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Revision A
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NORTHROP GRUMMAN NEWPORT NEWS
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MIL-S-901D Vendor LW/MW Shock Test Procedure (STP) Template & Guidance
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Distribution Statement C. Distribution authorized to U.S. Government agencies and their contractors; [reason]; [date]. Other
requests for this document shall be referred to [controlling DoD office].
WARNING - This document contains technical data whose export is restricted by Arms Export Control Act (Title 22, U.S.C.,
Sec. 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq.). Violations of
these export laws are subject to severe criminal penalties. Disseminate in accordance with the provisions of DoD Directive
5230.25.
Revision A
Dated 6/29/06
Table of Contents
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Title/Description
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Scope of the MIL-S-901D Vendor LW/MW Shock Test Procedure Template & Guidance ii
Instruction Key to the MIL-S-901D Vendor LW/MW Shock Test Procedure Template & Guidance ii
MIL-S-901D Vendor LW/MW Shock Test Procedure Template 1
A. PURPOSE 1
B. REFERENCES 1
C. UNIT UNDER TEST 3
D. TEST ACCEPTANCE CRITERIA 4
E. SHOCK TEST SET-UP 6
F. PRE-TEST INSPECTION 6
G. CONDUCT OF SHOCK TEST 6
H. POST-SHOCK TEST INSPECTION 9
I. RECONDITION & REFURBISHMENT 11
J. TEST REPORT 11
K. DATA SHEETS 12
L. ATTACHMENTS 12
M. SAMPLE SHOCK TEST DATA SHEET 13
Appendix A: General Appearance of Vendor LW/MW Shock Test Procedure A-1
Appendix B: Test Failure Analysis/Corrective Action Report B-1
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Scope of the MIL-S-901D Vendor LW/MW Shock Test Procedure Template & Guidance :
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This Vendor LW/MW Shock Test Procedure Template elaborates on the basic requirements of
MIL-S-901D for convenience and guidance, but does not provide any additional information beyond what
already exists in MIL-S-901D or the Data Item Description (DID) DI-EVNR-80709, “High-Impact Shock
Test Procedures” of MIL-S-901D. This template should be used for guidance only, and in no way relieves
the vendor from meeting all requirements of MIL-S-901D, component procurement specifications,
Appendix L of the purchase order, or any other contractually invoked requirements as applicable. The sole
purpose of this template is to provide the vendor with direction and a format when developing lightweight
and medium weight shock test procedures. The vendor is required to meet the contents of DID DI-EVNR-
80709. All shock testing in accordance with MIL-S-901D shall be conducted at an approved shock test
facility in accordance with Paragraph 4.2 of MIL-S-901D.
Instruction Key to the MIL-S-901D Vendor LW/MW Shock Test Procedure Template & Guidance :
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Text below is color coordinated to reflect direction. Text in BLACK is text that shall be included in
the Vendor Shock Test Procedure. Red italicized text captured in parentheses (RED) is text that provides
the vendor with content variables and options that shall be included in the Vendor Shock Test Procedure.
Only the applicable option shall be included. Blue italicized text captured in brackets [BLUE] is text that
provides direction to the vendor when writing the shock test procedure and should not be included in the
shock test procedure. In the event that the Vendor LW/MW Shock Test Procedure Template is received by
the vendor in a black and white version, the italicized text and “parentheses” or “bracket” indication will
allow the user to differentiate between what text shall be included and what text is for informational
purposes or poses an option. Appendix A is provided as a format example for a LW or MW shock test
procedure.
[The Vendor LW/MW Shock Test Procedure shall include at a minimum the following information.]
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[MIL-S-901D Vendor LW/MW Shock Test Procedure Template and Guidance]
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A. PURPOSE
The purpose of this (lightweight or medium weight) shock test is to prove the shock adequacy of the
(Component Name), Reference (a). The (Component Name) is Grade (A or B), Class (I, II, III or I/II),
Type (A, B or C), (Deck, Hull or Mast) mounted with (unrestricted or restricted) orientation. [If
orientation is restricted, state how it is restricted, e.g. main axis is parallel to Fore/AFT axis of ship].
B. STP REFERENCES
[All applicable/appropriate references required to develop and execute the shock testing procedure
shall be listed.]
[The indicated References shall be included in all shock test procedures, but may not encompass all
that may be required for shock testing. Others shall be added as required and placed in order they
are referenced.]
(a) [Component Drawing] (Title, Drawing Number, Revision, & Revision Date)
(b) MIL-S-901D, Requirements for Shock Test, H.I. (High Impact), Shipboard Machinery,
Equipment, and Systems
(c) [Component acquisition specification]
(d) [Shock test purchase order – LDY/Vendor]
C UNIT UNDER TEST
Shock testing in accordance with MIL-S-901Dshall be conducted at an approved shock test facility in
accordance with Paragraph 4.2 of MIL-S-901D.
