Attach 0009 WSDS FDSC Certified 16 Apr 21.pdf

CUI

16 April 2021

Failure Definition and Scoring Criteria (FDSC) for the Water Storage and Distribution System

(WSDS)

U.S. Army Futures Command

Futures and Concepts Center Futures Integration Directorate

RAM Engineering Division 950 Jefferson Avenue Fort Eustis, VA 23604

DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense (DoD) and U.S.

DoD contractors only to protect technical or operational data or information from automatic dissemination under the International Exchange Program or by other means, 7 March 2019. Refer other requests for this document to: U.S. Army Futures Command, Futures and Concepts Center, Futures Integration Directorate, RAM Engineering Division, 950 Jefferson Avenue, Fort Eustis, VA 23604.

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16 April 2021

Failure Definition and Scoring Criteria (FDSC) for

Water Storage and Distribution System

(WSDS)

Harishkumar Doshi

U.S. Army Futures Command

Futures Integration Directorate RAM Engineering Division

950 Jefferson Avenue Fort Eustis, VA 23604

DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense (DoD) and U.S.

DoD contractors only to protect technical or operational data or information from automatic dissemination under the International Exchange Program or by other means, 7 March 2019. Refer other requests for this document to: U.S. Army Futures Command, Futures and Concepts Center, Futures Integration Directorate, RAM Engineering Division, 950 Jefferson Avenue, Fort Eustis, VA 23604.

ii iii

Foreword

PURPOSE

The Failure Definition and Scoring Criteria (FDSC) serves as the user's primary tool for scoring and evaluating systems during developmental and operational testing events. The FDSC drives system design, development, and testing and evaluation. The following FDSC defines what the user considers degraded and unacceptable performance of the Water Storage and Distribution System (WSDS) and outlines the process for categorizing all failure events that occur during system testing. This FDSC will be the basis for the evaluation of the WSDS reliability requirement. There is no intent to address every situation that will arise during WSDS reliability testing. When discovering limitations to the FDSC, the capability developer RAM engineer in coordination with the materiel developer and independent evaluator will update and add appropriate information to the FDSC as required.

SYSTEM DESCRIPTION

The Water Storage and Distribution System (WSDS) is the Army’s primary large potable water bag farm storage and issuing capability and comes in five capacities: 20K, 40K, 100K, 300K and 800K gallons. It is comprised of collapsible storage tanks, engine driven centrifugal water pumps, meters, hoses, fittings and nozzles. The system also has hypochlorination units that automatically chlorinate water to Army standards. It interfaces with the Tactical Water Distribution System as well as all mobile bulk distribution assets to include the 5000 gallon Semitrailer Mounted Fabric Tank, Load Handling System Water Tankrack (Hippo), Unit Water Pod System (Camel), Unit Water Trailer (Buffalo) and the Unit Water Trailer (Bison) systems.

POINT OF CONTACT

Mr. Harish Doshi, Futures and Concepts Center, Futures Integration Directorate, Reliability, Availability and Maintainability (RAM) Engineering Division, Fort Lee Field Office, Commercial 804-734-1521, email: harishkumar.o.doshi.civ@mail.mil.

CERTIFICATION

Date: 16 Apr 21 Jeffrey L. Higgins Chief, Central RAM Engineering Branch RAM Engineering Division Futures Integration Directorate

Army Futures Command iv v

Table of Contents

Foreword ....................................................................................................................................... iii Purpose ....................................................................................................................................... iii System Description .................................................................................................................... iii Point of Contact .......................................................................................................................... iii Certification ................................................................................................................................ iii

Table of Contents ...........................................................................................................................v List of Figures ..............................................................................................................................v List of Tables ................................................................................................................................v

System Description, Essential Functions, and Failure Defintion System Description Essential Functions Failure Definitions

Scoring Criteria Test Data Collection Guidance

Appendix A – References ......................................................................................................... A-1 Appendix B – Glossary ..............................................................................................................B-1

