JAP 100A 01 Chap 14.6-UNCONTROLLED COPY WHEN PRINTED-Lifing of Explosives and Associated Ancillaries

Modern explosives are generally both costly and time-consuming to develop and procure, or to modify. It is therefore essential to realize the maximum safe life of explosives and to avoid early and expensive replacement or modification. Therefore, explosives and many of their associated ancillary items are subject to lifing procedures. The regulations governing lifing of explosives are both complex and specialist by nature, but are driven by the requirements of JSP 520, 4STANAG 4315 and AOP-46.3 This chapter seeks to regulate, in basic terms, the policy for lifing of explosives (including aerospace components that contain explosives) and associated ancillaries (such as suspension lugs) in the Military Air Environment (MAE). Should further advice be required, the Integrated Project Team (IPT) for the explosive concerned should be approached. Further information regarding the lifing of aerosystem components can be found in Chapter 5.3.1.

1.2 Associated publications

This chapter is associated with the following publications:

1 JSP 430 – Ship Safety Management Code.

2 JAP 100A-01 Chapter 14.1 – Organizations Responsible for Ordnance, Munitions and Explosives Safety.

1.3 Terms used

Throughout this chapter the term life extension is used to refer to the increase of the life of an explosive beyond its previously assessed life. Additionally, definitions of the following terms are contained in Chapter 0.4:

2 Policy on lifing of explosives and associated ancillaries

Explosive stores (including explosives in Aircraft Assisted Escape Systems (AAES)) and components containing explosive stores, and many non-explosive ancillaries such as suspension lugs, are to be allocated a life, which is known as the Service Life. This Service Life may include a Storage Life and/or an Operational Life.

3 Initial determination of explosives lives

After identifying that an explosive/ancillary is to be lifed, which is achieved wherever possible using whole life assessment planning as laid down in 4STANAG 4315 and AOP-463, and in consultation with the Defence Ordnance Safety Group (DOSG), IPTs are to determine, for each manner of failure that merits allotment of a life, the most cost-effective activity (eg maintenance, reconditioning or disposal) which will minimize the occurrence of failures in that manner. Where an explosive/ancillary has more than one mode of failure, a different maintenance activity may be required for each mode, thus giving it a number of lives, eg bay maintenance life, reconditioning life and disposal life.

3.1 Justifying explosives lifing

The assessment of explosives failure is carried out using data drawn, variously, from the Designer Safety and Suitability for Service (S³) trials, fault/performance reports, in-service surveillance, or from in-service experience; which determine that a failure will occur at a predictable stage within the maximum life envisaged for the explosive. Where, through lack of necessary data, an IPT is unable to allot a life to an in-service or new explosive or ancillary in accordance with Designer/DOSG recommendations, the explosive/ancillary is to be allotted a provisional storage, operational, maintenance, reconditioning or disposal life, as appropriate. The explosives concerned are then to be subject to a review of lifing measures or, if newly developed, to continued S³/qualification/testing in accordance with JSP 482 and/or JSP 520. The assessment of provisional lives may affect expenditure on initial provisioning and maintenance facilities. It is therefore desirable that any provisional lives allotted are the longest lives that can safely be permitted in the circumstances.

3.2 Approval of explosives maintenance policy

The responsibility for approving the maintenance policy for explosives/explosive components/ancillaries is vested in the appropriate IPT. Due to the costs involved in this exercise, the IPT, when deciding the maintenance life of an explosive in a failure mode that is not critical, must be confident that the expected improvement in availability or in-service life support costs will outweigh other considerations.

3.3 Example of explosives lifing

The following shows how an explosive item’s life may be determined:

1 The explosive item has a Service Life of 6 years, a Storage Life of 6 years and an Operational Life of 2 years. Therefore:

1.1 Service Life – The item will remain serviceable and safe for a maximum of 6 years calculated from the last day of the month of the year of filling.

1.2 Storage Life – The item will remain serviceable and safe in storage for a maximum of 6 years calculated from the last day of the month of the year of filling. The date calculated is not to exceed the Service Life.