[This section shall contain any background information pertinent to shock testing. This could be
system requirements or exceptions to standard testing practices of MIL-S-901D, etc. ]
[This section shall also contain the following component information.]
1. Item:
a. Name: ________________________
b. Type: _________________________
c. Nomenclature: ____________________
d. Rating: ________________________
e. Service: ________________________
f. Part Number: ________________________(NGNN and/or Vendor, as applicable)
g. Military Specification and Technical Manual Numbers: ________________ [include revision
and/or date]
2. Manufacturer (Name, Address & Cage Code): __________________________
3. Model Number and Serial Number: ___________________________________
4. Size or Capacity (If Applicable): _____________________________________
5. Drawing Number (Sectional Assembly and Outline, Revision and Date):______
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_________________________________
6. Foundation Drawing (Revision and Date): [If known] _____________________
7. Installation Drawing (Revision and Date): [If known] ____________________
8. Approximately Overall Size:
a. Length: _______________
b. Height: _______________
c. Width: _______________
d. Diameter: _____________
9. Weight (component dry & wet weights, and total weight on anvil plate, including test fixture, wet
and dry)
a. Dry: ____________________
b. Wet: ____________________
c. Total Weight Including Test Fixture(Dry): ____________________
d. Total Weight Including Test Fixture (Wet): ___________________
[For LWSM the total weight on the anvil plate shall not exceed 550 lbs and for MWSM the total
weight on the anvil shall not exceed 7400 lbs.]
10. Height of Center of Gravity above base of equipment: ___________________
11. Contract and/or Purchase Order (LDY/Vendor): ____________________________
12. Requirements of MIL-S-901D
a. Test Category: (Lightweight or Medium Weight) ____________________
b. Grade: (A or B) ________________
c. Equipment Class: (I, II, III or I/II) ___________________
[For Class II and III, mount displacement shall not exceed 1.5” for LWSM and 3” for
MWSM]
d. Shock Test Type: (A, B or C) __________________
[Type C tests shall only be preformed when specified by acquisition documents or approved
by acceptance authority.]
e. Mounting Location: (Deck, Hull or Mast) _____________
f. Test Fixture (s): (Figure 7 through Figure 12 of MIL-S-901D for LWSM and, Figure 13
through Figure 18 of MIL-S-901D for MWSM or Non-Standard Test Fixture)____________
[If a non-standard test fixture is used, provide drawing number, calculations and approval to
use the non-standard test fixture as required per paragraph 3.1.6.1 or 3.1.6.2 of MIL-STD-
901D. ___________________________________________________________
___________________________________________________________ ]
13. Mounting Aboard Ship
a. Plane: (Base, Front, Face, Back, Top, In-Line, Combination (w/ Description) or Other (w/
Description)) ____________________
b. Orientation: (Restricted or Unrestricted) _____________ [For restricted orientation,
explanation is required for MW items) _______________________________________]
[i.e., describe the shipboard orientation and corresponding restriction to be represented
during test - e.g. Display faces athwartship – test with display facing down 30 degree incline;
or shaft oriented fore/aft – test with shaft perpendicular to direction of 30 degree incline, etc.]
14. Hold-down fasteners or locating devices used for attachment of items to their foundation or test
fixture during shock tests [Identification of mounting fastener details is required to ensure the
same or better is used aboard ship.]
a. Grade: __________________
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b. Size: __________________
c. Material: ________________
d. Specification: ____________________
15. Hold-down bolt torque: _____________________[if specified]
16. Description of Resilient/Shock Mounts, if used: _______________________
[Government approval is required for the use of Shock Mounts] [Identify mount vendor and part
number(s).]
17. Operating Modes: [Describe the number and type(s) of significant operating modes of the
component. Identify which modes will be represented during testing]
___________________________________________
18. Major components and attached items in test (name, identification, manufacturer). [This includes
shipboard interface and any dummy weight(s) used. In general, any attachment that introduces
significant load or support shall be represented. If dummy weight(s) are used, an explanation
and description must to be provided on the basis for their selection. Drawing(s)/Sketch(es) of the
dummy weight(s) shall be provided in the shock test procedure.]
________________________________________________
________________________________________________________________
19. Test Laboratory and address: _______________________________________
20. Test instrumentation and monitoring equipment, if any: [Identity type and specific locations of
any test instrumentation).
______________________________________________________________________________
_____________________________________________ ]
21. Witnessed by Government Representative: (Yes or No) __________
[Representative(s) may witness on a sampling basis, shock testing, post-shock testing and
functional testing as defined in section 4.4 of MIL-S-901D]
22. (Additional Information:) [Any additional information pertinent to a full description of the shock
test. _______________________________________
______________________________________________________________ ]
D. TEST ACCEPTANCE CRITERIA
[This consists of pre-determined testing parameters as required by MIL-S-901D) and applicable
component or shipbuilding specifications, applicable acquisition documents and other appropriate
criteria developed by the component vendor. General shock test criteria are defined in Section 3.1.10
of MIL-S-901D. This will be the criteria by which the component will be evaluated to during shock
testing and post-shock testing/inspection.]
