SABAerospace AEROSPACE T reteset RECOMMENDED |S “S985 PRACTICE issued 2011-08 Fuel System Components: General Specification For RATIONALE This document is created as, (1) a public domain version of the US Navy's General Specification for Fuel System Components (MIL-F-8615) governing qualification requirements, and (2) an update of the same. The basic scope of the document is unchanged, and the revisions include removing cancelled references, adding requirements for new (since release of MIL-F-8618D) technology components, and general clarification of existing requirements. TABLE OF CONTENTS SCOPE... Purpose Classification... Non-standard environment BRR REFERENCES... Applicable Documents ‘SAE Publications.. ASTM International Publ ISO Publications... U.S. Government Publications... REQUIREMENTS Qualification. Item Specification Speciation Control Brawings (S60). Weight. Materials. Fungus proot. Metals.. Dissimilar Metals. Magnesium and copper. Castings and forgings. Elastomers Finishes and coatings Cadmium plating. Chromium plating Fluid Design and Construction. Pressure Leakage Extemal.. intemal nnn Plug-in units Strength. @NNNANNNNNNNaaaaaaaoo0o waonae SAE Technical Standards Soard Rules provide ta “This report is published by SAE to advance fe stato of teceical ard engineering sdlnavs. The uae of his ropor s ntl uray, ands ppicabiy and sutton parc se incudng Sy pat inngerert eng thereon, tesla eepensoily othe Lae SAE reviews each techical porta ast eer five years at wich ine may be refed ese of anced. SAE inves your wren comments ans suggests, ‘Copyrght ©2011 SAE ltematons ‘Al hts reserved. No pat f this publication may be reproduced, sored in a Yeteval sytem or vansmited, any form oF by any means, electron, mechanical phocopyng, recorang, or oerwee,waout tha pr writen perms of SAE: TOPLACEADOCUMENT ORDER: Tel: 97706-7223 (maids USA and Canada) _ [SAE values your input. To provide feedback Tot +17a47764070(outaide USA) ROA, Fac Taarrearee Se Emit: CustomerService@sse.org Ste Cee AEB ABTREE Sena cane rns tplwww.sae.org Keres aeameasintone wee8. 8 3.10.2 3.10.3 att 3414 3.11.2 44 42 43 434 43.2 4a 4a4 442 454 452 453 454 454.1 ARP861 Page 2 of 20 Mechanical load Shock resistance... Fatigue resistance. Bonding Electr Electrical connector.. Wiring... Solenoids Motors. Electrical fault containment Electrical insulation requirements. Electromagnetic interference. Thermal protection Shaft seals, d Traps and voids. Threaded connections. Threaded safety Lubrication. ‘Over speed... Performance. Calibration Altitude ‘Acceleration Gravity Force.. Endurance. Water and i Above freezing Ieing conditions. Operating Spee Sand and Dust Pressure surge. Thermal shock.. Thermal performance. Safety Analysis. Reliability Diagnostics. Maintainabilty Accessibilty. Seal replacement. Errorree maintenance Identification. olor identification Unique Item Identifier (Ui)... © 000000000000 ODDDORAHDDDDDDED VERIFICATION METHODS... Responsibility for Inspection Classification of Inspections. Qualification Test Program Test report. 7 Disposition of test articles Quality Conformance Inspections. Acceptance tests... ‘Sampling inspections... Test Conditions... Test fluid. Examination of product. Break-in run... Leakage Internal...TABLE 1 TABLE 2 TABLE 3 TABLE 4 TABLE 5 TABLE 6 ARP8615 Page 3 of 20 Extemal. Plugein unit. Calibration ANttud Operating Speed. Acceleration... Gravity Pressure Surge Fuel Resistance Test Fluids... 7 Functional operation during tests Test after each period. Endurance. ‘Combining of tests... Contaminated fuel tests Contaminated test liquid... Test Method..... ‘Accelerated corrosion Salt fog... Strength Mechanical shock Mechanical load Overspeed, Electrical... Electrical actuators. Electrical insulation test Explosion proof. Electromagnetic compatiblity Thermal protectors... Water and lee Environmental . Humidity Fungus resistance. Sand and Dust . Vibration. ‘Acoustical noise Thermal shock.. Bonding and lightning protection Thermal characteristics. Disassembly and inspection... Safety Analysis Report. Reliability and Maintainabilty... GLOSSARY... NOTES... ‘TEMPERATURE CLASSIFICATION COMPONENT PRESSURE SCHEDULES. QUALIFICATION TEST PROGRAM. ‘SCHEDULE FOR FUEL RESISTANCE TESTING. CONTAMINANT MIXTURE, DIELECTRIC TEST VOLTAGES (AC).SAE ARP8615 Page 4 of 20 1. SCOPE 1.4 Purpose This document describes the requirements for air vehicle fuel, vent, and propulsion fuel system functional components. 1.2. Classification Components shall be identified by class based upon a temperature environment in accordance with Table 1. TABLE 1 - TEMPERATURE CLASSIFICATION High Temperature °C Low Temperature Class 7 Tr Tat Fuel and Air “C A BOCzSC 7SCH5C 75°Cs5C “ST C2aC B 9 °C#5°C 115°C 25°C 175°C 25°C “57 -C24°C c WO5"C# EC 180°C#7°C 315° CH 10°C “STC 24°C T- High operational fuel temperature T= High fuel test temperature Ta- High ambient temperature 1.2.1. Non-standard environment: Whenever the temperature environment exceeds the classes of section 1.2, or where Unusual circumstances exist, the lowest and highest liquid, vapor, and ambient temperature shall be identified. A ‘component may still belong to one of the above classes if the exposure to a higher ambient temperature (Ta) is transitory and does not result in the heating the component more than 30 °C above the test temperature (Tj) for ‘more than 15 minutes total during 10 hours of operation. 2. REFERENCES 2.1 Applicable Documents The following publications form a part ofthis document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1. SAE Publications Available from SAE Intemational, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), wurw.s20.0°a. ARP868 Pressure Drop Test for Fuel System Components ARP 14014 Aircraft Fuel System and Component Icing Test AIR4246 Contaminant for Aircraft Turbine Fuel System Component Testing AMS-QQ-C-320 Chromium Plating (Electrodeposited) Suton me a Seater nen nvaw@rsereurene.con,SAE ARP8615 Page 5 of 20 2.1.2. ASTM International Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM-D471 Standard Test Method for Rubber Property—Effect of Liquids ASTM-D1655__ Standard Specification for Aviation Turbine Fuels ASTM-E498 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector or Residual Gas Analyzer in the Tracer Probe Mode ASTM-£427 Standard Practice for Testing for Leaks Using the Halogen Leak Detector(Alkali lon Diode) ASTM-E-515 Standard Practice for Leaks Using Bubble Emission Techniques ASTM-A630 Standard Test Methods for Determination of Tin Coating Weights for Electrolytic Tin Plate ASTM-A309___ Standard Test Method for Weight and Composition of Coating on Terne Sheet by the Triple Spot Test ASTM-A376 Standard Specification for Seamless Austenitic Steel Pipe for High Temperature Central Station Service ASTM-B117 Standard Practice for Operating Salt Spray (Fog) Apparatus ASTM-G69__Standard Test Method for Measurement of Corrosion Potentials of Aluminum Alloys ASTM-G47 Standard Test Method for Determining Susceptibility to Stress Corrosion Cracking of 2XXX and 7XXX Aluminum Alloy Products ASTM-E1282 Standard Guide for Specifying the Chemical Compositions and Selecting Sampling Practices and Quantitative Analysis Methods for Metals, Ores, and Related Materials ASTM-E172 Practice for Describing and Specifying the Excitation Source in Emission Spectrochemical Analysis 2.1.3. ISO Publications Available from Intemational Organization for Standardization, 1, rue de Varembe, Case postale 56, CH-1211 Geneva 20, Switzerland, Tel: +41-22-749-01-11, www.is0.0rg, 1SO 12103-1 Road vehicles - Test dust for filter evaluation - Part 1: Arizona test dust 2.1.4 U.S. