J.1(b)_Attachment_12_-_Representative_Maintenance_Procedures_-_02_03_2017.pdf

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J.1(b) Attachment 12

02/03/2017

Simlab Procedure Ames Research Center

Document #:

WI-2014

Rev.:

Title:

VMS Maintenance Procedures Page #:

REVISION HISTORY

REV Description of Change Author Effective Date

0 Original release. This procedure is a rewrite of SL- 014, changing to the new document format and numbering system and bringing the procedures into compliance with Center SLPs.

8/15/99

1 Fixed references to other procedures 5/26/00

2 Update the Responsibilities and Objective evidence sections

5/22/02

REFERENCE DOCUMENTS

Document Number Document Title QI-008 Project Management Procedures

Documents referenced in this procedure are applicable to the extent specified herein.

1. Purpose

This procedure describes the Hardware Systems Group’s process for supporting simulation operations and development.

2. Scope

This procedure applies to Simlab operational equipment.

The Project Management Procedure will be used for all projects to develop new hardware or software capabilities for general use at Simlab which might impact the quality of research data.

3. Definitions and Acronyms

3.1 Operational equipment which resides at Simlab, is in general use, and could Equipment affect the quality of research data

3.2 Sim Engineer the Engineer responsible for a simulation or their designated stand in

4. Flowchart

No flowchart is required for a complete understanding of this process.

5. Responsibilities

5.1 The Group Leader shall:

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5.1.1 Assign Work Requests to the technicians and enter Work Requests in the Work Request data base

5.1.2 Attend the pre-sim meeting and the meeting to provide input to the hardware development schedule

5.1.3 Pass information on configuration to technicians during staff meetings

5.1.4 Ensure technicians receive required training to avoid voiding warranty or maintenance contracts

5.1.5 Ensure someone carries the SSC pager at all times

5.2 The Shift Lead shall:

5.2.1 Create the PM schedule and track PM activities

5.2.2 Review the PM schedule and procedures approximately once every 2 years

5.2.3 Send test equipment with expired calibration stickers to the Calibration Lab and ensure that the metrology control document is kept for a year

5.2.4 Look for opportunities to improve the CM and PM process and implement changes as needed

5.2.5 Inform the Group Leader of significant deterioration of covered hardware, changes to the amount of downtime attributable to the equipment, or significant increase in cost of maintaining the equipment so that a trend analysis can be completed and recommendations made to Simlab management.

5.3 The Technician shall:

5.3.1 Enter PM and CM activities in the appropriate data bases

5.3.2 Use only test equipment with a valid calibration sticker. Return equipment with expired stickers to the Group Leader

5.3.3 Follow work instructions, use specified tools, and follow safety recommendations as required by procedures

5.3.4 Take the simulator if action is required for the safety of the equipment or people and complete the actions needed to return the simulator to a safe operating condition

5.3.5 Initial Task Handoff, cab change schedule, and VMS Daily log forms as work is completed

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5.3.6 Follow SSC procedures and update the log when acting as SSC Coordinator or responding to an SSC call

5.3.7 Update the Work Request data base as required and notify the Requester when the task is finished

5.3.8 Surface repeated non-conformances and potential process problems to line management

6. Procedure Maintenance on operational equipment shall be planned and conducted so as to maximize the availability and life cycle of the simulator.

6.1 Preventative Maintenance

Operational equipment shall be maintained in accordance with the manufacturer's or design engineer's recommended preventative maintenance procedures and schedule augmented by experience with the equipment in the VMS operating environment, changing requirements on the operation of the equipment, and age. PM procedures and schedule shall be reviewed by the Shift Lead approximately every 2 years. Evidence of completion of this review is kept in the Group Leader’s office at least two years. PM procedures and schedules will also be reviewed by the technician responsible for the equipment whenever a trend toward more frequent operational failures is noted; or when more diagnostic failures, adjustments, or repairs than historically required are noted during preventative maintenance. Upgrades or changes to the PM schedule or procedures will be reported to the Group Leader.

Every piece of operational equipment must have a written PM procedure.

The Shift Lead is responsible for creating the PM schedule, assigning technicians to PM activities, and tracking PM activities. The current status of scheduled preventative maintenance is found in the PM database. If a PM can not be performed within 1 month of the required interval, NASA management is notified and the Group Leader or the Shift Lead uses the normal equipment scheduling procedure to schedule time to complete the PM.

