1、 MIL-STD-3024 15 April 2008 DEPARTMENT OF DEFENSE STANDARD PRACTICE PROPULSION SYSTEM INTEGRITY PROGRAM (PSIP) AMSC N/A AREA SESS DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. NOT MEASUREMENT SENSITIVEProvided by IHSNot for ResaleNo reproduction or networking perm
2、itted without license from IHS-,-,-MIL-STD-3024 iiFOREWORD 1. This standard is approved for use by all Departments and Agencies of the Department of Defense. 2. The Department of Defense (DoD) is committed to ensuring a strong systems engineering approach in acquisition programs. This standard cover
3、s the procedures to be used to ensure propulsion system integrity during the System Development and cost and schedule risks managed through a series of disciplined, time-phased tasks. This standard details programmatic tasks for the development, acquisition, and sustainment of propulsion systems to
4、ensure their integrity while affordability of these United States Air Force (USAF) systems is maintained throughout their period of use. 1.2 Application. This standard provides information to develop a Propulsion System Integrity Program. The standard applies to a particular propulsion program and a
5、ir vehicle system, as follows: 1.2.1 Type of air vehicle. This standard is directly applicable to air vehicles which have a propulsion system based on or powered by a gas turbine engine. 1.2.2 Type of propulsion system. This standard applies to gas turbine propulsion systems. The term “Propulsion Sy
6、stem” in this document refers to an engine and engine accessories. Inlets, nacelles, pylons, engine bay, and ventilation components are not intended to be included in this document. Exhaust nozzles are intended to be included in this document, even those designed and manufactured by an airframe manu
7、facturer. 1.2.3 Type of program. This standard is applicable to new propulsion systems, to propulsion systems procured by the USAF but developed under the auspices of other government agencies or departments (such as the Federal Aviation Administration or United States Navy), and propulsion systems
8、modified or directed to new missions. 1.2.3.1 Program impact on tailoring. It is expected this standard will be tailored to fit the needs of a given program. Specific tailoring guidance is given in 6.4. Procurement of off-the-shelf, new or used propulsion systems for military use presents different
9、challenges than procurement of propulsion systems developed under the auspices of the military services. The concepts and intent of this document will apply to these types of systems, but may require significant tailoring. 1.3 Functional scope. This document details the PSIP requirements for the fun
10、ctional areas of Structures, Performance and Operability, and Controls and Subsystems. As will be described in section 4, development of the PSIP Master Plan is a significant requirement to achieve system integrity. The Master Plan is expected to be comprehensive, and include activities needed to at
11、tain integrity in other functional areas, such as Manufacturing, Safety, Reliability and Maintainability, etc. Detailed PSIP requirements for these functional areas are not included in this document due to the availability of other government guides, handbooks, and standards. 1.4 Document layout. Th
12、is document follows the prescribed format for military standards, which reserves section 4 for General Requirements and section 5 for Detailed Requirements. Within this construct this document covers three functional areas with five PSIP task categories. To achieve this, it was decided all Task I re
13、quirements were universally applicable to the three functional areas and would be included in section 4, General Requirements. Section 5, Detailed Requirements, contains three primary subsections, each identifying the Task II V requirements for each functional area. Although it could be argued that
14、Task V applies to all functional areas, it was considered unique for each for the initial release of this document. Appendix A contains tables which list guidance for Task completion criteria for the various program milestones. This guidance is to be used to develop criteria to move to the next prog
15、ram milestone as described in 4.4.2.2. Microsoft Wordand Adobe Acrobatversions of this document contain hyperlinks which are identifiable by blue-font characters. Once selected, a hyperlink will take the user to a referenced paragraph, table, figure, and Website. The simplest way to return to the pl
16、ace of origin within a Microsoft Worddocument is to click the “back arrow” on the “Web” toolbar. This toolbar can be displayed by selecting “View” and “Toolbars” on the menu bar, and then selecting the “Web” option. This same method can be employed in Adobe Acrobatversions of a document: select Prov
17、ided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3024 2“View” and “Toolbars” on the menu bar, and then select “Navigation.” The “back arrow” and “forward arrow” allow the user to return to the place of origin after a hyperlink has been selected. 2
18、. APPLICABLE DOCUMENTS. 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made
19、 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 standard, whether or not they are listed. 2.2 Government documents. 2.2.1 Specifications, standards, and handbooks. The following sp
20、ecifications, 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. DEPARTMENT OF DEFENSE Specifications JSSG-2007 Engines, Aircraft, Turbine Handbooks MIL-HDBK-
21、1783 Engine Structural Integrity Program (ENSIP) (Copies of these documents are available online at http:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094; 215 697-2179.) 2.2.2 Other Government documents, d
22、rawings, 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. UNITED STATES AIR FORCE INSTRUCTIONS
23、 AFMCI-21-102 Analytical Condition Inspection (ACI) Programs AFMCI-21-103 Reliability-Centered Maintenance (RCM) Programs (Copies of these documents are available online at www.e-publishing.af.mil.) 2.3 Non-Government publications. The following documents form a part of this document to the extent s
24、pecified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. PROPULSION CENTER OF EXCELLENCE (PCoE) BEST PRACTICES PCOE BP-01-11 Propulsion System High Cycle Fatigue Test Protocol (Copies of this document are available online to qualifie
25、d users at the PCoE Homepage, https:/www.acs.wpafb.af.mil/subpages/PRSS/pcoe/pcoe.htm.) RADIO TECHNICAL COMMISSION FOR AERONAUTICS (RTCA), INC. RTCA DO-178 Software Considerations in Airborne Systems and Equipment Certification (Copies of this document are available online at www.rtca.org.) Shock an
26、d Vibration Handbook, Cyril M. Harris, 4th edition, McGraw Hill, New York NY, 1995. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3024 3(Copies of this document are available to DoD users through horizon.afit.edu and all users at various pu