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-9495, hitos:/assist.daps.dla,mil/quicksearchy. MIL-STD-190 DoD STANDARD PRACTICE IDENTIFICATION MARKING OF U.S. MILITARY PROPERTY MIL-STD-202 Test Methods for Electronic and Electrical Components Parts MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems MIL-STD-810 Environmental Test Methods MIL-HDBK-2165. Testability Program for Systems and Equipments MIL-$-4040 Solenoid, Electrical, General Specification for rho a tae SAE attests een c00mvaNg>uRTELFEN comSAE ARP8615, Page 6 of 20 MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-PRF-7024 Calibrating Fluids, Aircraft Fuel System Components, Performance Specification MIL-M-7969 Motor, Alternating Current, 400 Cycle, 115/200-Volt System Aircraft General Specification for MIL-M-8609 Motor, DC, 28 Volt System, Aircraft, General Specification for MIL-A-21180 Aluminum Alloy Castings, High Strength MIL-DTL-83133 Turbine Fuel, Aviation, Grade JP-8 3. REQUIREMENTS 3.1, Qualification Unless otherwise specified, the assemblies furnished under this specification shall have been inspected and passed the qualification requirement specified herein, 3.2 Item Specification ‘A specification providing all design and performance details shall be submitted by the contractor to the procuring agency for approval. The item specification shall reiterate all applicable requirements of this ARP and the necessary specific requirements for the application of the subject component. The item specification shall include a specification control drawing. 3.2.1 Specification Control Drawings (SCD): The installation and outline drawings shall be provided to the procuring ‘agency. At the time and place of qualification approval, the data shall include the detail assembly drawing(s) with the mass properties and parts list showing the material, coating, temper, special finishes for all parts and processes and assembly procedures, as applicable. 3.2.2 Weight: The allowable wet and dry weights of the component shall be stated in the item specification. Any attaching hardware shall be called out separately and not included in the specification weight unless specified by the procuring agency. 3.3 Materials Materials and processes shall conform to applicable Government or commercial specifications. Materials conforming to Contractor's specifications may be used after approval by the procuring agency. All materials shall be resistant to fuels (including additives), fuel vapors, humidity, salt fog, and other environmental factors encountered in service. Resistant shall be defined as having no detrimental effect on performance or operating capability for the required useful ie, 3.3.1. Fungus proof: Materials that are nutrients for fungi shall not be used when directly exposed to the operating environment, without prior approval by the procuring agent. 3.3.2. Metals: Metals shall be of the corrosion-resistant type to resist corrosion due to contact with materials or exposure to environments likely to be met in storage or normal service. Metals shall be inspected in accordance with FED-STD-151. 3.3.2.1 _ Dissimilar Metals: Unless suitably protected against electrolytic corrosion, dissimilar metals shall not be used in close contact with each other. Dissimilar metals and isolation requirements are defined in MIL-STD-889, 3.3.2.2. Magnesium and copper: Magnesium and copper or alloys thereof shall not be used in contact with fuel without ‘approval from the procuring agency. 3.3.2.3 Castings and forgings: Castings shall be in accordance MIL-C-6021 or MIL-A-21180. The minimum acceptable elongation shall be 3 percent. Steel forgings shall satisfy the applicable requirements of SAE-AMS-F-7190.SAE ARP8615_ Page 7 of 20 3.3.3 Elastomers: Elastomeric materials shall conform to SAE-AMS-P-5315, MIL-R-6855 Class I, MIL-DTL-25988, MIL- R-2765 or AMS7276, AMS7259, AMS3216 and AMS3218. 3.3.4 Finishes and coatings: Any protective finish or coating that can not be shown to have demonstrated full ‘component useful life (by test, analysis or similarity) when exposed to all fuel system environments (including all specified fuel types, additives and contaminants) are prohibited, 3.3.4.1 Cadmium plating: Cadmium shall not be used on any fuel system components that can come into contact with fuel during life ofthe air vehicle 3.3.4.2 Chromium plating: Chromium plating shall conform to QQ-C-320, Class 2. 3.4 Fluids The item specification shall state the fluids with which the component is required to be compatible and qualified for use. Unless otherwise stated, fuel system components shall be compatible with MIL-DTL-S624, MIL-DTL-83133, ASTM D471, ASTM D-1655 (Types A, A-1, and B), MIL-C-7024, GOST-10227 (‘TS-1"), GB 6537-94, No.3 Jet Fuel (People's Republic of China specification) and other comparable commercial and military fluids. In normal operation, these fuels may contain various quantities of dissolved and free water, salts, gases, some solid contaminants, such as sand, dirt, composite particles and metal chips. 3.5 Design and Construction 3.5.1. Pressure: Fuel system components shall be compatible with the pressure schedules of Table 2, or the maximum ‘and minimum pressures in accordance with the item specification, ‘TABLE 2 - COMPONENT PRESSURE SCHEDULES. PRESSURE (psig) FLUID SYSTEM OPERATING, PROOF, BURST ENGINE FEED Positive 60 120 180 Negative (15) (30) (45) TRANSFER 60, 720 180. REFUELING Positive 90 180 270 Negative (3) (6) (a) VENT Positive 4 8 12 Negative (3) (8) (9) 3.5.2 Leakage 3.5.2.1 External: External leakage is defined as the sum of all leakage to atmosphere through extemal component walls or sealed joints when all components ports are pressurized to specified pressures. The item specification shall state the maximum leakage rate permitted for all operating conditions, 3.5.2.2 Internal: Internal leakage is defined as port-to-port leakage. The item specification shall state the permissible internal leakage requirements for all operating conditions. Any component that penetrates a structural boundary and is exposed to the atmosphere (such as a vent valve) shall have a zero internal leakage requirements unless otherwise specified. 