Each technician performing a PM must follow the PM procedures for the type of equipment, and log the maintenance action in the PM Database on the Maintenance Server. The log entry shall include the date of the PM, the type of PM performed, the technicians name, and any problems found or any adjustments, replacements, or repairs made during the PM. Details of system failures and repair activities must also be recorded in the Corrective Maintenance database.

6.2 Corrective Maintenance

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All corrective maintenance calls are initiated through the SSC (System Status Center). See the SSC procedures in section 6.5 below.

During simulation development or operations, the Sim Engineer has the authority to declare the simulation facility down and to turn it over for corrective maintenance, or to continue running in a degraded mode when failures occur. The technician will take the system if action is required for the safety of the equipment or people and complete the actions needed to return the simulator to a safe operating condition. The Sim Engineer verbally authorizes a return to operational status after corrective maintenance is complete.

All corrective maintenance actions taken on operational equipment shall be entered in the Corrective Maintenance Database. The log entry must include the date of the maintenance action, the technicians name, all major actions taken whether they corrected the problem or not, and the status of the equipment at the end of the actions taken. The technician may close a maintenance action when the equipment passes all relevant diagnostics and tests.

Technicians must observe all safety precautions noted in the OEM maintenance manuals. Where the use of specific tools or equipment are called for in the OEM manuals technicians shall use only the specified tools while performing maintenance. The maintenance action is not completed until the area is cleaned up; the equipment is buttoned up; the log entry is complete; tools, unused spares, and test equipment are put away.

All open calls that impact simulation operation are discussed every operational day in the Trouble Meeting. The Group Leader or a representative shall be present at every trouble meeting to answer concerns, update the status of maintenance efforts, and propose escalating efforts to resolve ongoing problems.

In cases where special training is required to maintain warranty or maintenance contract agreements, the Group Leader will ensure that some technicians receive the required training and that only those trained personnel work on the covered equipment.

6.3 Pre-simulation Support

6.3.1 Cab Build-up

The Group Leader or a representative must attend all pre-sim meetings to discuss the simulation configuration. The Group Leader will request a meeting with the NASA Hardware Manager to clarify any ambiguous information or if there will be any difficulties meeting the stated configuration, and a compromise will be worked out. Information on configurations will be passed down to the Shift Leads and the technicians at the staff meetings. The Pre-sim Configuration Requirements form (WI- 2070) will be filled out by the person attending the meetings and kept in the Pre-sim binder that is available in the maintenance shop.

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When the hardware configuration for the simulation is known, equipment that must be bench tested or PMed before use is removed from storage and the applicable OEM or local procedures for bench test and PM are completed. The completion of these procedures is logged in the equipment log.

The video technicians use the simulation configuration information and the lab video display and recording requirements from the Sim Engineer to generate the Video Switching Sheet for use in setting up the video switcher at the beginning of each operational shift.

The Group Leader will attend the meeting called by the NASA Hardware Manager and provide input to complete the Hardware Development Schedule. When this schedule is official, the technicians use the schedule, which is posted on the outside of the cab, to install the hardware in the cab. The Task Handoff Form (WI-2081) generated by the NASA Hardware Manager and attached to the side of the cab is signed off by the technician after installation of each hardware item and after the completion of the stand alone testing of each sub-system, and other actions specified on the schedule such as color balancing or window alignment.

6.3.2 Cab Change

If the cab is moving to the VMS, the NASA Hardware Manager will generate the cab change schedule. The Sim Tech Operations Group Leader will generate a checklist for cab checkout after the change and put it in the VMS lab during the checkout phase. The technicians will check off each test required on the checklist as the procedure is completed.

The Group Leader will pass information on installation and configuration of VMS lab video display or recording equipment to the technicians during group meetings. The technicians then generate a new Video Switching Sheet for use in setting up the video for the simulation in the VMS.

6.4 Simulation Operations Support

Before the start of every shift on which research data is taken, the technician assigned by the Shift Lead must complete the VMS Daily Log (WI-2049) and initial on the top section. An assigned technician will also use the Video Switching Sheet to ensure that the video is properly distributed.

