguna Hilly Trails LLT-W – Laguna Level Trails West MFS – Modular Fuel System PHG – Patton Hilly Gravel PLG – Patton Level Gravel PLS – Palletized Loading System PLT – Patton Level Trails

(3) Perform all loading/unloading cycles, transporting, and pumping operations interspersed throughout testing to create repeating periods of loading, transporting, pumping and unloading.

(4) Perform one LHS cycle for every 50 miles of transporting operations. One LHS cycle consists of loading and unloading the PRM to and from the prime mover or to and from the PLS trailer.

(5) Perform pumping operations on two PRMs as outlined in Table 2.4.3-2 for a duration of 1week (5 working days). Test personnel will perform pumping operations during R&M with the layout presented in Figure 2.4.3-2.

(6) Perform testing to simulate the retail layout as presented in Figure 2.4.3-1 using the Planned Reliability Layout shown in Figure 2.4.3-2. The distances depicted are not a requirement or specification of the MFS PRM and instead being utilized to simulate the maximum load that would be exerted on the system.

The farthest dispensing point from the PRM is approximately 450 feet.

Figure 2.4.3-1. Optimum retail layout.

Figure 2.4.3-2. Planned Reliability Layout.

c. Complete R&M testing on the PRMs as described in Table 2.4.3-2.

Table 2.4.3-2. Mission Breakdown Mission Number Mission Type Details

1 Loading Load two PRMs in the correct configurations on the prime mover and trailer in preparation for transporting IAW with the OMS/MP terrain profile.

2 Transport Accumulate miles on two PRMs IAW the OMS/MP terrain profile listed in Table 2.4.3-1.

3 Unloading Unload the PRM in preparation for pumping operations.

4 Pumping

Complete PRM pumping operations on two PRMs as follows:

a. Recirculate fuel for 2 hours at 220 gpm and then put the PRM in idle for a couple of minutes.

b. Issue fuel for approximately 30 minutes, at 200 gpm until the bottom load valves close on both TRMs.

c. Transfer (recirculate) fuel back into the system (20 minutes) and then put the PRM in idle for a couple of minutes.

d. Issue fuel for approximately 15 minutes, at 400 gpm until the bottom load valves close on both TRMs.

e. Transfer (recirculate) fuel back into the system (20 minutes) and then put the PRM in idle for a couple of minutes.

f. Issue fuel for approximately 10 minutes, at 400 gpm until the bottom load valves close on both TRMs.

g. Transfer (recirculate) fuel back into the system (20 minutes), turn the PRM off for a couple of minutes, and then restart it.

h. Recirculate fuel for the remainder of the shift (approximately 2 to 3 hours).

i. Evacuate the hoses at the end of the shift.

LEGEND:

Gpm – gallons per minute IAW – In accordance with LHS – Load Handling System MFS – Modular Fuel System OMS/MP – Operational Mode Summary/Mission Profile PRM – Pump Rack Module TRM – Tank Rack Module

NOTE: A total of four PRMs will be tested, with two PRMs conducting transport operations and two PRMs conducting pumping operations simultaneously. Missions 1 through 4 will be repeated until 350 miles and 100 pump engine hours have been accumulated between the two PRMs combined.

j. Perform all unscheduled and scheduled maintenance actions utilizing YTC maintenance personnel. FSRs will be on-site at all times to support testing and provide expertise on the system.

k. Inspect and service the PRM, Prime Mover, and trailer IAW the PMCS outlined in the operational trainee guide provided by the manufacturer prior to daily operations. During all inspections, the PRMs will be visually inspected for cracks, interferences, leaks, and other test incidents, with all discrepancies documented and reported.

l. Perform jury ride speeds IAW Standard Operation Procedure (SOP) YP-TYCA-P- 5001, Standard Operating Procedure for Conduction Automotive Testing (reference 7, appendix D) to establish test course speeds.

m. Record all failures of the PRMs observed during testing and report them through TIRs IAW DA PAM 73-1. Failures of the TRMs including pictures, will be included in daily status reports but will not be recorded through TIRs. YTC will provide preliminary scoring IAW the Failure Definition/Scoring Criteria (FD/SC) provided by the test sponsor. All TIRs will be made available through the VDLS.

n. Perform all schedule test item and test support item maintenance at the required intervals IAW the operational trainee guide.

o. Document any safety issues related to the PRM during testing in TIRs.

p. Record the total chargeable maintenance time, man-hours, delay time, and level of maintenance (LOM) for each maintenance action in the associated TIR. Disposition of failed components will be as directed by the test sponsor.

q. Record the following information on any modifications performed:

(1) Modification Number.