3.5.2.3 Plug-in units: When applicable, the item specification shall state the maximum allowable fuel loss when plug-in Units are removed and installed, including the leakage when the component is not installed.SAE 353 3.5.3.1 3.5.3.2 35.33 35.4 35.5 3.5.5.1 3.6.5.2 35.5.3 35.5.4 35.5.5 35.5.6 3.5.5.7 3.56 35.7 35.8 ARP8615, Page 8 of 20 Strength: The specific requirements of each of the following parameters shall be stated in the item specification as applicable. Mechanical load: The component shall be capable of withstanding operating maintenance loads without distortion or failure. The minimum design value of torque for installation and removal of fittings, fasteners, etc., shall be at least 125 percent of the normal maximum. ‘Shock resistance: The component mounting shall assure safe retention in place and not be a cause for leakage Of fuel in the event of a shock load within the envelope of the applicable structural design criteria set by the procuring agency. Fatigue resistance: The component shall be capable of withstanding the vibrations and acoustical noise of the installed environment as well as any other extemal force input that causes stress in any portion of the component. The vibration and acoustical noise environment shall be specified by the iter specification, and in accordance with the air vehicle specification. Bonding: Bonding for electrical requirements and lightning protection shall be in accordance with MIL-STD-464, Electrical: Electrical devices shall be compatible with the air vehicle electrical system (including power supplies), in accordance with MIL-STD-704 and shall satisfy the applicable requirements of MIL-STD-7080 and MIL-E- 25499, Electrical connector: Electrical connectors shall be as defined by the item specification in accordance with the applicable aircraft specification. Unless otherwise stated, the electrical connectors shall be in accordance with MIL-C-38999, Wiring: Electrical wiring shall be accordance with the air vehicle requirements, and SAE AES0881. Solenoids: Solenoids in fuel system components shall be continuous duty in accordance with MIL-S-4040. Motors: Electrical motors shall satisfy the applicable requirements of MIL-M-7969 and MIL-M-8609. Electrical fault containment: In accordance with the test procedure of section 4, the assembly housing shall be capable of containing any internal fault without failure of the housing. In no case shall an electrical short or internal explosion propagate to the outside of the housing or generate a condition which could affect the operation of the system. Electrical insulation requirements: The electrical components shall withstand, without damage, breakdown, or excessive current leakage, applications of test voltages in accordance with the test procedure of section 4. The AC dielectric current shall not exceed 2 milliamperes. Insulation resistance shall not be less than 100 megohms. {for motors, oF 200 megohms for other electrical components. Electromagnetic interference: The electrical components shall meet the applicable requirements of MIL-STD- 461 and meet the requirements of MIL-E-6051 Thermal protection: If normal operation or an electrical fault can generate unsafe temperatures, thermal protection shall be incorporated to assure that the assembly is maintained within safe temperature limits under all ‘operating or non-operating conditions. The peak temperature, from any heat source, of any portion of the assembly in contact with fuel or fuel vapors, shall not exceed 200 °C or a lower temperature in accordance with the item specification. Shaft seals, drains and vents: Motor-operated fuel system components shall provide shaft seals and a suitable drain chamber between the motor and the component, unless the rotating element of the motor is immersed in fuel. Electrical motor chamber vents shall not be connected to the seal drain chamber, and shall prevent flame propagation through the vent. Traps and voids: Fuel system components shall not contain unvented traps, pockets, or voids in which moisture ‘can freeze or contaminants can collect enough such that it affects performance or reliability.SAE 3.5.9 3.5.9.1 3.5.10 36.11 ARP8615 Page 9 of 20 ‘Threaded connections: Externally threaded mounting and all connection interfaces shall be clearly specified in the item specification by the procuring agency. Threaded safety: All threaded parts shall be positively secured or incorporate an anti-loosening device, in ‘accordance with applicable standards or other accepted practice. Whenever loosening of a self-locking nut ‘could possibly result in the nut or other parts entering the fuel system plumbing, approval of the installation shall be obtained from the procuring activity. The use of cotter pins or studs, lock-washers, staking, and lock-wire is Prohibited, unless authorized by the procuring agency. Lubrication: Fuel system components shall function within the item specification requirements without the need for periodic lubrication other than the fuel in which it operates during its useful service life. Over speed: Components containing rotating members that can over speed for any reason shall have a self- contained speed regulator, and shall also be designed to insure containment of any failure inside the housing. 3.6 Performance All necessary specific performance requirements shall be provided by the item specification. The following paragraphs shall be used as guides in preparing the item specification requirements, but they do not necessarily contain all the required performance parameters. 3.6.1 3.6.2 36.3 36.4 36.5 3.6.6 3.6.6.1 3.6.6.2 3.6.7 Calibration: All critical calibration points shall be specified, such as, flow rates, pressure schedules, pressure drop (or rise), liquid level, response adjustments, heat dissipation, and power requirements. Altitude: Fuel system components shall deliver the required performance at all required altitude(s), and during changes in altitude. If performance is required to be insensitive to altitude, the specification shall so state. ‘Acceleration: The required performance during changes in speed or change in direction, including the applicable rate of change shall be specified. Gravity Force: The component performance during periods of inverted flight or changes in the effective gravity shall be in accordance with requirements as stated in the item specification, Endurance: In general, fuel system components should be designed for a useful life not less than the useful life of the air vehicle or propulsion system for which it is being qualified. A component, whose operational life is time dependent, shall have a minimum endurance