Attachment0004SDD07Oct2015.docx

DOCX document 4 MB Posted Oct 19, 2015

Attached to: GAS TURBINES AND JET ENGINES, AIRCRAFT, PRIME MOVING; AND COMPONENTS
Solicitation number: W58RGZ15R0070
Issued by: Department of the Army Materiel Command Aviation and Missile Life Cycle Management Command

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Attachment 0004 SDD Revised 07 Oct 2015

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W58RGZ15R0070-0005.pdf	PDF	Nov 5, 2015
Attachment0001PWS23Oct2015.docx	DOCX document	Oct 26, 2015
Attachment0005TDS22Oct15.pdf	PDF	Oct 26, 2015
W58RGZ-15-R-0070_Amendment_0004_KO_signed.pdf	PDF	Oct 26, 2015
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Attachment0014RFPQuestionsAndResponses09Oct2015.pdf	PDF	Oct 9, 2015
Attachment0001PWSRevised01Oct2015.docx	DOCX document	Oct 2, 2015
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SPECIFICATION DEVELOPMENT DOCUMENT

ENGINES, AIRCRAFT, TURBOSHAFT

IMPROVED TURBINE ENGINE

13 Jun 13

07 OCTOBER 15

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. Other requests for this document shall be referred to ITE/FVL Project Office, Redstone Arsenal, AL 35898-5000

Table of Contents

1	SCOPE	8
1.1	Metric Requirements	8
1.2	Deviations	8
2	APPLICABLE DOCUMENTS	9
2.1	General	9
2.2	Government Documents	9
2.2.1	Specifications, Standards, and Handbooks	9
2.2.2	Other Government Documents, Drawings, and Publications.	10
2.3	NonGovernment Publications.	11
2.3.1	American Society for Testing and Materials (ASTM)	11
Standard Specification for Automotive Spark-Ignition Engine Fuel	11
Standard Specification for Aviation Turbine Fuels	11
Standard Specification for Anaerobic Single-Component Adhesives (AN)	11
2.3.2	Institute of Environmental Sciences	11
2.3.3	International Electrotechnical Commission (IEC)	11
2.3.4	International Organization for Standardization	12
2.3.5	Radio Technical Commission for Aeronautics, (RTCA), Inc.	12
2.3.6	Society of Automotive Engineers (SAE) International	12
2.3.7	American Society of Mechanical Engineers (ASME)	14
2.3.8	North Atlantic Treaty Organization (NATO)	14
2.3.9	American National Standards Institute (ANSI)	14
2.3.10	Aeronautical Radio, Inc. (ARINC)	14
2.3.11	Commercial Item Description (Authorized by the General Services Administration)	14
2.4	Order of precedence.	14
3	REQUIREMENTS.	15
3.1	Item Definition.	15
3.1.1	Item Diagram.	15
3.1.2	Interface Definition	15
3.1.3	Major Component List.	26
3.1.4	Reliability.	26
3.1.5	Maintainability	27
3.1.6	Engine Health Monitoring System (EHMS).	27
3.2	Characteristics.	29
3.2.1	Performance Characteristics.	29
3.2.2	Physical Characteristics.	40
3.2.3	Not used.	40
3.2.4	Not Used	40
3.2.5	Environmental Conditions.	40
3.2.6	Transportability.	45
3.2.7	External Surfaces.	46
3.2.8	Survivability and Vulnerability.	46
3.3	Design and Construction.	47
3.3.1	Materials, Processes, and Fasteners.	47
3.3.2	Not used.	49
3.3.3	Nameplate and Product Marking.	49
3.3.4	System Nuclear Survivability.	49
3.3.5	Interchangeability.	49
3.3.6	Safety.	49
3.3.7	Not used.	51
3.3.8	Structural Performance.	51
3.3.9	Design Control.	62
3.3.10	Not Used.	63
3.4	Not Used.	63
3.5	Logistics.	63
3.5.1	Maintenance.	63
3.6	Not used.	63
3.7	Major Component Characteristics.	63
3.7.1	Anti-icing System.	63
3.7.2	Engine Control System.	64
3.7.3	Fuel System.	71
3.7.4	Electrical Systems.	74
3.7.5	Ignition System.	77
3.7.6	Instrumentation Systems.	78
3.7.7	Engine Lubricating System.	80
3.7.8	Not used.	84
3.7.9	Starting System.	84
3.7.10	Exhaust Nozzle System.	85
3.7.11	Not used.	86
3.7.12	Not used.	86
3.7.13	Wash System.	86
3.8	Not used.	86
3.9	Quality Verification.	86
3.9.1	Engineering Evaluation Tests.	86
3.9.2	Preliminary Flight Rating (PFR).	87
3.9.3	Qualification Test (QT) Rating.	87
3.9.4	Operational Capability Release (OCR) Test.	87
3.9.5	Not Used	87
3.9.6	Engine Development Special Tests.	87
3.9.7	Acceptance Test (AT).	87
4	VERIFICATION.	88
4.1	General.	88
4.1.1	Responsibility.	88
4.2	Quality Conformance Inspections.	88
4.2.1	Quality Evidence.	88
4.3	Manner of Test and Reporting.	88
4.3.1	Test Surveillance.	88
