Attachment_0001_-_Test_Procedures.pdf

ATTACHMENT 0001 – TESTING PROCEDURES

1. TEST OBJECTIVES

The objectives of these tests are to evaluate the air worthiness, system safety, and mission suitability of candidate ABAVs during aircrew / aircraft compatibility and mission tasks.

The Government reserves the right to alter or change these testing procedures, however the same exact testing procedures will be used for all Offerors. There will be no deviation in testing procedures from one Offeror to the next.

2. AIRCRAFT

MH-60M

A / MH-6

MH-60 DAP

MD-60 Assault

MH-47

3. SCOPE

Assessment of the Offerors’ ABAVs is scheduled to take place during the summer and fall of 2017. Test configurations are found in Table 1 and tests and test conditions are presented in Table 2. Flights will be flown during day and night (aided), visual meteorological conditions. Hover test points will be conducted with sufficient visibility to avoid obstacles. Data will be recorded on flight test cards, digital voice recorders, photography, and post-flight questionnaires. Handheld instrumentation (e.g., stopwatch, measuring tape, etc.) may also be used.

Any ABAV activity requiring donning, doffing, ingress/egress of a helicopter, interoperability with existing USSOCOM equipment, weapons firing, fit, comfort, field of view / regard, and general physical compatibility with human participants will be evaluated using a questionnaire that will be provided to each participant. Each human participant will rate each of these categories using the rating system described in Paragraph M.1.2 (e.g.

unacceptable, marginal, acceptable, good, and outstanding).

4. GENERAL

The assessment of the Aviator Body Armor Vests (ABAV) will be conducted using MH-47G, MH- 60M, and A/MH-6M aircraft in the test configurations presented in Table 1. Tests and test conditions are summarized in Table

2. Human participants will have anthropometry data (stature, weight, thumb tip reach, bideltoid breadth, shoulder circumference, chest depth, chest circumference, and abdominal extension depth (sitting) documented using an anthropometry data sheet. The ABAVs will be worn by pilots, crew chiefs, flight engineers, flight medics, and other flight personnel as required during the conduct of their assigned ground and flight duties. Throughout all testing, participant comments and observations will be recorded on questionnaires and data worksheets.

TABLE 1

Configuration Description Items

A Standard

Aviator's Army Combat Uniform

HGU-56P Helmet

Flight Gloves

Flight Boots

ABAV

B Overwater Mustang MAC300 Dry Suit

HGU-56P Helmet

Flight Boots

ABAV Ensemble

TABLE 2

Test Configuration Altitude (ft) Airspeed (KIAS) Remarks

Initial Inspection/Physical Characteristics

N/A Ground 0 Inspection of test articles for damage or defects. Recording of physical dimensions, range of adjustment, and weight.

Reliability/Durability All As Required 0 Wear/use of components during ground and flight testing. Data collected by component and serial number.

Ensemble Fit and Adjustment All Ground 0 Assessed with participants as close as possible to 5th and 95th percentile persons.

Equipment Support/Accommodation All Ground 0 Assessment for adequate amount of surface area for carrying mission equipment. Also ease of use, equipment retention, and ease of access for removal and replacement of equipment.

Weapon Firing Position All Ground 0 Assess for interference in bringing up and maintaining all weapons to a proper firing position or adjust firing position from cockpit and cabin on the ground.

Cockpit Compatibility All Ground 0 Normal ingress and egress. Reach and functionality of emergency and mission systems.

Cabin Compatibility All Ground 0 Ingress, egress, and mission tasks conducted to assess for inadvertent disconnection, snagging, or anything that prevents task completion.

Emergency Egress All Ground 0 Assessments completed in each crew station in the cockpit and cabin.

ATM Mission Tasks A and/or B Field Elevation to 5,000

Hover to 120 During day time, flight tasks from crew stations. During night time, flight tasks from crew stations.

