JPR_5322.1.pdf

Johnson Space Center Procedural Requirements

JPR No.: 5322.1H

Effective Date: 01/25/2016

Expiration Date: 01/25/2021

Verify correct version before use at http://server-mpo.arc.nasa.gov/Services/CDMSDocs/Centers/JSC/Home.tml

JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

Verify that this is the correct version before use

Compliance is Mandatory

CONTAMINATION CONTROL

REQUIREMENTS MANUAL

Administrative Change 3, September 2018

Responsible Office: Safety and Mission Assurance Directorate

Contamination Control Requirements Manual

JPR No. 5322.1H

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TABLE OF CONTENTS

PREFACE

P.1 PURPOSE

P.2 APPLICABILITY

P.3 AUTHORITY

P.4 APPLICABLE DOCUMENTS AND FORMS

P.5 MEASUREMENT/VERIFICATION

P.6 WAIVERS AND DEVIATIONS……… . …………………………………………….10

P.7 CANCELLATION .. …………………………………………………………………..12

CHAPTER 1 PROCUREMENT AND ACCOMPANYING DOCUMENTATION

1.1 PROCUREMENT DOCUMENTATION

1.2 PROCUREMENT QUALITY ASSURANCE REVIEW

1.3 CERTIFICATION OF CLEANLINESS

1.4 DOCUMENTATION REVIEW

1.5 CERTIFICATION RETENTION

CHAPTER 2 REQUIREMENTS FOR FOREIGN OBJECT DAMAGE (FOD)

PREVENTION PROGRAM

2.1 FOD CONTROL PROGRAM

2.2 FOD FOCAL POINT

2.3 HOUSEKEEPING

2.4 CONTROL OF PERSONAL ITEMS, TOOLS, HARDWARE AND

CONSUMABLES

2.5 CONTROL OF HAZARDOUS MATERIAL

2.6 FOD AWARENESS AND PREVENTION TRAINING

2.7 MEASUREMENT AND PERFORMANCE

2.8 FOD INCIDENT INVESTIGATION REPORTING, AND CORRECTIVE

ACTION

2.9 EMPLOYEE AWARENESS AND FEEDBACK

CHAPTER 3 REQUIREMENTS FOR SURFACE CLEANLINESS LEVELS

3.1 SURFACE CLEANLINESS LEVELS

3.2 VISIBLE CLEANLINESS LEVELS

3.3 PRECISION CLEANLINESS REQUIREMENTS

CHAPTER 4 REQUIREMENTS FOR ENVIRONMENTALLY CONTROLED AREAS 23

4.1 ENVIRONMENTALLY CONTROLLED AREAS

4.2 CLEANROOM

4.3 LAMINAR FLOW CLEAN WORK STATIONS

4.4 CONTROLLED WORK AREA (CWA)

4.5 CERTIFICATION OF CLEANROOMS AND LAMINAR FLOW WORK

STATIONS…… .. ……………………………………………………………………..30

CHAPTER 5 REQUIREMENTS FOR GARMENTS AND CONSUMABLES USED IN

ENVIRONMENTALLY CONTROLLED AREAS

5.1 GENERAL

5.2 LAUNDERING REQUIREMENTS

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5.3 INSPECTION AND SAMPLING

5.4 CONSUMABLES

CHAPTER 6 REQUIREMENTS FOR PACKAGING

6.1 PACKAGING MATERIALS

6.2 PACKAGING MATERIAL REQUIREMENTS

6.3 PACKAGING METHODS

6.4 PACKAGING TECHNIQUES AND MATERIALS…………… .... ………………...38

6.5 DECALS… .. ………………………………………………………………………….38

CHAPTER 7 REQUIREMENTS FOR STORAGE AND PROCESSING OF

PRECISION CLEAN AND VISIBLY CLEAN (VC) ITEMS

7.1 GENERAL

7.2 FACILITY INTERFACES WITH FLIGHT HARDWARE

7.3 ASSEMBLY, CLEANING, FLUSHING, AND TESTING FLUIDS

7.4 SAMPLING

7.5 INSPECTION PRIOR TO USE

7.6 ACCESS CONTROLS

CHAPTER 8 REQUIREMENTS FOR MICROBIOLOGICAL CONTAMINATION

CONTROL……… ... ……………………………………………………………………………40

8.1 MICROBIOLOGICAL CONTAMINATION………… ... ...………………………….40

8.2 DI WATER OR HIGH PURITY WATER……………………………… .. …………40

CHAPTER 9 REQUIREMENTS FOR ELECTROSTATIC DISCHARGE (ESD)

CONTROL PROGRAM

CHAPTER 10 REQUIREMENTS FOR CLEANING PROCESS CONTROL–

VISIBLY CLEAN…………… ……………………………………………………………..43

10.1 VISIBLE CLEANLINESS REQUIREMENTS

10.2 CLEANING METHODS AND MATERIALS

10.3 HANDLING

10.4 INSPECTION

10.5 PACKAGING REQUIREMENTS

10.6 IDENTIFICATION, CERTIFICATION, AND STORAGE

CHAPTER 11 REQUIREMENTS FOR CLEANING PROCESS CONTROL –

PRECISION CLEAN

11.1 PRECISION CLEANING REQUIREMENTS

11.2 INSPECTION

11.3 PACKAGING AND STORAGE

11.4 PRECISION CLEANLINESS LEVELS

11.5 PRECISION CLEANING PROCESS CONTROLS

11.6 PACKAGING REQUIREMENTS

CHAPTER 12 REQUIREMENTS FOR PERSONNEL DISCIPLINES, PROTOCOLS,

AND TRAINING NECESSARY FOR ACCESS INTO ENVIRONMENTAL CONTROL

AREAS………………… ... …………………………………………………………………

12.1 PROTOCOLS

12.2 TRAINING FOR ENVIRONMENTALLY CONTROLLED AREA (ECA)

DISCIPLINES

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12.3 QUALIFICATION STATUS

CHAPTER 13 RECORDS

APPENDIX A DEFINITIONS

APPENDIX B ACRONYMS

APPENDIX C REFERENCE DOCUMENTS

FIGURE

Figure 2-1, No-FOD Logo/sign

LIST OF TABLES

Table 3-1, Classification of Cleanliness Level Requirements Table 4-1, Environmentally Controlled Area Requirements Matrix Table 4-2, Environmentally Controlled Area Garment Requirements………………24 Table 4-3, Cleanroom Classes by Particle Size Distribution Table 6-1, Packaging for Cleanliness Protection Table 13-1, Records

