AFOP_7900.3_002.pdf

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Armstrong Flight Research Center AFOP-7900.3-002, Revision P-9 Edwards, California 93523 Expires November 1, 2022

Compliance is mandatory.

SUBJECT:

Aircraft Maintenance & Safety Manual (AM&SM)

RESPONSIBLE OFFICE:

Flight Operations Directorate

Aircraft Maintenance & Safety Manual (AM&SM) AFOP-7900.3-002, Revision P-9 Expires November 1, 2022

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AFOP-7900.3-002, Aircraft Maintenance & Safety Manual (AM&SM) Concurrence Signatures

By signing this concurrence, I accept the requirements that apply to my organization.

Dana Purifoy, Director Date

Ralph Anton, Branch Chief Date Safety & Environmental Branch

Thomas Grindle, Aircraft Maintenance Chief Date

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CONTENTS

CHAPTER 1 : INTRODUCTION

1.1 PURPOSE OF DOCUMENT

1.2 SCOPE, APPLICABILITY, & WAIVER

1.2.1 Scope

1.2.2 Applicability

1.2.2.1 Applicability Exception

1.2.3 Waiver Authority & Process

1.2.3.1 AM&SM Waiver Process

1.2.3.2 Waiver Database

1.2.4 Waiver Submission Process Flowchart

1.3 OBJECTIVES & METRICS

1.4 BACKGROUND

1.5 PROCEDURES & GUIDANCE

1.5.1 OSHA Requirements

1.5.2 Additions to AM&SM

1.5.3 Update & Review Requirements for AM&SM

1.5.4 Workplace Safety Standards

1.6 AIRCRAFT IMPOUND PROCEDURE

1.7 MANAGEMENT RECORDS & RECORDS RETENTION

1.8 RELEVANT DOCUMENTS

1.8.1 Authority Documents

1.8.2 Referenced Documents

1.8.3 Forms

CHAPTER 2 : AIRCRAFT SUPPORT ORGANIZATIONS AND CAPABILITY

2.1 PURPOSE OF CHAPTER

2.2 FLIGHT OPERATIONS DIRECTORATE ORGANIZATIONAL LAYOUT

2.3 CONTRACTING OFFICER REPRESENTATIVE (COR) RESPONSIBILITIES .. 33

2.4 FLIGHT OPERATIONS AIRCRAFT SUSTAINMENT OFFICE

2.5 AIRCRAFT MAINTENANCE GROUP

2.6 AIRCRAFT RECORDS BRANCH

2.6.1 Maintenance Operations Office

2.6.2 Technical Information Specialist

2.7 PROGRAM SPECIALIST, PRODUCTION CONTROLLER, ENGINEERING

TECHNICIANS, & MANAGEMENT ANALYST

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2.8 AVIONICS & INSTRUMENTATION BRANCH

2.8.1 Lead Avionics Technicians

2.8.2 Avionics Technicians

2.8.3 Communications, Navigation, & Video (CNV) Systems Shop

2.9 ENGINEERING SUPPORT BRANCH

2.9.1 Environmental Testing Group

2.9.2 Calibration Group

2.9.3 Telemetry Group

2.9.4 Electronics Fabrication Group

2.9.5 Electrostatic Discharge (ESD) Control Program

2.10 MAINTENANCE BRANCH

2.10.1 Aircraft Maintenance Crew Chief

2.10.2 Aircraft Mechanic

2.10.3 Engine Shop

2.10.4 Tool Crib

2.10.5 Support Aircraft

2.10.6 Aerospace Ground Equipment Support (AGE)

2.11 EXPERIMENTAL FABRICATION BRANCH

2.11.1 Machine Shop

2.11.2 Sheet Metal Shop

2.11.3 Fluids Shop

2.11.4 Composite Shop

2.11.5 Weld Shop

2.12 CHEMICAL CRIB

2.13 QUALITY INSPECTION BRANCH

2.14 QUALITY ASSURANCE BRANCH

2.15 OPERATIONS ENGINEERING BRANCH

2.16 FLIGHT CREW BRANCH

2.17 LIFE SUPPORT BRANCH

2.18 FLIGHT OPERATIONS AVIATION SAFETY

2.19 RESEARCH & ENGINEERING DIRECTORATE SUPPORT & FUNCTIONS

2.20 INFORMATIONAL LINKS

CHAPTER 3 : QUALIFICATION & TRAINING

3.1 PURPOSE OF CHAPTER

3.2 TRAINING REQUIREMENTS

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3.2.1 Certification Training