Extended Duration Flight A and/or B 2,000 to 8,000 60 to 120 Day and/or night flight of at least 2 hours in duration with each post-down select ensemble.

Extended User Evaluation A and/or B As Required As Required Wear/use of each post-down select ensemble during mission scenarios as part of a 160th SOAR training event.

5. INITIAL INSPECTION / PHYSICAL CHARACTERISTICS

The overall objective of this test is to assess whether the ABAV is complete, consistent with specifications, undamaged, and ready for testing. Particular attention will be placed on identifying damage, bent or racked parts, abrasions, tears, missing parts, incomplete/loose bonds (transitions to metal, stitching), and loose parts. Test article weight and dimensions will be recorded while conducting an inventory of the equipment received for testing. All serial and part numbers will also be documented. Any manufacturer names, logos, or other identifying marks that were not already removed will be covered or discarded.

6. RELIABILITY/DURABILITY

The objective of this test is to document incidents / failures and operating / wear time of the ABAV. Each ABAV will be properly fitted, adjusted, and worn by the test participants in accordance with instructions as provided by the test sponsor.

All test incidents will be documented to characterize durability and abrasion resistance of the ABAVs during extended operations. A log will be used to record all ground and flight wear / operation time to the nearest 0.1 hour.

The log will include each ABAV and each model of aircraft for ground tasks (mission planning, preflight / postflight, and other activities), aircraft maintenance and flight tasks (all rotors turning tasks conducted while wearing flight vests). All operating time of the ABAV components in the aircraft will be tracked based on the time entered on DA Form 2408-12.

7. ENSEMBLE FIT AND ADJUSTMENT

Assembly, adjustment, and reconfiguration of the ABAVs will be assessed with participants as close as possible to 5th percentile and 95th percentile. Participants will be observed as they don/doff the ABAV ensembles in the test configurations and with the additional equipment in Table 1. The time to don/doff the ensemble will be measured to the nearest second using a stopwatch. During the timed trials, the fastening mechanisms will be assessed for complexity, ease of use, and durability. Problems concerning donning/doffing will be investigated to determine the extent of the problem and the component(s) responsible and reported in the final report.

Adjustability of the fit of the ABAV ensembles will be assessed with participants wearing configuration A (Table 1) with no gloves and the ABAV minimally and maximally loaded. Participants will attempt fine adjustments of any straps, harnesses, cummerbunds, or any other type of adjustment system while wearing the entire ensemble without removing it. The assessment will be repeated with the participants in configuration B and/or cold weather gloves.

Each ABAV will be qualitatively assessed on the ground for equal weight distribution and shoulder-hip distribution.

Participants will don fully loaded ABAVs and assess the weight distribution while standing, walking, and operating in mission representative areas / postures in the aircraft. Participants will conduct the assessment in configurations A and B.

8. EQUIPMENT SUPPORT/ACCOMMODATION

Each ABAV will be assessed for adequate amount of surface area for carrying mission essential equipment tailored to duty position, legacy load carriage backwards compatibility, and the accommodation of the following equipment:

SPEAR Cut Generation V Stand-alone, Swimmer Cut Front, Back, and Side Plates

Under-Arm Flotation System Modular Water Wing Design SEA LV2 (Emergency Breathing Device) M-4 Magazines (Qty: 3) M-9 Magazines (Qty: 2) CAT Tourniquet Individual Medical Aircrew Kit (5.5 in. long by 5.5 in. wide by 3.25 in. deep) Individual Survival Aircrew Module (5.5 in. long by 5.5 in. wide by 3 in. deep) Universal radio pouch capable of holding the CSEL or 148 series Radio with Thales GPS Side Mate

Module Assembly.

Modular holster for M-9 Beretta capable of being mounted and reconfigured between the vest and belt, and capable of being mounted vertically, horizontally, or angled on the vest.