4.3.2	Test Article Configuration.	88
4.3.3	Test Apparatus.	89
4.3.4	Test Condition.	90
4.3.5	Data.	91
4.3.6	Reports.	93
4.4	Engineering Evaluation Tests.	95
4.4.1	Customer Bleed Air.	95
4.4.2	Engine Heat Rejection and Oil Cooling.	95
4.4.3	Oil Flow Interruption Test.	95
4.4.4	Not Used.	96
4.4.5	Engine Vibration Survey.	96
4.4.6	Starting Torque.	96
4.4.7	Not used.	96
4.4.8	Not used	96
4.4.9	Not used.	96
4.4.10	Verification of Correction Factors.	96
4.5	Preliminary Flight Rating (PFR).	96
4.5.1	Endurance Test	96
4.5.2	Engine Component Tests.	103
4.5.3	Altitude Tests.	117
4.5.4	Structural Tests.	119
4.5.5	Environmental Tests	122
4.6	Qualification Test (QT) Rating.	122
4.6.1	Engine Endurance Test.	122
4.6.2	Engine Component Tests.	130
4.6.3	Altitude Tests.	159
4.6.4	Engine Environmental and Ingestion Tests.	160
4.6.5	Engine Characteristics and Fuel Tests.	171
4.6.6	Structural Tests.	171
4.7	Acceptance Test (AT).	179
4.7.1	Test Apparatus.	180
4.7.2	Test Conditions.	181
4.7.3	Test Records.	181
4.7.4	Test Data.	182
4.7.5	Test Procedure.	184
4.7.6	Test Completion.	187
4.7.7	Sampling Plan.	188
4.8	Operational Capability Release (OCR) Test.	188
4.8.1	Accelerated Endurance Test (AET).	188
4.8.2	Accelerated Mission Test (AMT).	195
4.8.3	Maintainability Evaluation Testing.	198
4.9	Engine Development Special Tests.	199
4.9.1	PFR Phase.	199
4.9.2	QT Phase.	200
5	PACKAGING.	201
5.1	Packaging.	201
6	NOTES.	202
6.1	Intended Use.	202
6.2	Acquisition Requirements.	202
6.3	Definitions.	202
6.4	Symbols, Subscripts, Abbreviations, and Acronyms.	211
6.5	Material Safety Data Sheet.	214
6.6	Subject Term (Key Word) Listing.	214
6.7	Metrication. Not used.	214
6.8	Engine Specification Preparation.	214
6.8.1	Instruction for Preparation.	214
6.9	Additional Guidance Documents.	215
Appendix A	Not Used	285
Appendix B	Requirements for Preliminary Flight Rating	286
Appendix C	Requirements for Qualification Testing	290
Appendix D	Requirements for Operational Capability Release	295
Appendix E	Requirements for Strength, Life and Creep Analysis Report	296
E.1	Scope	296
E.2	Applicable Documents	296
E.3	Definitions	296
E.3.1	General.	296
E.4	General Requirements.	296
E.4.1	General.	296
E.4.2	Content.	296
E.4.3	Material Property Curves.	297
E.4.4	Analysis Models.	297
E.4.5	Points of Life.	297
E.4.6	Delivery.	297
E.5	Detailed Requirements.	297
E.5.1	Introduction.	297
E.5.2	Configuration.	298
E.5.3	Analyses Methodology/Results.	298
Appendix F	Requirements for Vibration and Stress Report	307
F.1	Scope	307
F.2	Applicable Documents	307
F.3	Definitions	307
F.4	General Requirements.	307
F.4.1	General.	307
F.4.2	Content.	307
F.4.3	Material Property Curves.	307
F.4.4	Analysis Models.	307
F.4.5	Delivery.	308
F.5	Detailed Requirements.	308
F.5.1	Introduction.	308
F.5.2	General Component.	308
Appendix G	Requirements for Software/Programmable Hardware Development	311
G.1	Introduction.	311
G.2	Software Lifecycle Processes.	312
G.2.1	System Process.	312
G.2.2	Software Planning Process.	321
G.2.3	Software Requirements Process.	324
G.2.4	Software Design Process.	327
G.2.5	Software Coding Process.	331
G.2.6	Software Integration Process.	334
G.2.7	Software Test Verification Process.	335
G.2.8	Software Approval Process	336
G.3	Software Hazard Criticality Index (SHCI).	337
G.3.1	Software Hazard Criticality Index (SHCI) Definitions.	338
G.3.2	SHCI Assignment Method.	338
G.3.3	Guidelines for Determining SHCI Assignment Levels.	338
G.4	Software Lifecycle Process Requirements.	339
G.5	Software Change Procedures.	343
G.5.1	Post Baseline.	343
G.5.2	Developmental Flight Test.	343
G.6	Programmable Hardware Lifecycle Processes	343
G.6.1	Programmable Hardware Planning Process	343
G.6.2	Programmable Hardware Design Processes	345
G.6.3	Programmable Hardware Supporting Processes	346
G.7	Testing Requirements and Terminology.	348
G.7.1	Robustness Test Case.	348
G.7.2	Software Test Environment Validation.	349
G.7.3	Tool Qualification.	349
G.7.4	Model Based Development.	349
G.7.5	Dead and Deactivated Code.	349
G.7.6	Software Load Integrity.	350
Appendix H	Helicopter Drive System Torsional Stability.	351