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Change History Log

Revision Date Originator Description of Changes

Baseline 9/1970 Initial Release

A 12/1974 Not available

A, Change 1 8/1980 Not available

B 11/1982 Not available

C 2/1994 Not available

C, Change 1 9/1995 Not available

D 5/2000 Not available

E 11/2000 Not available

E, Change 1 8/2001 Not available

F 2/2004 NS/Paul Torrance 483-

Complete rewrite. Changed document type from ‘JPG’ to ‘JPR’.

G 6/2009 NS/Paul Torrance 483-

Deleted section 2.1

Revised cleanliness levels to be in compliance with Shuttle, ISS and Constellation requirements.

Revised definition to be in line with CXP 70145, Constellation Program Contamination Control Requirements.

Revised language to clean to VC-sensitive level instead of VC level in section 5.5.2.1 & 5.5.2.2.

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Revision Date Originator Description of Changes

Revised language to always require gloves for handling VC-cleaned hardware.

Revised language to require double bagging of VC-cleaned hardware.

Revised language to seal precision-cleaned orifices with compatible packaging material rather than tape.

Added language to reference the JSC FOD Prevention Program, JPR 5335.5.

Revised language of items cleaned to VC level to require double bagging to be consistent with 8.1.5.2.

Section 18, Reference Documents section moved to Preface.

Admin Change 1

7/2010 NS/Paul Torrance 483-

Editorial correction to Table V: Changed single bagging to double bagging. Note 1 changed single bag to outer bag.

Change 1 2/2012 NS/Paul Torrance 483-

Section 3: Added authority document NPD 8730.5, NASA Quality Assurance Program Policy

Section 4: Added applicable documents:

JPR 1440.3, JSC Records Management Procedural Requirements; JPR 5322.1 ,JSC Contamination Control Requirements Manual;

JWI 8730.4, Quality Assurance Record Center Discrepancy Reporting and Tracking;

Society of Automotive Engineers (SAE) AS 9100 SAE Aerospace Standard; National Aerospace Standard NAS 412 Foreign Object Damage/Foreign Object Debris (FOD) Prevention

Section 1.4. Added the foreign object debris areas and points of contact.

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Revision Date Originator Description of Changes

Section 13: The requirements of JPR 5335.5 JSC Foreign Object Debris (FOD) Damage Prevention Program were merged into Section 13 of this manual, so that all contamination control information and guidance (including FOD) are located in one central document.

Appendix C: JSC Organization List of FOD Control Areas added.

Updated signatory.

Admin Change 2

9/2013 NT/David Dyer/281-483-

Per QPID 2163, the following administrative changes are made:

P.2: Clarified applicability statement.

P4: Corrected references. Removed reference to cancelled document JPR 5322.1.

Removed JWI 8730.4 and replaced with JSC 66552.

P5:

Reworded Measurement/Verification to include language from Table IV that was deleted.

Clarified the area FOD control effectiveness periodic check is the responsibility of the designated FOD control area focal points

Replaced Safety and Test Operations Division with Quality and Flight Equipment Division throughout the document.

Removed Appendix C, JSC Organization, List of FOD Control Areas. Table is obsolete.

Table VI:

Removed Table VI and replaced with correct reference to JSC 66552. Table

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Revision Date Originator Description of Changes

VI language extracted from JSC 66552.

Moved language from Table VI for effectiveness to P.5 Measurement/ Verification and audit actions to Section 13.2.1.

Remove reference to a NT managed FOD web site in Section 13.2.2.

Clarified the AOD FOD prevention program and plan In Section 13.3.1.

Corrected references for FOD control programs in Chapter 13.0.a and Section 13.3.2.c.

H

12/2015 NT/Arnold Baldwin/281- 244-2836

The document has been rewritten and restructured to include more emphasis on FOD prevention. Editorial modifications were implemented to update the format and make the document more user friendly, and correct documentation omissions and errors. Chapters one (1) thru 12 are the requirements chapters.

Chapter 13 is the records chapter followed by the Appendices. The chapters include the figure and tables in the test vs. the appendices.

Admin Change 1

03/2018 NT/David Dyer 281-483-4334

Section P.4.k: Replaced JSC 66552, “Electrostatic Discharge Control Requirements for the Protection of Electronic Components and Assemblies” with JPR 8730.12, “Electrostatic Discharge Control Requirements for the Protection of Electrical and Electronics Parts, Assemblies and Equipment (Excluding Electrically Initiated Devices)”

Replaced “JSC 66552, Electrostatic Discharge Control Requirements for the Protection of Electronic Components and Assemblies” with JPR 8730.12 in the following sections

Section 4.2.1, Note1

Section 4.3.1 Note

Chapter 9 paragraph

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Revision Date Originator Description of Changes

Admin Change 2

8/15/18 NT/Arnold Baldwin 281- 244-2836

Chapter 6, Section 6.2.5, Table 6-1 Packing For Cleanliness Protection modifications:

All precision cleaned items except for LOX or GOX add NOTE 4.

Precision cleaned items for LOX and GOX service identified the incorrect inner bag of Nylon 6. Should be inner bag of Aclar 22 A, approximately 38 µm (1.5 mils) thick.

Added - Items cleaned to VC + UV shall require Double bagging technique, inner bag of Nylon 6, approximately 51 µm (2 mils) thick.

Outer bag of antistatic polyethylene film, approximately 152 µm (6 mils) thick. (NOTE 1, 4)

Modified - Items cleaned to VC shall require Double bagging technique.

Bagging material consisting of antistatic polyethylene film, approximately 152 µum (6 mils) thick.