3.2.2 Exclusions

3.2.3 Responsibilities

3.3 CERTIFICATION TRAINING & RECERTIFICATION REQUIREMENTS

3.4 EGRESS/COCKPIT FAMILIARIZATION TRAINING

CHAPTER 4 : AIRCRAFT MAINTENANCE & MODIFICATION

4.1 PURPOSE OF CHAPTER

4.2 GENERAL MAINTENANCE

4.3 AIRCRAFT MAINTENANCE

4.3.1 Maintenance Plans

4.3.2 Aircraft Covered by Documentation

4.3.3 Aircraft with Modified Documentation

4.3.4 Control of Documentation

4.4 MAINTENANCE FORECASTING

4.4.1 Forecasted Maintenance Guide, OG/OM/OE

4.5 AIRCRAFT DOCUMENTATION

4.5.1 Major Subassemblies

4.6 HOW MAINTENANCE IS REQUESTED, AUTHORIZED, & PERFORMED

4.7 WORK ORDERS (WO)

4.8 GENERATION OF SYSTEM TEST PROCEDURES

4.9 WORK PERFORMED AT AFTC

4.10 AIRCRAFT MAINTENANCE CREW RESPONSIBILITIES

4.11 ENGINE MAINTENANCE

4.12 AIRCRAFT INSPECTIONS

4.12.1 Aircraft Acceptance Inspection

4.12.2 Preflight, Thru-Flight, & Postflight Aircraft Inspections

4.12.3 Major Aircraft Inspections

4.12.3.1 Periodic / Phase

4.12.3.2 Calendar

4.12.3.3 Special Inspection

4.12.4 Mandatory Closeout Photography/Mishap Inspection Requirements

4.12.5 Mandatory Closeout/Mishap Photography Procedure

4.13 NONDESTRUCTIVE INSPECTIONS (NDI)

4.14 LIFE SUPPORT & EGRESS MAINTENANCE

4.14.1 Life Support Systems

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4.15 REVIEWS & AUDITS

4.15.1 Cockpit Safety Review

4.15.2 Quality Assurance Audits

4.15.2.1 Audit Schedules

4.15.3 Airworthiness Reviews

4.16 CONFIGURATION & DRAWING CONTROL

4.17 MAINTENANCE DIRECTIVES

4.18 WEIGHT & BALANCE

4.19 DUTY HOURS & SHIFTS FOR MAINTENANCE PERSONNEL

CHAPTER 5 : AIRCRAFT SERVICING

5.1 PURPOSE OF CHAPTER

5.2 SERVICING

5.2.1 General

5.2.2 Risks and Hazards

5.2.3 Fueling & Defueling Operations for Aircraft Without Instructions

5.3 FUELING OPERATIONS SAFETY PRECAUTIONS

5.3.1 Fueling & Defueling Process

5.4 HYDRAULIC FLUID, ENGINE OIL, & GREASES

5.4.1 Safety Precautions

5.4.1.1 SKYDROL® Exposure Protocol

5.4.2 Sampling

5.4.3 Greases

5.5 OXYGEN PURGING & SERVICING

5.5.1 Oxygen Purging

5.6 TOXIC & EXOTIC FUELS

5.6.1 Hydrazine

5.6.2 Safety Precautions

5.7 HAZARDOUS SUBSTANCES & MATERIALS

5.7.1 Safety Precautions

5.7.2 Aircraft Pyrotechnic Operations

5.7.3 Explosives Loading Operations

5.7.4 Use of Chemicals

5.8 AIRCRAFT STORAGE & PRESERVATION

5.8.1 Configuration Control of Aircraft in Storage

5.8.2 Procedures for Aircraft & Flight Hardware Storage, Including Pylons

5.8.2.1 Parking Aircraft Longer Than 30 Days (Flyable Storage)

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5.8.2.2 Long Term Storage of Hardware