List of Tables/Figures

Table IA: Performance 15°C (59°F), sea level static conditions with _______ nozzle.	216
Table IB Performance 32.1°C. (90°F) sea level static conditions with _______ nozzle.	217
Table IC Performance 50°C. (122°F) sea level static conditions with _______ nozzle.	218
Table IIA: Performance 0.61 km, (2000 ft.) 21.1°C (70°F) static conditions with _______ nozzle.	219
Table IIB: Performance 1.22 km, (4000 ft.) 35°C (95°F) static conditions with _______ nozzle.	220
Table IIC: Performance 1.83 km, (6000 ft.) 35°C (95°F) static conditions with _______ nozzle.	221
Table IID: Performance 6.1 km (20,014 ft.), 0.35 Mach number standard day with _______ nozzle.	222
Table III: Low Cycle Fatigue Damage Fraction Table	223
Table IV: Component test report documentation requirements	224
Table V: Gearbox pads and drives.	228
Table VI: Engine Temperature Limits.	229
Table VII: Not used.	230
Table VIII: Not used.	230
Table IX: Critical Safety Items Low Cycle Fatigue Lives.	231
Table X: Fuel contamination	232
Table XI: Fuel contamination	233
Table XII: Data recording requirements	234
Table XIII: Sea level antiicing conditions	238
Table XIV: Schedule of salt spray injection endurance cycle	239
Table XV: Electromagnetic compatibility test methods.	241
Table XVI: Provisions for engine condition indication.	241
Table XVII: EHMS BIT code data.	241
Table XVIII: Components requiring functional bench calibration or ATP	241
Table XIX: Engine split-line flange leakage.	241
Table XX-A: Component tests for PFR	242
Table XX-B: Component tests for QT	243
Table XXI: Test plan documentation requirements	245
Table XXII: Maintainability Requirements	247
Table XXIII: Turboshaft engine 1.22 km (4000 ft), 35°C (95°F) output shaft speed droop requirements.	250
Table XXIV: Parts classification	252
Table XXV: Component Test Plan Documentation Requirements.	253
Table XXVI: Plans and Reports Front End Matter.	256
Figure 1: Externally Applied Forces	259
Figure 2: Engine Surface Temperature versus Engine Length	260
Figure 3: Engine Surface Emissivity versus Engine Length	261
Figure 4: Not Used	261
Figure 5-1: Idle Gas Generator Speed	262
Figure 5-2: Idle Output Shaft Torque	263
Figure 6: No Load Gas Generator Speed	264
Figure 7: Engine Altitude and Operating Envelope.	265
Figure 8: Operating Limits	266
Figure 9: Engine Attitude Limits	267
Figure 10-1: Estimated Acceleration Time versus Altitude	268
Figure 10-2: Estimated Acceleration Time versus Power	268
Figure 10-3A: Through 10-3G Power Absorber Loading for Acceleration	269
Figure 11: Continuous Maximum Icing Conditions	270
Figure 12: Intermittent Maximum Icing Conditions	271
Figure 13: Exhaust Invisibility Limit	272
Figure 14-1: Oxides of Nitrogen	273
Figure 14-2: Gaseous Emissions	274
Figure 15: Relationship Between Control Lever Torque and Control Lever Angles	274
Figure 16: Control Limiter Regimes	275
Figure 17: Starting Torque and Speed	276
Figure 18: Engine Ground Start Time versus Ambient Air Temperature – Static, No RAM, Sea Level to 5km	277
Figure 19: Engine Altitude and Starting Test Points	278
Figure 20: Not Applicable	278
Figure 21: Not Applicable	278
Figure 22: Not Applicable	278
Figure 23: Engine Corrosion Operating Cycle	279
Figure 24: Ambient Temperature Extremes versus Altitude	280
Figure 25: Jet Wake	281
Figure 26: Reference Exhaust Nozzle	281
Figure 27: Not Used	281
Figure 28: Component Surface Limit Temperatures	281
Figure 29: Engine Vibration Spectrum	282
Figure 30-1: Near Field Octave Band Sound Pressure Level Contour (Db – Ref. 0.0002 µbars), Center Frequency - 250 Hz	282
Figure 30-2: Far Field Overall Sound Pressure level Contours (Db – Ref. 0.0002 µbars)	283
Figure 30-3: Estimated Overall Sounds Pressure Level Contours at Idle	284
Table E-I: Major Cycle Maximum Component Stresses	301
Table E-II: Major Cycle Minimum Component Stresses	301
Table E-III: Major Cycle Principal/Equivalent Stresses	301
Table E-IV: Minor Cycle Maximum Component Stresses	302
Table E-V: Minor Cycle Minimum Component Stresses	302
Table E-VI: Minor Cycle Principal/Equivalent Stresses	302
Table E-VII: Low Cycle Fatigue Life	303
Table E-VIII: Low Cycle Fatigue Life Sensitivities	303
Table E-IX: Low Cycle Fatigue Life Damage Fractions	304
Table E-X: Creep/Stress Rupture Life	305
Table E-XI: Burst Margin	305
Table E-XII: Oxidation Life	306
Table E-XIII: Containment	306
Table F-I. Summary of Component Vibration and Stress Analysis.	310
Table F-II. Vibratory Strain Survey.	310
Figure G.1-1. Aviation Propulsion System Software Lifecycle	311
Figure G.1-2. Requirements Flow Down Process	312
Figure G.2.1-1. System Safety Process Flow	314
Table G.3.1-1: System Categories and Definition	338
Table G.3.3-1: Flight Aid System SHCI Table	338
Table G.3.3-2: Manned Aircraft SCHI Table	339
Table G.4-1: Software Safety Lifecycle Process Requirements	340

SCOPE

This Specification Development Document (SDD) provides the guidance, requirements and interface configuration definitions for development of the Engine Model Specification (EMS) for the Improved Turbine Engine. The specific guidance for using this document in the development of the Engine Model Specification (EMS) is contained in paragraph 6.8. Note that within this document the contractor is given directions on what will be expected throughout the program. This Statement of Work language should not be used in the contractor's EMS; however, the contractor may use this information to help plan for verification documentation. Additionally, there are placeholders for specific engine design parameters (e.g. “contractor to insert”). The contractor will insert the required data prior to submission of their original EMS as well as language that may appear to be work statements, but are required to adequately describe the requirement. Engine parameters, characteristics and requirements will be stated as definitively as possible in the EMS. The contractor should include the requirements of this document, along with the requirements defined in the System Requirements Document (SRD), in the development of the EMS. The US Army retains final judgment authority upon submittal of applicable test plan, analysis report or design review. The EMS will establish engine requirements, their satisfactory completion and acceptance for Preliminary Flight Rating (PFR), Qualification Rating (QT), and Operational Capability Release (OCR) of the product engine.

Metric Requirements Not Applicable.

Deviations Any projected design for a given application which will result in improved system performance, reduced lifecycle cost, or reduced development cost through deviation from this SDD, or where the requirements of this SDD result in compromise in operational capability, will not be considered for approval unless brought to the attention of the Using Service in writing.

APPLICABLE DOCUMENTS

General The documents listed in this section are specified in sections 3, 4, or 5 of this SDD. This section does not include documents cited in other sections of this SDD or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this SDD, whether or not they are listed.