(NOTE 1, 4)

Modified - NOTE 4 – Antistatic polyethylene film (pink polyethylene or similar film) shall not contain tertiary compounds, which may contaminate hardware.

Admin Change 3

9/6/2018 NT ODC Table 3-1: Changed asterisked note for Level 150 from “Unlimited [*8], [*9]” to “Unlimited [*5], [*9]”.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

PREFACE

P.1 PURPOSE

This JSC Contamination Control Requirements Manual establishes the minimum requirements and controls necessary to establish and maintain an effective contamination control system.

P.2 APPLICABILITY

a. This manual is applicable to JSC organizations responsible for designing, developing, manufacturing, testing, inspecting, and handling spaceflight equipment and associated ground support equipment. The AOD 34100, Maintenance Manual, establishes the contamination requirements supporting all NASA aircraft and ancillary equipment utilized by the Aircraft Operations Division. This JPR is applicable to all other JSC NASA organizations, including White Sands Test Facility (WSTF), Ellington Field, and the Sonny Carter Training Facility, except for the Office of Inspector General (IG) and the NASA Engineering and Safety Center (NESC) Offices at JSC.

b. This manual applies to contractors, grant recipients, or parties to agreements only to the extent specified or referenced in the appropriate contracts, grants, or agreements.

c. In this manual, all mandatory actions (i.e., requirements) are denoted by statements containing the term “shall.” The terms: “may” or “can” denote discretionary privilege or permission, “should” denotes a good practice and is recommended, but not required, “will” denotes expected outcome, and “are/is” denotes descriptive material.

d. All document citations in this manual are assumed to be the latest version unless otherwise noted.

P.3 AUTHORITY

JPD 1280.1 “Quality Policy”

P.4 APPLICABLE DOCUMENTS and FORMS

a. NPR 1441.1, “NASA Records Management Program Requirements”

b. JPR 1281.13, “Control of Nonconforming Product”

c. JPR 1281.17, “JSC Audits”

d. JPR 1440.3, “JSC Records Management Procedural Requirements”

e. JPR 8730.12, “Electrostatic Discharge Control Requirements for the Protection of Electrical and Electronic Parts, Assemblies, and Equipment (Excluding Electrically Initiated Devices)”

f. IEST-RP-CC002.3, “Unidirectional Flow Clean Air Devices”

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g. IEST-RP-CC006.3, “Testing Cleanrooms”

g. IEST-RP-CC027.2, “Personnel Practices and Procedures in Cleanroom and Controlled Environments”

h. IEST-STD-CC1246E, “Product Cleanliness Levels – Applications, Requirements, and Determination”

i. ISO 14644-1, “Cleanrooms and Associated Controlled Environments”, Part 1:

“Classification of Air Cleanliness”

j. JSC 08080-2A, F-27,”Design and Procedural Standards”

k. MPCV 70156, “Cross Program Fluid Procurement and Use Control Specification”

l. SSP 30573, “Space Station Program Fluid Procurement and Use Control Specification”

m. JSC Form JF1615, “Clean Room Work Request and Laboratory Report”

n. NAS 412, “Foreign Object Damage/Foreign Object Debris (FOD) Prevention”

P.5 MEASUREMENT/VERIFICATION

The measurement and verification of contamination control and Foreign Object Debris prevention programs shall be conducted through the certification/re-certification process, audits as prescribed in JPR 1281.17, and routine monitoring conducted by Quality and Flight Equipment Division personnel.

P.6 WAIVERS AND DEVIATIONS

If compliance with this manual is not possible, the responsible technical organization shall initiate a waiver, or deviation and submit in sufficient time to allow for evaluation and disposition through the formal concurrence and approval process.

Note: All requests for waivers and deviations shall be submitted by a memorandum to the Director, Safety and Mission Assurance (S&MA), the approval authority. The S&MA Director may delegate the approval authority to the Quality and Flight Equipment Division by memorandum for individual or all waiver requests.

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P.7 CANCELLATION

JPR 5322.1, Revision G, Contamination Control Requirements Manual, Dated June 30, 2009, is cancelled.

Original Signed By:

Vincent D. Watkins for William S. McArthur Director, Safety and Mission Assurance

Distribution:

JDMS

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CHAPTER 1 PROCUREMENT AND ACCOMPANYING

DOCUMENTATION

1.1 Procurement Documentation

Appropriate contamination control requirements shall be included in procurement documentation by the requirement initiator for spaceflight and spaceflight-related equipment, environmental test facilities, facility fluid systems, precision-cleaned packaging materials, and garment maintenance services.

Note: The Quality and Flight Equipment Division will, upon request, assist JSC organizations in the selection of cost-effective contamination control requirements.

1.2 Procurement Quality Assurance Review

Contamination control provisions of contracts shall be submitted to Procurement Quality Assurance (PQA), and the responsible Materials and Processes organization for review prior to procurement.

1.3 Certification of Cleanliness

The requirement initiator shall assure that procurement documents for systems, subsystems, and major assemblies require that the contractor submit a certification of cleanliness, which identifies the cleanliness level to which the contract item was cleaned and verified.

1.3.1 The cleanliness level certified by the contractor shall be correlated to the levels identified in Chapter 3 of this manual, Requirements for Surface Cleanliness Levels, or by an acceptable alternative, IEST-STD-CC1246E.

1.3.2 The verification methods and data shall be provided by the contractor as part of the Certification of Cleanliness.

1.4 Documentation Review

Documentation accompanying precision, visibly clean (VC), or VC + ultraviolet (VC + UV) cleaned items shall be reviewed by the owner of the item for compliance with applicable contract requirements, including any certification of cleanliness. Such documentation and/or item certification shall be maintained by the owner of the item as a permanent record traceable to the item received.

Note: This includes items fabricated or assembled on site from externally supplied parts, such as flex hose assemblies.

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1.5 Certification Retention

Center-sponsored facilities shall retain certification records beyond the life of the facility according to agency retention requirements (as referenced in Chapter 13).