IZLID 200P

Participants will don each ensemble in configuration A and with cold weather gloves and assess the accessories for ease of use, equipment retention, and ease of access for removal and replacement of equipment into the pocket(s) or pouches. The M-9 holster will be assessed for time required to reconfigure to a different orientation. The relative motion between attached equipment-filled pockets and the ABAV will be assessed during participant movements in and around an aircraft on the ground.

The ABAVs will be assessed in configurations A and B (where appropriate) on the ground for compatibility with existing USSOCOM equipment when minimally or fully loaded in accordance with operational practices.

Incompatibilities observed during testing will be documented in the final report. Existing USSOCOM equipment used during the assessment will include:

Fast Rope Static Line Parachute equipment Backpacks Equipment Belts Mission Oriented Protective Posture IV (MOPP IV)

9. WEAPON FIRING POSITIONS

From the cockpit and cabin of the aircraft on the ground, the ABAVs will be assessed for interference or hindrance in allowing the aircrew to bring-up and maintain all weapons to a proper firing position or adjust firing position while in configurations A and B. The ABAVs will be tested fully loaded and will include M-9, M-4, M-320 (AH-6 only), and crew served weapons. The assessment will be conducted using unloaded weapons or blank training rounds and include an assessment of the ease in which the participants can reach and retrieve magazines from ABAV pouches for reloading the respective firearm.

10. COCKPIT COMPATIBILITY

Normal ingress and egress into/from the cockpit and simulated mission tasks will be assessed and will include the manual connection/disconnection of the pilot’s restraint harness, all electrical and communications connections, and others as appropriate in configurations A and B.

Participants will exercise all flight controls through the full range of motion and assess their ability to view instruments / displays. Participants will focus on physical compatibility, restrictions to the field of regard, and range-of-body motion. Assessments will be conducted regarding the ability of pilots to reach all required aircraft system controls and mission equipment controls that are within the various reach zones defined in MIL-STD-1333B.

All flight critical and emergency controls as defined in the operator’s manuals will be evaluated with the restraint harness locked and unlocked. All other controls will be evaluated with the restraint harness unlocked with the participant free to move. Identified compatibility problems will be investigated to determine the extent of the problem and the component(s) responsible and eliminated or controlled before flight test. Participant comments and test personnel observations will be recorded on the cockpit compatibility worksheet.

11. CABIN COMPATIBILITY

Crew activities of ingress, egress, and mission tasks will be observed to determine if ensembles cause inadvertent disconnection, snagging problems, or otherwise prevent task completion. Participants will conduct the tests while wearing configurations A and B. Participants will also assess for detriment to range-of-motion during the operation of weapon system and other cabin mission equipment. Any compatibility issues that impact safety will be eliminated or controlled before flight test. Participant comments and test person el observations will be recorded on the cabin compatibility worksheet.

12. EMERGENCY EGRESS

Emergency egress will be performed with the participants in configurations A and B. The participant will perform a series of three egress demonstrations using each cockpit door and through the cabin door(s) and/or window(s), as appropriate for each aircraft. Participants will start in the seated position with restraint harness buckled, hands on the controls/weapon, and helmet unplugged. The time from a start signal until the last participant reaches a point 5 ft from the aircraft will be measured to the nearest second on each demonstration. Emergency egress times will be presented and discussed as to the impact on aircrew safety. The use of emergency exits may require that maintenance personnel remove doors/hatches or cockpit covers before actual testing to conduct the test in a nondestructive manner. If any emergency doors, windows, etc, are removed to prevent damage, then an appropriate amount of time will be added to the egress time to account for not having to remove them during the actual timed event.

13. PERSONNEL EXTRACTION

The extraction / retention system of each ABAV will be assessed for integration into the rest of the ensemble. Crew chiefs and flight engineers will demonstrate the hookup and use of the ensemble chest connection point to a tether/restraint strap in the cabin/cargo compartments. Belts as part of the ABAV ensembles will be assessed as an independent method of extraction and retention. The hoist in the aquatics training facility or in the ALSE technician office will be utilized to assess ensemble movement and support during the hoisting of a participant while wearing each ABAV in configuration B. The chest connection point will be assessed, both as a single point and in conjunction with the belt, for retention and extraction.