List of Figures

Figure 1 – Scoring Process Flow Chart

Figure 2 – Scoring Process Flow Chart Steps

List of Tables

Table 1 – Leak Definitions, Descriptions, and Classifications vi

System Description, Essential Functions, and Failure Definition

SYSTEM DESCRIPTION

The Water Storage and Distribution System (WSDS) is the Army’s primary large potable water bag farm storage and issuing capability and comes in five capacities: 20K, 40K, 100K, 300K and 800K gallons. It is comprised of collapsible storage tanks, engine driven centrifugal water pumps, meters, hoses, fittings and nozzles. The system also has hypochlorination units that automatically chlorinate water to Army standards. It interfaces with the Tactical Water Distribution System as well as all mobile bulk distribution assets to include the 5000 gallon Semitrailer Mounted Fabric Tank, Load Handling System Water Tankrack (Hippo), Unit Water Pod System (Camel), Unit Water Trailer (Buffalo) and the Unit Water Trailer (Bison) systems.

ESSENTIAL FUNCTIONS

Essential functions are the minimum operational tasks that the WSDS must be capable of performing to successfully complete its mission. The loss of an essential function, regardless of when it occurs is an essential function failure (EFF).

Water Storage. This function includes the ability to layout the fabric tanks with reasonable effort, receive water via pump and safely store water at system’s capacity without leakage or contamination.

Water Distribution. The pump and distribution system consisting of manifolding, hose reels, hoses, valves, couplings, and nozzles must allow the WSDS to perform water delivery at throughput rates consistent with pump rating and receiving entities acceptance rate.

Chlorination. The system must perform chlorination of the water in compliance TB MED 577 (Sanitary Control and Surveillance of Field Water Supplies).

FAILURE DEFINITIONS

Essential Function Failure (EFF). Score any of the following events as an EFF:

• Any event that causes the inability of the WSDS to perform one or more of its essential functions (EF)

• Any event that causes the use of the system to be discontinued, to include those events posing threat of serious injury to personnel or equipment.

• Any event that renders stored water non-potable.

• Severe Class III water leaks or any Class III fuel or Class III oil leak that not corrected by the operator within 15 minutes using only on-board tools and repair or spare parts. Leak classification is addressed in Table 1 on page 3.

Non-Essential Function Failure (NEFF). Events that are malfunctions but that do not involve the loss of an essential function are NEFFs. Examples include:

• Minor water leaks (Class I or II) which do not interrupt water flow or which do not necessitate shutdown of pumping operations due to safety or other concerns.

• Class I or II oil or fuel leaks.

Rapidly Recoverable Event (RRE). Minor events corrected by the operator/crew within 10 minutes as Rapidly Recoverable Events (RRE) if the repair procedure is in the operator’s manual and performed by the operator/crew using only on-board tools and repair or spare parts. If more than three RRE occur during a storage/distribution mission, score any additional RRE as EFF or Non-Essential Function Failures (NEFF) as appropriate.

Dependent Event (DE) A DE is a secondary failure induced by the primary malfunction and typically occurring simultaneously or near simultaneously with the primary event. Analysis of the failure event must positively confirm that it occurred as the direct result of a specified primary event. Dependent events are not included in the calculation of Mean Time Between Essential Function Failure, however any maintenance incurred will be considered in the calculation of system maintainability metrics.

Table 1. Leak Definitions, Descriptions, and Classifications Army Class Hydraulic Leak Description

Applicable to Oil Leakage Term SAE

Classification Dust-free Dusty Dust-free Dusty

No indications of moisture DRY DRY 0 0D n/a Dust-Free: Non-recurring fluid Dusty: Dry collection which does not propagate

WEEP WEEP-

DUST

1 1D I

Dust-Free: Recurring fluid that does not result in the formation of a droplet Dusty: Moist thin layer (under 3 mm) of dust

SEEP MOIST-A 2 2D

Dust-Free: Recurring fluid that results in the formation of a non-falling droplet.

Dusty: Moist thick layer (over 3 mm) of dust with wetness near the sealing member

DROPLET MOIST-B 3 3D II

Dust-Free: Recurring fluid where a droplet forms and falls Dusty: Recurring fluid forms on vertical surfaces, dripping occurs at bottom of surfaces or pools of oil collect on the top of horizontal surfaces.