This section shall contain, but not limited to the following:
a. Minimum acceptable performance parameters
i) Alignment
ii) Dielectric Strength
iii) Pressure-tight integrity
iv) Deformation
v) Clearances
vi) Input-Output of Component
vii) Operating temperatures (bearing and coil winding)
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b. Extent of momentary malfunction, if permitted
c. Degree of permanent functional impairment allowed
d. Allowable leakage, if permitted]
[Acceptance criteria detailed below shall be included in all shock test procedures, but does not
encompass all acceptance criteria for shock testing. Other detailed acceptance criteria are required
to be added as appropriate. Acceptance criteria shall be objective rather than qualitative to the
extent practical. Objective values shall include a limit or tolerance. For example, if a component
needs to have a certain resistance reading, the acceptance criteria could state that the resistance
value shall be 100 Ω ± 0.05 Ω. Satisfaction of noise and vibration standards is not required.]
[Identification of momentary malfunctions which are acceptable during shock testing. Paragraph
3.1.10.1(d) of MIL-S-901D provides direction for acceptability of momentary malfunctions.
Examples are provided in Paragraph 6.4(t) of MIL-S-901D.]
1. The (Component Name), portions thereof, or the contents thereof shall not come adrift or result in
a condition which may create a hazard, thereby, causing possible damage to Grade A equipment
or injury to personnel operating or manning Grade A equipment. (Items that will not violate this
criteria and whose release is permissible are: _____________________ ) [All items shall satisfy
criteria 1 at a minimum. Note, this is typically the sole criteria for Grade B items. Identify those
items specific to the test unit which the vendor concludes are likely to be released but present no
hazard potential. (e.g., water leak, small label plates, etc). List to be specific and closed ended.]
2. The (Component Name) shall not suffer unacceptable degradation of its performance, utility, or
substantial shorting of its useful life. Physical damage not violating this requirement, such as
small cracks, minor yielding, and out-of-tolerance clearances, are permissible. [ For Grade A
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items (per B.12.b) only , criteria 3 and 4 shall be included in all shock test procedures and shall
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satisfy the letter and intent of Section 3.1.10.1 of MIL-S-901D. Momentary malfunction (that is
automatically self-correcting / manually correctable) (is/is not) permissible for this item. Where
applicable, explicitly define whether momentary malfunction or other temporary performance
degradation is permitted.]
3. [Specific requirements][Add other detailed acceptance criteria based on the acquisition specs
and particularly the vendors insights as appropriate.
a. Examples of Possible Acceptance Criteria Statements
i. Injurious, flammable, radioactive, acidic, caustic, or otherwise hazardous agents shall not
be released. The (Component Name) shall not demonstrate a potential for fire hazards
including any evidence of electrical shorts, release of flame, smoke or sparks. The
following lists those issues applicable to the (Component Name): _________________
[The vendor shall positively identify those additional hazards that may issue from the test
item.]
E. SHOCK TEST SET-UP
[This section shall consist of step by step instructions explaining in order, how to set-up the shock
test. This shall include reference to drawing(s), sketch(es) and/or schematic(s).]
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[Deck mounted Class II and Class I/II equipment may be subject to limitations that may prevent the use
of the lightweight or medium weight shock machine (see 3.1.6.1 or 3.1.6.2 of Reference (a)).]
[Principal units shall be mounted for testing in a manner which dynamically simulates the most severe
mounting condition likely to be encountered in the actual shipboard installation. For Class I/II
Principal units, this may result in a requirement for both Class I and Class II testing. Class II principal
units containing mounts that exhibit viscous damping, (e.g., dashpot, oil dampers, but not including
material (hysteretic) damping) shall be treated as Class I/II.]
[Mast mounted items shall be tested on a machine and fixture as proposed by the Contractor and
approved by the Acceptance Authority.]
[All subsidiary components which comprise a principal unit shall be shock tested with the principal
unit unless the acceptance authority specifically permits simulation of one or more (but not all) of a
group of identical subsidiary components which are installed in the principle unit (see 6.2.1). Dummy
masses used for simulating subsidiary components shall possess the same fundamental dynamic
characteristics and means of attachment as the actual subsidiary component. For dummy masses, the
fundamental dynamic characteristics shall be considered to be the same if they have the same mass (±
10%), C.G. relative to the points of attachment (± 10%), and mass moment of inertia (± 10%).]