(2) Nomenclature.

(3) Serial Number.

(4) Date of Installation.

As used in this test plan, the term ”modifications” refers to changes made to the PRM that are implemented after arrival at YTC during initial inspection and/or during the MFS PRM Test as a result of circumstances encountered during the MFS PRM Test with concurrence of the Project Manager (PM).

r. Record the following data:

(1) Test course profiles

(2) Distance traveled (±1 miles).

(3) Test hours (±0.1 hours).

(4) Pump engine hours. **For Info: Control panel display only shows whole hours. **

(5) Clock and man-hours to conduct any unscheduled maintenance (±0.25 hours).

(6) Any special tools or equipment to complete all unscheduled maintenance.

(7) Clock and man-hours for scheduled maintenance actions (± 0.25 hours).

(8) Parts replaced.

(9) TIRs for all discrepancies, maintenance actions, and/or failures.

(10)Photographs of failures, as necessary.

(11)Modifications applied, as applicable.

2.5 PUMPING PERFORMANCE

2.5.1 Objective

To determine if the performance characteristics of the PRM meet the criteria in the ATPD 2336G.

2.5.2 Criteria and Data Analysis

Test personnel will analyze the data gathered during this test as presented in table 2.5.2-1.

Table 2.5.2–1. Criteria and Data Analysis

(App A, Item No.) Remarks/Analysis

2 – Operation This criterion will be considered met if the operator is capable of performing all PRM loading, unloading, and dispensing operations while the MFS is sitting on the ground, flat and on slopes up to 5 degrees.

3 – Starting, Operation, and

Stopping

This criterion will be considered met if:

a. Starting. The PRM is capable of starting within 5 minutes under any environmental conditions or combination of conditions as specified in 3.8 of the ATPD 2336G. The MFS starts and operates on inclines up to ±5 degrees from horizontal.

b. Operation. The PRM is capable of operating under any environmental condition or combination of conditions as specified in 3.8 of ATPD 2336G.

No leakage, contamination, or damage to the MFS resulted from operation.

c. Stopping. The PRM is equipped with a manual stop to stop the flow of fuel within 5 seconds after activation.

8 – Pump Capacity

A portion of this criterion will be considered met if (ref appendix A for the remaining applicable subtests of this criterion):

a. The PRM is capable of providing filtered fuel at the minimum rate of

400gpm in both retail and bulk configurations as shown in Fig. 2.4.3-1 and 2.4.3-2:

(1) Bulk refueling at a rate of 400 gpm (threshold).

(2) Retail refueling at a rate of 50 gpm to eight nozzles simultaneously.

b. Spacing between the dispensing points and PRM are a minimum of 100 feet.

c. The pumping assembly can operate continually for four hours at maximum performance without being refueled or serviced.

12 – Operational Fault Controls

This criterion will be considered met if:

a. In addition to the emergency manual stop, as a minimum, operational automatic fault shut-offs are incorporated into the PRM to prevent system damage or minimize hazard to personnel as a result of:

(1) Engine overspeed, low operating pressure, high product temperature, and high engine temperature

(2) Low fuel level/run-dry operation

(3) Excessive electrical currents and voltages (if system is equipped with an on- board electrical power generator)

(4) High or low pumping assembly suction and discharge pressure

b. When a shut-off is activated, sufficient indication of the condition(s) are provided to the operator via the control panel.

c. After the condition that caused activation of the shut-off is resolved, the system is capable of resetting to a normal operating status.

d. Manual override of shut-off conditions is provided.

e. A toggle switch is provided on manual overrides.

f. Each toggle switch includes a red toggle switch safety cover in order to prevent any accidental manipulation of the override.

17 – Fuel Dispensing Points

This criterion will be considered met if:

a. The PRM is capable of refueling a minimum of eight vehicles or four aircrafts simultaneously; this includes the capability to perform retail refueling using eight 1-1/2-inch automatic shut-off open port nozzles.

b. All nozzles, fittings, and valves required to refuel, bottom load, and fill drums are equipped with sexless dry break couplings.

c. Each dispensing point is a minimum of 100 feet from the PRM.

d. Spacing between the dispensing points are a minimum of 100 feet apart.