1.3 Operational Life – The item may be installed in/loaded to a component/weapon/platform at any time during its Service/Storage Life. However, if for example the item is brought into use during the last 2 years of its Service/Storage Life, some of the Operational Life will be lost. The Operational Life is not to exceed the Service Life.

Note:

The prescribed lifing of an explosive in the MAE may vary if the item concerned is to be stored/operated in the Sea environment.

4 Promulgation of explosives lives

The responsible IPT is to publish explosives lives in one (or more if appropriate) of the media listed below; however, if the explosive is contained within a platform component the requirement to publish the life in the aircraft Topic 5A1 or equivalent publication is mandatory:

1 The Component Life Register (CLR) and Component Replacement List of the relevant Topic 5A1 or equivalent publication (and, if appropriate, the Topic 5K) in accordance with the requirements of Chapter 8.1.1.

2 The appropriate Topic 2(N/A/R)1 or Ammunition and Explosive Regulations (A&ER) Pamphlet.

3 Section 2 of the 4Joint Service Munitions Control Register.3

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In the case of lifed explosives with a multi-user application, the IPT is to ensure that relevant platform/equipment IPTs are advised of any lifing requirements.

Note:

Promulgation of Service/Operational Life to RN Stns/Ships/Units is also carried out using a 4Defence Information Notice (DIN).3

4.1 Changes to explosives lives

The promulgation of amendments to/review of published explosives lives is to be managed by the responsible IPT. Stns/Ships/Units may be provided with advanced notification of the changes by issuing one (or more, if appropriate) of the following:

1 Routine Technical Instruction; see Chapter 10.5.3. Advanced notification may allow units to change and/or segregate explosives pending the receipt of formal amendment to the Topic 5A1. Advanced notification action is particularly important where component lifing details are contained electronically (eg LITS or WRAM) and the system affords IPTs the ability to amend details centrally.

2 Advanced Information Leaflet to the appropriate Topic 2(N/A/R)1 or A&ER Pamphlet; see Chapter 8.2.2.

3 Signal amendment to the 4Joint Service Munitions Control Register.3

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In the case of lifed explosives with a multi-user application, the IPT is to ensure that relevant platform/equipment IPTs are advised of any revised lifing requirements.

5 Recording of life consumption

A record of life consumed is to be maintained for every lifed explosive, component containing an explosive, or associated non-explosive ancillary.

5.1 Marking

With certain exceptions, lifed explosives, when first opened for use (or in the case of AAES explosives, at the point of installation), are to be marked in accordance with the instructions in the appropriate Topic 2(N/A/R)1 or Maintenance Procedure (eg with the life expiry date and the equipment/platform serial number) using a suitable or specified medium.

5.2 Engineering Record Cards (ERC)

When an explosive, a component containing an explosive, or a non-explosive ancillary is introduced into service, the IPT is to determine whether the item requires an Engineering Record Card (ERC). The requirement for an ERC is normally determined during the logistic support analysis process. The IPT is to specify ERC requirements and promulgate them in the relevant section of the Topic 5A1 or the appropriate Topic 2(N/A/R)1 or A&ER Pamphlet. Instructions for the use of ERCs for explosives are in paragraph 5.3 (see also Chapter 14.9). Alternatively, a record of life consumed may be maintained, if appropriate, wholly by an electronic system (such as LITS) and a hard copy of the ERC printed when required.

5.3 Use and control of ERCs for explosives

Unless otherwise stated in the Topic 2(N/A/R)1, user units are to maintain the following minimum information on ERCs:

1 Domestic Management Code, Section Reference Number, NATO Stock Number orAmmunition Descriptive Asset Code and Nomenclature.

2 Maker/filler, lot number and date or Batch Key Identity (BKI).

3 Serial number (if appropriate).

4 Where fitted/installed/exposed.

5 Date fitted/installed/exposed.

6 Hours/sorties flown.

7 Date removed/repacked.

When an explosive/ancillary is removed from a platform/equipment for maintenance, the ERC is to be completed with details of the removal, the life consumed, and the activity undertaken (eg periodic maintenance, component replacement, etc). If the explosive item/ancillary is sent to another Stn/Ship/Unit, the ERC is to be attached to the MOD F731 and dispatched with the item.