DRIP WET 4 4D

III

Dust-Free: Recurring fluid where the frequency of droplets makes a measurable stream Dusty: Recurring fluid where the frequency of droplets makes a measurable stream

FLOW WASHED 5 5D

The following applies to water leaks only:

Class I: Seepage of fluid (as indicated by wetness) or leakage great enough to form drops, but not enough to cause drops to fall.

Class II: Leakage great enough to result in more than a slow dripping from the leaking item.

Class III: Rapid dripping or spray deemed to be a safety hazard or has the potential to damage other equipment.

Scoring Criteria

SCORING CRITERIA

The scoring criteria section describes the process for classifying all test incident reports (TIR) generated during a reliability test. The Reliability Scoring Conference (RSC) members use the scoring criteria to assign TIRs into proper categories, sub-categories, and chargeability. Figure 1 is a scoring flow chart depicting this process. TIR categories are: Reliability Event (i.e., failure), Non-Reliability Event (applicable to maintainability), or Other Test Event (not applicable to RAM). Appendix A – Glossary includes the scoring process flowchart definitions. Figure 2 describes the scoring process flowchart steps.

Figure 1. Scoring Process Flow Chart.

SCORING PROCESS

GENERAL PROCEDURE

TEST INCIDENT

As reported on a Test Incident Report (TIR)

RELIABILITY

EVENT

NON-RELIABILITY EVENT (NRE)

(APPLICABLE to MAINTAINABILITY)

Other Test Event (OTE) (NOT APPLICABLE to RAM)

ESSENTIAL

FUNCTION

FAILURE (EFF)

NON-ESSENTIAL

FUNCTION

FAILURE (NEFF)

RAPID

RECOVERABLE

EVENT (RRE)

FAILURE WAS CAUSED BY

PREVENTATIVE

MAINTENANCE CHECKS

AND SERVICES (PMCS)

SCHEDULED

MAINTENANCE

ROUTINE OPERATING

PROCEDURES (ROP)

PRE/POST-TEST CHECKOUT

EQUIPMENT MODIFICATION

(HARDWARE or SOFTWARE)

TEST PECULIAR EVENT

(TPE)

ABUSE OR MISUSE

UNRELATED DAMAGE

NON-RAM ORIENTED /

INFORMATION

PERFORMANCE LIMITATION

ACCIDENT

SUPPORT EQUIPMENT

INDETERMINATE

HARDWARE-GFE

MAINTENANCE

PERSONNEL

CREW/OPERATOR

TRAINING

TECH DOCS / MANUALS

ON-CONDITION

MAINTENANCE

HARDWARE-CFE

SOFTWARE-CFE

DEPENDENT

FAILURE (DF)

PRIMARY FAILURE

SOFTWARE-GFE

Figure 2. Scoring Process Flowchart Steps.

1. Test Incident Report (TIR) Scoring. Select the appropriate category below and proceed as directed.

• Test Incident is a “Reliability Event.” Proceed to step 2.

• Test Incident is a “Non-Reliability Event.” Proceed to step 4.

• Test Incident is an “Other Test Event.” Proceed to step 5.

2. Reliability Event. Identify the reliability event as one of the following sub-categories and proceed to step 3. A reliability event can include post-test TIRs, with or without maintenance actions, if the failure occurred during record test.

• Essential Function Failure (EFF)

• Non-Essential Function Failure (NEFF)

• Rapidly Recoverable Event (RRE)

• Dependent Failure (DF)

3. Failure Chargeability. Identify a single root cause of the reliability failure from the following list and proceed to the next test incident.

• Accident

• Support Equipment

• Indeterminate

• Technical Documentation/Manuals

• Primary Failure

• Hardware Government Furnished Equipment (GFE)/Contractor Furnished

Equipment (CFE)

• Software GFE/CFE

• Maintenance Personnel

• Training

• Crew/Operator

4. Non-Reliability Event (Applicable to Maintainability). Select the sub-category from the list below and proceed to the next incident.