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CHAPTER 2 REQUIREMENTS FOR FOREIGN OBJECT DEBRIS

(FOD) PREVENTION PROGRAM

2.1 FOD Control Program

Each Directorate that manufactures, fabricates, assembles, tests, or handles space flight equipment shall designate an individual(s) as the FOD Focal Point, and develop and maintain a written FOD Control Plan(s) to comply with NAS 412 and address the elements discussed in this chapter, at a minimum.

Note: Most FOD can be attributed to poor housekeeping, facilities deterioration, improper maintenance, careless assembly, or inadequate operational practices. An effective FOD prevention program identifies potential problems, corrects negative factors, promotes awareness, provides for effective employee training, and uses “lessons learned” for continual improvement.

2.2 FOD Focal Point

The FOD Focal Point shall:

a. Develop, update, and maintain a written FOD Control Plan in accordance with the requirements of this manual.

b. Designate FOD Awareness Areas – Areas where FOD prevention, monitoring and additional training greatly reduces the likelihood and repercussions of FOD entrapment, migration and impact damage.

c. Perform a periodic FOD risk review for facilities containing areas designated as FOD Awareness Areas.

d. Verify FOD Awareness Areas are designated by appropriate signs (conforming to Figure 2-1), barriers and other visual cues necessary to alert personnel they are entering a FOD Awareness Area.

e. Verify established FOD protocols are being followed when flight hardware is present.

f. Provide a documented FOD Awareness Area listing to the Quality and Flight Equipment Division annually or when new FOD Awareness Areas are established.

Note: The list must define the facility name, location (building and room number), applicable FOD Control Plan number, FOD Focal Point’s name and phone number.

g. Coordinate with Center Operations Directorate to assure adequate precautions are included in lifting, handling, and transportation plans to protect FOD sensitive items during logistic operations.

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h. Determine areas within a FOD Awareness Area, if any, which may be acceptable for facilities custodial personnel to clean.

i. Specify necessary FOD prevention tools (FOD containers, FOD organizer belt pouches, tethers, stanchions, etc.) for use in FOD Awareness Areas.

j. Ensure FOD incidents, the results of FOD walk downs, and FOD audits are documented in an official repository.

k. Investigate FOD incidents and recommend corrective action.

l. Ensure signs, barriers stanchions, floor tape, FOD posters, other FOD control visual cues, etc. are removed when a FOD Awareness Area is terminated.

Figure 2-1 NO FOD LOGO

2.3 Housekeeping in FOD Awareness Areas

2.3.1 Employees assigned to work in FOD Awareness Areas shall be informed that housekeeping is a part of their job and that compliance with FOD housekeeping protocols will be a part of their performance evaluation.

2.3.2 Employee training and daily operations shall incorporate “clean-as-you-go” as a required work ethic to prevent debris from migrating into flight hardware.

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2.3.3 Floors, aisles, support structures, access platforms, and other facility surfaces shall be cleaned on a routine schedule to maintain good housekeeping standards that enhance FOD elimination.

2.3.4 Sweeping, dusting, vacuuming, and other facility cleaning methods shall remove debris in a manner that precludes migration or distribution onto flight hardware or onto work surfaces that could provide a migration path to flight hardware.

Note: Cleaning methods that continuously remove debris rather than relocate it, such as filtered vacuum cleaners, externally exhausted house vacuum, and damp wiping, are preferred.

2.4 Control of Personal Items, Tools, Hardware and Consumables

2.4.1 Personal items shall be controlled (prohibited or secured) within FOD Awareness Areas in accordance with the appropriate protocol for the specific FOD Awareness Area.

Personal items are any items an individual brings into a FOD Awareness Area that are not identified as required for the manufacturing, fabrication, assembly, test, or quality assurance operation via work instructions. Personal items include clothing items; badges and badge holders; eyeglasses; watches; personal medical devices; keys; jewelry; office supplies; cell phones; wallets; coins; etc.

2.4.2 A protocol specific to each FOD Awareness Area for controlling tools, small parts, and shop consumables (stock fasteners, wipers, gloves, etc.) to prevent these items from becoming FOD shall be documented. The objective of a tool and small parts control program is to eliminate damage to hardware from dropped items or entrapment of FOD in flight hardware related to lost tools, small parts, or consumables that are inadvertently left behind or migrate into flight hardware.

2.4.3 The appropriate protocol for each specific FOD Awareness Area shall be posted and visible prior to entry.

2.5 Control of Hazardous Material

2.5.1 Only chemicals specified on approved work instructions shall be permitted within a FOD Awareness Area. Control of chemicals and process fluids including cleaning solvents, and water is necessary to prevent accidental spillage.

2.5.2 Fluids shall be contained in a pre-moistened wipes or in small, unbreakable, spill-proof dispenser bottles commensurate with specific need to minimize the spill hazard.

2.5.3 Dispenser bottles containing fluids shall not be placed directly on flight hardware.

2.5.4 The bulbs of non-flight lamps containing mercury, such as those used in hardware ground processing and fluorescent dye penetrant inspection of flight parts, shall be protected by a non-shatterable, leak-proof outer container.

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Note: Overhead light bulbs and inspection lamps containing mercury present a potentially serious FOD hazard to flight hardware should they fall and break.

Bulbs containing mercury should be avoided when possible.

2.6 FOD Awareness and Prevention Training

2.6.1 The primary objective of a FOD prevention training program is to increase employee awareness to the causes and effects of FOD, promote active involvement through specific techniques, and stress good work habits through work disciplines. A FOD prevention training Program associated with development, manufacturing, fabrication, assembly, test, operations, repair, modification, refurbishment, and maintenance is required as part of initial job orientation and recur on a periodic basis.