Government Documents Specifications, Standards, and Handbooks The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

Specifications Federal

A-A-52557A

Fuel Oil, Diesel; for Posts, Camps and Stations

A-A-52624A NOT 1

Antifreeze, Multi Engine Type

FED-STD-313D(1)

Material Safety Data, Transportation Data and Disposal Data for Hazardous Materials Furnished to Government Activities

Department of Defense

MIL-DTL-5624U NOT 1

Turbine Fuel, Aviation, Grades JP-4 and JP-5

MILPRF7808L

Lubricating Oil, Aircraft Turbine Engine, Synthetic Base, NATO Code Number 0-148

MILPRF23699F

Lubricating Oil, Aircraft Turbine Engine, Synthetic Base, NATO Code Number 0-156

MIL-PRF-46170D NOT 1

Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic Hydrocarbon Base, NATO Code No. H-544

MIL-PRF-83282D(1)

Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base, Metric, NATO Code Number H-537

MIL-DTL-38999L SUP 1

Connector, Electrical Circular, Miniature, High Density Quick Disconnect (Bayonet, Threaded and Breech Coupling), Environment Resistant, Removable Crimp and Hermetic Solder Contacts, General Specification for

MIL-PRF-7024F

Calibrating Fluids, Aircraft Fuel System Components

MIL-DTL-83133H

Turbine Fuels, Aviation, Kerosene Types, JP-8 (NATO F-34), NATO F-35 and JP-8+100 (NATO F-37)

MIL-DTL-85470B NOT 1

Inhibitor, Icing, Fuel System, High Flash, NATO Code Number S-1745

MIL-PRF-85704C

Cleaning Compound, Turbine Engine Gas Path

MS3336

Accessory Drives, Aircraft Engine, Reference Chart For

MS3459D

Connector, Plug, Electrical, Self-Locking, Coupling Nut, Rear Release, Crimp Contact, An Type

DOD-PRF-85734

Lubricating Oil, Helicopter Transmission System, Synthetic Base

Standards Department of Defense

MIL-STD-130N

Identification Marking Of U.S. Military Property

MIL-STD-461F

Control of Electromagnetic Interference Emissions and Susceptibility, Requirements for the

MIL-STD-704

Aircraft Electric Power Characteristics

MIL-STD-810C and G

Environmental Test Methods and Engineering Guidelines

MIL-STD-882E

System Safety

MIL-STD-1553B NOT 4

Digital Time Division Command/Response Multiplex Data Bus

MIL-HDBK-454B

General Guidelines for Electronic Equipment

MIL-HDBK-704-8 NOT 1

Guidance for Test Procedures for Demonstration of Utilization Equipment Compliance to Aircraft Electrical Power Characteristics – 28 Vdc

MIL-HDBK-781A

Handbook for Reliability Test Methods, Plans and Environments for Engineering, Development Qualification, and Production

MIL-HDBK-1559(2) NOT 1

Numbers, Serial, Aircraft Gas Turbine Engine and Engine Module, Assignment of

MIL-HDBK-1812

Type Designation, Assignment and Method for Obtaining

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available online at https://assist.daps.dla.mil/quicksearch/ Other Government Documents, Drawings, and Publications.

The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

Department of Defense

DODD 5000.01

The Defense Acquisition System

DODI 5000.02

Operation of the Defense Acquisition System

(These documents are available online at http://www.dtic.mil/whs/directives/.

Department of Transportation FAA Advisory Circular No: 20-135 Powerplant Installation and Propulsion System Component Fire Protection Test Methods, Standards, and Criteria

AC20-135

Powerplant Installation and Propulsion System Component Fire Protection Test Methods, Standards and Criteria

AC33-28-3

Guidance Material for 14 CFR § 33.28, Engine Control Systems

(Application for copies should be addressed to Department of Transportation, FAA Aeronautical Center, AML-611, P.O. Box 25082, Oklahoma City OK 73125-5082.)

(For copies go to <https://rgl.faa.gov and www.faa.gov/regulations_policies/advisories_circulars/>.)

Naval Air System Command NAVAIR 01-1A-509 and Air Force TO 11689 Avionics Cleaning and Corrosion Prevention/Control Technical Manual

(Application for copies should be addressed to Naval Publications & Forms Directorate, Attn: Code 301, 5801 Tabor Ave., Philadelphia PA 191205099) United States Army

*ADS-37A-PRF

Electromagnetic Environmental Effects (E3) Performance And Verification Requirements

CRDC-SP-84023

Guide-lines-Design to Minimize Contamination and to Facilitate Decontamination of Military Vehicles and Other Equipment: Interiors and Exteriors

(*Application for copies should be addressed to USA RDECOM Aviation Engineering Directorate, RDMR-AE, Redstone Arsenal, AL 35898.)

NonGovernment Publications.

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

American Society for Testing and Materials (ASTM)

ASTM D5001-10

Standard Test Method for Measurement of Lubricity of Aviation Turbine Fuels by the Ball-on-Cylinder Lubricity Evaluator (BOCLE) (Adopted by DoD)

ASTM D 910-11

Stand Specification for Aviation Gasolines (Adopted by DoD)

ASTM D4814 - 12

Standard Specification for Automotive Spark-Ignition Engine Fuel

ASTM D1655 - 13

Standard Specification for Aviation Turbine Fuels

ASTM D5363-03

Standard Specification for Anaerobic Single-Component Adhesives (AN)

(Application for copies should be addressed to the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken PA 428-2959.)

Institute of Environmental Sciences

IEST-RP-PR001.1

Management And Technical Guidelines For The ESS Process

(Application for copies should be addressed to Institute of Environmental Sciences and Technology, Arlington Place One, 2340 South Arlington Heights Road, Suite 100, Arlington Heights, IL 60005-4516; www.iest.org.)

International Electrotechnical Commission (IEC)

IEC 61672-1

Electroacoustics – Sound level meters – Part 1: Specifications

IEC 61672-2

Electroacoustics – Sound level meters – Part 2: Pattern evaluation tests

IEC 61260

Electroacoustics – Octave-band and fractional-octave-band filters

IEC 179

Precision Sound Level Meters

IEC 225

Octave, Half-Octave, Third-Octave Band Filters

(Application for copies should be addressed to American National Standards Institute, 11 West 42nd Street, New York NY 10036.)

International Organization for Standardization

ISO 12103-1:1997

Road vehicles – Test Dust for Filter Evaluation-Part 1: Arizona Test Dust

(Application for copies should be addressed to International Organization for Standardization, Case Postale 56, CH-1211, Geneva 20, Switzerland; www.iso.org.)

Radio Technical Commission for Aeronautics, (RTCA), Inc.