• Preventive Maintenance Checks and Services (PMCS)

• Scheduled Maintenance

• Routine Operating Procedure (crew-performed IAW manual)

• On Condition/Condition Based Maintenance

5. Other Test Event (OTE) (Not applicable to RAM). Select the sub-category from the list below and proceed to the next test incident.

• Pre/Post-test Checkout

• Equipment Modification (Hardware or Software)

• Test Peculiar Event (TPE)

• Abuse or Misuse

• Unrelated Damage

• Non-RAM Oriented/Information (NRO)

• Performance Limitation (PL)

TEST DATA COLLECTION GUIDANCE

This section includes any specific instructions to testers to facilitate accurate collection and recording of data relevant to RAM scoring. TIRs document all incidents where a system is non-operational, operates with degraded performance, or responds differently than expected. They should contain as much information as possible with regard to failures and, when possible, to the root cause of the failures. Below is a typical list of data and information to record within a TIR:

• Failure initiation date (date, time, location, malfunction indicators).

• System operation(s) attempted at time of failure.

• Operating hours, miles, cycles, or other measurement(s) used to quantify the age or life of the system/component at time of failure.

• Maintenance Actions performed.

• Maintenance level used.

• Maintenance man-hours.

• Maintenance clock-hours.

• Military Occupational Specialty (MOS) used.

• Spare or repair parts used.

• Petroleum, Oil, and Lubricant (POL) quantity used.

• Indication of Built-in-test/Built-in-test-equipment (BIT/BITE) false alarm.

• Indication of BIT/BITE successful detection.

• Indication of BIT/BITE successful isolation.

A-1

Appendix A – References

Army Regulation 702-19. Reliability, Availability, and Maintainability. Headquarters Department of the Army, Washington, DC. 12 February 2020.

Guide for Developing Reliability Failure Definition and Scoring Criteria (FDSC), 5th Edition.

US Army Futures Command, Fort Eustis, VA. 4 November 2020.

WSDS Capability Production Document (CPD), Version 4.2, dated 10 March 2017.

WSDS Clarification Memo #2, dated 1 June 2020.

WSDS Operational Mode Summary/ Mission Profile (OMS/MP) dated 1 June 2015.

Army Techniques Publication (ATP) 4-44, Water Support Operations, dated 2 October 2015

A-2

B-1

Appendix B – Glossary

Abuse or Misuse. Events in which official test participants (crewmembers or maintenance personnel) cause damage to the system either willfully or through gross negligence are subject to being classified as abuse (ultimately, a decision for the Scoring Conference members to make after considering the facts). This category also includes any incidents in which the tester directs the deliberate misuse of the system (e.g. a test excursion to exceed the performance limits of the system), whether called for by the test plan or not.

Accident. Failure Chargeability category for accident induced failure/damage not attributable to the design of the system or operator negligence.

Crew/Operator. Failure chargeability category that includes all incidents attributable to crew/ operator error.

Dependent Failure. A reliability event that is a secondary malfunction caused by the failure of another item, which normally occurs simultaneously or nearly simultaneously with the causing event.

Equipment (System) Modification (hardware or software). Installation of hardware kits, software modifications, or incorporation of redesigned components or software upgrades.

Essential Function Failure (EFF). A failure or malfunction causing degradation below an established level or causing complete loss of an essential function(s).

Hardware. Chargeability category that includes malfunctioning hardware as well as personnel related incidents that are attributable to the hardware's design. This category may be broken down further into hardware that is “Contractor Furnished Equipment (CFE)” and/or “Government Furnished Equipment (GFE)”.

Indeterminate. Chargeability category for incidents that do not have sufficient information/data to permit a determination of chargeability.

Maintainability. A measure of a system’s ease of maintenance.

Maintenance Personnel. This chargeability category includes all incidents attributable to maintenance personnel errors not due to hardware/software design/coding problems, poorly written manuals, human factors/ergonomic issues, or faulty embedded diagnostics.

Malfunction. Failure to properly perform a specified action or activity.

B-2

Non-Essential Function Failure (Non-EFF). Events that result in loss of or degradation in non-essential functions or minor degradation in essential functions, which do not reach the levels to qualify as an EFF.