5.8.2.3 Short Term Storage of Hardware

5.8.3 Responsibilities

5.8.4 Storage Process

5.9 BATTERY SERVICING & MAINTENANCE

5.9.1 Aircraft Batteries

5.9.2 Aircraft Battery Storage

5.9.3 Rechargeable Batteries

5.9.4 Aircraft Subsystem Batteries

5.9.5 Special Circumstances

CHAPTER 6 : GROUND & ENGINE OPERATIONS

6.1 PURPOSE OF CHAPTER

6.2 AIRCRAFT TAXI

6.3 AIRCRAFT MARSHALING

6.4 ARRIVALS & DEPARTURES OF TRANSIENT AIRCRAFT

6.5 AIRCRAFT MOVEMENT & TOWING

6.5.1 Safe Towing Conditions

6.5.2 Braking

6.5.3 Chocks

6.5.4 Wing & Tail Walkers

6.5.5 Tow Vehicle Operators

6.6 AIRCRAFT HANGAR PARKING & GROUNDING

6.7 FUEL LOADS FOR HANGARED AIRCRAFT

6.8 AIRCRAFT FLIGHT LINE PARKING & GROUNDING

6.9 PERSONNEL & FOD SAFETY

6.10 AIRCRAFT ENGINE GROUND RUN OPERATIONS

6.10.1 Authorization

6.10.2 Engine Run Hours of Operation & Location

6.10.3 Pre-Engine Start Safety

6.10.3.1 Exceptions

6.10.4 Engine Start, Run, & Shutdown Safety

6.10.5 Center (Area A – NASA Ramp 19) Trim Pad Requirements

6.11 SPILLS & FIRE PREVENTION

6.11.1 Minor Spills

6.11.2 Major Spills

CHAPTER 7 : PROCEDURES & GUIDANCE

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7.1 PURPOSE OF CHAPTER

7.2 FUEL SURVEILLANCE PROGRAM

7.3 AIRCRAFT ENGINE OIL SAMPLING AND ANALYSIS

7.4 ELECTRO-STATIC DISCHARGE / ELECTROSTATIC SENSITIVE DEVICES

(ESD) CONTROL PROGRAM

7.5 AEROSPACE GROUND EQUIPMENT (AGE)

7.5.1 Control of AGE

7.5.2 Maintenance of AGE

7.6 ON-BOARD FIRE EXTINGUISHER BOTTLES

7.7 FACILITIES & HANGAR REQUIREMENTS

7.7.1 Facility Guidelines

7.7.2 Hangar Guidelines

7.8 HANGAR FIRE SAFETY SYSTEMS

7.8.1 Actions to be Taken in the Event of Fire

7.8.2 Fire Protection & Prevention

7.9 SOLDERING IRON & HEAT GUN OPERATIONS

7.10 ELECTRICAL POWER GUIDELINES

7.11 HYDRAULIC POWER GUIDELINES

7.12 CARTS & ROLLING EQUIPMENT

7.13 HOUSEKEEPING

7.14 INSPECTION, POLICING, & SWEEPING OF OPERATIONAL AREAS

7.15 FOD PREVENTION PROGRAM ROLES, RESPONSIBILITIES, &

PROCEDURES

7.15.1 FOD Program Manager

7.15.2 Supervisors & Site Managers

7.15.3 Inspection Branch & Quality Assurance Branch

7.16 FOD PREVENTION STEPS DURING AIRCRAFT MAINTENANCE &

OPERATIONS

7.16.1 FOD Prevention Steps

7.16.2 Vehicle FOD Prevention Steps

7.17 AIRCRAFT PARTS CONTROL, HANDLING, STORAGE, PURCHASING, &

MANAGEMENT

7.18 TOOL & EQUIPMENT CONTROL

7.18.1 Requirements for Controlled Toolboxes

7.18.2 General Information

7.18.3 Accounting for & Reporting Missing Tools, Equipment, & Material

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7.18.4 Tool Crib Operation

7.18.4.1 Loanable Items

7.18.4.2 Issued Items

7.19 BENCH STOCK & SIMILAR ITEMS

7.20 TEST EQUIPMENT

7.20.1 Equipment Maintenance & Inspection Monitoring

7.20.2 Equipment Calibration

7.21 USE OF ELECTRICAL TOOLS & EQUIPMENT IN AIRCRAFT HANGARS ... 126

7.21.1 Use of Battery Powered Tools on Flight line

7.22 APPAREL & PROTECTIVE EQUIPMENT

7.23 OPEN FUEL CELLS, FUEL TANKS, & MAINTENANCE

7.23.1 Safety Precautions

7.23.2 Instruction

7.23.3 Operations

7.24 LIFTS & CRITICAL LIFTS

7.25 AIRCRAFT JACKING

7.25.1 Safety Precautions

7.26 FALL PROTECTION REQUIREMENTS

7.26.1 Passive Fall Protection

7.26.2 Active Position Restraint Fall Protection

7.26.3 Other Active Fall Protection

7.26.4 Procedural Controls Fall Protection

7.26.5 Fall Protection Plans

7.26.6 Fall Protection Guidance

7.27 CLEANING & PAINTING OF AIRCRAFT

7.27.1 Aircraft Cleaning

7.27.2 Cleaners & Solvents

7.27.3 Aircraft Painting

7.28 VEHICLE OPERATIONS ON THE FLIGHT LINE & IN HANGARS

7.28.1 Vehicle Operation on the Flight line

7.28.1.1 Exception

7.28.2 Controlled Movement Area (CMA) Operations

7.28.3 Vehicles Operating in Hangars

7.29 BICYCLES

7.30 MISHAPS, INCIDENTS, & CLOSE CALLS

7.30.1 Aircraft Maintenance Ground Safety Program

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7.30.2 Definition of Mishap, Incident, or Close Call

7.30.3 Incident Reporting: Close Calls, Anomalies, & Hazards

CHAPTER 8 : AIRCRAFT DOCUMENTATION

8.1 PURPOSE OF CHAPTER

8.1.1 Designations

8.1.2 General

8.1.2.1 Aircraft Documentation

8.1.2.2 Aircraft Symbology

8.1.3 NAMIS Use on Other Than Flight Vehicles

8.1.4 Aircraft Release Authority

8.1.5 NF 1673a – Aircraft Flight Preparedness Report & Servicing Record

8.1.6 NAMIS Aircraft Maintenance Module (AMM) & Flight Data Capture (FDC) Aircraft Maintenance Discrepancy / Work Request (WR)

8.1.7 Discrepancies or Work to be Accomplished

8.1.8 WR Technical Reference & Other Documentation Requirements

8.1.9 Documenting Part Removals & Installations

8.1.10 Removal of Obvious Exterior Panels

8.1.11 Use of a Panel Log & Panel Rack

8.1.12 Completion of Work Requests (WR)

8.1.13 Outstanding Open UP Work Requests

8.1.14 Documenting Red Ball Maintenance (See AFOP-7900.3-026)

8.1.15 Seat Report

8.1.16 Optional Form & Record

8.1.17 NAMIS & Aircraft Supplemental Workbook Form Review Process

8.2 CLEARING OR DEFERRING A RED DOWN ARROW

8.2.1 Red Down Arrow Entered in Error

8.2.2 Changing a Green Up Arrow to a Red Down Arrow

8.2.3 Clearing a Work Request

8.2.4 Deferred Discrepancies

8.2.4.1 Changing a Red Down Arrow That Has Had Partial Corrective Action .. 157

8.2.4.2 Temporary Deferral of an Uncorrected Red Down Arrow

8.2.5 Unrecovered Tools or Items: Symbol Assignment & Document Process

8.3 TRANSPORTING SUPPLEMENTAL WORKBOOK FORMS & NAMIS

UNAVAILABILITY

CHAPTER 9 : AIRCRAFT OPERATIONS QUALITY INSPECTION PROGRAM

9.1 GENERAL

9.2 ROLES & RESPONSIBILITIES

9.2.1 Chief, Quality Inspection Branch

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9.2.1.1 Inspection Stamp Coordinator

9.2.1.2 Quality Inspectors

9.2.1.3 Designated Inspectors (DI)

9.2.1.4 Quality Assurance Branch

9.3 TRAINING

9.3.1 Quality Inspection Training

9.3.2 Quality Inspection Branch Training Requirements

9.4 AIRCRAFT OPERATIONS DESIGNATED INSPECTION SYSTEM

9.4.1 Designated Inspection Stamps

9.4.2 Designated Inspector (DI)

9.5 INSPECTION PROGRAM

9.5.1 Inspection of Aircraft Parts Replacement

9.5.2 Aircraft Repairs

9.5.3 Aircraft Periodic Inspections

9.5.4 Aircraft Modifications

APPENDIX A, DEFINITIONS

APPENDIX B, ACRONYMS

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CHAPTER 1: INTRODUCTION

1.1 PURPOSE OF DOCUMENT

The Aircraft Maintenance and Safety Manual (AM&SM) references governing policies and provides guidance and direction for all persons who maintain, modify, inspect, and operate Armstrong Flight Research Center (AFRC, hereinafter referred to as the Center) aircraft and/or who have duties in aircraft hangars, shops, and/or on flight lines.