DO-160G

Environmental Conditions and Test Procedures for Airborne Equipment

DO-178C

Software Considerations in Airborne Systems and Equipment Certification

DO-254

Design Assurance Guidance for Airborne Electronic Hardware

DO-331

Model-Based Development And Verification Supplement

(Applications for copies should be addressed to RTCA, Inc. 1150 18th Street; Suite 910, Washington, DC 20036; www.rtca.org) Society of Automotive Engineers (SAE) International Aerospace Material Specifications

AMS 2518C

Thread Compound, Anti-size, Graphite-Petrolatum (Adopted by DoD)

Aerospace Recommended Practice

ARP 492C

Aircraft Engine Fuel Pump Cavitation Endurance Test (Adopted by DoD)

ARP 704A

Helicopter Engine – Rotor System Compatibility

ARP 994

Recommended Practice for the Design of Tubing Installation for Aerospace Fluid Power Systems (Adopted by DoD)

ARP 1179D

Aircraft Gas Turbine Engine Exhaust Smoke Measurement (Adopted by DoD)

ARP 1256D

Procedure for Continuous Sampling and Measurement of Gaseous Emissions from Aircraft Turbine Engines (Adopted by DoD)

ARP 1420B

Gas Turbine Engine Inlet Flow Distortion Guidelines (Adopted by DoD)

ARP 1533B

Procedure for the Calculation of Gaseous Emissions from Aircraft Turbine Engines

ARP 1587B

Aircraft Gas Turbine Engine Health Management System Guide

ARP 1797A

Aircraft and Aircraft Engine Fuel Pump Low Lubricity Fluid Endurance Test

ARP 4024

Aircraft/Engine Fuel Pump Net Positive Suction Pressure Test and Evaluation

ARP 4028

Aircraft/Engine Fuel Pump Two Phase (Slugging Flow) Inlet Performance Test and Evaluation

ARP 4671

Guidelines and Methods for Conducting the Safety Assessment Process on Civil Airborne Systems and Equipment

ARP 4754A

Guidelines for Development of Civil Aircraft and Systems

ARP 5580

Recommended Failure Modes and Effects Analysis (FMEA) Practices for Non-Automobile Applications

ARP 5757

Guidelines for Engine Component Tests

Aerospace Resource Document

ARD50015

A Current Assessment of the Inlet/Engine Temperature Distortion Problem

Aerospace Standard

AS 568C

Aerospace Size Standard for O-Ring Sizes (Adopted by DoD)

AS 681J

Gas Turbine Engine Steady-State Performance Presentation for Digital Computer Program (Adopted by DoD)

AS 755D

Aircraft Propulsion System Performance Station Designation and Nomenclature (Adopted by DoD)

AS 870D

Wrenching Configuration, Bi-Hexagon (12 point) Drive, Design Standard for (Adopted by DoD)

AS 972B

Spline Details, Accessory Drives and Flanges (Adopted by DoD)

AS 1055D

Fire Testing of Flexible Hose, Tube Assemblies, Coils, Fittings and Similar System Components (Adopted by DoD)

AS 4111

Validation Test Plan for the Digital Time Division Command/Response Multiplex Data Bus Remote Terminals

AS 4273A

Fire Testing of Fluid Handling Components for Aircraft Engines and Aircraft Engine Installations (Adopted by DoD)

AS 4395B

Fitting End, Flared, Tube Connection, Design Standard (Adopted by DoD)

Aerospace Information Report

AIR 1419A

Inlet Total-Pressure-Distortion Considerations for Gas-Turbine Engines

AIR 5687

Inlet / Engine Compatibility – From Model to Full Scale Development

(Application for copies should be addressed to the SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001; www.sae.org.)

American Society of Mechanical Engineers (ASME) Performance Test Codes

PTC19.1-2005

Test Uncertainty

(Application for copies should be addressed to the American Society of Mechanical Engineers, PO Box 2300, , Fairfield, NJ, 07007-2300; www.asme.org.).)

North Atlantic Treaty Organization (NATO)

NATO Code F-24, F-34, F-40, F-44 and F-54

NATO Logistics Handbook, Aviation Fuels

American National Standards Institute (ANSI)

B92.1

Spline, Module Involute (Adopted by DoD)

Aeronautical Radio, Inc. (ARINC)

ARINC 429

Specification 429, Part 1, Appendix A

(Application for complete copies of the ARINC Specification can be obtained by contacting ARINC at: Aeronautical Radio, Inc., 2551 River Road, Annapolis, MD 21401, or go to the ARINC website at www.arinc.com.)

Commercial Item Description (Authorized by the General Services Administration)

A-A-52557A NOT 1

Fuel Oil, Diesel; for Posts, Camps and Stations

Order of precedence.

Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

REQUIREMENTS.

The paragraphs of this SDD and all references herein comprise the complete set of engine requirements. All requirements that are classified shall be provided in a classified appendix, as part of this SDD. Terms, symbols, acronyms, and definitions shall be in accordance with Section 6.

Item Definition.

A brief description of the salient features of the engine shall be provided in the Engine Model Specification (EMS). This shall include, if applicable, a description of the inlet particle separator, compressor(s) including number of stages, variable geometry provisions, acceleration/customer bleeds; combustor type, including method of all injection; turbine components, including number of stages, cooling provisions; exhaust nozzle; engine control features; prognostics and health monitoring systems; necessary gearbox provisions; type of lubrication and scavenge system; starting ignition system; number and location of main bearings; instrumentation and performance indicating provisions.

The performance ratings shall be as specified in Tables IA, IB, IC, IIA, IIB, IIC and IID. Terms, symbols, and their definitions shall be in accordance with (IAW) sections 6 and 7 and with AS755. The performance is based upon a referee nozzle which shall be provided by the engine contractor for development and acceptance engine testing only.

The engine shall include an emergency power capability as defined in 6.3.

Item Diagram.

Item diagrams for lubrication system, cooling and sealing air system, IPS, anti-icing system, fuel system, electrical system, and engine control system shall be included in the Engine Model Specification (EMS).

Interface Definition The interface requirements include all physical installation and performance requirements necessary for engine installation. All interface definitions shall be as shown on the Engine Configuration and Envelope Computer-Aided Design (CAD) models or in the text describing the applicable functional system.

Drawings.