2.6.2 The FOD Awareness and Prevention Training content shall include, but not be limited to the following:

a. Awareness of FOD entrapment hazards, and susceptibility of hardware to impact damage, leaks and spills

b. An introduction to the causes and effects of FOD on hardware, FOD prevention approaches, familiarization with FOD control logos, signs, area agreements, and general work rules

c. Proper storage, shipping and handling of material, components, and equipment

d. Techniques to control debris

2.6.3 Personnel to receive the FOD Awareness and Prevention Training shall include but not be limited to the following:

a. Personnel who are assigned to work in, or who occasionally require entry into FOD Awareness Areas

b. Personnel who create written lifting and handling instructions for FOD Sensitive hardware

c. Personnel assigned to serve as FOD Monitors for FOD Awareness Areas

2.7 Measurement and Performance

FOD Control Plans shall address measurement and performance. The FOD Focal Point is the responsible person for ensuring compliance, in accordance with Section 2.2 FOD Focal Point. FOD Prevention Programs should provide management and workers with visibility to problem areas and trends, inspection results, incident/mishap reports, and feedback of progress. Measurement and performance improvement indicators may include, but not be limited to, the following:

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a. Visibility Charts – Statistical graphics derived from audit or incident data. Usually provided on a periodic schedule, e.g., weekly, or monthly.

b. Trend Analysis – Where have you been? Where are you going?

c. Report Card – A checklist of areas routinely inspected that shows specific problem areas.

d. Performance Review – A review of worker conformance to standards or expectations.

e. Customer comments, concerns, or complaints.

2.8 FOD Incident Investigation Reporting, and Corrective Action

a. When FOD results in damage or suspected damage, the FOD Focal Point shall lead and/or support an investigation into the incident and identify corrective action as part of the overall FOD trending and measurement assessment.

b. When FOD is suspected or known to have caused damage to flight hardware or test article hardware, the event will trigger a Discrepancy Report/Material Review Record (DR/MRR) or the appropriate nonconformance documentation for customer supplied product in accordance with JPR 1281.13. The Customer’s representative shall be notified of the known or suspected damage as required per customer’s directions.

Note: While a DR/MRR is initiated to flag, investigate, and disposition damage to a hardware item, the purpose of the FOD investigation is to flag and determine corrective action for the FOD item found on or near hardware to prevent recurrence.

2.9 Employee Awareness and Feedback

Employee awareness and feedback is vital to continual improvement efforts. Workers need specific information about what is wrong before they can be expected to improve processes.

a. FOD signage in accordance with Figure 2-1 should be posted at entrances and within FOD Awareness Areas to serve as a visual cue and reminder that one is entering or within a FOD Awareness Area.

Note: The FOD logo shown in Figure 2-1 is a nationally recognized logo used for FOD control in the United States.

b. Metrics specific to the FOD Awareness Area shall be posted in a prominent location within or near the entrance to all FOD Awareness Areas. These metrics should be discussed, in a timely manner, in employee team meetings where all team members are encouraged to provide suggestions for improvement.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

CHAPTER 3 REQUIREMENTS FOR SURFACE CLEANLINESS

LEVELS

3.1 Surface Cleanliness Levels

The responsible design or user organization shall select cleanliness levels from the following two categories that meet a wide range of cleanliness needs: visible clean or precision clean.

3.2 Visible cleanliness levels

Visible cleanliness levels defined for JSC hardware shall be identified as Generally Clean (GC); Visibly Clean (VC); and Visibly Clean, Ultraviolet (VC+UV).

3.2.1 GC Level

GC level items shall be free of manufacturing residue, dirt, oil, grease, processing debris, or other extraneous contamination.

Note: Cleaning is only required if the item does not pass inspection. Heat-sealed bagging protection is not required, but normal protection is required for handling, shipping, and storage. The GC level should be specified for hardware that is not sensitive to contamination and is easily and quickly cleaned or re-cleaned. Customer requirements may preclude usage of GC items.

3.2.2 VC Level

a. VC items shall be cleaned and qualitatively verified to be free of all particulate and non-particulate material visible to the normal (or corrected to normal) vision with a specified illumination.

b. Hardware cleaned to VC levels shall be continuously protected using heat-sealed double bagging.

c. Items which cannot be heat sealed because of size, weight, or configuration and which have critical surfaces cleaned to VC levels shall be prepackaged to cover all exposed critical surfaces.

d. Levels of VC requirements shall be based on incident light levels and inspection distances to include:

(1) VC Standard – Incident light level ≥ 500 lm/m2 (50ft-candles); inspection distance

1.5 to 3 m (5 to 10 ft).

(2) VC Sensitive – Incident light level ≥ 500 lm/m2 (50ft-candles); inspection distance

0.6 to 1.2 m (2 to 4 ft).

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(3) VC Highly Sensitive - Incident light level ≥ 1000 lm/m2 (100ft-candles); inspection distance 0.15 to 0.45 m (6 to 18 in)

e. For all VC levels, areas of suspected contamination may be inspected at closer distances than specified above.

f. VC level inspections are limited to exposed and accessible surfaces. The use of inspection aids such as wipes, mirrors, borescopes, or tape lifts is permissible for those areas of suspect condition with limited or no direct line of sight.

g. When inspection of piece parts at the minimum inspection distance specified for the required cleanliness level is impractical (for example, having to hold parts cleaned to level VC Standard 1.5 m [5 ft away], closer inspection is permitted.

h. When interior volumes do not provide sufficient access to physically conduct an inspection within the defined VC range, the inspection can be conducted at a distance that deviates from the defined range only to the extent required to physically perform the inspection.

i. Evidence of inspection and acceptance shall be documented and maintained.

3.2.3 VC + UV Level

a. Hardware items shall be free of all visible particulate and non-particulate contamination augmented by inspection under UV light (UV light of 3,200 to 3,800 angstroms wavelength).

b. Any evidence of fluorescence during UV inspection shall be cause for re-cleaning.

c. If the surface to be inspected is inaccessible, a wipe test will be performed and the wiping medium shall be inspected under UV light.

d. All items cleaned to VC+UV level shall be continuously protected using heat-sealed double bagging, unless it is not practical.

e. Evidence of inspection and acceptance shall be documented and maintained.

3.3 Precision Cleanliness Requirements

3.3.1 Precision cleanliness levels shall be selected from Table 3-1, Cleanliness Levels, unless otherwise defined by the programmatic requirements.

3.3.2 Sampling, cleaning, and verification tasks to attain the specified precision cleanliness levels of this manual shall be performed by personnel trained in accordance with Chapter 12, Requirements for Personnel Disciplines, Protocols, and Training for Access into Environmentally Controlled Areas.