[Test configuration:
Details of the set-up required and mounting orientation for performance of shock testing shall be
provided. An engineering sketch or drawing shall be developed and provided as a figure or
attachment to the shock test procedure. Sufficient information should be provided via the
description and sketch/drawing to build the test set-up. The following information shall be
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included in the sketch/drawing as applicable for all three mounting orientations: hangers, pipes,
dummy weights (piping, wiring, etc.), mounting plate, component outline, fabrication details,
location and size of fasteners and welds. Whenever possible, the set-up for the pre-shock test and
shock test should be identical. All material/instrumentation/special equipment to support testing
(pre-test, shock test and post-test) shall be identified in a list of material/special equipment. The
component shall be mounted in accordance with the mounting requirements section of MIL-S-
901D, Paragraph 3.1.6. The total weight on anvil table shall be recorded. For LWSM the total
weight shall not exceed 550 lbs and for MWSM tests the total weight on the anvil plate shall not
exceed 7400 lbs.] S
[Simulation of items:
Simulation of items (e.g. dummy weights) during shock testing shall be in accordance with MIL-S-
901D, Section 3.1.7 and the acquisition specification.]
[Simulation of operating conditions:
If a required operational condition is impracticable, define a simulation technique to be used for
acceptance authority approval.]
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F PRE-SHOCK TEST INSPECTION
[Pre-testing requirements are to be clearly stated in this section. Testing requirements from MIL-S-
901D, MIL-STD-798, as modified by the CVN Shipbuilding Specification, or any other applicable
component or shipbuilding specifications should be used to develop pre-testing criteria. The
requirements of pre-testing are similar to production test criteria. The pre-test inspection shall
consist of step by step instructions, in sequential order for carrying out the pre-test inspections
and/or tests. Where post-test inspections or tests are required, these same inspections shall be done
as part of the pre-test inspections or tests to ensure a proper baseline of comparison.]
[Pre-test requirements for Grade A items may include, but are not limited to: hydrostatic tests,
leakage tests, operational tests, torque, dielectric, continuity, insulation resistance. No dimensional
examinations are needed unless required by component specifications. However, a visual inspection
shall be completed to ensure there has been no damage due to shipping and handling.]
[Grade B items do not require operability pre-test inspection, since MIL-S-901D does not require
Grade B components to operate following a shock event and states that they do not require
operational testing following shock testing. However, in order to establish a baseline for
performance, it is recommended that pre-test inspections be performed on Grade B items to
demonstrate they do not present a hazard (e.g. retain hydrostatic pressure, no electrical shorts, no
leakage of hazardous gas or liquids, etc)]
[See also, the commentary under Section F.3, Conduct Shock Test regarding pre-test fastener
measurement.]
[All findings, results, comments, etc shall be documented in the proper section of the attached shock
test procedure data sheets.]
G. CONDUCT OF SHOCK TEST
[The minimum information needed to shock test the component is identified in this section.
Paragraphs 3.1.2 (a) & (b), 3.1.8 through 3.1.8.2 and 3.1.8.4 through 3.1.8.6, all of MIL-S-901D,
should be reviewed to identify applicable requirements.]
[For each orientation to be tested, the following information shall be specified:
a. Equipment normal operating mode during each set of shock blows with the parameters that
make up the operating mode. Grade A equipment must be shock tested in each normal
operating mode, position or condition. Equipment shall also be tested at the rated pressures
and conditions. See MIL-STD-798, Section 11, Table V as modified by the CVN Shipbuilding
Specifications for valves, valve operators, and special fittings operating conditions. For
components that have many operating conditions, representative conditions that are judged
critical by the cognizant component engineer can be represented during testing. Unless
otherwise judged critical by the cognizant component engineer or as specified by the
acquisition specification, no more than three most significant operating conditions are
required to be shock tested.
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b. Groups and number of blows that must be performed for each orientation, MIL-S-901D states
the following:
(i) Lightweight components are subjected to one shock blow at each of 1, 3, and 5 feet for
three mutually perpendicular axes of the component being tested. The nine blow series is
conducted for each operating condition represented during the shock test.
(ii) Medium weight components are subjected to shock blows of varying hammer heights and
intensity, based on the total weight on the anvil plate of the medium weight machine.
Hammer heights and intensities shall be in accordance with Table 1 of MIL-S-901D.
Testing will be done using either six or nine shock blows to account for all mounting
orientations. Additional groups of blows may be necessary to cover all operating modes.
c. Tests and other inspections that follow each set of shock blows and/or each shock blow may
be required to demonstrate acceptability.
d. The applicable component procurement specification may identify requirements for
monitoring certain parameters continuously through the shock blow. An example of this
requirement could be monitoring for intermittent short circuits and open circuits in electrical
equipment.
e. Paragraphs 3.1.8.1 and 3.1.8.2 of MIL-S-901D, state that new components maybe substituted
for each additional set of nine blows for lightweight shock tests, if desired by the contractor or
substituted for components which have been exposed to six or more medium weight shock test
blows, subject to the approval of the acceptance authority.]
[This section shall contain, but not limited to the following:
a. Step by step instructions, in sequential order for carrying out the shock test
b. Test item normal operational requirements
i) Define equipment operating modes and settings during each set of shock blows per MIL-S-
901D 3.1.8.4.