27、blic library sites.) 2.4 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, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and
28、regulations unless a specific exemption has been obtained. 3. DEFINITIONS. 3.1 Acronyms. ACI Analytical Condition Inspection AMT Accelerated Mission Test ASIP Aircraft Structural Integrity Program ASMET Accelerated Simulated Mission Endurance Test ATP Acceptance Test Procedure AVIP Avionics Integrit
29、y Program CIP Component Improvement Program CMC Ceramic Matrix Composites COTS Commercial Off-The-ShelfCSC Computer Software Configuration CSCI Computer Software Configuration Item DTR Design Target Risk ECS Environmental Control System EFH Engine Flying Hour ELMP Engine Life Management Plan ENSIP E
30、ngine Structural Integrity Program FDA Failure Detection and Accommodation FEM Finite Element Model FFR Full Flight Release FMECA Failure Modes Effects and Criticality Analysis HCF High Cycle Fatigue ICD Interface Control Document IFPC Integrated Flight/Propulsion Controls IFR Initial Flight Release
31、 IMP Integrated Master Plan IMS Integrated Master Schedule IR Infrared ISR Initial Service Release K1CStress intensity factor LCF Low Cycle Fatigue LPB Low Plasticity Burnishing LSP Laser Shock Peening MAC Modal Assurance Criteria MECSIP Mechanical Equipment and Subsystems Integrity Program MFHBF Me
32、an Flight Hours Between Failure MTTR Mean Time To Replace NDE Non-Destructive Evaluation NDI Non-Destructive Inspection OCR Operational Capability Release OEM Original Equipment Manufacturer PHM Prognostic Health Management PIDS Prime Item Development Specification POD/CL Probability Of Detection/Co
33、nfidence Level RCM Reliability Centered Maintenance Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3024 4RFP Request For Proposal RPM Revolutions Per Minute RDT and engine subsystems, controls, accessories, and externals (controls and subsys
34、tems). This expansion was accomplished by incorporating the relevant criteria from the highly-successful ASIP, AVIP, MECSIP, and ENSIP. 4.2 PSIP goals. The PSIP is an organized and disciplined engineering and management process to assure that the integrity of the engine is achieved in the developmen
35、t program and maintained throughout operational service. The PSIP process consists of phased tasks that increase knowledge of the true characteristics of the propulsion system being developed. The goal of the PSIP process is to use the knowledge gained from these tasks to balance cost and risk and m
36、aximize product maturity. The phased tasks will focus on the following: Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-3024 6a. Application of a disciplined “system engineering approach” to design and development with emphasis on determining
37、 and understanding failure processes and consequences on operational performance. b. Understanding the total system operational and support needs and the development of subsystem and component requirements and characteristics to assure that these needs are met. c. Emphasis on realistic integrity req
38、uirements, required operational service life, required performance/operability/functionality, understanding of usage and environments (including maintenance and support) as the basis for design and qualification. d. Early trade studies to evaluate operation and support factors together with cost, we
39、ight, and performance, and to ensure compatibility between design solutions and support equipment needs and maintenance concepts. e. A disciplined design and development process scheduled to assure early evaluation of component response to design usage, material characteristics, manufacturing proces
40、ses, and the establishment of operational limits (failure modes and service lives) in terms of design usage. f. An integrated analysis and ground test program to evaluate design performance and integrity characteristics and to verify requirements. g. Scheduling of tests and demonstrations to assure
41、that test findings are incorporated into design in advance of major economic and/or qualification initiation and production commitments. h. Quality assurance strategy with special emphasis on planning, supplier quality, control of manufacturing variability, failure investigation, and corrective acti
42、on to assure quality and integrity of hardware throughout production. i. Development of force management requirements (including maintenance and inspection requirements) based on the results of the development process. j. Follow-up control for the fielded engines through maintenance, inspection, and
43、 data gathering. k. Investigation of the need to track usage on components and subsystems in service. l. A program to accomplish force management. 4.3 General description of the primary PSIP tasks. The PSIP follows a five-task element approach. This approach has been derived from the systems enginee
44、ring process. The systems engineering process is shown on figure 1. Systems engineering begins with the definition of top-level system requirements, allocating those requirements to a lower level, designing hardware to meet the requirements, followed by verification that the requirements have been m
45、et. And, as the figure indicates, the process can be iterative. The five-task PSIP approach accomplishes the systems engineering process. As the tasks are accomplished, knowledge of the system characteristics increases. The PSIP represents a logical, methodical, technically-sound development strateg
46、y in which engineering assumptions are verified and component limits are accurately defined before parts are released to production. Potential failure mechanisms are identified, understood, and controlled. Increased emphasis is placed on performing early analyses and conducting incremental engineeri
47、ng development tests to verify analytical assumptions. The process also emphasizes that sufficient knowledge is gained on engine components in support of major program milestones and suggests that performance and durability tests that simulate realistic operating environments are one way to demonstr
48、ate that knowledge. A general description of the five integrity tasks is given in the following sections. Engineering judgment needs to be used to tailor these tasks to fit the needs of each unique program. Knowledge-based criteria should be the basis of any engineering judgment used to tailor the P
49、SIP, and should be clearly communicated in the initial PSIP Master Plan and any updates. New engine programs may need to do most, if not all, of the sub-tasks outlined here. Derivative programs may need only a smaller sub-set. The sub-tasks descriptions which follow are not intended to be all-inclusive, but rather to represent considerations for typical engine development. The major sub-tasks or elements contained in each of the five tasks