This manual is the governing document for aircraft maintenance, servicing, modifications, and inspections at the Center. An aircraft’s technical orders (TOs) and other detailed maintenance, inspection, and/or servicing documents are used to perform maintenance, servicing, and inspections except where superseded by this document.

Any conflicts between the above mentioned documentation and Center practices will be brought to the attention of the Aircraft Maintenance Chief or Deputy Aircraft Maintenance Chief for resolution. In the case of contractors, contractual requirements or their Quality Assurance Plan (QAP) or equivalent processes are followed only if more stringent than this manual.

1.2 SCOPE, APPLICABILITY, & WAIVER

1.2.1 Scope

This procedure applies to all aircraft controlled by the Flight Operations Directorate regardless of geographical location.

As used in this document, the Center includes the Air Force Test Center (AFTC) site as well as building 703 (B703) in Palmdale.

1.2.2 Applicability

This procedure will be adhered to by all personnel that work on Center aircraft or work in the Center hangars or on the flight line (Facilities Engineering & Logistics Branch, Protective Services Branch, Flight Operations Directorate, Mission Operations & Office of the Chief Information Officer Directorate, Programs and Projects Directorate, Research and Engineering Directorate, Safety and Mission Assurance Directorate, Strategic Communication, and the Office of the Center Director). Additionally, contractor maintenance personnel or host operations will adhere to the AM&SM unless they are operating to other approved processes (Statement of Work (SOW) and/or contractual obligations) that comply with or are more stringent than those defined within.

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The Flight Operations Directorate will accept other National Aeronautics and Space Administration (NASA) Centers’ or outside contractors’ licensing as certification of training for use of equipment on the flight line and in hangars including flight line drivers training with proof of certificate or license.

NOTE

All references in this document to the Aircraft Maintenance Chief also include the Deputy Aircraft Maintenance Chief with the same decision authorities.

1.2.2.1 Applicability Exception

Flight Operations back shops do not have to comply with the AM&SM for activities that are accomplished within the confines of that particular shop, unless otherwise stipulated. However, they will comply with established good housekeeping and safety processes, and this document in its entirety, if their work requires them to work on or around aircraft subassemblies and on the flight line or ramps.

1.2.3 Waiver Authority & Process

Waivers and deviations to Center-defined requirements that involve airworthiness or are safety of flight critical will be recorded on form AFRC 10117f, Request for Deviation or Waiver, and will be approved by the:

A. Requesting project in accordance with the project’s Configuration Management Plan

B. Appropriate project level technical authority(ies)

1) Project chief engineer or

2) Operations engineer or

3) Safety and Mission Assurance representative

C. Branch Chief of the engineering or technical branch responsible for the requirement

D. Single-letter Director responsible for applicable Branch

E. Center Chief Engineer

Once airworthiness or safety flight critical issues stated in AFPR-7123.2-001 requirements are met (items A-E, above), the process below will be followed in the AM&SM Waiver Database. If the waiver does not involve airworthiness or safety flight critical issues, the process below will also be followed in the AM&SM waiver database.

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The Flight Operations Aircraft Maintenance Chief or his designee is the only authority allowed to waive requirements in the AM&SM. The following is the only authorized process for deviations from this document, except where documented with more stringent standards, technical data, practices, and procedures.

Proposed changes to the AM&SM can be presented to the Flight Operations Management Analyst for processing through the Aircraft Maintenance Chief and the Internal Controls and Management Systems Branch.

All AM&SM waivers will be reviewed by the Inspection Branch. The Inspection Branch will get written concurrence from the Safety & Environmental Branch, and the Center Authority Having Jurisdiction (AHJ) for any environmental, industrial, fire safety, or chemical-related waiver requests.

Approval for variances from NASA safety standards will be accomplished per variance requirements in NPR 8715.3, NASA General Safety Program Requirements. NASA does not have approval authority for variances to federal, state, or local regulations (e.g., Occupational Safety and Health Administration (OSHA, Cal OSHA), nor to consensus standards that are referenced by Federal regulations (e.g., American National Standards Institute (ANSI), American Conference of Governmental Industrial Hygienists) that apply to NASA. Any variance of a federal, state, or local regulation will be reviewed by the Agency OSMA prior to submittal to the appropriate Federal, State, and/or local agency for approval. For example, the NASA Alternate Safety Standard for Suspended Load Crane Operations was approved by OSHA. Waivers to fire codes require the approval of the Center-designated Authority Having Jurisdiction. Before a waiver from federal or state safety requirements can be approved, a variance will be obtained from OSHA or CAL-OSHA.

Except where documented within more stringent or restrictive standards, practices, and procedures, any deviation(s) from this manual will be documented through the AM&SM waiver process. See AM&SM Waiver Process, below. The waiver database and process can be accessed through the Aircraft Work Order System.

1.2.3.1 AM&SM Waiver Process

An approved waiver (AM&SM waiver) is the only authorized deviation from the AM&SM. For any affected aircraft, a scanned copy of each accepted waiver will be maintained in the NASA Aircraft Management Information System (NAMIS) as an open work request (WR). Upon expiration, rescission, or cancellation of an accepted waiver, the affected waivers WR will be closed. The status of all waivers will be

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maintained and can be viewed via the Aircraft Work Order System.

This database is the formal and official waiver repository. Printed copies of waivers are for reference only.

Once created, an electronic record may not be deleted. The status and determination of any waiver can be changed by the Aircraft Maintenance Chief. Once changed, the Aircraft Maintenance Chief will ensure notification is sent to the affected individual(s) responsible for complying with the waiver so that the new status or determination can be properly reflected in NAMIS or flight binder reference copies.