consistent with the unit's prescribed overhaul period. This overhaul period shall be consistent with the fuel system's maintenance plan. For components whose operation is intermittent, and are operated 10 times or more per fight or a component whose failure can impose a Hazard Risk Index (HRI) greater than 7 (as defined by MIL-STD-882) shall have a minimum endurance of 100 000 cycles. For components that operate less frequently, and have an HRI less than 8, the required endurance shall be 10 000 cycles. ‘The endurance test shall encompass all operational conditions from sea level to maximum altitude, including high and low temperature exposure as well as dry operation (without fuel Water and Ice: Water (and ice) shall not be a cause of a fuel system component functional failure, whether it is ‘mechanical or electrical. The water may come from any available source, such as free or dissolved water in the fuel, vapor in a bleed air system, clouds, rain, etc. Any fuel system component whose failure, due to water (or ice) which could prevent transfer of fuel, or could cause a buildup of pressure, either positive or negative, in excess of design allowances, shall demonstrate the capability to satisfy specified performance in the presence of ‘water, either in the fuel or in the surrounding atmosphere. ‘Above freezing: The component shall demonstrate the ability to perform in the presence of water when the temperature is above freezing. Icing conditions: The minimum endurance and required performance under icing conditions shall be specified. Operating Speed: Where applicable, the time for a valve opening and closing shall be specified. Whenever a ‘component contains a speed control device, or whenever a variation in the amount of fluid in a component can result in a speed change, the minimum and maximum performance requirements shall be specified.SAE ARP861 Page 10 of 20 3.6.8 Sand and Dust: Components installed in locations exposed to ambient conditions shall be capable of withstanding the effects of sand and dust, when the test of section 4 is imposed, without degradation in performance below the item specification requirements, 3.6.9 Pressure surge: Fuel system components shall not cause pressure surges in the fuel tubing greater than the proof pressure of Table 2. Surge pressures are pressure peaks, lasting less than several seconds, above the system pressure, caused by component operation. 3.6.10 Thermal shock: The component shall withstand the thermal cycling effects of the environment and fluid temperature changes without degradation in either performance or endurance and without any other failure. Where applicable, thermal shock performance requirements shall be specified. 3.6.11 Thermal performance: Power consumption and heat dissipation (including to the ambient environment, any cooling fluids and fuel) and performance requirements shall be specified in the item specification. 3.7 Safety Analysis, Where applicable, all possible failure modes and their impacts to the component performance shall be examined in accordance with the air vehicle system safety requirements, and relayed to the procuring agency in a failure modes and effects report. 38 Reliability ‘The reliability of the component shall be stated in the item specification, as needed to satisty system requirements. A test plan shall be prepared for demonstrating the required reliability and presented to the procuring agency for approval. 3.9 Diagnostics Component diagnostic and prognostic requirements shall be specified in the item specification. 3.10 Maintainabilty The maintainability plan shall provide an estimate of maintenance man-hours, total clock-hours, and tools needed for intermediate shop and overhaul maintenance of the component. No special tools shall be needed to remove and replace the component from the air vehicle, without approval from the procuring agency. The maintainability plan shall be ‘consistent with and in accordance with the air vehicle maintainability plan, 3.10.1 Accessibility: Fuel system components which require routine service checking, adjustment, or parts replacement, shall provide accessibility for this routine maintenance without requiring teardown, or disassembly of the housing from the airframe, fluid lines or electrical components. 3.10.2 Seal replacement: Wherever seals are partially exposed and subject to possible damage, the seal unit shall be readily replaceable and preferably without removal of the main housing from its mounted position. 3.10.3. Error-free maintenance: The following general guidance will reduce the possibility of errors during assembly and maintenance of system components, if applicable: a. Stacked assemblies shall use arrangements that prevent improper assembly, such as the use of indicator markings that are exposed if parts are omitted b. Similar components shall either be identical and interchangeable, or shall have some design feature to prevent their interchange. The use of right and left hand parts should be avoided unless approved by the procuring agency. c. When bolts of different sizes are used in proximity to the same location, the different sizes shall be specified ‘Two bolts identical except for length should not be used in similar or adjacent locations. Provision should exist to protect against damage to parts caused by accidental use of screws or bolts that are too long. Paneer ed ‘siesta reve gn. RvangpneToUrENe couSAE ARP861 Page 11 of 20 4. Where reversed or rotated mounting of a part cannot be tolerated, non-symmetrical mounting arrangements {including key-ways or pins) shall be used €. Identical cable receptacles shall not be used in adjacent locations unless internal functions are identical and interchangeable. 3.11. Identification All assemblies and parts shall be marked in accordance with requirements of the item specification. The information must be permanent and may be etched, engraved, embossed, or stamped in a sultable location on the assembly or on a corrosion resistant nameplate securely attached to the component. The information shall be located where it can be read with the component mounted in place, insofar as practical. Identification should include (at a minimum): manufacturer, manufacturing date, part number and serial number of the component. 3.11.1. Color identification: When required by the procuring agency, the component shall be color coded to indicate fuel by means of a red color. The color shall be permanent and shall not deteriorate, loosen or fade due to contact, with fuel or the operational environment. The marking may consist of a red band 0.25 inch or wider around the ‘component body or a stripe at least 1 inch long on opposite sides of the component or by coloring the entire outer surface of the principal body, or by use of a nameplate with a red background color. 