AIR FORCE MIL-STD-1798 C-2013 MECHANICAL EQUIPMENT AND SUBSYSTEMS INTEGRITY PROGRAM.pdf

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1、MIL-STD-1798C 8 August 2013 SUPERSEDING MIL-STD-1798B 24 January 2010 DEPARTMENT OF DEFENSE STANDARD PRACTICE MECHANICAL EQUIPMENT AND SUBSYSTEMS INTEGRITY PROGRAM AMSC N/A AREA SESS DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. NOT MEASUREMENT SENSITIVE Provided

2、by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798C ii FOREWORD 1. This standard is approved for use by all Departments and Agencies of the Department of Defense. 2. The purpose of this standard is to establish programmatic tasks for the development

3、, acquisition, modification, operation, and sustainment of the mechanical elements of airborne, support, and training systems. The Mechanical Equipment and Subsystems Integrity Program (MECSIP) consists of a series of disciplined, time-phased actions which, when applied in accordance with this stand

4、ard, will help ensure the continued operational safety, suitability, and effectiveness of the mechanical systems throughout all phases of the weapon system life. 3. Comments, suggestions, or questions on this document should be addressed to AFLCMC/ENRS, 2145 MONAHAN WAY, WRIGHT-PATTERSON AFB OH 4543

5、3-7017 or e-mailed to AFLCMC/EN_EZ Engineering Standards. Since contact information can change, you may want to verify the currency of this address information in the ASSIST Online database at https:/assist.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license

6、 from IHS-,-,-MIL-STD-1798C iii CONTENTS Paragraph Page 1. SCOPE 1 1.1 Purpose . 1 1.2 Use 1 1.3 Program approach . 1 1.4 Program overview 2 1.5 Applicability 2 2. APPLICABLE DOCUMENTS . 3 2.1 General 3 2.2 Government documents . 3 2.2.1 Specifications, standards, and handbooks . 3 2.2.2 Other Gover

7、nment documents, drawings, and publications . 4 2.3 Non-Government publications 6 2.4 Order of precedence 6 3. DEFINITIONS 7 3.1 Aborts 7 3.2 Analysis . 7 3.3 Bad Actors Program . 7 3.4 Bulletin boards . 7 3.5 Cannibalization 7 3.6 Critical Application Item (CAI) 7 3.7 Critical Safety Item (CSI) 7 3

8、.8 Damage tolerance 8 3.9 Demonstration . 8 3.10 De-rating of electrical equipment 8 3.11 Design loads/environment spectrum 8 3.12 Design service life 8 3.13 Durability 8 3.14 Durability-critical component 8 3.14 Durability-noncritical component 8 3.15 Economic Impact (Major versus Minor) 9 3.16 Fau

9、lt detection . 9 3.17 Fault injection . 9 3.18 Fault isolation . 9 3.19 Flammable vapor zone. 9 3.20 Flammable fluid leakage zone 9 3.21 Flying qualities . 9 3.22 Level I flying qualities . 9 3.23 Level II flying qualities 9 3.25 Fracture-critical traceable part 10 3.26 Functional Hazard Analysis 10

10、 3.27 Functional Systems Integrated Database (FSID) . 10 3.28 Hazard Analysis (HA) . 10 3.29 Improbable occurrence 10 3.30 Inspections. 10 3.31 Integrity 11 3.32 Leak before burst . 11 3.33 Maintenance-free operating period 11 3.34 Maintenance Planning Data (MPD) Document . 11 Provided by IHSNot for

11、 ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798C iv 3.35 Maintenance Significant Item (MSI) . 11 3.36 Maintenance Steering Group 3 (MSG-3) analysis . 11 3.37 Mission-critical component . 11 3.38 Mean Time Between Failures (MTBF) 12 3.39 Not Mission Capable (N

12、MC) (M), (S) (B) 12 3.40 Other/expendable components 12 3.41 Probability of detection (POD) 12 3.42 Production Quality Deficiency Report (PQDR) . 12 3.43 Proof testing . 12 3.44 Required operational service life 12 3.45 Redundancy . 12 3.46 Redundancy management . 13 3.47 Reliability Centered Mainte

13、nance . 13 3.48 Remote rate of failure 13 3.49 Restoration 13 3.50 Reversionary control modes 13 3.51 Safe-life . 13 3.52 Safety-critical . 13 3.53 Safety-critical software . 13 3.54 Serially managed part 13 3.55 Serial number MTBF 14 3.56 Severe Wind and Moisture Prone (SWAMP) areas 14 3.57 Similar

