1、MIL-STD-1798B 24 January 2010 SUPERSEDING MIL-STD-1798A 15 April 2008 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-1798B 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 ASC/ENRS, 2530 LOOP RD WEST, WRIGHT-PATTERSON AFB OH 45433-
5、7101 or e-mailed to Engineering.Standardswpafb.af.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at http:/assist.daps.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without lic
6、ense from IHS-,-,-MIL-STD-1798B iii CONTENTS Paragraph Page 1. SCOPE 1 1.1 Purpose 1 1.2 Use . 1 1.2.1 Structure . 1 1.3 Program approach 2 1.4 Program overview . 2 1.5 Applicability . 3 2. APPLICABLE DOCUMENTS . 3 2.1 General . 3 2.2 Government documents 3 2.2.1 Specifications, standards, and handb
7、ooks 3 2.2.2 Other Government documents, drawings, and publications . 4 2.3 Non-Government publications . 4 2.4 Order of precedence . 5 3. DEFINITIONS 5 3.1 Analysis 5 3.2 Damage tolerance . 5 3.3 Demonstration . 5 3.4 De-rating of electrical equipment . 5 3.5 Design loads/environment spectrum . 5 3
8、.6 Design service life . 5 3.7 Durability . 5 3.8 Durability-critical component . 6 3.9 Durability-noncritical component . 6 3.10 Economic life. 6 3.11 Nondestructive inspection (NDI) 6 3.12 Improbable occurrence . 6 3.13 Integrity . 6 3.14 Leak before burst 6 3.15 Maintenance-free operating period
9、6 3.16 Mission-critical component 6 3.17 Other/expendable components . 7 3.18 Probability of detection (POD) . 7 3.19 Proof testing 7 3.20 Required operational service life . 7 3.21 Redundancy 7 3.22 Safe-life . 7 3.23 Safety-critical component 7 3.24 Similarity (legacy systems) 8 3.25 Slow damage g
10、rowth structure 8 3.26 Test . 8 3.27 Up-rating . 8 3.28 Usage . 8 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798B iv CONTENTS - Continued Paragraph Page 4. GENERAL REQUIREMENTS 9 4.1 Mechanical Equipment and Subsystems Integrity Program
11、 (MECSIP) 9 4.1.1 Tailoring approach. 13 4.1.2 Implementing SOW . 13 5. DETAILED REQUIREMENTS 14 5.1 (Task I) Preliminary Planning 14 5.1.1 Program strategy . 14 5.1.2 Trade studies 14 5.1.3 Requirements development . 14 5.1.4 Preliminary integrity analysis . 14 5.1.5 Technical reviews 15 5.2 (Task
12、II) Design Information 15 5.2.1 MECSIP Master Plan 15 5.2.2 Design criteria . 16 5.2.2.1 Damage tolerance criteria . 16 5.2.2.1.1 Damage tolerance design concepts 16 5.2.2.2 Risk-based criteria 17 5.2.2.2.1 Risk-based design concepts . 17 5.2.3 Design service life/design usage . 18 5.2.4 Component c
13、lassification. 18 5.2.4.1 Aviation-Critical Safety Items 20 5.2.5 Maintenance concepts 20 5.2.6 Material and process selection and characterization . 20 5.2.7 Product integrity control plan . 21 5.2.8 Corrosion prevention and control . 21 5.2.9 Environmental emissions. 22 5.2.10 Physical and operati
14、onal interfaces . 22 5.2.11 Risk mitigation planning 22 5.2.12 Supportability planning 22 5.3 (Task III) Design Analyses and Development Tests 22 5.3.1 Manufacturing and quality assessment 22 5.3.2 Design analyses 23 5.3.2.1 Load analyses 23 5.3.2.2 Design stress/environment spectra development 23 5