(1) Grade B items shall be operating only where potential for violation of acceptance
criteria is increased.
(2) Grade A items shall be tested under load where practicable. See also Section D,
Shock Test Set-Up commentary.
(3) Continuous monitoring of certain parameters may be necessary for identification of
momentary malfunctions defined in the Section C, Test Acceptance Criteria.
Examples include intermittent short and open circuits, contact bounce, switch or
valve state and pressure loss.
(4) Functional tests maybe required between shock blows
(5) For Lightweight Shock Tests
(a) The nine blow series shall be repeated for each operating mode represented
(6) For Medium Weight Shock Tests
(a) The normal operating mode shall be represented during Groups I and III blows
and other operating modes shall be represented during Group II blows
(i) If there are 3 operating modes, there shall be two series of Group II blows
c. Mounting method to shock test machine, drawings/sketches, shall be included in the shock test
procedure.
d. If applicable, non-standard shock test fixture drawings shall be included in the shock test
procedure.
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e. Requirements, if any, for on-site evaluation of test instrumentation results. All test
instrumentation data evaluations needed to show either compliance or non-compliance with
the test acceptance criteria.
f. Any non-compliance shall be identified to the vendor to ensure recognition of discrepant
conditions via a corrective action report (located in Appendix B of this Template/Guidance)
before proceeding with additional shock blows.]
[Steps detailed below shall be included in all shock test procedures, but do not encompass all steps
that may be required for shock testing. Other detailed steps may be required to be added and placed
in sequential order.]
[All findings, results, comments, etc shall be documented in the proper section of the attached shock
test procedure data sheets.]
1. Perform the shock test in accordance with paragraph [if lightweight shock test] (3.1.8.1 of MIL-S-
901D for lightweight shock testing or [if medium weight shock test] 3.8.1.2 of MIL-S-901D for
medium weight shock testing). [If lightweight shock test] (The test shall consist of nine (9) blows,
three blows at hammer heights of 1, 3, and 5 feet, to be applied to each of the mutually
perpendicular axes) [additional blows may be necessary when there are 2 or more significant
operating modes] [or if medium weight shock test] (The test shall consist of X blows (of Y groups
of Z blows each) applied to the component. [Where X number of required shock blows are
applied as per MIL-S-901D Paragraph 3.1.8.2. The Y number of groups and Z number of blows
will depend on the number of operating modes and orientations of the component being tested as
defined by MIL-S-901D Paragraph 3.1.8.2. A minimum of 6 blows is required for restricted
orientation items and 9 blows for unrestricted (6 blows if using Figure 18 fixture). Additional
groups of blows may be necessary where there are two or more significant operating modes.]
[For medium weight shock test] For each group, the height of the hammer and anvil table travel
shall be as shown in Table 1 of MIL-S-901D.
2. Inspect the (Component Name) and mounting fixture after each blow for any damage (including
loose bolts, deformation, cracks, loose terminal connection, broken wires, or other condition in
violation of the acceptance criterion). [Components shall not be opened or disassembled between
shock blows to inspect. Only general visual inspections shall be completed following each blow.]
[Items can be added or subtracted depending on the component, use discretion.] [Any failure or
inelastic response in the test fixture invalidates the test.] Record finding on applicable Data
Sheet.
3. Fasteners (exposed bolting, screws, and similar exposed fasteners – equipment foundation bolts
included) can be retightened to a specified or pre-shock torque only after the first blow to account
for seating-in with no verification of fastener yielding. [If it is deemed necessary to retighten the
fasteners, the test facility is required to accurately measure the length of the fasteners before
equipment installation on the shock test fixture. After subsequent blows (blow #2 and follow-on
blows), it must be demonstrated as per Paragraph 3.1.8.6 of MIL-S-901D, that the bolts have not
lengthened and fastener loosening is caused by additional seating-in of mating surfaces. Seating-
in of mating surfaces is defined as a bearing surface crushing or a bearing surface being slotted,
allowing the bolts to loosen without yielding. Direction is per NAVSEA Letter, Naval Surface
Warfare Center, Carderock Division, Philadelphia, PA, 9072 SER 623/141, dated 11/22/00. If it
is deemed necessary to retighten the fasteners after each blow, detailed instructions shall be
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added to the shock test procedure (including pre and post-test sections), to address verifying the
length of the fasteners. For more direction, please contact the component cognizant engineer.]
4. If there is/are any shock test damage or failure(s), the vendor (and subsequently the Lead Design
Agent) shall be contacted via a corrective action report requesting direction to resolve
discrepancies. [A Test Failure Analysis/Corrective Action Report is located in Appendix B of this
Template/Guidance. Identify test instrumentation data evaluations needed to show compliance
with acceptance criteria (including criteria, if any, regarding momentary malfunctions) to ensure
recognition of discrepant conditions before proceeding with additional shock blows.]