14、ity (legacy systems) . 14 3.58 Slow damage growth component . 14 3.59 Technology needs 14 3.60 Test 14 3.61 Time Change . 15 3.62 Time Change Item (TCI) 15 3.63 Up-rating 15 3.64 Usage 15 3.65 Work Unit Code (WUC) Manual . 15 3.66 Acronyms . 15 4. GENERAL REQUIREMENTS 17 4.1 Mechanical Equipment and

15、 Subsystems Integrity Program (MECSIP) . 17 4.1.1 Tailoring approach . 17 4.1.2 SOW implementation . 17 5. DETAILED REQUIREMENTS 18 5.1 (Task I) Preliminary Planning . 18 5.1.1 Program strategy . 18 5.1.2 Trade studies . 18 5.1.3 Requirements development . 18 5.1.4 Preliminary integrity analysis 19

16、5.1.5 Technical Data Package (TDP) 19 5.1.6 Technical reviews 19 5.1.7 Identify technical needs 19 5.1.8 MECSIP Master Plan . 20 5.2 (Task II) Design Information . 20 5.2.1 Corrosion prevention and control . 20 5.2.2 Environmental emissions . 21 5.2.3 Physical and operational interfaces 21 5.2.4 Des

17、ign service life/design usage 21 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798C v 5.2.5 Supportability planning . 21 5.2.6 Prognostic Health Monitoring (PHM) planning 21 5.2.7 Initial Failure Modes Effects and Criticality Analysis (FME

18、CA) . 21 5.2.8 Initial Hazard Analysis (HA) . 21 5.2.9 Component classification . 22 5.2.10 Aviation-Critical Safety Items . 24 5.2.11 Prevention of failure for Safety-Critical Parts 24 5.2.12 Design criteria 25 5.2.12.1 Damage tolerance design concepts . 25 5.2.12.2 Other design concepts . 28 5.2.1

19、2.3 Design Criteria for in-direct failure mode effects . 29 5.2.12.3.1 Uncontained failure control 30 5.2.12.3.2 Components operating in a flammable zone 30 5.2.12.3.3 Components operating in a flammable fluid leakage zone . 30 5.2.12.3.4 Flammable fluid carrying line and wire harnesses 30 5.2.12.3.

20、5 Electromagnetic compatibility . 30 5.2.13 Aerospace castings 30 5.2.13.1 Casting requirements . 30 5.2.13.2 Guidelines for digital radiography (DR) inspections of castings 30 5.2.14 Maintenance concepts . 31 5.2.15 Electrical Wiring Interconnect System (EWIS) Design Actions, Task One (See EWIS MIL

21、-HDBK-525 for more details.) . 31 5.2.16 Product Integrity Control Plan 31 5.2.17 Identify Technical needs (Task II) 32 5.2.18 Update the MECSIP Master Plan . 32 5.3 (Task III) Design Analyses and Development Tests . 33 5.3.1 Manufacturing and quality assessment. . 33 5.3.2 Design analyses. 33 5.3.2

22、.1 Load analyses. . 33 5.3.2.2 Design stress/environment spectra development . 33 5.3.2.3 Performance and function sizing analyses . 33 5.3.2.4 Thermal/environmental analyses and tests 34 5.3.2.5 Stress/strength analyses 34 5.3.2.6 Durability analyses . 34 5.3.2.7 Damage tolerance analyses . 34 5.3.

23、2.7.1 Damage tolerance inspections . 35 5.3.2.7.2 Damage tolerance action categories and guidance 35 5.3.2.7.3 Fail-safe . 35 5.3.2.7.4 Slow damage growth . 35 5.3.2.7.5 Leak before burst . 35 5.3.2.7.6 Proof test analysis 36 5.3.2.8 Risk-based analyses 36 5.3.2.9 Vibration/dynamics/acoustic analyse

24、s 36 5.3.3 Development tests . 36 5.3.3.1 Material characterization tests 36 5.3.3.2 Design development tests 37 5.3.4 Flight Control Systems analysis and test 37 5.3.4.1 Dynamic modeling (flight control) . 37 5.3.4.2 Failure detection and accommodation (flight control) . 37 5.3.4.3 Stability and re

25、sponse (flight control) . 37 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798C vi 5.3.4.4 Control laws, schedules, architecture, and power management (flight control) . 37 5.3.5 Electromagnetic effects and lightning . 38 5.3.6 Software pe