15、.3.2.3 Performance and function sizing analyses 23 5.3.2.4 Thermal/environmental analyses 23 5.3.2.5 Stress/strength analyses 23 5.3.2.6 Durability analyses . 23 5.3.2.7 Damage tolerance analyses . 24 5.3.2.7.1 Damage tolerance inspections . 24 5.3.2.7.2 Damage tolerance action categories and guidan
16、ce 24 5.3.2.7.3 Fail-safe . 25 5.3.2.7.4 Slow damage growth . 25 5.3.2.7.5 Leak before burst . 25 5.3.2.7.6 Proof test analysis . 25 5.3.2.8 Risk-based analyses. 25 5.3.2.9 Vibration/dynamics/acoustic analyses 25 Provided by IHSNot for ResaleNo reproduction or networking permitted without license fr
17、om IHS-,-,-MIL-STD-1798B v CONTENTS - Continued Paragraph Page 5.3.3 Development tests. 26 5.3.3.1 Material characterization tests 26 5.3.3.2 Design development tests 26 5.3.4 Performance 26 5.3.4.1 Dynamic modeling 26 5.3.4.2 Failure detection and accommodation (FDA) 27 5.3.4.3 Stability and respon
18、se 27 5.3.4.4 Control laws, schedules, architecture, and power management . 27 5.3.5 Electromagnetic effects and lightning 27 5.3.6 Software 27 5.3.6.1 Software performance and testing requirements . 27 5.3.7 Assessments . 27 5.3.7.1 Abnormal operation (design margin) . 27 5.3.7.2 Manufacturing and
19、assembly processes . 27 5.3.8 Reliability and maintainability 28 5.3.9 Electrical/optical cable maintainability . 28 5.3.10 Ground handling 28 5.3.11 Obsolescence . 28 5.3.12 De-rating/up-rating 28 5.3.13 Equipment prognostic systems 28 5.4 (Task IV) Component Development and Systems Functional Test
20、s 28 5.4.1 Component and rig test descriptions . 29 5.4.2 Testing risk mitigation 29 5.4.3 Hardware and systems rig testing . 29 5.4.3.1 Subsystem performance . 29 5.4.3.2 Dry rig . 29 5.4.3.3 Wet rig 29 5.4.3.4 Mechanical systems . 29 5.4.4 Hardware component 30 5.4.4.1 Component development 30 5.4
21、.4.2 Abnormal operation (design margin) . 30 5.4.5 Reliability growth demonstration 30 5.4.6 Oil interruption and depletion . 30 5.4.7 Component fit checks 30 5.4.8 Component qualification 30 5.4.9 Vibration and dynamic response . 31 5.4.10 Fire proof/fire resistance 31 5.4.11 Software testing 31 5.
22、4.12 Functional tests . 31 5.4.13 Strength testing . 31 5.4.14 Durability testing 31 5.4.15 Vibration/dynamics/acoustics tests 32 5.4.16 Damage tolerance tests 32 5.4.17 Thermal, environment, and loads survey . 32 5.4.18 Overspeed/overtemperature 32 5.4.19 Maintainability/reparability demonstrations
23、 33 5.4.20 Evaluation and interpretation of test results . 33 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798B vi CONTENTS - Continued Paragraph Page 5.4.21 Integrated test plan 33 5.4.22 Final integrity analysis . 33 5.4.23 Maintenance
24、planning and task development 34 5.4.24 Airworthiness certification 34 5.5 (Task V) Force Management . 34 5.5.1 Equipment manufacturing and integration . 34 5.5.2 Sustainment of equipment prognostic systems 35 5.5.3 Reliability-Centered Maintenance (RCM) 35 5.5.4 Component tracking/monitoring progra
25、m . 35 5.5.4.1 Operational usage data 35 5.5.5 Preventive maintenance actions 36 5.5.5.1 Flight-hour time change 36 5.5.5.2 Calendar time change . 36 5.5.5.3 On-equipment repairs . 36 5.5.5.4 Lubrication/cleaning and adjustments . 36 5.5.5.5 Overhaul of systems . 37 5.5.5.6 Replacement of original e