3.3.3 Evidence of inspection and acceptance shall be documented and maintained.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

TABLE 3-1 SURFACE CLEANLINESS LEVELS

A. CLEANLINESS LEVELS AND DESCRIPTIONS

LEVEL NAME DESCRIPTION

GC Generally Clean [*1] Hardware shall be free of visible manufacturing residue, dirt, oil, grease, processing debris, or other extraneous contamination. Customer requirements may preclude usage of GC.

VC Visibly Clean [*2] Hardware shall meet the requirements of the GC Level, and qualitatively verified to be free of all particulate and non-particulate material when viewed from a specified distance with normal unaided (or corrected-to normal) vision with a specified illumination level.

VC+UV

Visibly Clean + Ultraviolet

[*3] Hardware shall meet the requirements of the specified VC Level, and qualitatively verified by inspection under UV light (3,200 to 3,800 angstroms) to be free of surface film residue.

PC Precision Clean Hardware shall meet the requirements of the specified VC Level, and quantitatively verified as clean by direct or indirect sampling using particle counting and/or Non-Volatile Residue (NVR) analysis.

B. PARTICULATE MATTER CONTAMINATION LEVELS [*3], [*4], [*5], [*6], [*7], [*8], [*9]

Level Particle Size Range [*3]

(micrometer) Maximum Number of Particles per 0.1 m2

Level Particle Size Range [*3]

(micrometer)

Maximum Number of

Particles per 0.1 m2

< 5 Unlimited [*5], [*9]

< 100 Unlimited [*5], [*9]

5 to 15 19 100 to 200 39

> 15 to 25 4 > 200 to 250 3

> 25 0 > 250 0

< 15 Unlimited [*5], [*9]

< 100 Unlimited [*5], [*9]

15 to 25 17 100 to 250 93

> 25 to 50 8 > 250 to 300 3

> 50 0 > 300 0

< 25 Unlimited [*5], [*9]

< 100 Unlimited [*5], [*9]

25 to 50 68 100 to 250 1075

> 50 to 100 11 > 250 to 500 27

> 100 0 > 500 0

< 50 Unlimited [*5], [*9]

< 250 Unlimited [*5], [*9]

50 to 100 47 250 to 500 205

> 100 to 150 5 > 500 to 750 9

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

TABLE 3-1 SURFACE CLEANLINESS LEVELS

> 150 0 > 750 0

< 50 Unlimited [*5], [*9]

< 500 Unlimited [*5], [*9]

50 to 100 154 500 to 750 34

> 100 to 200 16 > 750 to 1000 5

> 200 0 > 1000 0

C. NON-VOLATILE RESIDUE (NVR) CONTAMINATION LEVELS (mg per 0.1 m2) [*7], [*8]

Level Maximum Quantity Level Maximum Quantity Example:

Most levels for oxygen service are 50A, 100A, and 300A, with designation level “100A” most common.

1. “100” refers to the particulate level -defined as the maximum number of particles of specified size per unit surface area [*3].

2. “A” refers to NVR level expressed in mg per

0.1 m2 [*8].

A 1 F 7

B 2 G 10

C 3 H 15

D 4 J 25

E 5 X [*8] As Specified [*8]

NOTES [*]:

1. GC: GC items do not require cleaning before inspection. Cleaning / recleaning is required only if the item does not pass GC inspection.

2. VC / VC+UV: Surface cleaning with an approved, compatible solvent is mandatory for VC and VC+UV items, unless otherwise specified.

3. Particulate sizes are approximate. Allowable particulate and NVR levels are based on 0.1 m2 (1.08 ft2) of surface area, with a flush fluid quantity of 100 milliliters per 0.1 m2 (1.08 ft2) of surface area. Small parts should be grouped together to obtain 0.1 m2 (1.08 ft2) of surface area.

4. Maximum quantity is per 1.0 m3 (35.31 ft3) of effluent gas when a system is evaluated by purging at the maximum operational flow rate.

5. “Unlimited”: Particulates of this size and smaller are not counted. The sample will be rejected if particulate accumulation / silting interferes with analysis.

6. Particulate Matter: Contaminants with observable length, width, and thickness.

7. Non-Particulate Matter: Contaminants without definite dimension (e.g., surface films).

8. Other precision particulate or NVR levels may be specified when design requirements dictate their use. The Quality and Flight Equipment Division must concur in the selection and use of classifications that are not baselined in this table.

9. No silting permitted.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

CHAPTER 4 REQUIREMENTS FOR ENVIRONMENTALLY

CONTROLLED AREAS

4.1 Environmentally Controlled Areas

Environmentally controlled area (ECA) operations shall be controlled by approved protocols and procedures in accordance with Table 4-1, Environmentally Controlled Area Requirements Matrix and Table 4-2, Environmentally Controlled Area Garment Requirements.

Note: “Areas designated as environmentally controlled areas (ECAs) include cleanrooms, laminar flow clean workstations, and controlled work areas (CWAs).”

TABLE 4-1 ENVIRONMENTALLY CONTROLLED AREA REQUIREMENTS MATRIX

CLEAN ROOMS

AREA REQUIREMENTS

(SEE NOTE BELOW)

LAMINAR

FLOW

NON-LAMINAR

FLOW

LAMINAR FLOW

CLEAN WORK

STATIONS

CWA

s

ANNUAL CERTIFICATION X X X --

CONTROLLED BY APPROVED

DOCUMENTED PROCEDURES X X X X

HEPA FILTER SYSTEM X X X --

POSITIVE PRESSURE X X -- --

AIRBORNE PARTICLE MONITORING X X X --

TEMPERATURE CONTROL X X -- --

RH CONTROL X X -- --

LAMINAR FLOW CRITICAL X -- X --

ROOM AIR CHANGE CRITICAL -- X -- --

SPECIAL TOOL CONTROLS X X X X

SPECIAL GARMENTS X X X X

CONTAMINANT-GENERATING

OPERATIONS MAY BE AUTHORIZED

X

STRICT PERSONNEL DICIPLINE X X X X

FORMAL PERSONNEL TRAINING X X X X

NOTE: This matrix provides a comparison of significant requirements for cleanrooms laminar flow clean workstations and CWAs. It should not be inferred that this matrix represents all requirements necessary for the design operation, and maintenance of ECAs.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