Non-RAM Oriented/Information. Category for Test Incident Reports (TIR) excluded from RAM computations. Examples include suggested improvements, reports on inadequate test procedure, unusable or unacceptable replacement parts discovered prior to or during installation, test schedule delays, suggested human factors improvements or recommended changes to the system support package not related to a specific test event.

Non-Reliability Event (Applicable to Maintainability). Event, which is not a reliability failure, but may have implications on system maintainability.

On-Condition/Condition Based Maintenance (CBM). Incident recording maintenance performed to replace a used or worn part/component that has met its life expectancy criteria (i.e., its durability or service life requirement). The part must still be functioning at the time of its replacement. The system technical documentation must have specific criteria to identify conditions for replacement. Examples of “on-condition” maintenance include replacement of tires due to normal wear (tread wear indicators showing/tread depth less than “wear-out” standards) or gun tube replacement based on the specified item meeting the necessary interval (e.g. rounds, hours, or miles), or durability requirements. It may be necessary to further record whether the item being replaced is Contractor Furnished Equipment (CFE) or Government Furnished Equipment (GFE), depending on the nature of the R&M requirements.

Other Test Event (OTE) (Not Applicable to RAM). Events not applicable to RAM evaluation of the system.

Performance Limitation. Inability of a system to meet performance specifications without incurring a malfunction. The classic example is a vehicle with a speed requirement of 90 miles per hour (mph). However, the design of the drivetrain prevents the vehicle from ever reaching the required speed. No malfunction has occurred which prevents the achievement of the required speed.

Pre-test/Post-test Checkout. Events observed during burn-in, pre-test/post-test inspection, or other pre-test/post-test activities.

Preventive Maintenance, Checks and Services (PMCS). Maintenance actions of a preventive nature normally performed by operator or crew.

Primary Failure. Category for failure events caused by an earlier or concurrent primary failure.

This category applies to those events scored as dependent failures.

B-3

Rapidly Recoverable Event (RRE). An RRE is a malfunction correctable by the crew/operator and falling within the set time constraints through the execution of maintenance/repair procedures using authorized tools, repair parts, and spares carried on-board the system. This category captures incidents that normally would be EFF but can be RRE if the constraints are met.

Reliability. Probability that an item can perform its intended function without failure for a specified time interval under stated conditions.

Reliability Event. This category captures any test incidents that document failure or malfunction of an item.

Reliability Event Chargeability. Section of the scoring criteria documenting the root cause of a failure.

Routine Operating Procedures (ROP). Operating procedures routinely performed by the operator & prescribed in the user manual. Typically, they are tasks the operator or crew may quickly perform and are not reliability failures.

Scheduled Maintenance. Maintenance actions performed by a maintainer in accordance with applicable technical documentation/manuals.

Software. This chargeability category includes all incidents attributable to software contained within the system (application, interface, or firmware). This category may be broken down further into software that is “Contractor Furnished Equipment (CFE)” and “Government Furnished Equipment (GFE)” Software.

Support Equipment. Chargeability category for incidents caused by special tools, common tools, Test Measurement and Diagnostic Equipment (TMDE), software programs, or other equipment not a component of the operational system.

Technical documents/Manuals. This chargeability category includes all events that are attributable to misleading, incorrect, or nonexistent-but-needed information in the technical documents/manuals.

Test Peculiar. Malfunctions caused by outside equipment not part of the system under test or people not acting as test players (crew or maintenance personnel). Engineering evaluations to analyze the cause of test peculiar malfunctions, as well as any malfunctions and/or maintenance efforts caused by the engineering evaluation are scored as "OTE". This also includes maintenance evaluations conducted as a part of the test plan and malfunctions to or caused by test peculiar instrumentation.

Training. This includes any event attributed to inadequacies in training due to omitted or incorrect training procedures, or inappropriate training material such as information above the general level of understanding of the target audience.

B-4

Unrelated Damage. This includes damage caused by natural phenomena (e.g., lightning, earthquakes, etc.) or other influences beyond control of the operational elements of the system.