Any conflict between a printed copy of a waiver and the database will default to what is reflected within the database.

1.2.3.2 Waiver Database

A. Waiver Database Changes – Any changes or deviation to the waiver database system will be processed through the Flight Operations Management Analyst, and approved by the Aircraft Maintenance Chief or their respective designees.

B. Waiver Database Access

1) All originators will log into the waiver system with an individual password to create and/or edit a waiver. To do this, they either will be in or added to the password database to receive an individual password. Only the originator can edit the waiver.

2) Reviewed by signatures can only be signed by a Branch Chief or designee. In order to sign the Reviewed by function, they will be either in or added to the password database, with reviewer authority, and receive an individual password.

3) The Aircraft Maintenance Chief has authority in the password database to make the waiver determination and approve or disapprove the waiver. The approval can only be done after both the Reviewed signature and Inspection Branch approval signature have been obtained.

4) The Flight Operations Management Analyst has the authority to grant a designee permission, through the WO administrator, to make waiver determinations in the event the Aircraft Maintenance Chief is unavailable.

C. Waiver Database Record Review – Electronically access the WO database and select the “AM&SM Waiver Database” button. When prompted for a password, select the “OK” button. There is no password needed to review the records.

The waiver database will be reviewed at least annually by the Aircraft Maintenance Chief to determine which waivers need to be

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added permanently to the AM&SM and the appropriate status of each waiver.

D. Waiver Initiation – Electronically access the WO database and select the “AM & SM Waiver Database” button. When prompted for a password, type Originator. This will allow you to create a new waiver request within the database. Upon writing the waiver, contact your supervisor or appropriate Branch Chief for review.

The Aircraft Maintenance Chief and all aircraft branch chiefs will be notified automatically when a new waiver is initiated.

E. Review & Concur Process (supervisor or branch chiefs) – If clarification is needed or material added, notify the originator to make the necessary changes. Once satisfied, select the “Concur” button and electronically sign and date the Reviewed By block and notify the Aircraft Maintenance Chief for his decision. If the waiver needs to be modified and the originator disagrees or is unavailable to correct the problem, then the Reviewer selects the “Nonconcur” button and notifies the Aircraft Maintenance Chief for this determination.

F. Determination Process, Aircraft Maintenance Chief

1) If the reviewer rejects the waiver, but Aircraft Maintenance Chief believes it should be granted, the Chief may select a determination of “Accepted” after Inspection Branch and Safety & Environmental Branch concurrence. The Aircraft Maintenance Chief will electronically sign and date the Determined By segment of the waiver and notify the originator and the reviewer who rejected the waiver of their determination.

The determination of “Accepted” officially authorizes the waiver requested. As a courtesy, the Branch Chief should be notified of this determination and the reason for overriding the reviewer.

2) If the reviewer concurs with the waiver, and the Aircraft Maintenance Chief does not, a determination of rejection is reflected by selecting the “Rejected” button. The Aircraft Maintenance Chief will electronically sign and date the Determined By segment of the waiver and notify the originator and reviewing individuals of the rejection determination. The determination of “Rejected” officially disallows the waiver requested. If the rejection is with recommendations, it is up to the originator to work with the Aircraft Maintenance Chief to work out a solution so the waiver can be approved.

3) If the waiver request is determined to be acceptable, the Aircraft Maintenance Chief will select “Accepted”, and notify the originator of the determination. The determination of “Accepted” officially authorizes the requested waiver.

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1.2.4 Waiver Submission Process Flowchart

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1.3 OBJECTIVES & METRICS

None

1.4 BACKGROUND

Aircraft documentation processes and requirements for hosted programs are dictated through the individual project offices and their Memorandum of Agreement (MOA), Memorandum of Understanding (MOU), or Space Act Agreements. However, for Center-controlled aircraft, the required method of aircraft documentation is through the use of the automated NAMIS system outlined and referenced throughout this manual.

The Aircraft Maintenance Chief or designee will review all aircraft loan agreements annually for currency or extensions.

The Center uses a management systems structure detailed within many documents in the Center’s management system document library. Many aircraft maintenance, safety, and flight operations policies and procedures, not covered in detail within this document are detailed within documents residing in the document library. See Online Document Information Exchange (ODIE), accessed via the Center’s Xnet, for more information.

1.5 PROCEDURES & GUIDANCE

Procedures, guidance, and other directions are found throughout all chapters.

1.5.1 OSHA Requirements

Flight Operations complies with applicable regulations of other federal, state, and local agencies exercising regulatory authority over NASA in specific areas (i.e., Department of Labor’s Occupational Safety and Health Administration, Department of Transportation, etc.).

1.5.2 Additions to AM&SM

In the event that this manual is found to be insufficient to cover a specific topic or it is discovered that this manual has not covered a valid topic, then the assigned operations engineer from the project that made the discovery is responsible to ensure that, with the concurrence of the Aircraft Maintenance Chief, a document is created, approved, and in place to correct the oversight.

1.5.3 Update & Review Requirements for AM&SM

Twenty percent (20%) of the AM&SM is to be reviewed at least annually. Any waivers in the AM&SM Waiver database (discussed in Section 1.2.3, AM&SM https://odie.ndc.nasa.gov/SitePages/Home.aspx

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Waiver Process) and any applicable OFIs are to be reviewed at the same time.

All waivers that have been accepted and are of a permanent nature will be incorporated into this document during its review. Those waivers, once incorporated, will then be categorized as incorporated within the AM&SM waiver database and placed in the archive category.

A document history log can be found on the last page of this document, after all appendices. This log is for information only. Waivers that become permanent changes to this procedure will be incorporated into this document and changes will be noted in the document history log.