The Sim Engineer may request support for special requests or configuration changes in support of research objectives at any time during the simulation by going through the Group Leader or Shift Lead who will assign a technician to support the request.

6.5 SSC (System Status Center) Procedures

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The Group Leader will ensure that someone carries the SSC pager at all times.

The person carrying the pager (the SSC Coordinator) must:

Answer all pages immediately Take all pertinent information about the failure from the caller such as; the location and time, symptoms, conditions during which the failure is observed, repeatability and frequency of the failure

Assign and notify a technically cognizant individual who will respond immediately to the caller

Notify the Group Leader, Shift Lead, or Shift Coordinator who will inform the VMS Lab Manager by phone call whenever a simulation is down or running in a degraded mode. The Lab Manager will be called at home if the problem occurs outside normal office hours

The responder must:

Make contact with the caller immediately Gather any additional information, printouts, set-ups, etc. from the caller Report to Group or Shift Lead who will make an entry in the SSC log if required including date and time of call, pertinent information, and group assign to the call

Take the system and begin corrective maintenance action if approved by the caller, or arrange a time to begin corrective maintenance action if system will still be used in degraded mode

Ask the Group Leader for additional help as required at any time during the corrective maintenance action

Keep management updated on the maintenance action's progress Update the Corrective Maintenance Database (and SSC log if the problem is entered there) when the problem is fixed, when shift change occurs, before the Trouble Meeting each operational day, or whenever maintenance is stopped to be resumed later

The Shift Lead or Group Leader will update management and technical staff at shift change

Confirm the fix by having the caller test the system

6.7 Work Requests

Anyone needing help from the group for other than preventive or corrective maintenance, cab build-up, or simulation support must fill out a Work Request and submit it to the Technical Monitor for approval. If approved, the Technical Monitor will forward it to the Task Manager who will forward it to the appropriate Group Leader after Task Manager approval. The Group Leader will assign the task to a technician and enter the Work Request in the Work Request Data Base.

The data base will be updated by the assigned technician at least once a month, when any major milestone is completed, or when the status of the task changes.

The assigned technician will notify the requester via e-mail when the Work Request is complete.

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Pre-Sim Configuration Requirements

Techs, Group Leader

Maintenance Shop During cab build-up and the simulation

Corrective Maintenance Data Base Techs, Shift Lead Maintenance Information Server

Life of equipment -one yr active on server

Work Request Data Base Techs Shift Lead, Group Leader

Maintenance Information server

Life of contract - one yr active on server

PM Data Base Techs, Shift Lead Maintenance Information server

Life of contract - one yr active on server

SSC log Techs Shift Lead, Group Leader

Maintenance Information server

Life of contract - one yr active on server

Video Switching sheet Techs Video shop During the simulation

Metrology Control Document Shift Lead Maintenance Shop Until superceded

Records of CM and PM review completion

Group Leader Group Leader’s office At least 2 years

9. Form(s)

Forms applicable to this document:

Form Number Title WI-2070 Pre-sim Configuration Requirements

Form WI-2081 Task Handoff Form WI-2049 VMS Daily Log ARC 755 Corrective Action Request (CAR)

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• When using compressed air, appropriate personal protective equipment must be worn, such as safety glasses/goggles, and use an OSHA–approved air nozzle.

• When doing work in the pump room and any of the pumps are running, proper hearing protection must be worn.

• When performing maintenance under the simulator, a hard hat must be worn if there is a danger that one’s head may come in contact with the simulator structure.

3.1 Hydraulic Plumbing Inspection / Weekly

• Inspect plumbing of the entire hydraulic system, actuator assemblies (including all tubing), pipe fittings, and hose assemblies for leakage and damaged parts and use degreaser and wipes to clean up any fluid.

3.2 Temperature/Pressure Setting Check / Weekly

• With the motion pump running, check pressure gauge on motion pump control panel in pump room. Pressure should read approximately 1350 PSI. Temperature gauge should read less than 115 degrees F.

Figure 3.2.1 – Motion Pump Control Panel located on Hydraulic Power Unit (HPU)

3.3 Hydraulic Pump Room Equipment Inspection /Weekly

• Visually check the following areas of the pump equipment for loose or damaged mechanical connectors, deteriorated parts, structural integrity and leaks.