6 Latitudes to explosives lives

To facilitate maintenance planning and avoid unnecessary restrictions on system availability, some flexibility in the application of authorized lives to individual explosive items is essential. The latitudes permissible are detailed in paragraphs 6.1, 6.2, 6.3 and 6.4, though anticipation or extension of maintenance life may be limited or prohibited by the appropriate specialist regulations, the Front Line Command (FLC) or the responsible IPT.

6.1 Anticipation of explosives lives at Stn/Ship/Unit

An authority level J may authorize the anticipation of any explosive life expiry unless this action is prohibited in the Topic 2(N/A/R)1. Such anticipation has resource implications; therefore, when anticipating an explosive life expiry, every effort must be made to ensure that the action does not result in an MOD-wide shortage of the explosive item concerned. Stns/Ships/Units should therefore liaise with the responsible IPT beforehand.

6.2 Extension of explosives lives by the Integrated Project Team (IPT)

The IPT responsible for the item under consideration may, after considering all the relevant factors, authorize extensions to the Service/Operational Lives of explosives. This would normally be based on Designer/DOSG advice, but in certain circumstances (eg where operational capability may otherwise be adversely affected), an IPT may authorize an extension to the Service/Operational lives of explosives without such recourse.

6.3 Extension of explosives lives by the Front line Command (FLC) or Stn/Ship/Unit

The extension of an explosive’s Service/Storage or Operational Life at FLC or Stn/Ship/Unit level is prohibited regardless of whether it applies to either critical or non-critical failure modes. Requests for life extension should be made to the appropriate IPT, providing the following information:

1 Aircraft/component type and number (CLR reference if applicable) and quantity involved.

2 Maker/filler, lot number and date or BKI.

3 Present life consumed.

4 Type of life due and extension required.

5 Reason for request.

6 Planned date of component change.

7 New expiry date if extension granted.

8 Other considerations that may affect its life, eg storage conditions in a sea environment.

6.4 Extension of maintenance lives

Provided extension is permitted in the Topic 2(N/A/R)1, an authority level K may authorize extensions to maintenance lives as follows:

1 Up to 10% on components with lives allotted to safeguard against critical failure modes.

2 Up to 25% on components with lives allotted to safeguard against non-critical failure modes.

Stns/Ships/Units wishing to extend maintenance beyond these limits are to apply to the appropriate IPT stating how much extension has already been granted. In consultation with the IPT responsible for the explosive concerned, where appropriate, and after considering all the relevant factors, the IPT may further extend the maintenance life beyond the 10%/25% detailed above.

Note:

3 Before extending a maintenance life, a check is to be made to ensure that the extension granted does not compromise the Service/Operational Life of any explosive component fitted.

4 Critical and non-critical failure modes are described in Chapter 5.3.1.

7 Disposal of life-expired explosives

Explosives that have completed their Service/Operational life are an important source of material for life extension trials/proof testing. Stns/Ships/Units are therefore not to dispose of life-expired explosive/ancillary items without prior reference to the IPT concerned where no instructions for disposal are detailed in the Topic 2(N/A/R)1. Pending receipt of disposal instructions, Stns/Ships/Units are to store life-expired explosives under the same conditions as new stock.

8 References

This chapter refers to the following publications:

1 Ammunition and Explosives Regulations.

2 JSP 482 – MOD Explosives Regulations.

3 JSP 520 – Ordnance Munitions and Explosives Safety Management.

4 4STANAG 4315 – The Scientific Basis for the Whole Life Assessment of Munitions. https://nsa.nato.int/3

5 4Joint Service Munitions Control Register.3

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7 Topic 2(N/A/R)1 – General Orders and Special Instructions.

8 Topic 5A1 – Master Maintenance Schedule.

9 Topic 5K – Schedule of Component Lives.

10 4AOP-46 – The Scientific Basis for the Whole Life Assessment of Munitions.3