1.5.4 Workplace Safety Standards

Workplace safety standards promote the philosophy that “all accidents are preventable: ZERO is the GOAL” and that ANY PERSON can terminate operations that compromise safety. The term “knock-it-off” will signify safely ceasing operations or activities to address the concerns of the person.

Activities in the hangar, on the flight line, and aircraft maintenance, modification, and inspection will adhere to requirements in the AM&SM, safety and health documents, and applicable aircraft documentation.

GENERAL OPERATING PRINCIPLES

A. Define the scope of work. Take the time to plan the task and understand its risks and hazards. (Threat and Error Analysis)

B. Wear the appropriate protective clothing and personal protective equipment (PPE) for the task.

The following eating restrictions do not apply to hangar areas used for approved events such as holiday parties or ‘all hands’ meetings where appropriate cleaning and removal of hazardous materials has been accomplished, in accordance with safety requirements.

C. Eating, drinking, and food utensil storage is prohibited in hangar work areas where toxic materials are used or stored. Eating is allowed at desks (not workbenches) within hangars if the desks have been adequately cleared of all toxic materials such as hydraulic fluid, oils, greases, solder, epoxy, metal filings, etc. (See definition of toxic material in Appendix A, Definitions). Additionally, the work area will be clear of any hazardous operations in the

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immediate vicinity that may pose a potential ingestion hazard, such as ambient dust concentrations generated from sanding, grinding, or painting in adjacent areas. Food may only be stored in refrigerators designated used for food storage only. Wash hands thoroughly with soap and water before eating.

D. During hours of darkness (official sunset to official sunrise), reflective belts or vests will be worn by personnel working on the flight line.

E. MP3 (i.e., music, video) players and other electronic devices using earbuds, headphones, or other in- or over-ear speakers are prohibited while performing maintenance on the aircraft unless required for a specific aircraft operation.

F. Use proper equipment for the task and inspect equipment or tools prior to use.

G. Keep walkways clear of equipment. When hoses, power cords, or any other trip hazards cross walkways, use walkway covers to reduce trip hazards and protect hoses and cords.

H. Keep fire cannon areas clear from obstruction to enable proper fire suppression.

I. Keep all electrical panels clear of obstruction for easy access and emergency shut off. Required electrical panel clearance area is width of the panel or 30 inches, whichever is greater, and outward 36 inches directly in front of the panel. All Flight Operations Directorate aircraft maintenance personnel will be familiar and comply with electrical safety and arc flash principles and policies per AFOP-8715.3-011, Electrical Safety, and AFOP-8715.3-010, Lockout Tagout.

J. Quickly clean or barricade spills to prevent slips, falls, or environmental damage. (Exception: For biohazard materials or fluids, contact the Health Unit for cleanup.)

K. Comply with warning lights, signs, or barriers, and areas cordoned off by tapes or ropes.

L. Use proper lifting techniques, and do not lift awkward loads or loads over 50 pounds by yourself.

M. All hangar electrical connections will be eighteen (18) inches minimum above hangar floors. To avoid unnecessary arcing, ensure all electrical equipment is turned off before plugging or unplugging power cords.

N. Machines and devices using electrical, mechanical, or pressurized fluids or gaseous energy will be de-energized prior to maintenance.

Perform Lockout / Tagout in accordance with AFOP-8715.3-010.

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WARNING

Never charge an unattended battery in a hangar or within an aircraft.

Permanently installed facility equipment such as ER-2 hydrazine warning system with battery backup systems are exempted.

See NFPA 410 for hangar battery charging requirements.

O. Aircraft batteries, or batteries on equipment within aircraft, will NOT be charged in hangars or on aircraft outdoors without an approved procedure per AFOP-7900.3-016, Aircraft Systems Test Procedures Preparation and Release, or a waiver initiated and approved per the waiver process in this document. Such approved procedure or waiver will not allow unattended battery charging within hangars or onboard aircraft under any circumstances.

Exceptions: Aircraft batteries, or batteries on equipment within aircraft, may be charged under the following circumstances without AFOP-7900.3-016 approved procedure or AM&SM waiver when:

1) Battery charging is approved by T.O. or aircraft maintenance manual for charging within hangars of sealed lead acid or nickel cadmium aircraft batteries installed in aircraft that are charged when electrical power is applied, and such incidental charging is not part of battery servicing or maintenance. Other production battery types will have an effective on-ground venting system

2) Ikhana aircraft batteries (UPB13150), following established OEM charging procedures, under constant monitoring.

3) Battery charging is performed as part of normal systems operations per an approved maintenance or flight crew procedure or checklist. Operations performed specifically to charge batteries or during battery servicing or maintenance require an approved AFOP-7900.3-016 approved procedure.

Such approved procedure will not allow unattended battery charging within hangars or onboard aircraft under any circumstances.

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WARNING

Laptop batteries will be disconnected from their charger or docking station if the area is not occupied or fire or explosion may occur if battery or charger malfunctions.

Other rechargeable batteries (non-aircraft batteries or batteries not on equipment within an aircraft) may be charged in the hangar as long as:

a) The charger and device being charged are UL approved.

b) They are 50 feet from aircraft.

c) They are at least 18 inches above the floor.

d) They are not left unattended while charging.

e) All battery chargers inside hangars or aircraft will be disconnected from their power sources when the area is not occupied

WARNING

E-cigarettes will not be charged in any hangar under any circumstances.

P. Hazardous chemicals will be stored in the Center HAZMAT tool / chemical crib or an approved satellite location when not in use.

Q. If an unsafe condition is observed and needs to be stopped to prevent injury or damage, stop it by stating “knock-it-off” and report it.

R. Aircraft operations are dangerous. All personnel not assigned as part of the maintenance crew will ask the crew chief or his designee for permission before approaching any aircraft.

S. Hangars, flight line areas, environmental testing labs, and fabrication shops can have hazardous operations occurring and are not thoroughfares. Any personnel not involved with specific operations could be denied access at the discretion of the crew chief, group lead, and Flight Operations Directorate management.