3.11.2 Unique Item Identifier (Ull): When required by procuring agency, the component shall incorporate a two dimensional Data Matrix with machine-readable data elements, in compliance with MIL-STD-130, 4. VERIFICATION METHODS 4.1. Responsibility for Inspection Unless otherwise specified in the contract, the contractor is responsible for the performance of all inspection requirements {as specified herein. The contractor may use his own or other suitable facilities unless disapproved by the procuring activity. The procuring activity reserves the right to perform any of the inspections set forth in the specification where ‘such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. 4.2. Classification of Inspections The inspection and testing of the components shall be classified as follows: . Qualification Testing b. Quality conformance inspection. 4.3. Qualification Test Program The qualification test program shall consist of all applicable inspections and tests herein, and any additional tests shall be in accordance with the item specification. The number of test articles and the order of tests shall be sufficient to meet all ‘specification requirements. A qualification test plan shall be submitted by the contractor and approved by the procuring ‘agency prior to the start of the qualification test program. For more complex components, Table 3 provides guidance for test unit versus test applicability 4.3.1 Test report: The test report, covering all details of the qualification test program shall be prepared and submitted to the procuring agency for approval. The report shall include the assembly and cross-section drawings of the component, copies of the test log sheets and all applicable sketches and photographs necessary to understand the test setup, procedures, results of all testing, and final condition of the components tested. Fossler SSUES EE heme mernrrencconSAE ARP8615, Page 12 of 20 ‘TABLE 3 - QUALIFICATION TEST PROGRAM Inspection Requirement Test Test Aricle 7 2 3 0 Examination 32,310 452 x x x 1_Break-in run 32. 45.3 x x x 2 Calibration 36.1 455 x x x 3 Speed 3.67 45.7 x x x 4 Leakage 3.52 454 x x x Electrical Insulation 355.6 45.162 x x x 6 Fuel Resistance 33; 45.11 x Corrosion Resistance 33) 45.14 x Endurance 3.65 457 x 9 Contaminated Fuel 34 45.13 x 10 Altitude 3.62 456 x 11 Gravity” 364 459 x x 12 Acceleration™ 3.6.3 458 x x 13 Vibration” 3.533 45.184 x x 14 Water” 3.66 45.17 x x 15 kcing™ 3.66) 45.173 x x 76 Sand and Dust™ 3.68 45.183 x x 17 Pressure Surge 3.6.9 4.5.10 x "18 Mechanical Shock 3.5.3.2 45.151 x 19 Mechanical Load 3.5.3.1 45.152 x x 20 Overspeed 3.5.11 45.153 x 21 Electrical Actuators 355384 45.161 x 22 Explosion Proof 3.5.6, 45.163 x 23 Electrical Compatibliiy= 35.5.6 45.164 x x 24 Thermal Protectors 3.5.6 45.165 x 25 Humidity 33.366 45.181 x 26 Fungus Resistance 3.34 45.182 x 27 Acoustical Noise™ 35.33 45.185 x x 28 Thermal Shock” 3.6.10 45.186 x x 29 Thermal Performance 3.6.11 45.20 x '30 Bonding and Lightning 354 45.19 x x x 31 Disassembly 34 45.21 x x x NOTES:* Individual tests marked with an asterisk may be conducted on either test article identified in the table. A) Inspections 2, 3, 4 & 5 shall be repeated at the end of the tests for each test article, prior to disassembly. B) Inspection 6 shall be conducted prior to any other higher number in the list. ) Inspections 7, 8 & 9 shall be conducted in the order listed, D) Inspections 17, 19, 20 & 21 shall be conducted after inspection 9. 4.3.2 Disposition of test articles: All items subjected to test shall be available for the qualification test program and thereafter shall be retained or delivered to the procuring agency in accordance with contract requirements, acc... Fi alataSAE ARP8615 Page 13 of 20 4.4 Quality Conformance Inspections ‘The quality conformance inspections shall consist of individual tests. 4.4.1 Acceptance tests: Each assembly shall be subjected to acceptance tests prior to delivery in accordance with the detail specification. This should consist of at least the following. a. Examination b. Breakin run c. Leakage rate tests 4. Calibration or performance checks fe. Electrical insulation tests Electrical bonding tests 4.4.2 Sampling inspections: The sampling inspections, whether based upon a production lot quantity or upon calendar intervals shall be conducted in accordance with the item specification. These may consist ofthe following: a. Calibration (4.5.5) b. Strength (4.5.15) 4.5 Test Conditions Unless otherwise specified, the atmospheric pressure, temperature and humidity shall be the local ambient. 4.5.1 Test fluid: Unless otherwise specified, the test fluid shall be the principal fluid the component shall experience in use. 4.5.2 Examination of product: All component assemblies shall be inspected and certified to be in accordance with the applicable drawings and specifications, including all requirements of section 3 for which tests are not appropriate. 4.5.3 Break-in run: If specified, a break-in run (either dry or wet) shall be conducted in accordance with the item specification, 4.5.4 Leakage: Leaking testing shall be conducted at several pressures, including the minimum and maximum pressures. The duration of test at each pressure shall be long enough to allow accurate leakage data to be recorded. Where leaks are critical to the operation of the component, the pressure shall be held for a minimum of ‘5 minutes. Timed pressure decay shall only be used with the approval from the procuring agency. 4.5.4.1 Internal: Internal leakage tests are to be conducted from minimum up to proof pressure, and back down again to minimum. The pressure levels and allowable leakage rate shall be specified. 4.5.4.2 External: There shall be no visible external leakage except as permitted by the item specification from minimum pressure up to burst pressure. 