The following drawings, as figures, shall form a part of the engine specification. Reduced size copies of these figures shall be included in the Engine Model Specification (EMS). These drawings shall be updated as required to reflect the latest engine configuration.

a. Engine Configuration and Envelope Figure. This drawing or CAD model shall be detailed profiles in all planes to show and identify the physical inner features of the engine. The drawing shall show mounting details and tolerances for the engine and all installation items, clearances for installation and removal of accessories and components subject to separate removal, access for adjustments and other maintenance functions, and center of gravity of the complete bare engine. This drawing shall show the maximum space required by the engine including tolerances and dimensional changes due to manufacturing, thermal effects, vibration, and operating and externally applied loads. Vibration and temperature measurement locations shall be specified on the drawing.

b. Electrical Installation Connection Figure. This drawing shall show and identify all engine systems external electrical circuit requirements and installation interface connection details. If an Electrical Interface Control Document (EICD) is provided as a supplement, it shall be referenced on the connection figure.

Not used.

Installation Interfaces.

Engine features affecting engine installation interfaces shall be identified and defined in the Engine Model Specification (EMS).

Moments of Inertia.

The Engine Model Specification (EMS) shall specify:

a. The maximum effective mass moment of inertia (slug-feet squared) of the complete dry engine about three mutually perpendicular axes with the origin at the center of gravity.

b. The maximum effective mass moment of inertia (slug-feet squared) of each engine rotor system about the resultant rotational axis, together with the effective direction of rotation of the inertia and the direction and location of the resultant rotational axis. For engines with geared rotor systems, the shaft to which all inertias of each rotor system have been algebraically referred shall be specified.

c. The maximum effective mass moment of inertia (slug-feet squared) of the complete power output system (including the reduction gear train) referred to the output shaft speed.

d. The maximum effective mass moment of inertia (slug-feet squared) of the rotating parts which are cranked by the engine starter.

Externally Applied Forces.

The engine shall function satisfactorily under the conditions specified in 3.1.2.6 and Figure 1 (combined linear and angular effects) and shall meet the requirements specified within the Engine Model Specification (EMS) during and after exposure to those conditions without permanent deformation and shall operate satisfactorily, thereafter. The engine shall also not fail catastrophically when subjected to static loads equivalent to 1.5 times those values but the engine need not operate satisfactorily thereafter. The engine shall not fail catastrophically when subjected to the crash load factors identified below:

Direction

Applied Separately

Applied Simultaneously

Case 1

Case 2

Case 3

Axial

+/-20

+/-10

Lateral

+/-18

+/-9

+/-18

Vertical

+10/-20

+5/-10

+10/-20

+5/-10

NOTE: Values are in g’s. For the vertical direction, up is positive (+). Down loads (negative vertical load factors) occur during pullout.

The limit loads shall be based on a mass factor consisting of the dry mass of the engine, increased by the specific mass allowed for all engine mounted accessories and operating fluids. If airframe components are supported by the engine, the mass of these components shall be included in the mass factor.

Externally applied forces shall include loads produced by takeoff, landing, in-flight maneuvers, gusts, vibration, installation, and crash conditions.

For control and external components, the components shall meet the requirements specified within the Engine Model Specification (EMS) during and after exposure to the external forces induced by the installation, based on the anticipated usage and handling. MIL-STD-810C and MIL-STD-810G shall be used to establish the design and performance requirements.

The externally applied forces analysis shall account for the entire engine with regard to its capability to withstand the loads specified in this paragraph, 3.1.2.5.1, and 3.1.2.6.1 and 3.1.2.14.1.

Gyroscopic Moments.

At all speeds up to at least maximum allowable steady-state rotor speeds, the engine shall operate satisfactorily when exposed to gyroscopic moments defined by the operating conditions in paragraphs a through d. Loads shall include the worst case impact of all engine mounted airframe hardware. Engine mounted airframe hardware includes, but shall not be limited to, the inlet and exhaust components supported by the engine.

a. A steady angular velocity of 2.5 radians per second in any axis in a plane perpendicular to the rotor axis, combined with a vertical load factor of either +1g or -1g for a total time of 30 seconds. The limit of allowable occurrences under this condition shall be no more than two (2).

b. A steady angular velocity of 0.4 radians per second in any axis in a plane perpendicular to the rotor axis for 24% of duty cycle life.

c. A steady angular velocity of 0.9 radians per second in any axis in a plane perpendicular to the rotor axis for 20% of duty cycle life.

d. A steady angular velocity of 1.4 radians per second in any axis in a plane perpendicular to the rotor axis for 1% of duty cycle life, with each event having a duration of 0.5 seconds.

The definition of “the engine shall operate satisfactorily” is as follows:

a. Loss of engine power shall not prevent safe flight and return to base without exceeding any engine operating or physical limits.

b. Engine operability margins are sufficient to avoid engine stall with normal acceleration and deceleration rates.

c. Damage to engine components is limited to tip and seal rubs.

d. Remaining part life is not reduced relative to life prior to exposure to the gyroscopic induced load.

Mounts.

Main Mounts.

The engine mounts shall retain the engine, including retained fluids and externals, at all flight, takeoff and landing, and ground conditions and shall meet the requirements of this SDD during and after exposure to limit loads of (contractor to insert) without permanent deformation and ultimate loads of (contractor to insert) without fracture.

The main mounts shall meet the damage tolerance requirements of 3.3.8.11.

Mounting provisions shall be of sufficient strength to prevent loss of engine retention when subject to a single attachment point failure at any location at the end of the engine mount service life and able to handle limit Figure 1 loads. The locations and descriptions of all engine mounts shall be as specified in the Engine Configuration and Envelope Figure. The engine mounts shall be consistent with the mounting approach in the UH-60 and AH-64 installations.

The maximum system limits shall be specified in units of force and in reference to the engine. The specified values shall include, but not be limited to, the effects of the following requirements and specific design characteristics: externally applied forces (e.g., accelerations) of 3.1.2.5, gyroscopic moments of 3.1.2.5.1, all air vehicle loads which are supported through the engine structure (if such loads exist) and safety factors of 3.3.8.4.1, cyclic fatigue, engine mass, material strength and mechanics and service life. The bending moment limits shall be specified in the axial, vertical, and lateral directions. The engine mounts shall meet the applicable requirements of 3.3.8 and subparagraphs.