5. Record the findings of each inspection on the applicable Data Sheet(s). [All findings, results,
comments, etc shall be documented in the Data Sheets (to be attached).]
6. Photographs shall be taken of every test setup and any damage.
H. POST-SHOCK TEST INSPECTION
[The minimum information needed to perform the post-shock test functional testing and inspections
on the shock tested component, are identified in this section. Paragraphs 3.1.9 through 3.1.9.2 of
MIL-S-901D and 3.2.4 of DI-ENVR-80708 should be reviewed to identify applicable requirements.]
[Post-test inspections demonstrate that the established acceptance criteria have been successfully
met.
a. Grade A functional testing (see pre-test requirements) and inspection(s) are required per
MIL-S-901D to establish post-shock test acceptance. An inspection, including disassembly, is
needed to find any breakages, deformations, misalignments or any other condition that would
be a cause for failure. Only dimensions of critical tolerance areas should be checked. Where
cracking would be a cause for failure, areas that are highly stressed may be required to be
checked for cracks using dye penetrant, magnetic particle or other tests.
b. Grade B components need only be inspected to determine the existence of any condition that
could create a hazard causing possible damage to Grade A equipment or injury to personnel
operating or manning Grade A equipment (failure to hold pressure and electrical shorts). A
visual inspection can verify if all parts of the component are intact and/or contained.
Operability is not a criterion for failure.]
[Where practicable, perform all inspections at the test site.]
[This section shall contain, but is not limited to the following:
a. Inspection Procedures following shock testing:
i) Breakage
ii) Deformation
iii) Yielding
iv) Misalignment
v) Unbalance
vi) Cracks (visual, dye penetrate, radiographic or magnetic particle)
vii) Separation
viii) Critical tolerance clearances
ix) Bolting torques
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b. Tests following shock testing
i) Functional tests to include:
(1) Input-Output of component or equipment
(2) Operating temperatures (bearing and coil winding)
(3) Cyclic operations to determine compliance with design specifications
(4) Tests assessing satisfaction of Section C, Test Acceptance Criteria
ii) Hydrostatic tests to include:
(1) Hydraulic, pneumatic, and fluid systems equipment
(2) Demonstration of strength
(3) Leakage
iii) Electrical
(1) Insulation breakdown (shorts)
(2) Electrical Continuity
(3) Dielectric Strength]
[Requirements, if any, for on-site evaluation of test instrumentation results. All test instrumentation
data evaluations needed to show either compliance or non-compliance with the test acceptance
criteria.]
[If there is/are shock test failure(s), the vendor shall be contacted via a corrective action report
(provided in Appendix B of this Template/Guidance) requesting direction to resolve discrepancies
and they may be resolved in accordance with Paragraph 3.1.11 of MIL-S-901D.]
[Post-shock test inspections/requirements in most cases shall be identical to the pre-shock test
inspections/requirements detailed in the above section. If post-shock test inspections or tests are
required, the inspections shall be done as part of the pre-shock test inspections or tests to ensure a
proper baseline of comparison.]
[Steps detailed below shall be included in all shock test procedures, but do not encompass all steps
required for post-shock test inspections. Other detailed steps may be required to be added and
placed in sequential order.]
[All findings, results, comments, etc shall be documented in the proper section of the attached shock
test procedure data sheets.]
1. Visually inspect the (Component Name) and mounting fixture following the shock test for loose
bolts, deformation, cracks, loose terminal connection, broken wires or any other damage or any
condition in violation of the acceptance criteria. [Any failure or inelastic response in the test
fixture invalidates the test.]
2. [Examples of Possible Post-Test Inspection Statements
a. On-site evaluation of test instrumentation results. Identify test instrumentation data
evaluations needed to show compliance with acceptance criteria (including criteria, if any,
regarding momentary malfunctions) to ensure recognition of discrepant conditions.
b. After testing is completed conduct functional tests. Functional testing is required only for
Grade A items. Define tests that verify each objective or qualitative performance requirement
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in the Acceptance Criteria. Functional tests may be performed after completion of all testing
at the risk of discovering damage requiring a complete retest.
c. Conduct the following inspections after completion of shock and/or functional testing.
Identify those efforts, such as detailed tear-downs, conducted after completion of testing.]
3. Record the findings of each inspection on the applicable Data Sheet(s). [All findings, results,
comments, etc shall be documented in the Data Sheets (to be attached).]
4. If there is/are shock test failure(s), the vendor shall be contacted via a corrective action report
requesting direction to resolve discrepancies. [A Test Failure Analysis/Corrective Action Report
is located in Appendix B of this Template/Guidance. Identify test instrumentation data
evaluations needed to show compliance with acceptance criteria (including criteria, if any,
regarding momentary malfunctions) to ensure recognition of discrepant conditions before
proceeding with additional shock blows.]