4.5.4.3 Plug-in units: The quantity of fuel loss resulting from engagement and disengagement of plug-in units shall satisfy specification requirements.455 456 457 458 459 45.10 45.11 ARP8615, Page 14 of 20 Calibration: Calibration tests shall be conducted to demonstrate compliance with 3.6.1. For qualification and ‘sampling tests, sufficient data points shall be taken to demonstrate the complete performance characteristics of the component. For acceptance tests, the number of data points may be limited to only one or two critical points, {as required by the item specification. Altitude: Attitude tests shall be conducted to demonstrate as specified in 3.6.2. Analysis may be submitted in lieu of testing if it can be shown that the component is not altitude sensitive. The tests may be conducted concurrently with the endurance requirements as specified in 3.6.5. ‘Operating Speed: Tests shall be conducted to demonstrate performance as specified in 3.6.7 ‘Acceleration: Tests shall be conducted in accordance with MIL-STD-810, to demonstrate performance as Specified in 3.6.3, Gravity: Tests shall be conducted to demonstrate performance in accordance with 3.6.4. Pressure Surge: Tests shall be conducted in accordance with the setup description provided in paragraph 4.6.2.4 of MIL-V-38003 to demonstrate performance as specified in 3.6.9. The surge pressure limit shall be as specified in the MIL-V-8003 setup, unless otherwise specified by the item or associated air vehicle specifications. The instrumentation shall automatically record a time history plot capturing the rate of pressure change and all minimum and maximum peak values, Fuel Resistance: This test is applicable to all components having any parts whose physical properties are affected by contact with fuel. The test shall be conducted in a continuous manner in accordance with the schedule of Table 4. Each period shall follow the preceding one in the order noted with a minimum of delay. The ‘soak periods shall be conducted with the component submersed in the body of fluid. For the dry periods, the ‘component shall be drained, without disassembly, and blown dry with the ports open and placed in a test chamber having air continuously circulating around the component at the test temperature, 4.5.1.1 Test Fluids: The test liquid for the fuel resistance test shall be specified in the item specification, The test fluids for the fuel resistance test shall be in accordance with ASTM D471, (Reference Fuel A and 8), MIL-PRF-5624 and JP-5. For the high temperature soak periods, itis advisable to perform the soak in a closed container with {pressure not to exceed 15 psi to prevent boiling. TABLE 4 - SCHEDULE FOR FUEL RESISTANCE TESTING PHASE PHASET PHASE Mi TEST PERIOD. Soak Dy Soak Dy ‘Soak. “Ambient & fluid test Tr Ta i i “87 £46 temps (Table 1) Test Fluid During Soak Class A ASTM Air ASTM ‘Air ASTM, D471 Ref 8 D471 Ref B D471 Ref A Class 8 ‘ASTM Air ‘ASTM ‘Air ‘ASTM, D471 Ref 8 D471 Ref 8 D471 Ref A Class WPS Ar IPS Air ‘ASTM, D471 Ref A Period Duration Whours __24hours _ 18hours __S0hours _ 18hours ‘minimum ‘minimum ‘minimum Test fluids to be used ASTM ASTM ‘ASTM ‘ASTM, ‘ASTM for tests D471 RefB D471 RefA D471 RefB D471 RefA_D471 Ref ASAE ARP8615 Page 15 of 20 4.5.1.2 Functional operation during tests: At least once each day during the soak periods, components with moving arts shall be operated. Intermittent duty components shall be operated through a minimum of 4 cycles. Continuous duty or motor operated components shall be operated for 1 hour or a minimum of 25 cycles. For ‘components with more than one normally commanded position (ie., valves commanded open and closed) at least one soak period should be conducted in each position. During dry periods, actuation shall be ‘accomplished if the component may be operated in the dry condition when installed. The item specification shall define the specific actuation requirements (ie.. power supply, force, etc). 4.5.1.3. Test after each period: At the conclusion of each soak or dry period, the component shal be actuated through 4 ‘oycles or operated for 5 to 10 minutes and subjected to a leakage test. Following the Phase | and I! periods, the tests shall be conducted at room temperature. The liquid to be used following the soak periods shall be ASTM D471 Ref B and following the dry periods, ASTM D471 Ref A fuel. Following the Phase Ill period, the test shall be conducted at -57 °C + 4 °C using ASTM D471 Ref A fuel, and repeated at room temperature. The ‘component actuation and leakage shall satisfy the specification, except that following the dry periods, some increased leakage, as defined by the item specification or in the qualification test plan as approved by the procuring agency may be permitted for no more than 15 minutes, or as defined by the item specication. 4.5.12, Endurance: The endurance test is applicable to all fel system components in order to demonstrate conformance to paragraph 3.6.5. The test shall be a simulation of the operating conditions of the component for the design operational life between overhauls. It shall be accomplished without disassembly, lubrication, other maintenance, except as provided by the item specification. Calibration and leakage tests shall be accomplished following each phase to verify performance. For power operated components, which ate subjected to variation in power input, the test shall be conducted with these variations. The test set-up shall not provide for surge pressure relief and shall simulate the air vehicle installation as defined by the procuring agency. If operation of the unit causes Pressure surges greater than 50% of the normal operating pressure, then time history plots ofthe rate of pressure change and the pressure peaks and valleys shall be recorded after every 10% of the endurance test duration. 4.5.12.1 Altitude: When specified in the test plan, this test shall be conducted at the various critical operating conditions ‘occurring at altitude. If operation at altitude produces some special effect, such as slow start-up, overspeed, or heating, the test should include a reasonable number of these cycles or duration of time for the special effect. This test shall comprise at least 20 percent of the total endurance test. 4.5.12.2 High temperature: The high temperature endurance test is applicable to all components and shall consist of 20 percent of the total required endurance test. The test liquid and ambient temperature shall be in accordance with the appropriate class. 4.5.12.3 Low Temperature: The low temperature endurance testis applicable to all components and shall consist of at least 10 percent ofthe total required endurance test 45.124 Dry: The dry endurance test is applicable to all components that may be operated dry when installed in the air vehicle. The test is applicable, whether the operation occurs by design or is inadvertent. If the unit contains an automatic dry shut-off feature, the dry endurance test shall demonstrate the operation of this feature. The dry endurance shall consist of at least 5 percent of the total endurance test. The test shall consist of at least four periods of dry operation between periods of wet operation. The test chamber temperature shall be the highest ambient temperature required. 4.5.12.5 Room temperature: The room temperature endurance test shall consist of the remaining portion of the unassigned endurance hours or cycles after the other phases have been assigned their share. 4.5.12.6 Combining of tests: Half of the high temperature and low temperature endurance runs may be combined with the altitude test; especially when the combinations simulate a realistic operating environment. 4.5.13 Contaminated fuel tests: This test is applicable to all components required to perform the endurance test as specified in 4.5.12. 