• cables

• connectors

• hoses

• fittings/couplings

• valves

• manifold-mounted components

• hose strain-relieves

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• Check fluid level sight gauge on reservoir. Ensure that fluid level in sight gauge is at least 3/4 full. If necessary, add fluid (type: MIL-H-83282C )

Figure 3.3.1 – Oil level sight gauge on HPU

3.4 Actuator Inspection / Weekly

• Visually inspect the actuator assemblies and hoses for leaks, loose connections or obvious wear.

• Inspect areas where hoses may rub against other hoses or objects, thus wearing out the protective outer covering.

3.5 Local/Manual Erection of Simulator / Weekly

• Close all cab interlocks: cab console consent switch, cab door, upper gate and stairway gate.

• Press reset button on motion cabinet and ensure Interlock LED is green.

• Ensure all leg control pots on the motion cabinet front panel are at the 12-o’clock/0 position.

• Press motion pump on switch.

• Turn key to local mode.

• After 10 seconds, the relief valve closes. Check system pressure is 1350 PSI and cooling pump is running in the pump room.

• Press erect switch. Reduced-flow and full-flow valves come on about 10 seconds apart without pressure shock to the system.

• Cab should erect to the neutral position.

• Flashing erect switch stops flashing.

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• Press erect/settle switch.

• Settle switch flashes.

• Simulator will settle and stairs will erect.

• After stairs warning horn and light go out, return key to the remote position.

Figure 3.5.1 – Motion Cabinet Control Panel

3.6 Actuator Settle Switch Inspection / Monthly

• Ensure motion cabinet power is off.

• Ensure that the settle switch is in contact stop plate.

• Insert a .01” feeler gauge between the switch roller and the plate to ensure there is enough free play in the switch actuator.

• If there is not enough room to insert the feeler gauge, the switch contact may be bottoming out and is at risk of being damaged. Adjust switch position so feeler gauge may be inserted, by loosening the two screws for the switch mounting bracket.

Figure 3.6.1 – Actuator Upper Settle Switch

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3.7 Motion Cabinet Power Supply Check / Monthly

• Ensure that the motion cabinet is turned on.

• Measure DC voltages at the front panel test point for +5, +24, and +/- 15vdc voltages +/- 0.01vdc)

Figure 3.7.1 – Motion Cabinet Power Distribution Panel at bottom of Motion Control Cabinet

3.8 Accumulator Inspection / Quarterly

• Check fittings for hydraulic leaks or damage.

• Check nitrogen pre-charge in all accumulators (one at the motion pump, 3 at the motion base for pressure of 400 (+100,-50) PSI

• Remove valve stem cap.

• Turn needle valve handle to let pressure enter the gauge on the accumulator.

• Read pressure.

• Close needle valve and release pressure on valve by depressing the core in valve to release the nitrogen, and replace cap if no recharge is necessary.

• If hydraulic fluid comes out of the valve when pressure is released, it could mean that the rubber bladder is ruptured and needs to be replaced.

Figure 3.8.1 – Motion Base Accumulator

• To recharge an accumulator:

• Put nitrogen tank from highbay wall onto tank cart.

• Attach regulator to tank.

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• Attach hose and output gauge to regulator if not already present.

• When recharging accumulators, fill them slowly to prevent freezing of components due to sudden temperature drop.

• Attach the charging hose gauge assembly to the accumulator.

• Open tank main valve and set regulated valve for 500PSI. If you use 400PSI, the closer you get to 400, the less volume of gas is transferred, so it will take longer to get to 400 PSI.

• Open valve at accumulator and you should start to hear gas transfer.

• Close accumulator valve when 400 PSI is reached.

• When finished, disconnect regulator from nitrogen tank and secure tank back to the wall.

• Check all gas fittings and connections for leakage using soapy water.

3.9 Filter Contaminate Switch Inspection / Quarterly

• Inspect the contamination indicators on all 9 filter housings (6 @ motion base, 3

@ pump room). Check that the dial indicator is in the clean section.

• Use a feeler gauge to check for 0.035- 0.045-inch clearance between the cam and the switch actuator of the telltale filter unit.

• Simulate a contaminated condition by manually activating the differential pressure switch located at the base of each filter housing and verify that the corresponding red filter warning LED illuminates on the motion cabinet front panel.