26、quipment . 37 5.5.5.7 Replacement of obsolete equipment . 37 5.5.5.8 Environmental regulations 37 5.5.6 Flight manual . 38 5.5.7 Production/overhaul quality . 38 5.5.7.1 Acceptance Test Procedures 38 5.5.7.2 Component test bench calibrations . 38 5.5.8 Monitoring of repairs/overhauls . 38 5.5.8.1 Fi
27、eld/Base-level maintenance . 38 5.5.8.2 Depot-level maintenance 38 5.5.9 Inspection criteria 39 5.5.9.1 Safety-critical component maintenance requirements . 39 5.5.10 Analytical Condition Inspection (ACI) Program 39 6. NOTES 40 6.1 Intended use . 40 6.2 Acquisition requirements . 40 6.3 Data require
28、ments 40 6.4 Subject term (key word) listing 41 6.5 Responsible Engineering Office (REO) . 41 6.6 Changes from previous issue 41 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798B vii CONTENTS - Continued Paragraph Page APPENDIX A A.1 SCOP
29、E 42 A.2 APPLICABLE DOCUMENTS . 42 A.3 DEFINITIONS 43 A.3.1 Acronyms 43 A.3.2 Milestone definitions 43 A.4 GUIDANCE 45 A.4.1 Key elements 45 APPENDIX B B.1 SCOPE 57 B.2 APPLICABLE DOCUMENTS . 57 B.3 DEFINITIONS 58 B.3.1 Acronyms 58 B.4 GUIDANCE 59 B.4.1 Objectives of a MECSIP Master Plan 59 B.4.1.1
30、MECSIP Master Plan for legacy weapon systems 59 B.4.1.1.1 Subtask 1: data gathering and task planning 61 B.4.1.1.1.1 Establish a reliability analyses team within the Engineering department to develop and monitor the system management program 61 B.4.1.1.1.2 Establish the sustainment philosophy (i.e.,
31、 preventive maintenance versus current USAF philosophy of fly to fail) 62 B.4.1.1.1.3 Gather available maintenance data and design information 62 B.4.1.1.1.3.1 Review available data 62 B.4.1.1.1.3.1.1 Identify safety- and mission-critical components . 62 B.4.1.1.1.3.1.2 Identify durability-critical
32、items 63 B.4.1.1.1.3.1.3 Analytical Condition Inspections (ACIs). 63 B.4.1.1.1.3.1.4 Identify durability-noncritical/expendable components 63 B.4.1.1.1.4 Review the -6 TOs for all inspection requirements 63 B.4.1.1.1.5 Review WUC Manual 64 B.4.1.1.1.6 Review identified OEM-recommended time change it
33、ems (TCIs) . 64 B.4.1.1.1.7 Ensure technical data is available for Field and Depot users 64 B.4.1.1.1.8 Field/Base-level maintenance . 64 B.4.1.1.1.9 Depot-level maintenance 65 B.4.1.1.1.10 Determine maintenance data requirements 65 B.4.1.1.1.11 Establish Product Quality Deficiency Reporting (PQDR)
34、procedures . 65 B.4.1.1.2 Subtask 2: development of a Functional Systems Integrated Database (FSID) . 65 B.4.1.1.2.1 Design a tracking and monitoring program for system components 65 B.4.1.1.2.2 Develop risk assessment and FMECA program 66 B.4.1.1.2.3 Define safety- and mission-critical component in
35、spection and/or replacement interval . 66 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798B viii CONTENTS - Continued Paragraph Page B.4.1.1.2.4 Develop component MAP levels . 66 B.4.1.1.2.5 Develop a program to identify items which fail
36、to meet the MAP (alerts) 66 B.4.1.1.2.6 Develop a program to allow Engineering to communicate with Field personnel . 66 B.4.1.1.2.7 Develop HSC and ISO inspection tracking programs 66 B.4.1.1.2.8 Develop a tail number component tracking program for serial-number-controlled components . 67 B.4.1.1.2.