4.5.13.1 Contaminated test liquid: The test liquid shall contain the types and concentrations of the contaminant mixture as specified in Table 5 or AIR4246. The liquid circuit shall insure that the contaminants remain in suspension in the liquid and enter the component under test.SAE ARP8615, Page 16 of 20 4.5.13.2 Test Method: The component shall be subjected to rated flow and pressure for 2-1/2 hours or 500 cycles and between 10 and 25 percent rated flow for 2-1/2 hours or 500 cycles. The operation of the component during this time shall be in accordance with the specification. For components with no moving parts, the above test shall be sufficient. For components with moving parts, the above test shall be repeated once. If fuel flows in both directions in the system, the test shall be conducted with flow in both directions. 4.5.13.3 Tests following contaminated fuel endurance: Following the above tests, the component may be flushed with clean test liquid to loosen contaminants, but it shall not be disassembled for cleaning. The component shall pass a functional and leakage test in accordance with the item specification. TABLE 5 - CONTAMINANT MIXTURE CONTAMINANT PARTICLE SIZE ‘QUANTITY (microns) (grams per 1000 liters) Tron Oxide 0-5 9 5-10 1.0 Sharp Silica Sand 7150-300 OT 300-420 O7 180 Fine Dust Mixture 53 Cotton Linters, ‘Staple Below 7 0.07 Iron Chips 150-500 10 ‘Aluminum Chips 7150-500, 10 Salt water solution Entrained 0.07% (4 parts NaCl to 96 parts H20) (by volume) Graphite Epoxy Composite 0-45 (23%) 52 45 - 150 (26%) 150 - 300 ( 8%) 300 - 425 (32%) 425-710 (11%) Explosion suppressant Foam 0-100 O75 particles Random distribution of particles defined and ‘generated in accordance with MIL-PRF-87260B and cut using the methods in section ‘4.2.4 of said standard, excluding hot wire cutting. 4.5.14 Corrosion resistance: The corrosion resistance test shall consist of both accelerated corrosion and salt fog, unless otherwise specified. There shall be no evidence of corrosion that could adversely impair component function or strength. These tests may be abbreviated or deleted when it can be demonstrated that all materials individually and in contact in the assembly, are not subject to any manner of corrosive deterioration, whether chemical, electrolytic or stress accelerated. Following each test, leakage and calibration tests shall be conducted ‘There shall not be any excessive leakage, deterioration or any malfunction due to the tests.SAE ARP861 Page 17 of 20 4.5.14.1 Accelerated corrosion: The component (except for open electrical connectors) wit all fuel ports open shall be submerged and, if practical, operated manually or otherwise for 3 cycles in a 5% salt solution The unit shall then be drained for 30 seconds and operated as necessary to remove trapped salt solution. The component shall be placed immediately in a test chamber maintained at a temperature of 30 °C #2 °C with a relative humidity of 100 percent for a period of 20 minutes. Upon completion of the humidity exposure period, the unit shall be placed in an air oven maintained at a temperature of 55 to 60 °C for a period of 20 minutes. The immersion, high humidity and drying sequence shall be repeated for a total of 50 cycles. The component shall ‘not be operated between cycles. Immediately after completion, the component shall be washed with warm Water, dried, wetted with fuel, and actuated as in normal service. Salt fog: The component shall be subjected to salt fog in accordance with ASTM G 85.A4. Unless otherwise stated by the procuring activity, test conditions shall be 500 hrs with a sea salt concentration corresponding to salt fallout equal to 200 ppb. At the end of the test period, the component shall be washed with warm water to remove the deposits, dried, wetted with fuel, and actuated as in service, 15 Strength: The following tests shall be conducted for qualification test program and sampling inspections in ‘accordance with the item specification. Following each test, leakage and calibration tests shall be conducted. 4.5.15.1 Mechanical shock: The component shall be subjected to a crash safety test in accordance with the requirements of the shock tests of MIL-STD-810. The mounting shall simulate the air vehicle installation as close as possible, including tubing and wiring. Cavities may be filed with water or other suitable test fluid, and. pressure applied, if required. The component shall demonstrate performance specified in 3.5.3.2 and the item ‘specification. 4.5.1.2 Mechanical load: With the component mounted in the normal manner, it shall be subjected to the most severe tension, compression, bending, or torsion loads that would be expected to occur in service to demonstrate Performance specified in 3.5.3.1 and in the item specification. There shall be no evidence of failure, permanent distortion, excessive leakage or deterioration in performance. 4.5.1.3 Overspeed: Overspeed analysis and testing shall be conducted to demonstrate compliance with paragraph 3.6.11 4.5.16 Electr I: The following tests are applicable to components incorporating electrical equipment. 4.5.16.1 Electrical actuators: Tests shall be conducted to demonstrate compliance in accordance with MIL-S-4040 and MIL-M-7969, as applicable. 45.16.2 Electrical insulation tests: The following tests shall be conducted for qualification test program and sampling inspections in accordance with the item specification. 4.5.16.2.1. Dielectric withstanding voltage: A test shall be conducted in accordance with MIL-STD-202, Method 301, and Table 6. There shall be no disruptive discharge, flashover, or breakdown. Each appropriate test potential shall be applied between all mutually insulated circuits. It shall also be applied between all circuits tied together ‘and the unit case or chassis. Leakage current shall not exceed the requirements as specified in 3.5.5.6. Whenever any test herein this document invokes a dielectric test in accordance with this paragraph, it shall be understood to mean one application at each test point.SAE ARP8615, Page 18 of 20 TABLE 6 - DIELECTRIC TEST VOLTAGES (AC) ‘System Voltage Initial Test Alitude* Repeat Tests 4 Minute. 410 Seconds 1 Minute 10 Seconds 28 VDC 1050 1250 500 500 270 voc 1500 1800 700 700 115 VAC. 41250 1800 500 600 115/200 VAC 1500 1800 700 700 * If not specified, use 9.8 psia pressure. 4.5.16.2.2 Insulation resistance: The insulation resistance test shall be conducted in accordance with MIL-STD-202, Method 302. For equipment operating at less than 250 volts rms, the test potential shall be 500 volts. For equipment operating at voltages between 250 and 500 volts rms, the test potential shall be 1000 volts. The insulation resistance shall not be less than as specified 3.5.5.5. 