TABLE 4-2 ENVIRONMENTALLY CONTROLLED AREA GARMENT REQUIREMENTS

GARMENT

ECA

ISO CLASS 5

ISO CLASS 7 ISO CLASS 8 CWA

COVERALLS REQUIRED REQUIRED OPTIONAL OPTIONAL

HOODS REQUIRED REQUIRED NOTE 2 NOTE 2

SMOCKS -- NOTE 4 REQUIRED REQUIRED

CAPS

REQUIRED

(NOTE 2)

REQUIRED

BOOTIES REQUIRED OPTIONAL OPTIONAL OPTIONAL

SLIP-ON SHOE COVERS

REQUIRED REQUIRED

(NOTE 5)

OPTIONAL

HAND COVERINGS NOTE 6 NOTE 6 NOTE 6 NOTE 6

BEARD COVERS NOTE 3 NOTE 3 NOTE 3 -

NOTES:

1. In laminar flow clean work stations, garments are only required for those parts of the body that are extended into the clean area such as hands, arms, upper torso, facial and head hair.

2. Hoods shall be worn when caps do not fully cover head hair.

3. Beard covers shall be worn to fully cover facial hair.

4. Smocks may be used in lieu of coveralls in ISO Class 7 vertical laminar flow cleanrooms provided applicable airborne particulate requirements are met and all activities are performed at floor level (i.e. not working above the hardware).

5. Shoe coverings may be deleted from use in these classes of vertical laminar flow cleanrooms provided applicable airborne particulate requirements are met and all activities are performed at floor level (i.e., not working above the hardware).

6. The use of hand coverings such as gloves depends upon the type of operation being performed. Hand coverings are mandatory for handling exposed critical surfaces of precision or VC cleaned items. When hand coverings are used in the handling of LOX/GOX components with exposed critical surfaces, they shall be constructed of an approved compatible material.

4.2 Cleanroom

4.2.1 Cleanroom operating requirements shall be established to ensure effective contamination control of items to be processed.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

Note 1: At a minimum, operating procedures will describe the cleanroom monitoring, personnel discipline, packaging, and garmenting functions to comply Table 4-1, Environmentally Controlled Area (ECA) Requirements Matrix; Table 4- 2, Environmentally Controlled Area Garment Requirements; Table 6-1, Packaging for Cleanliness Protection; and JPR 8730.12.

Note 2: Cleanroom requirements may be selected from, but are not limited to, those contained in ISO 14644, Parts 1, 3, and 5.

Note 3: When selecting a cleanroom class to be used, consider the surface cleanliness level required, the articles that will be processed, and the time required for processing. As the processing time increases, the airborne particulate control required becomes more stringent; therefore, two articles requiring the same surface cleanliness level, but greatly different processing times, may also require different clean room classes.

Note 4: Regardless of cleanroom class, prolonged exposure of unprotected surfaces will result in contamination in excess of the allowable cleanliness level; therefore, specify in operating procedures intermediate protective covers or packaging of all items when the items are not actually being processed.

4.2.2 All cleanrooms used for final cleanliness verification, assembly, testing, and packaging of precision, VC + UV, and VC level cleaned articles shall be certified by a documented procedure to meet the requirements in Table 4-1, Environmentally Controlled Area Requirements Matrix.

Note: The requirements for certification of cleanrooms are specified in section 4.5.

4.2.3 Cleanliness classes of cleanrooms used at JSC and offsite contractors providing precision cleanliness certified items shall comply with the airborne particle cleanliness requirements in Table 4-3, JSC Baselined Cleanroom Classes by Particle Size Distribution.

4.2.4 Airborne particle monitoring shall be performed to ensure continued compliance with Table 4-3, JSC Baselined Cleanroom Classes by Particle Size Distribution.

4.2.5 The minimum positive pressure differential between the cleanroom and any adjacent area subject to lesser cleanliness requirements shall be 1.27 millimeters (0.05 inches) of water, with all entryways closed.

Note: When the entryways are open, there should be adequate blower capacity to maintain an outward flow of air from the cleanroom to minimize contaminants migrating into the room.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

4.2.6 The temperature shall be maintained in the range 19-24 oC (67-75 oF) with the exception of those laboratories or work areas for which other temperatures are required by the items being processed.

TABLE 4-3

JSC BASELINED CLEANROOM CLASSES BY PARTICLE SIZE AND DISTRIBUTION

[*1], [*2]

CLEANROOM CLASS MAXIMUM PARTICLE COUNT BY PARTICLE SIZE / AREA

ISO 14644-1 FED-STD-209E [*4]

≥ 0.5 µm ≥ 5.0 µm m3 ft3 m3 ft3

5 100 3,520 100 29 < 10 [*3]

6 1,000 35,200 1,000 293 < 10 [*3]

7 10,000 352,000 10,000 2,930 65

8 100,000 3,520,000 100,000 29,300 700

Notes [*]:

1. Particle size distribution curves may be found in ISO 14644, Part 1.

2. Additional cleanroom classifications (ISO 1-4, and 9) and iterative classifications, such as ISO Class 5.4, 6.8, or 7.3, may be specified for particle size and distribution levels where unique situations dictate their use.

3. Counts below 10 particles per 0.028 m3 (1.0 ft3) are unreliable, except when a large number of samples are taken.

4. FED-STD-209E was cancelled in November 2001. It is included here for reference only.

4.2.7 The relative humidity (RH) shall be maintained between 30% and 70 % unless other ranges are actually required for the items being processed.

Note: Corrosion of parts can occur at RH above 50%. At low RH, surface static charge on dielectric materials or parts can result in particle deposition on the surface due to electrostatic attractive forces.

4.2.8 All work locations within the cleanroom shall provide shadowless, uniform, incident lighting of 800 to 1,000 lm/m2 (75 to 100 ft-candles).