5. Photographs shall be taken of all damage.
I. RECONDITION & REFURBISHMENT
[When the testing is complete, the component(s) should be reconditioned and refurbished as required
by the subject procurement or component specification to assure compliance with all applicable pre-
delivery requirements. If component can not be reconditioned and refurbished to the subject
procurement or component specification, the component shall be discarded as directed by the
manufacturer or component cognizant engineer. Refurbishment should not be conducted where its
cost would exceed that of a wholly new unit.]
[Steps detailed below shall be included in all shock test procedures, but do not encompass all steps
that may be required for reconditioning and refurbishment. Other detailed steps may be required to
be added and placed in sequential order.]
1. Upon completion of shock testing and post-shock test examination, the (Component Name) shall
be reconditioned and refurbished to pre-shock test condition. If the (Component Name) can not or
should not be reconditioned or refurbished, the component shall be discarded per direction of the
manufacturer or component cognizant engineer. Any piping system castings, fittings, or other
components that have been subjected to shock testing shall not be installed in the ship on the sea
side of any hull valve.
J. TEST REPORT
[Items detailed shall be included in all shock test reports. These may not encompass all items
S S
required by the procurement specifications or necessary to a complete description of the tests and
their results. Other content shall be added as required or appropriate.]
1. At the conclusion of shock and post-shock testing, prepare a shock test report in accordance with
DID DI-ENVR-80708 of Reference (b).
2. The report shall include
Page 11
Revision A
Dated 6/29/06
a. A comparison between the pre-shock tested and the post-shock tested component
configuration.
b. A comparison between the pre-shock test and post-shock test measured operational
performance.
c. The recorded data (as applicable) shall be provided in the shock test report. The acceleration
data shall be filtered at 250Hz through a low pass 2 pole filter and plotted. The data shall also
be provided in an agreed electronic format, both filtered and unfiltered.
d. The shock test procedure shall be an attachment to the shock test report.
e. Pictures shall be included in the shock test report of all tested arrangements and any damage,
yielding, or anomalies that occurred during or after the shock test.
K. DATA SHEETS
[This section shall contain a list of the data sheets required for the shock test. Data sheets shall be
included in the shock test procedure to document all pre-shock test, shock test, and post-shock test
requirements/inspections/tests. An example data sheet is provided at the end of the template.]
L. ATTACHMENTS
[Items listed shall be included in all shock test procedures as applicable, but may not encompass all
items that may be required or appropriate. Other items may be required to be added and placed in
sequential order.
(1) Drawings/sketches showing Mounting Details and arrangement on shock test machine mounting
fixture
(2) Shock test intermediate structure/foundation drawings/sketches
(3) Mounting Fixture drawing/sketch (any non-standard mounting fixtures shall include justification
for suitability and calculations which demonstrate adequacy)
(4) Pre/Post Test Sensor Output Signal Test Sketch
(5) Electric Schematic]
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Revision A
Dated 6/29/06
M. SAMPLE SHOCK TEST DATA SHEET
[SAMPLE ONLY]
U
Page 13
Appendix A
General Appearance of Vendor LW/MW Shock Test Procedure
A-1
The proceeding pages reflect the general appearance of the template with all guidance and variables
removed. This is provided to show the preparer of the Vendor LW/MW Shock Test Procedure what the
procedure should resemble. The blank spaces (____________) below represent variables that would be
chosen for the specific unit under test. Certain sections are left blank since they are specific to the unit
under test.
A-2
A. PURPOSE
The purpose of this ____________shock test is to prove the shock adequacy of the __________
Reference (a). The ____________ is Grade ______ Class ______ Type ____, _______ mounted with
________ orientation.
B. STP REFERENCES
(a) _____________(Component Drawing, etc.)
(b) MIL-S-901D, Requirements for Shock Test, H.I. (High Impact), Shipboard Machinery,
Equipment, and Systems
C. UNIT UNDER TEST
Shock testing in accordance with Reference (b) shall be conducted at an approved shock test facility
in accordance with Reference (b) Paragraph 4.2.