26、rformance and testing requirements 38 5.3.7 Abnormal operation design margin 38 5.3.8 Reliability and maintainability . 38 5.3.8.1 Electrical/optical cable maintainability 38 5.3.8.2 Ground handling 38 5.3.8.3 De-rating/up-rating . 38 5.3.8.4 Equipment Prognostic Health Monitoring (PHM) systems 39 5

27、.3.8.5 Obtain Original Equipment Manufacturer (OEM) data 39 5.3.9 Flight Manual . 39 5.3.10 Create Work Unit Code (WUC) Manual 39 5.3.11 Identify Technical Needs (Task III) . 39 5.3.12 Update MECSIP Master Plan . 39 5.4 (Task IV) Component Development and Systems Functional Tests . 40 5.4.1 Componen

28、t and rig test descriptions 40 5.4.2 Testing risk mitigation 40 5.4.3 Hardware and systems rig testing 40 5.4.3.1 Subsystem performance 40 5.4.3.2 Dry rig 40 5.4.3.3 Wet rig . 40 5.4.3.4 Mechanical systems . 41 5.4.4 Hardware components . 41 5.4.4.1 Component development . 41 5.4.4.2 Abnormal operat

29、ion (design margin) 41 5.4.5 Reliability growth demonstration 41 5.4.6 Oil interruption and depletion . 41 5.4.7 Component fit checks 41 5.4.8 Component qualification. 42 5.4.9 Vibration and dynamic response 42 5.4.10 Strength testing 42 5.4.11 Durability testing 42 5.4.12 Vibration/dynamics/acousti

30、cs tests 43 5.4.13 Damage tolerance tests . 43 5.4.14 Thermal, environment, and loads survey . 43 5.4.15 Overspeed/overtemperature tests of rotating parts 43 5.4.16 Maintainability/reparability demonstrations . 44 5.4.17 Acceptance Test Procedures . 44 5.4.18 Evaluation and interpretation of ground

31、test results 44 5.4.19 Evaluation and interpretation of flight test results . 44 5.4.20 Integrated test plan 44 5.4.21 Final integrity analysis 44 5.4.22 Maintenance planning and task development 45 5.4.23 Airworthiness certification 45 5.4.24 Identify technical needs (Task IV) 45 5.4.25 Update MECS

32、IP documents (including the MECSIP Master Plan) . 45 5.5 (Task V, Sustainment) Force Management 45 5.5.1 Subtask 1: Data gathering and task planning 48 5.5.1.1 Establish a Reliability Analyses Team (RAT) . 48 5.5.1.2 Establish the sustainment philosophy (e.g., preventative maintenance) . 49 Provided

33、 by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798C vii 5.5.1.3.1 Update or Generate Failure Mode Effects and Criticality Analysis (FMECA) 49 5.5.1.3.2 Generate Hazard Analysis (HA) . 49 5.5.1.3.3 Execute EWIS Task 1 - Document overall EWIS and ide

34、ntify critical circuit paths and functions 50 5.5.1.4 Classify MECSIP components for criticality 50 5.5.1.5 Review the aircraft scheduled inspection and maintenance tasks (for USAF aircraft these are found in the Dash 6 TOs) . 50 5.5.1.6 Review WUC Manual . 50 5.5.1.7 Review Time Change Items (TCIs)

35、 51 5.5.1.8 Verify Technical Data for both on- and off-equipment repair/overhaul is available and current 51 5.5.1.9 Determine maintenance data requirements 51 5.5.1.10 Establish Product Quality Deficiency Reporting (PQDR) procedures . 51 5.5.1.11 Equipment manufacturing and integration 51 5.5.1.12

36、Cost of unreliability model 52 5.5.1.13 Include MECSIP in the overall aircraft maintenance program 52 5.5.2 Subtask 2: Develop and utilize a Functional Systems Integrated Database (FSID) . 52 5.5.2.1 Component inspection and/or replacement interval 52 5.5.2.2 Component Minimum Acceptable Performance

37、 (MAP) levels 52 5.5.2.3 Identify items which fail to meet the MAP (alerts) . 53 5.5.2.4 Facilitate Engineering communication with Field personnel . 53 5.5.2.5 Develop a Scheduled Inspection (e.g., HSC and ISO) Tracking Program 53 5.5.2.6 Develop a tail number part tracking program for serial-number