Access can be granted to the general population of the Center during special events.

T. Before and after contractor-supplied or locally manufactured flight test equipment is installed into the aircraft, a closeout for flight inspection will be performed per Section 4.12.4.

U. During lightning, high heat, and high wind advisories, the Aviation Ground Safety Office or the Aircraft Maintenance Chief or his designee may declare that all noncritical, outside operations will be

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curtailed, and flight line equipment secured to prevent objects from blowing across the ramps. The Aviation Ground Safety Officer (AGSO) or the Aircraft Maintenance Chief or his designee will give the all clear to resume normal operations.

1) Heat Stress

a) Black: 15 minutes outside, 45 minutes indoor in controlled environment drinking water. Postpone all noncritical tasks.

No single worker tasks performed outside; buddy system will be used.

b) Red: 30 minutes outside, 30 minutes indoor in controlled environment drinking water. Recommend postponing noncritical tasks. No single worker tasks performed outside;

buddy system will be used.

c) Yellow: 45 Minutes outside, 15 minutes indoor in controlled environment drinking water.

2) Lightning

a) 5 Miles: Warning, cease all outdoor operations. No personnel permitted outdoor until all clear is given. Hangar doors will be closed.

b) 10 Miles: Warning, prepare to cease all outdoor operations.

All personnel should begin moving indoors until all clear is given. Hangar doors to be closed if it does not interfere with operations.

c) 15 Miles: Warning, cease all noncritical outdoor activities.

Hangar doors to be closed if it does not interfere with operations.

d) 30 Miles: Warning, no action required, maintain vigilance.

3) Winds

a) 25 knots: Advisory, winds could be an issue for outside operations. Verify support equipment chocked or internal braking systems engaged.

b) 30 knots: Warning, aircraft canopies to be closed if not required to be open. Verify support equipment chocked or internal braking systems engaged.

c) 50 knots: Cease all outdoor operations. Aircraft canopies to be closed, down, and locked. Verify support equipment chocked or internal braking systems engaged.

V. Footwear worn in hangars and on aircraft ramps will cover the majority of the foot. No open toed footwear is allowed. Heels will be no higher than 1” (measured from the front of the heel). Soles

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will be no higher than 2 ½’. Heel/floor contact area will be 1 square inch minimum.

AIRCRAFT

No electrical power is to be left connected to an aircraft when not attended. While unattended, turn off aircraft power external power switch(es), hangar wall external power source(s) or electrical power cart(s), and disconnect external power cable(s) from aircraft.

Experiments or equipment on or near aircraft will not be left powered if unattended.

A. Before approaching, touching, or climbing on an aircraft, obtain permission from the crew chief.

B. With aircraft parked in hangars, no welding, exposed heating elements (including ‘blow-dryer’-type heat guns), or spark-generating devices will be used

Exception for SOFIA project: Compressed air is not allowed in the telescope cavity because of possible oil and water vapor contamination; therefore, an infrared heat gun is authorized for use in the telescope cavity of the SOFIA project. The following precautions apply:

1) The heat gun will not be left unattended.

2) The heat gun will be unplugged after use.

3) An approved portable fire extinguisher will be staged within 10 feet of the heat gun operation (Amerex-Halotron 1-A:10BC or equivalent for no discharge residue).

C. Due to the narrow taxiway between the front row and the back row on the Center’s main aircraft parking ramp, all aircraft with research-type pitot booms installed on their nose, or other equipment that would extend into the taxiway, are restricted to parking on the front row of the ramp.

D. Communications devices (such as cell phones, radios, pagers, laptops, etc.) not marked to be “intrinsically safe” may be used in hangars within:

1) 25 feet of an aircraft with open fuel cells

2) 5 feet of fuel vents or drains

3) 25 feet of an aircraft with engines operating and/or performing RF transmission

4) 25 feet of ejection seat or other pyrotechnic devices undergoing maintenance.

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NOTE

Inside these limits, communication devices will be switched OFF.

Exceptions: Cell phone use in cabin class aircraft (i.e., King Air, DC-8,

747) is permissible if there are no open fuel cells and the flight or maintenance crew grants their use. (T.O. 00-25-172)

VEHICLES

Executive Order (EO) 13043, Increasing Seat Belt Use in the United States, dated April 16, 1997, as amended, requires all Federal employees to use seat belts while on official business. The EO states seat belt use is required by Federal employees operating or in any vehicle with seat belts while on Federal business.

See Section 7.28, Vehicle Operations on the Flight line & In Hangars, for more information.

A. The driver will hold a valid flight line driver’s license to operate any vehicle on the flight line. The driver will wear seat belts on all equipment or vehicles equipped with them per NPR 8715.3. The driver is responsible for passenger seat belt use.

B. Drivers will observe speed limits and signs and yield right-of-way to pedestrians and aircraft on the facility.

C. Vehicles will not be left running while parked on a ramp or in hangars. The only exception is for aircraft tugs, which will have the vehicle gear lever placed in the “park” or “neutral” position, parking brake set, and at least one wheel chocked.

D. A spotter should be used when backing any vehicle on the flight line during nighttime hours.

E. Vehicles should be parked or staged to minimize vehicle backing during flight line operations.

F. Vehicles are not allowed within 25 feet of an aircraft with open fuel cells.

G. Vehicles that are used inside hangars that have fueled aircraft will meet the requirements of National Fire Codes NFPA 505, Fire Safety Standard for Powered Industrial Trucks Including Type Designations, Areas of Use, Conversions, Maintenance, and Operations

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1.6 AIRCRAFT IMPOUND PROCEDURE

AFPL-8621.1-001, Center Mishap Preparedness and Contingency Plan, will be followed if a mishap occurs.