4.5.16.3 Explosion proof: The test shall be conducted in accordance with MIL-STD-810 to demonstrate that the component can be operated in an explosive environment without causing an explosion, and prevent propagation of an internal explosion outside the component, as applicable, and with the following modifications: ‘a. The fuel to be used shall be the principal fuel to be used in service. If a different fuel is used, additional tests shall be conducted to demonstrate that the explosive vapor possesses the same rate or greater pressure rise and peak pressure as the fuel to be used in service, b. The chamber temperature shall be the high vapor temperature (Ta) of Table 1 unless it can be shown that a lower temperature provides equivalent results. c. The electrical equipment shall be operated, in both wet and dry conditions, for sufficient time for the temperature of the equipment to stabilize and demonstrate that no external hot spot, which exceeds the ‘automatic ignition point of fuel, exists to cause a fire or explosion. 4.5.16.4 Electromagnetic compatiblity. The electrical equipment shall be tested in accordance with MIL-STD-462 for Class A1 equipment. The minimum test shall be in accordance with method CE03. Additional tests shall be in accordance with the item specification. 4.5.16.5 Thermal protectors: Tests shall be conducted to demonstrate that the thermal protectors are capable of repeated cycles of heating and cooling without causing deterioration in the capability to operate in accordance with specification requirements. 4.5.17 Water and Ice: Tests shall be accomplished to demonstrate in the requirements of 3.6.6 through 3.6.6.2, and as specified in ARP1401A,. The test requirements for components using air or subject to externally applied water shall be in accordance with the item specification. 4.5.18 Environmental: The following environmental inspections and tests, as applicable, shall be conducted in accordance with the item specification. There shall be no degradation in performance except as permitted in the specification.SAE ARP8615, Page 19 of 20 4.5.18.1 Humidity: This test applies to all components containing electrical equipment and shall be conducted in accordance with MIL-STD-810. Component operation during the test shall be in accordance with the item specification. Within 2 hours of the completion of the last cycle, a calibration shall be conducted in fuel at -57 °C 24°C, 4.5.18.2 Fungus resistance: This test applies to all components containing any material that can be a nutrient. The test shall be performed in accordance with MIL-STD-810, except that substitution of a specified fungus may be made, if authorized by the procuring agency. 4.18.3 Sand and Dust: This test applies to all components installed in vent systems or external fuel tanks. If not defined in the air vehicle detailed specification, the air contamination levels should be as defined in MIL-STD- 810. The test shall be performed in accordance with MIL-STD-810. The internal source air contamination requirements of any pneumatic component should be tailored in accordance with the filtration capability provided by the air vehicle. 4.5.18.4 Vibration: This test is applicable to all fuel system components and shall be accomplished in accordance with MIL-STD-810 and the item specification. The item specification shall provide the range of vibration levels for the specific location installed in the fuel system or in the air vehicle as shown in the item specification figure, ‘Components containing electrical switches shall be monitored for contact bounce and resistance variations. 4.5.18.5 Acoustical noise: The acoustical noise test is applicable to all components located near a jet engine exhaust and other high noise level areas. It shall be conducted in accordance with MIL-STD-810. 4.5.18.6 Thermal shock: The thermal shock test shall be performed in accordance with MIL-STD-810, 4.5.19 Bonding and lightning protection: Tests shall be conducted to demonstrate performance in accordance with 3.6.4, 45.20 Thermal characteristics: Testing shall be conducted to demonstrate the power consumption and heat dissipation requirements specified in 3.6.11. 4.5.21 Disassembly and inspection: Following completion of all tests, including repetition of inspection 2, 3, 4, and 5 of Table 3, each component submitted to test shall be disassembled for inspection. There shall be no evidence of any degradation which effects performance, endurance or safety. Photographs shall be taken of all parts and of any critical area discussed in the test report, as needed. 4.6 Safety Analysis Report ‘The safety analysis and proof-of-safety test report shall be prepared as required by the item specification and the procurement documents, 4.7 Reliability and Maintainabilty The reliabiity and maintainabilty demonstration plans shall be submitted as required by the procurement documents. 5. GLOSSARY Specification: The specification is a document that defines all performance requirements and characteristics of a ‘component. This can include item and detail specifications, which are used interchangeably. Contractor:The contractor is the individual, group or company that is producing and selling the component. Procuring agency:The procuring agency is the individual, group, company or organization that is purchasing the ‘component. Operating Pressure: The operating pressure is dependent on the system architecture, specified in the item specification, and is defined as the normal maximum steady state intemal pressure to which the item will be exposed.SAE ARP8615, Page 20 of 20 Proof Pressure: The proof pressure is typically twice the operating pressure, but depending on the system architecture ‘and operating pressure, it may be different. The component shall be capable of operation when exposed to proof pressure as defined in the component specification, Burst Pressure: The burst pressure is typically three times the operating pressure, but depending on the system architecture and operating pressure, it may be different. The component shall be capable of structural stability and leak integrity when exposed to its burst pressure, but not necessarily functionality, as defined in the component specification. 6. NOTES 6.1 A change bar (|) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. 6.2 Ordering Data. Procurement documents should specify: ‘a. Title, number and date of item specification and of specification control drawing (3.1). . Instructions concerning delivery of test reports and the test articles to the procuring agency or the responsible engineering office (4.3.1). ©. Preparation for delivery instructions. 4d. Instructions concerning delivery of sampling test data (4.4.2) @. Instructions concerning delivery of reliability and maintainability demonstration plans (4.7). PREPARED BY SAE COMMITTEE AE-5, AEROSPACE FUEL, OIL, AND OXIDIZER SYSTEMS