1. Item:
a. Name: ________________________
b. Type: _________________________
c. Nomenclature: ____________________
d. Rating: ________________________
e. Service: ________________________
f. Part Number: ________________________
g. Military Specification and Technical Manual Numbers: ________________
2. Manufacturer (Name, Address & Cage Code): __________________________
3. Model Number and Serial Number: ___________________________________
4. Size or Capacity (If Applicable): _____________________________________
5. Drawing Number (Sectional Assembly and Outline, Revision and Date):______
_________________________________
6. Foundation Drawing (Revision and Date): _____________________
7. Installation Drawing (Revision and Date): ____________________
8. Approximately Overall Size:
a. Length: _______________
b. Height: _______________
c. Width: _______________
d. Diameter: _____________
9. Weight (dry, wet, and total weight including test fixture, wet and dry)
a. Dry: ____________________
b. Wet: ____________________
c. Total Weight Including Test Fixture(Dry): ____________________
d. Total Weight Including Test Fixture (Wet): ___________________
10. Height of Center of Gravity above base of equipment: ___________________
11. Contract and/or Purchase Order: ____________________________
12. Requirements of Reference (b)
a. Test Category: ____________________
A-3
b. Grade: ________________
c. Equipment Class: ___________________
d. Shock Test Type: __________________
e. Mounting Location: _____________
f. Test Fixture (s): ____________
13. Mounting Aboard Ship
a. Plane: _______________
b. Orientation: _____________
14. Hold-down fasteners or locating devices used for attachment of items to their foundation or test
fixture during shock tests
a. Grade: __________________
b. Size: __________________
c. Material: ________________
d. Specification: ____________________
15. Hold-down bolt torque: _____________________
16. Description of Resilient/Shock Mounts, if used:
a. Size: __________________
b. Type: __________________
c. Location: ________________
d. Specification: _____________
17. Operating Modes: ___________________________________________
18. Major components and attached items in test (name, identification, manufacturer).
_____________________________________________________________________
19. Test Laboratory and address: _______________________________________
20. Test instrumentation and monitoring equipment, if any:_______________________________
21. Witnessed by Government Representative: __________
D. TEST ACCEPTANCE CRITERIA
1. The ____________, portions thereof, or the contents thereof shall not come adrift or result in a
condition which may create a hazard, thereby, causing possible damage to Grade A equipment or
injury to personnel operating or manning Grade A equipment.
2. The __________ shall not suffer unacceptable degradation of its performance, utility, or
substantial shorting of its useful life. Physical damage not violating this requirement, such as
small cracks, minor yielding, and out-of-tolerance clearances, are permissible.
E. SHOCK TEST SET-UP
F. PRE-SHOCK TEST INSPECTION
G. CONDUCT SHOCK TEST
1. Perform the shock test in accordance with paragraph 3.8.1.2 of Reference (b) for medium weight
shock testing. The test shall consist of 9 blows (of 3 groups of 3 blows each) applied to the
A-4
component. For each group, the height of the hammer and anvil table travel shall be as shown in
Table 1 of Reference (b).
2. Inspect the ___________ and mounting fixture after each blow for loose bolts, deformation,
cracks, loose terminal connection, broken wires, or other condition in violations of the acceptance
criterion. Record finding on applicable Data Sheet.
3. Fasteners (exposed bolting, screws, and similar exposed fasteners – equipment foundation bolts
included) can be retightened to a specified or pre-shock torque only after the first blow to account
for seating-in with no verification of fastener yielding.
4. If there is/are shock test failure(s), the vendor shall be contacted via a corrective action report
requesting direction to resolve discrepancies.
5. Record the findings of each inspection on the applicable Data Sheet(s).
6. Photographs shall be taken of every test setup and any damage.
H. POST-SHOCK TEST INSPECTION
1. Visually inspect the_________ and mounting fixture following the shock test for loose bolts,
deformation, cracks, loose terminal connection, broken wires or other condition in violation of the
acceptance criteria.
2. Record the findings of each inspection on the applicable Data Sheet(s).
3. If there is/are shock test failure(s), the vendor shall be contacted via a corrective action report
requesting direction to resolve discrepancies.
4. Photographs shall be taken of all damage.
I. RECONDITION & REFURBISHMENT
1. Upon completion of shock testing and post-shock test examination, the____________ shall be
reconditioned and refurbished to pre-shock test condition. If the ____________ can not or should
not be reconditioned or refurbished, the component shall be discarded per direction of the
manufacturer or component cognizant engineer.
J. TEST REPORT
1. At the conclusion of shock and post-shock testing, prepare a shock test report in accordance with
DID DI-ENVR-80708 of Reference (b).
2. The report shall include
a. A comparison between the pre-shock tested and the post-shock tested component
configuration.
b. A comparison between the pre-shock test and post-shock test measured operational
performance.
c. The recorded data (as applicable) shall be provided in the shock test report. The acceleration
data shall be filtered at 250Hz through a low pass 2 pole filter and plotted. The data shall also
be provided in an agreed electronic format, both filtered and unfiltered.
d. The shock test procedure shall be an attachment to the shock test report.
e. Pictures shall be included in the shock test report of all tested arrangements and any damage,
yielding, or anomalies that occurred during or after the shock test.
A-5
K. DATA SHEETS
L. ATTACHMENTS
A-6
A-7
Appendix B
Test Failure Analysis/Corrective Action Report
B-1
TEST FAILURE ANALYSIS/
CORRECTIVE ACTION REPORT
Date________
Sheet __ of __
VENDOR: P.O. NUMBER: PREPARED BY:
ITEM: APPROVED BY:
INFORMATION REQUIRED
1. Test Date
2. Type of Test
3. Test Failure Cause Analysis
4. Corrective Action Taken
USE OF ADDITIONAL SHEETS AS REQUIRED
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