If an aircraft is involved in a mishap, or for other reasons at the discretion of the Aircraft Maintenance Chief or Chief of the Quality Assurance Branch, the aircraft, the aircraft’s support equipment, the aircraft’s records, and any other applicable evidence will be impounded. The aircraft will be impounded by first, initiating a downing aircraft discrepancy WR with the word “Impounded” at the beginning of the title; followed by clarifying details if known. Next, the impound feature of NAMIS will be utilized to impound the aircraft. The use of the impound feature will lock NAMIS records at the time of impoundment. Impoundment WRs will only be signed off by the Aircraft Maintenance Chief or Director of Flight Operations. The Aircraft Maintenance Chief will also notify the Aircraft Records Branch and request the impoundment of the aircraft’s records (NAMIS and any paper records). The Aircraft Records Branch will notify the Aircraft Work Order System administrator, the Quality Assurance Branch, and request the impoundment of the aircraft’s WOs (and associated project and experiment WOs).

No maintenance, servicing, inspections, etc., including routine post-flight servicing, towing, de-paneling, etc., will be performed on the impounded aircraft without approval from the Aircraft Maintenance Chief. Maintenance personnel will also receive approval by the Aircraft Maintenance Chief before performing or assisting in any mishap investigation activities involving the aircraft.

1.7 MANAGEMENT RECORDS & RECORDS RETENTION

Destruction of any records, regardless of format, without an approved schedule is a violation of Federal law.

See the Flight Operations Directorate record types and records plan for storage location, retention requirements, and ultimate disposition for the following management records associated with this procedure.

Where applicable, management records and record retention are detailed in each subsequent chapter or appendix.

1. Form AFRC 70618, Tool Inventory Control Verification, will be retained for a minimum of 2 years in accordance with NRRS 1441.1.

2. Form AFRC 70620, Hangar and Flightline Controlled Tool Box Audit Checklist, the supervisor’s toolbox audit inspection record, will be retained for a minimum of 2 years in accordance with NRRS 1441.1.

3. The Certificate of Airworthiness, NF 1677, is approved, filled out, and signed in accordance with NPR 7900.3, paragraph 2.2.1, and the official form is kept

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in the Maintenance Operations Office per NRRS 1441.1 until the aircraft is transferred to another agency.

4. Training records will be maintained in the System for Administration, Training, and Educational Resources for NASA (SATERN) when possible. Branch Chiefs are responsible for assigning and maintaining aircraft-related, task-specific, and on-the-job training records in their branch files; trainers, however, are responsible for the creation and recording of training they administer to employees.

5. Individual aircraft maintenance records will be kept on-site six years after disposal, or sent with the aircraft if it is transferred from the Center to another organization, in accordance with NRRS 1441.1.

6. Recordkeeping copies of maintenance manuals for unique or customized aircraft are considered permanent and are transferred to the National Archives in 5 year blocks after they become superseded or obsolete. All other general maintenance or modification records are destroyed when six years old or when superseded or obsolete, whichever is later.

7. Closeout photos will be permanently archived by the Photo Lab.

Records will be destroyed upon transfer or separation of employee or when 5 years old, whichever is sooner, in accordance with NRRS 1441.1.

1.8 RELEVANT DOCUMENTS

1.8.1 Authority Documents

Flight Operations Directorate follows NASA Agency safety and health directives in carrying out its mission. Therefore, directives and documents from the Safety & Mission Assurance Branch are the cornerstone of the safety requirements identified within this Aircraft Maintenance and Safety Manual (AM&SM).

14 CFR 25.851, Airworthiness Standards, Fire Extinguishers 29 CFR 1910 Fall Protection 29 CFR 1910.109, Explosives and Blasting Agents 42 U.S.C. 2473I(1), Section 203 I(1), National Aeronautics and Space Act of 1958 (as amended) 49 CFR 172, Transportation of Explosives AF Manual 91-201, Explosives Safety Standards AFI91-203, Chapter 24, Aircraft Flight Line – Ground Operations And

Activities FAA AC 20-132, Public Aircraft NASA-STD 8739.6 Implementation Requirements For NASA

Workmanship Standards NASA-STD-8719.11, Safety Standard for Fire Protection

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NASA-STD-8719.12, Safety Standard for Explosives, Propellants, and Pyrotechnics

NASA-STD-8719.9, Standard for Lifting Devices and Equipment NAVAIR 01-1A-35, Aircraft Fuel Cells and Tanks NFPA 407, Standard for Aircraft Fuel Servicing NFPA 70, National Electrical Code NFPA 410, Standard on Aircraft Maintenance NPD 4100.1, Supply Support and Material Management Policy NPD 7900.4, NASA Aircraft Operations Management NASA-STD-8739.12, Metrology & Calibration NPD 8730.5, NASA Quality Assurance Program Policy NPR 1600.1, NASA Security Program Procedural Requirements NPR 1620.3, Physical Security Requirements for NASA Facilities and

Property NPR 1800.1, NASA Occupational Health Program Procedures – 2:15:Shift

Work and Balancing Work-Rest Cycles NPR 4100.1, NASA Supply Support and Material Management NPR 7900.3, Aircraft Operations Management Manual NPR 8715.3, NASA General Safety Program Requirements NPR 8735.1, Procedures for Exchanging Parts, Materials, And Safety

Problem Data Utilizing the Government-Industry Data Exchange Program (GIDEP) and NASA Advisories

TO 00-25-172, Ground Servicing of Aircraft and Static Grounding / Bonding

TO 1-1A-14, Installation and Repair Practices Aircraft Electric And Electronic Wiring

TO 1-1B-50-CD-1, Aircraft Weight & Balance Manual TO 42A1-1-1, Evaluation and SVC Testing of Materials – Cleaning, Painting, Sealing, Protective Treating, Anti-Corrosion, Inspection…