• Reset each filter switch and ensure that the red LED extinguishes and the green LED comes on.

Figure 3.9.1 – Filter Contaminate Switch

3.10 Lubrication of Motion Base / Every 6 months

• At the three upper joint assemblies, use the grease gun (Alvania 2 grease MIL-G-

18709, Aeroshell Grease 6, or equivalent) to grease each joint assembly in 8 places.

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Figure 3.10.1 – Upper Joint Assembly

• At the lower joint assemblies, grease each joint in 8 places.

Figure 3.10.2 – Lower Joint Assembly

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3.11 Hydraulic Fluid Sample Analysis

• Use appropriate eye and hand protection when working with hydraulic fluid.

• Get an 8 oz. pre-cleaned clear glass jar (Lab Safety P/N 16156-2) from the cabinet in the pump room.

• Turn off power at the high bay motion cabinet.

• Turn off power at motion pump control box on the ACFS motion pump in the pump room and place key to OFF and remove key.

• Remove oil filler cap/strainer from top of reservoir by removing the 6 mounting screws located around the cap flange.

• Insert 2 clean plastic pipettes into reservoir through cap opening.

• Seal off top of pipettes with your thumb.

• Remove pipettes and hold end of pipettes over jar.

• Release thumb and fluid will drain into jar.

• Repeat until jar is full.

• Replace cover on jar.

• Re-install filler cap/strainer.

• Reinsert key to the remote position, and turn power on at motion pump control box and high bay motion cabinet.

• Label jar with the following information:

• ACFS Motion System

• Hydraulic fluid type: MIL-H-83282C

• Date:

• Place jar in protective Styrofoam packing found in box on top of pump room cabinet.

• Obtain a copy of the Material Safety Data sheet for this fluid. It can be found in the

MSD binder in N257 room 201.

• Fill out a fluid analysis Material Request and turn it in with the fluid sample and the

MSD sheet.

3.12 Replace Hydraulic Filter Elements / Annually

• Proper personal protective equipment must be worn, like chemical splash-proof goggles and gloves.

• Turn off motion cabinet and turn keyswitch off at the ACFS pump in the pump room. Remove key.

• Ensure motion system pressure has had time to bleed off. It is best to change filters first thing in the morning before the hydraulic systems are turned on for the day. The lines will have had time to drain overnight.

• Replace 26 filter elements by removing the bleeder bolt and unscrewing the top cover of each filter housing.

• 18 J3s at the motion base

• 6 J3s at the pump

• 2 Parker 924464s at the pump

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Figure 3.12.1 – Tools required to open top of filter assembly

• Inspect the “O” rings in each filter cap assembly and replace as necessary.

• Reinstall the filter caps and bleeder bolts and tighten.

• Reinstall key to the local position and turn on the motion cabinet power.

• Turn on motion pump, and check pump filters for leaks.

• Erect simulator and check filter assemblies at the motion base for leaks.

3.13 Motion Base Bolt Tightening

• Torque all motion base bolts to specification found in the Motion System

Maintenance Manual LTP503:

• Upper Joint Assembly

• Nuts or bolts (15/16”socket) that fasten upper joint casting to motion plateform-185ft/# for bolts/125 ft/# for nuts

• 3/8”bolts that retain the bearing cover-30-35 ft/lbs.

• 1 1/4” 12pt. Bolt that retain clevis to actuator assy-375-425 ft/#

• 1/2” hex head bolts (5/16”sckt) that secure actuator heads-50 /ft/#

Figure 3.13.1 – Upper Joint Assembly Torque Specifications

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Figure 3.13.2 – Clevis/Upper Actuator Torque Specifications

• Lower Joint Assembly

• hex head bolts that secure pad to floor-80-90 ft/#

• hex head bolts that secure lower joint casting to pad-80-90ft/#

• 3/8” 12 pt. Bolts that secure nearing covers-30-35 ft/#

• Actuator is secured to the lower joint assembly with 4 nuts: 65-70ft/#

(7/8” socket)

Figure 3.13.3 – Lower Joint Assembly Torque Specifications

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Figure 3.13.4 – Lower Joint Assembly Torque Specifications

4. Log Activity Update the HSG PM Database.

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