38、-controlled parts 53 5.5.2.7 Develop a system to track enroute and/or deployed system reliability 54 5.5.2.8 Develop a program to track MICAP hours assessed to each component . 54 5.5.2.9 Develop a program to capture CANN actions by WUC 54 5.5.2.10 Develop a program to identify and monitor MSIs 54 5

39、.5.2.11 Develop a program to identify component contribution to Not Mission Capable (NMC) (S)(M)(B) status . 55 5.5.2.12 Develop a program to identify components causing aborts 55 5.5.2.13 Develop a preview and in-depth analysis program . 55 5.5.2.14 Develop a program to identify “Bad Actors” 55 5.5

40、.2.15 EWIS Task Two Develop a program for routine health assessment of Electrical Wiring Interconnect System (EWIS) 55 5.5.3 Subtask 3: Force Management Execution . 56 5.5.3.1 Component repairs and overhauls . 56 5.5.3.2 Monitor component inspection and replacement criteria . 57 5.5.3.2.1 WUC Manual

41、 . 57 5.5.3.2.2 Scheduled inspection requirements and replacement schedule . 58 5.5.3.2.3 Time changes 58 5.5.3.2.4 Inspection work cards 58 5.5.3.2.5 Program Depot Maintenance requirements 58 5.5.3.2.5.1 Overhaul of systems 59 5.5.3.2.5.2 Monitoring of repairs/overhauls 59 5.5.3.2.5.3 Depot-level c

42、heck on organizational- and intermediate-level full and partial overhauls 60 5.5.3.2.5.4 Component test bench calibrations 60 5.5.3.3 Monitor mishaps, HAZREPS and deficiency reports for applicability to MECSIP components . 60 Provided by IHSNot for ResaleNo reproduction or networking permitted witho

43、ut license from IHS-,-,-MIL-STD-1798C viii 5.5.3.4 Monitor data integrity . 60 5.5.3.5 Risk Assessments 61 5.5.3.6 Perform analysis 61 5.5.3.6.1 Perform preview analysis . 61 5.5.3.6.2 Perform in-depth analysis 61 5.5.3.6.3 Analytical Condition Inspections (ACIs) 61 5.5.3.6.4 Equipment usage and env

44、ironments 62 5.5.3.7 Manage Safety- and Mission-critical components 62 5.5.3.8 Manage Durability-critical components . 63 5.5.3.9 Manage Durability-noncritical/expendable components 63 5.5.3.10 Develop new MECSIP Parts 63 5.5.3.10.1 Follow MECSIP development tasks (Tasks I, II, III and IV) . 63 5.5.

45、3.10.2 Update FMECAs and HAs . 63 5.5.3.10.3 Replacement of obsolete equipment 63 5.5.3.10.4 Environmental regulations 63 5.5.3.10.5 Update the CSI list . 64 5.5.3.11 Tasks for Commercial Derivative Aircraft programs maintained via Contract Logistics Support (CDA/CLS) 64 5.5.3.11.1 Maintenance Plann

46、ing Data (MPD) Document . 64 5.5.3.11.2 CDA Maintenance Program . 64 5.5.3.11.3 MPD revisions 65 5.5.3.11.4 Use of FAA Certified Mechanics 65 5.5.3.11.5 Service literature 65 5.5.3.11.6 Service Difficulty Reports . 65 5.5.3.11.7 Usage monitoring . 65 5.5.3.11.8 CDA Reliability Program 65 5.5.3.11.9

47、CDA modifications . 66 5.5.3.11.10 FAA support . 66 5.5.3.12 Identify Technical Needs (Sustainment Phase) 66 5.5.4 Subtask 4: Preventative Mainenance Actions . 66 5.5.4.1 Reliability Centered Maintance (RCM), Maintenance Steering Group -3 (MSG-3), CBM+, or equivalent analysis . 66 5.5.4.2 Develop a

48、program for routine health assessment of EWIS. 68 5.5.5 Subtask 5 Manage Service Life Extension and Final Five Years Prior to Retirement 68 5.5.5.1 MECSIP considerations during a Service Life Extention Program (SLEP) . 68 5.5.5.1.1 Service Life Assessment Program . 68 5.5.5.1.2 Service Life Assessment of hydromechanical systems 68 5.5.5.1.3 Service Life Assessment of EWIS 69 5.5.5.1.3.1 EWIS Task Three (See EWIS MIL-HDBK-525 f