37、9 Develop a system to track enroute system reliability . 67 B.4.1.1.2.10 Develop a program to track MICAP hours accessed to each component 67 B.4.1.1.2.11 Develop a program to capture CANN actions by WUC . 67 B.4.1.1.2.12 Develop a program to identify and monitor MSIs 67 B.4.1.1.2.13 Develop a progr
38、am to identify each component with Not Mission Capable (NMC) (S)(M)(B) status 68 B.4.1.1.2.14 Develop a program to identify components causing aborts . 68 B.4.1.1.2.15 Develop a computerized Preview and In-depth analysis program . 68 B.4.1.1.2.16 Develop a program to identify Bad Actors . 68 B.4.1.1
39、.2.17 Develop a program to perform routine health assessment of the aircraft Electrical Wiring Interconnect System . 69 B.4.1.1.2.18 Develop a model to quantify the cost of unreliability for the weapon system 69 B.4.1.1.3 Subtask 3: force management execution 69 B.4.1.1.3.1 Monitoring of components
40、repairs and overhauls . 69 B.4.1.1.3.1.1 Fleet MTBF 69 B.4.1.1.3.1.2 Serial number MTBF . 70 B.4.1.1.3.1.3 ISO/HSC inspections . 70 B.4.1.1.3.1.4 Not Mission Capable (NMC) (S)(M)(B) 70 B.4.1.1.3.1.5 Aborts 70 B.4.1.1.3.1.6 Bulletin boards . 70 B.4.1.1.3.1.7 Cannibalizations 70 B.4.1.1.3.1.8 PQDRs 70
41、 B.4.1.1.3.2 Monitor component inspection and replacement criteria . 70 B.4.1.1.3.2.1 Work Unit Code (WUC) Manual . 70 B.4.1.1.3.2.2 Scheduled inspection requirements and replacement schedule. 71 B.4.1.1.3.2.3 Time changes 71 B.4.1.1.3.2.4 Inspection work cards 71 B.4.1.1.3.2.5 Program Depot Mainten
42、ance requirements . 71 B.4.1.1.3.3 Monitor data integrity 72 B.4.1.1.3.3.1 Data entries . 72 B.4.1.1.3.3.2 Risk assessments 72 B.4.1.1.3.4 Perform analysis . 72 B.4.1.1.3.4.1 Preview analysis 72 B.4.1.1.3.4.2 In-depth analysis . 72 B.4.1.1.3.4.3 Analytical Condition Inspections 73 B.4.1.1.3.4.4 Equi
43、pment usage and environments 73 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798B ix CONTENTS - Continued Paragraph Page B.4.1.1.4 Subtask 4: preventive maintenance actions . 73 B.4.1.1.4.1 Lubricating or servicing . 73 B.4.1.1.4.2 Operat
44、ional checks . 73 B.4.1.1.4.3 Visual examination . 73 B.4.1.1.4.4 Restoration . 74 B.4.1.1.4.5 Time change 74 B.4.1.1.4.6 Combination . 74 B.4.1.1.4.7 Common sense approach 74 B.4.1.1.5 Subtask 5: manage systems final five years prior to retirement . 75 B.4.1.1.5.1 Establish IPT 75 B.4.1.1.5.1.1 Sup
45、ply . 75 B.4.1.1.5.1.2 Establish liaisons at Primary Bases . 75 TABLES TABLE I. Mechanical System Integrity Program life-cycle tasks 10 TABLE A-I. Task I Preliminary Planning . 46 TABLE A-II. Design Information . 47 TABLE A-III. Design Analyses and Development Tests Task Completion Criteria 49 TABLE
46、 A-IV. Component Development and Systems Functional Tests Task Completion Criteria 51 TABLE A-V. Force Management 54 TABLE B-I. MECSIP Master Plan for legacy systems . 60 FIGURE FIGURE 1. Critical part selection flowchart. 19 Provided by IHSNot for ResaleNo reproduction or networking permitted witho
47、ut license from IHS-,-,-MIL-STD-1798B 1 1. SCOPE. 1.1 Purpose. The purpose of this standard is to describe the general process to achieve and maintain the physical and functional integrity of the mechanical elements of airborne, support, and training systems. The goal of this integrity program is to
48、 ensure the operational safety, suitability, and effectiveness (OSS select “Word Options”; and then select “Customize”. In the “Choose commands from” list, select “All Commands” and then select “Back”; click “Add”; then select “Forward” and click “Add”. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-1798B 2 This same method can be employed in Adobe Acrobatversions of a document: select “View” and “Toolbars” on the menu bar, and t