A mannequin equipped with each ABAV will be used to assess the functionality of the extraction handle during dynamic motion. The test will be conducted by dragging a dummy weighing approximately 400 lbs over a distance of 50 feet utilizing the handle.

14. WATER OPERATIONS

Each ABAV modular floatation system will be assessed for ease of installation and removal by an ALSE technician and for the floatation system’s impact on usable vest surface area. The installation and removal of the floatation system by the technician will be timed using a stopwatch to the nearest second. The floatation system of each ABAV will be deployed automatically while being worn by a submerged participant in configuration B using the equipped floatation charged canisters. With the floatation system deployed, the participant will climb from the water into a one and eight person life raft (manufacturer part number LRU-18/U and FLO-4381-HD, respectively).

After servicing by the ALSE technician, the floatation system will be deployed manually by the participant accessing and using a manual fill tube.

Access and deployment of the survival egress air (LV2) bottle system equipped on each ABAV will be assessed by a participant using the shallow water egress trainer. The time required to release an unloaded and fully loaded ABAV using one or both hands while submerged will also be assessed.

The ABAV ensembles will be assessed for water retention, drainage, and drying time after being submerged for two hours. Weight criteria after two hours of drying will be an increase 0% to 10% more than dry weight, and not more than a 20% increase over dry weight.

15. TACTICAL CASUALTY COMBAT CARE

Medics will simulate treating / transporting patients in each aircraft while wearing and retrieving equipment attached to the ABAV ensembles (configuration A and B). The ingress/egress of medics to and from a Polaris MRZR 4 configured for litter transport will also be assessed.

16. NIGHT VISION GOGGLE COMPATIBILITY

Qualitative night vision goggle (NVG) compatibility will be conducted in a darkened room with a light source simulating glow from aircraft displays to assess for objectionable reflections from each ABAV. Operation of the NVG power / battery pack while wearing the ABAV will be assessed for reach and function.

17. AIRCREW TRAINING MANUAL MISSION TASKS

After final proposal revisions, remaining ABAVs will be assessed in-flight by SIMO experimental and development test pilots during the performance of Aircraft Training Manual Mission Tasks. Any hazards noted during ground compatibility testing will be mitigated or eliminated before flight testing. Flight testing will consist of one day flight and an optional night flight in each crew station while wearing the remaining ABAVs. Flight crews consisting of a pilot, copilot, crew chief, flight engineer(s), and where appropriate a flight medic, will assess aircraft mission compatibility while performing flight and mission tasks. Additional tasks identified by the test team may be performed and will be documented in the final report. Participants will assess their ability to perform mission-related tasks to the standard in the Aircrew Training Manual Mission Tasks by monitoring and operating mission equipment in the cockpit and cabin area (to include armament), as appropriate. After completing the assessment, participants will complete a questionnaire. Project personnel will conduct follow-up interviews to clarify and/or expand information contained in the questionnaires, as required.

18. EXTENDED DURATION FLIGHT

The objective of this test is to assess pilot and crewmember comfort after wearing an ABAV ensemble in configuration A for an extended period of time in flight. Flights of at least two hours in duration will be conducted in each aircraft to assess for “hot spots” and other discomfort experienced by the aircrew.

19. EXTENDED USER EVALUATION

Each remaining ABAV after final proposal revisions will be assessed during a scheduled 160th SOAR training event. Multiple participants from each aircraft mission design series will wear the post-down select ABAV ensembles during the performance of mission tasks in an operational environment. The specific tasks performed will depend on training location and training asset availability. Participants will complete a post-flight questionnaire after flying while wearing an ABAV ensemble. Project personnel will conduct follow-up interviews to clarify and/or expand information contained in the questionnaires, as required.