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

Note: Inspection of VC-Sensitive items should be conducted with hand-held inspection lighting. Inspection of VC-Highly Sensitive items requires an incident light level of ≥ 1000 lm/m2 (100 ft–candles); hand-held inspection lighting may be used to provide this higher level of illumination.

Note: Certain hardware may require higher luminosity.

4.2.9 Records created by operating procedures shall be maintained according to Chapter 13.

4.3 Laminar Flow Clean Work Stations

4.3.1 Laminar flow clean work station operating requirements shall be established to ensure effective contamination control of items to be processed.

Note: At a minimum, operating procedures will describe the laminar flow clean work station monitoring, personnel discipline, packaging, and garmenting functions to comply with Table 4-1, Environmentally Controlled Area (ECA) Requirements Matrix; Table 4-2, Environmentally Controlled Area Garment Requirements; Table 6-1, Packaging for Cleanliness Protection; and JPR

8730.12.

4.3.2 All laminar flow clean work stations used to process spaceflight, spaceflight-related equipment, or associated ground support equipment shall be certified by a documented procedure to meet the requirements in Table 4-1, Environmentally Controlled Area (ECA) Requirements Matrix, and maintained to the ISO Class cleanliness level determined by its application with the user organization.

Note: The requirements for certification of laminar flow clean workstations are specified in section 4.5.

4.3.3 Airflow velocity shall be maintained at 27.5 meters per minute (90 ft. per minute) average with a uniformity of ± 20% across the entire area of the exit.

4.3.4 The laminar flow clean work station shall be monitored at regular intervals to verify continued compliance with the requirements in Table 4-1, Environmentally Controlled Area (ECA) Requirements Matrix.

4.3.5 Monitoring and maintenance records shall be maintained for each laminar flow clean work station in accordance with Chapter 13.

4.4 Controlled Work Area (CWA)

4.4.1 Laboratories, special work rooms, vacuum chambers, or other facilities requiring environmental and contamination controls, which are not cleanrooms but do meet the minimum requirements of Tables 4.1 and 4.2 shall be identified as CWAs.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

4.4.2 In accordance with Chapter 2, Requirements for Foreign Object Debris (FOD) Control, housekeeping procedures, personnel controls, and contaminant-generation constraints shall be specified in operating procedures for CWAs to obtain and maintain an acceptable level of work area cleanliness and to protect work piece cleanliness.

4.4.3 Although annual certification is not required for CWAs, the minimum facility requirements stated below shall be observed.

4.4.4 The environment in and around the CWA shall be clean air filtered.

Note: An ante-room is not required for glove boxes or flow benches.

4.4.5 Humidity shall be controlled to the extent necessary to prevent condensation or corrosion on critical and sensitive surfaces, or to preclude buildup of electrical static charges.

4.4.6 A separate area shall be provided at the entrance to a CWA for storage of protective garments and for dressing.

Note: This area should be separated from the CWA operating areas by an enclosed ante-room or by a partition.

4.4.7 Protection from contamination resulting from overhead operations such as cranes, high-lifts, or facility maintenance shall be provided.

Note: A certified clean film may be used for this purpose.

4.4.8 Visual or wipe evidence of dust, dirt, or oils shall be reason for ceasing operations in the immediate area and cleaning the affected area to the VC-Standard level.

Note: Articles subjected to out-of-control conditions will be inspected to verify cleanliness at the required VC level.

4.4.9 All parts, equipment, tools, test fixtures, and apparatus shall be cleaned and verified to the VC-Standard level before they are placed in the CWA.

4.4.10 Assembly, disassembly, modification, or repair of systems or subsystems, which require that a system cleanliness level be maintained, shall be performed under localized clean conditions.

4.4.11 All exposed surfaces, lines, or parts shall be protected with standard closures or be covered with certified clean inner packaging film as specified in Table 6-1, Packaging for Cleanliness Protection.

4.4.12 Contaminant-generating operations, such as sanding, grinding, chipping, drilling, welding, and painting, shall not be performed in CWAs unless specifically allowed by an approved FOD Control Plan.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

4.5 Certification of Cleanrooms and Laminar Flow Work Stations

4.5.1 Newly installed cleanrooms and laminar flow clean workstations shall be certified initially before operation.

4.5.2 All cleanrooms and laminar flow clean workstations shall be recertified annually.

Note: Evaluation for re-certification will include all items required for initial certification. More frequent re-certification will be performed for special applications or when requested by the user organization.

4.5.3 Certification records shall be retained according to Chapter 13.

4.5.4 Instruments and applicable equipment, including permanent cleanroom monitoring equipment, used during the certification process shall have current calibration status.

4.5.5 A documented procedure shall be used for certification of cleanrooms and laminar flow work stations.

Note: The Quality and Flight Equipment Division will, upon request, help prepare the certification procedure. Procedures for certification verification are provided in ISO 14644, Parts 2 and 3, IEST-RP-CC002.3 and IEST-RP-

CC006.3.

4.5.6 Certification Testing Requirements for Cleanrooms

a. Operating specifications in section 4.2 shall be verified.

Note: ISO 14644, Part 3 provides guidelines for performing the tests.

b. The following tests shall be performed:

(1) HEPA filter particulate leak test to verify the absence of leaks. Sampling shall be performed at a scan rate of approximately 2 meters (approximately 6 feet) per minute at a distance within 8 to 15 centimeters (3 to 6 inches) from the filter protection screen.

(2) Room airborne particulate counting. The particle count shall be determined for particle size of 0.5 μm and larger and 5.0 μm and larger (Table 4-3, JSC Baselined Cleanroom Classes by Particle Size Distribution).

(3) Temperature and relative humidity (RH) within the cleanroom.

(4) Differential air pressure to verify the facility maintains the specified pressure difference between the cleanroom and the surrounding area, and between the separate spaces within the installation.

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JSC Form JF2420B (Revised April 3, 2012) (MS Word August 28, 2006)

(5) Light intensity to verify the specified lighting levels and the uniformity of lighting within the room have been met.

c. Consistent performance shall be demonstrated by performing and recording the airborne particle sampling, temperature checks, and RH checks for…