Ground Handling Mounts.

The ground handling mounts shall support the engine, including all engine mounted equipment and externals, components, and operating fluids, under the following maximum inertia load conditions, without deformation to the mounts or damage to the engine: 4g axial, 2g lateral, and 3g vertical acting in combination at the engine center of gravity.

The locations and descriptions for the individual ground handling mounts shall be as specified in the Engine Configuration and Envelope Figure. The arrangement shall be compatible with Maintenance Trailer, National Stock Number 1730-01-026-1653, Data List 4920-EG-081.

Engine Stiffness and Modes.

The estimated stiffness of the engine in resisting loads and moments applied at the outboard end of the output shaft, relative to the engine mounting points, shall be stated within the Engine Model Specification (EMS). Translational stiffnesses in the three orthogonal directions shall be presented relative to the engine mount point(s) where that direction is constrained. Rotational stiffnesses in the three orthogonal directions shall be presented with the engine mount points constrained as designed. The first lateral and vertical engine bending modes shall be specified with the mount points constrained as designed. The loads shall include, but not be limited to, the effects of externally applied forces and gyroscopic moments.

Pads and Drives.

Pads and drives suitable for mounting and driving accessories shall be IAW the basic configuration and rating requirements specified in the Engine Model Specification and presented as shown in Table V. The engine component drive system and accessory drive system shall be capable of simultaneous operation of all the drives when each drive is subjected to 1.25 times the maximum permissible torque or power rating specified for the individual drive. All drive splines shall be positively lubricated by engine oil. Complete dimensions and details of the drive pads including the clearance envelopes and alignment requirements shall be shown on the Engine Configuration and Envelope Figure. No part of the gearbox shall prevent independent removal of any one accessory mounted on these drives. Pads and drives for accessories shall conform to the standards listed on MS 3336, except compliance with the military standard tabulated data need not be maintained.

Engine Surface Temperature and Heat Rejection.

The maximum operating surface temperatures of the engine and heat rejection rates shall be specified as shown in Figure 2. Factors such as engine bay cooling flows, accessory pad loading, compressor bleed air conditions, anti-ice operation, oil system cooling requirements, engine skin temperature and radiation properties, and air and gas leakage from engine case flanges and split lines shall be taken into consideration in establishing engine heat rejection rates. The conditions surrounding the engine and the engine power condition shall be as stated in items a, b, c and d. The oil system temperatures for which the surface temperatures are applicable shall be provided in an appendix. For components and accessories on the surface of the engine, the specified component and accessory surface temperature and heat generation curves may differ from the engine temperature as shown by the dashed lines on Figure 2. The engine surface emissivity shall be as presented on Figure 3. The heat rejection and surface temperature data shall be for the conditions listed below. The engine case and split line flange leakage(s) shall be as shown on Table XIX.

a. Maximum power, sea level, 60°C (140°F) ambient, static.

b. Maximum power, 4000 ft, 45°C (113°F) ambient, maximum stagnation inlet air temperature.

c. Maximum power, absolute altitude, hot atmosphere, maximum stagnation inlet air temperature.

d. Contingency power, sea level static, 60°C (140°F) ambient.

Engine Component Limiting Temperature.

Engine components when mounted on the engine shall not exceed their allowable temperature under the following conditions. For the engine control system all channels shall be operating:

a. Continuous operation with ambient air at the maximum stagnation temperature or 80°C (176°F), whichever is warmer.

b. Flight shutdown from the most adverse condition and continued soaking with ambient air at maximum stagnation temperature or 80°C (176°F) whichever is warmer.

c. Ground shutdown with ambient air at 60°C (140°F) with no special cooling such as forced ventilation, refrigeration, or rotation of rotors.

d. Off-engine mounted components shall not exceed their component limiting temperature as shown on Figure 28 when surrounded by air at 90°C (194°F). No additional cooling beyond natural convection shall be required for operation (all channels operating for an off engine mounted engine control system) at or below this temperature.

A tabulation of the maximum limiting surface temperature for all components shall be as shown on Figure 28.

The specific points of measurement, where the ambient air temperature and surface temperature with respect to the three coordinate axes of the component are maximum, shall be defined prior to the completion of Preliminary Flight Rating (PFR) testing and shall be provided in the Engine Configuration and Envelope Figure identified in 3.1.2.1.a.

Heat Rejection and Cooling Analysis.

A heat rejection and cooling analysis shall verify the heat rejection and surface temperature data presented in 3.1.2.8. Engine test data shall be used to substantiate the analysis. An engine heat rejection and cooling schematic diagram showing component and station locations, including temperature limits, shall be included in the Engine Model Specification (EMS).

Air and Gas Leakage.

The engine shall minimize air and gas leakage. There shall be no locations where leakage flow will be of sufficient temperature and concentrated impingement to present a safety hazard or affect installation requirements.

Engine Air Inlet System.

Air Inlet Design and Dimensions.

The engine shall have an inlet attachment flange that accepts a quick-disconnect clamp. Interface dimensions for the attachment of the inlet duct shall be as shown on the Engine Configuration and Envelope Figure.

Allowable Inlet Connection Loads.

The maximum allowable shear, axial, and overhung moment loads at the engine inlet flange shall be specified in the engine specification for static (1g) conditions.

The allowable loads at the engine inlet flange shall also be specified for the maximum allowable maneuver loads as defined in Figure 1 (combined linear and angular effects).

Static (1g)

Maximum Allowable Maneuver Loads

Shear

(contractor to insert)

Axial

(contractor to insert)

Overhung Moment

(contractor to insert)

Maneuver Load Factor

10 minimum

Crash Load Factor

25 minimum

As a starting point the minimum static (1g) capability shall be as follows:

Axial Load

48 pounds

Shear Load

48 pounds

Overhung Moment

55 pound-feet

Inlet Airflow Distortion Limits.