19 – Fuel Evacuation

This criterion will be considered met if:

a. The PRM is capable of evacuating all but residual fuel from the suction and discharge hoses and other system components prior to teardown.

b. Evacuation, teardown, and recovery do not require MHE.

20 – Fuel Flow Rate Measurement

This criterion will be considered met if:

a. The PRM is capable of determining the fuel flow rate and total amount of fuel passed into and out of the PRM at any given time within ±1 percent of the true flow rate.

b. The electronic flow meter assembly has a minimum range of zero to 630 gpm at 150 psi with a resettable counter and a totalizer and is capable of providing an electronic signal to a data acquisition system to be added at a later date.

c. The indicator, counter, and totalizer are sealed for protection from moisture and dust.

19 – Fill and Discharge

This criterion will be considered met if while utilizing the PRM, the MFS is capable of self-loading and unloading fuel at the rate of 400 gpm (threshold).

21 – Environmental Hazard Prevention

This criterion will be considered met if, during testing at its entirety, the PRM prevents inadvertent product discharge or leakage during operation, storage, and maintenance.

LEGEND:

ATPD – Automotive Tank Purchase Description GPM – Gallons per minute MFS – Modular Fuel System psi – pounds per square inch

2.5.3 Test Procedures and Data Required

a. Prior to the start of performance testing, test personnel will install the following instrumentation to the MFS:

(1) Flow meter in the main suction line.

(2) A pulse counter to measure engine speed.

(3) Pressure transducers to measure differential pressure in the filter separator to verify an accuracy of the manual site gauge to be within ±0.5 psi, and to verify an accuracy of the control panel reading accuracy to be within ±2 percent (ref Section 2.2, Physical Characteristics).

(4) Battery voltage and current usage.

(5) Alternator current supplied to the batteries.

b The PRMs and TRMs will be interconnected as shown in Figures 2.5.3-1 and 2.5.3-2.

Figure 2.5.3-1. Retail Fuel Layout

Figure 2.5.3-2. Bulk Fuel Layout

c. For retail and bulk layouts, test personnel will operate the PRM at maximum flowrate, from when the supply TRMs are full (2500 gallons each) to when they are empty. The TRMs will be emptied at the same time. The pressure at the suction side of the pump will be carefully monitored for signs of cavitation throughout the test.

1. The ability of the PRM to meet the requirement of at least 400 gpm during bulk and retail refueling will be determined.

2. The accuracy of the flow meter will be measured by comparing its output to the integrated value of the flow rate measured at the main dispensing line flow meter.

3. The output of the pressure gauge will be compared to the difference in pressures of the two instrumented pressure transducers for each pumping scenario.

4. The distance between the PRM and the TRMs will be the maximum allowable per the TM or as otherwise provided by the PM.

5. The ability of the PRM to pump continuously for four hours at maximum flow rate will be determined.

6. The accuracy of the totalizer and pressure gauge will be determined during both the 4-hour maximum flow test and over four additional 30-minute scenarios, which will be performed at flow rates of 100 - 400 gpm in 100 gpm increments.

7. The output of the fuel totalizer will be compared to the integrated value of the flow rate measured at the flow meter.

8. The output of the pressure gauge will be compared to the difference in pressures of the two instrumented pressure transducers.

9. The ability of the PRM to operate on slopes will be determined by propping up one edge of the PRM to 5 degrees, then pumping for one hour at maximum flow rate. This procedure will be performed four times, each with a different edge (front, rear, left, or right) propped to 5 degrees. The accuracy of the totalizer and pressure gauge will be measured during all four scenarios.

10. The ability of the emergency stop to completely stop the flow of fuel within 5 seconds will be determined.

11. The PRM will be evacuated, and its ability to operate for 5 minutes at no-flow conditions will be determined.

Table 2.5.3-1 presents the data required for this subtest.

Table 2.5.3-1. Data Required

Flow rate at one location (gpm) Totalizer reading (gallons) Pressure drop (instrumentation and PRM readout) (psi) Engine speed (rpm) Battery voltage (V) and current (A) Alternator current (A)

LEGEND:

A – amperes gpm – gallons per minute psi – pounds per square inch rpm – revolutions per minute V –…