The engine shall not surge, stall, flameout, or incur any damage with the steady state or time variant inlet distortion (pressure, temperature, swirl or any combination thereof) shown within the Engine Model Specification (EMS). The aerodynamic interface plane shall be identified on the Engine Configuration and Envelope Figure. Where exhaust nozzle backpressure effects on the engine affect tolerance of the engine to inlet air pressure variation, the effect shall be specified in the engine system specification. Engine stability and performance assessments shall use the methodology and inlet distortion descriptors defined in ARP 1420, AIR 1419, AIR 5687 and ARD50015 for total pressure and temperature distortion. Concurrent inlet pressure and temperature distortion methodology shall be specified within the Engine Model Specification (EMS). Stability audits using the methodology of SAE ARP 1420 are performed.

Engine distortion limits at which the engine shall operate without stall, rotating stall, and surge throughout the complete environmental and operating envelope shall be defined in the qualification altitude test and shall be included as an appendix in the Engine Model Specification once they are defined.

An engine stability and performance assessment for total pressure and total temperature distortion shall be performed using the methodology and inlet distortion descriptors defined below:

a. A distortion descriptor methodology, based on the guidance of ARP 1420, indicating the maximum distortion limits at which the engine shall operate without stall, rotating stall, and surge, throughout the complete environmental conditions and operating envelope, due to steady-state and timevariant inlet air total pressure and temperature variation, shall be defined in an appendix in the Engine Model Specification.

b. Using the distortion descriptor methodology, approximately five sets of pressure distortion patterns (screens) shall be provided, that, with Using Service approval, reflect the most severe conditions permitted within the limits of the distortion descriptor specified for the engine. All distortion patterns (screens) shall be used during QT engine altitude testing. One of the patterns (screens), if required by the Using Service, shall be used for the Acceptance Test surge and stall margin test. For each set of inlet flow distortion data specified, the engine interface operating conditions shall be defined, as applicable, in terms of Mach number, altitude, power setting, customer bleed air, customer power extraction, etc. Measurements of the engine inlet total pressure, temperature, and flow variation shall be made at the engine inlet (aerodynamic interface plane). All inlet instrumentation utilized in measuring airflow, pressures and temperatures, the arrangement, location, response, and instrumentation accuracies shall be consistent with the guidelines of ARP 1420. For each set of specified inlet flow distortion data, the total airflow, average total pressure recovery and pressure and temperature for each individual probe shall be specified. The available surge margin, maximum distortion limits, and the differences between the contractor’s methodology and ARP 1420 shall be presented in the Engine Model Specification.

c. A stability audit shall be performed to investigate stall and surge margin throughout the engine operating and environmental envelope using the methodology of ARP 1420. The stability audit will be updated subsequent to the QT altitude test data analysis. Regions of low stability margin will be identified on an engine altitude vs Mach number operating envelope in the distortion appendix of the Engine Model Specification (EMS).

Pressure and Temperature Rate of Change.

The engine shall withstand the following rate-of-change of pressure and temperature, separately or in combination, without stall, rotating stall, surge, flameout, or mechanical damage:

Parameters

Rate-of-change

Duration

Engine inlet pressure

7 psi/sec

0.4 sec

Engine inlet temperature

1800°F/sec

0.15 sec

Compressor Vent.

If compressor venting is used, the location, interface dimensions, and installed limits of the compressor vent port shall be as shown on the Engine Configuration and Envelope Figure. The maximum compressor vent air temperature, pressure, and flow shall be shown within the Engine Model Specification (EMS) for both vent inflow and outflow conditions. No compressor vent air shall be discharged to the engine nacelle compartment. Compressor vent air that must be discharged during engine operation shall have provisions for external ducting with air pressure, temperature and mass flow compatible with airframe and engine externals capability. The pressure, temperature and airflow conditions of the compressor vent shall be included in the performance computer program. Provisions for external duct attachment shall be provided. Installation of external ducting shall require the approval of the contractor and the Using Service. Compressor vent attachment details for compressor vent air ducted overboard to include compressor vent screening or FOD prevention requirements shall be specified in the Engine Configuration and Envelope Figure.

Allowable Vent Connector Loads.

If compressor venting is used, the maximum allowable static (1g) and maneuver loads as defined in Figure 1 at the compressor vent connection shall be specified within the Engine Model Specification (EMS).

Customer Bleed Air System.

The engine shall provide for customer bleed air extraction for aircraft use from the compressor. The locations and interface dimensions of all customer bleed air ports shall be shown on the Engine Configuration and Envelope Figure. During customer bleed air extraction, control lever modulation shall not be required to maintain engine stability and limits within the environmental conditions and operating envelope of the engine. The pressure and temperature of customer bleed air extracted from idle to maximum power at all operating altitudes, air inlet temperatures, and flight speeds, and the effects upon engine performance when bleeding this air from the engine from any number of ports, shall be included in the performance computer programs of 3.2.1.2 and 3.2.1.2.2. The maximum bleed air temperature and pressure and the stage from which it is extracted shall be specified in the Engine Model Specification.

The maximum continuous flow capability of each bleed air port in percent of total airflow shall be specified in the engine specification. All bleed air ports shall be sized to prevent engine failure in event of a single failure in the aircraft bleed system. Bleed ducts with external surfaces exceeding 370°C (698°F) shall be insulated to prevent hazards from combustible fluid leakage. The engine provided customer bleed air extraction system shall insure that no upstream malfunction of the engine will cause specified contamination limits to be exceeded.

The bleed air energy required is defined in the Improved Turbine Engine Envelope and Mechanical Interface Drawing.

Allowable Customer Bleed Connection Loads.

The maximum allowable axial, shear, and overhung moment loads on the customer bleed air connections shall be specified in the Engine Model Specification for static (1g) conditions.

The maximum allowable loads at these connections shall also be specified for the maximum allowable maneuver loads as defined in Figure 1 (combined linear and angular effects).

Static (1g)

Maximum Allowable Maneuver Loads

Shear

(contractor to insert)

Axial

(contractor to insert)

Overhung Moment

(contractor to insert)

Maneuver Load Factor

10 minimum

Crash Load Factor

25 minimum

As a starting point the minimum static (1g) capability shall be as follows:

Axial Load

1 pound

Shear Load

1 pound

Overhung Moment

15 pound-inch

Start and Acceleration Bleed…

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