SOW_Attachment_3_LMS_TD-0940.pdf

LMS-TD-0940

Revision H: RSD

Verify correct revision before use by checking the LMS Web site.

Langley Research Center General Aircraft Maintenance Manual for Research Services Directorate (RSD)

Prepared by

Dale Bowser

Approval

Original signed on file March 7, 2014

Organizational Unit Manager, RSD Date

Table of Contents

PREFACE

GENERAL AIRCRAFT MAINTENANCE

CHAPTER 1

INTRODUCTION

1.1 Purpose

1.2 Applicability

1.3 Governing Sources of Information

1.4 Organization

CHAPTER 2

PROCEDURE/AUTHORITY/RESPONSIBILITY

2.1 Procedure

2.2 Authority

2.3 Responsibilities

CHAPTER 3

QUALIFICATION AND CERTIFICATION REQUIREMENTS

3.1 Flight Crews

3.2 Maintenance

3.3 Quality Assurance

3.4 Training

3.5 Certification/Re-Certification/Qualification Cycle

CHAPTER 4

QUALITY ASSURANCE/INSPECTION

4.1 System

4.2 Government Mandatory Inspection Points (GMIP)

4.3 Designated Inspectors

4.3 Clearance Authority

CHAPTER 5

AIRCRAFT MAINTENANCE

5.1 Civil Service Support

5.2 Contract Support

5.3 Center Support

5.4 Flight Readiness Review(s) and Maintenance Test Flight(s)

CHAPTER 6

SERVICING/CLEANING/CORROSION CONTROL

6.1 Fuel Storage, Transportation and Servicing

6.2 Safety Requirements for Refueling/Grounding

6.3 Defueling/Grounding

6.4 Contamination Checks

6.5 Off Base Refueling

6.6 Oil Service

6.7 Oxygen Service

6.8 Tire Inspection/Storage/Servicing

6.9 Exterior/Interior Aircraft Cleaning

6.10 Corrosion Control

6.11 Hazardous Waste Disposal

CHAPTER 7

GROUND HANDLING OF AIRCRAFT

7.1 Taxiing

7.2 Towing

7.3 Arrivals/Departures

7.4 Engine Run Ups and Power Checks:

7.5 Aircraft Marshaling

CHAPTER 8

GENERAL

8.1 Flight Request Procedures

8.2 Maintenance Release Procedures

8.3 Life Support and Personal Equipment

8.4 Aircraft Fire and Evacuation Procedures

8.5 Hangar Fire and Evacuation Procedures

8.6 Ground Support Equipment Maintenance

8.7 Housekeeping

8.8 Personal Protective Equipment

8.9 Safety Precautions

8.10 Receiving Inspection

8.11 Customer Supplied Parts

8.12 Controlled Stores

CHAPTER 9

MAINTENANCE OF AIRCRAFT SYSTEMS AND COMPONENTS

9.1 Isolation/Deactivation and Reactivation of Aircraft Systems

9.2 Electrical Systems

9.3 Avionics, Radio Navigation, and Radar

9.4 Aircraft Batteries

9.5 Hydraulic Systems

9.6 Pneumatic Systems

9.7 Landing Gear, Wheels, Brakes

9.8 Aircraft Jacking Procedures

9.9 Aircraft Control Systems

9.10 Pilot Escape Systems (Ejection Seats and Canopies)

9.11 Aircraft Engines and Propeller Systems

9.12 Aircraft Weight and Balance

9.13 Fuel and Oil Systems

CHAPTER 10

DOCUMENTATION PROCEDURES

10.1 Inspections

10.2 Status

10.3 Entering and Clearing the Status

10.4 Changing of Status

10.5 Maintenance Action Deferrals

10.6 Aircraft Inspection Requirements

10.7 Aircraft Forms

CHAPTER 11

FOREIGN OBJECT DAMAGE PROGRAM

11.1 Application

11.2 FOD Explained

11.3 Causes of FOD

11.4 FOD Prevention

11.5 FOD Inspections

11.6 Training

CHAPTER 12

OIL ANALYSIS PROGRAM

12.1 Program and Frequencies

12.2 Oil Samples

CHAPTER 13

BATTERY MAINTENANCE

13.1 Inspection

CHAPTER 14

TOOL CONTROL PROGRAM

14.1 Training

14.2 Tools and Control Procedures

14.3 Unaccounted-for Tools

14.4 NASA Supplied Tools

14.5 Torque Wrench Verification

14.6 Equipment Usage

Preface

General Aircraft Maintenance

All aircraft assigned to NASA Langley Research Center (LaRC) are maintained and inspected in accordance with standard aircraft safety practices. This manual prescribes requirements pertaining to maintenance, repair, and modification of aircraft and equipment. It is not intended to cover every contingency that may arise or every rule of safety.

Chapter 1

Introduction

1.1 Purpose

The purpose of this manual is to establish aircraft and allied equipment maintenance procedures and practices.

1.2 Applicability

This manual applies to all organizational elements, experimenters, companies, and contractors performing maintenance or research modifications to aircraft under the control of the Research Systems Integration Branch (RSIB), Research Services Directorate (RSD), regardless of geographical location.

1.3 Governing Sources of Information

The instructions and procedures contained in this manual are not intended to replace or duplicate but to clarify the governing documents. Personnel performing aircraft maintenance, modifications, and inspections are responsible for becoming familiar with the use of these documents as they pertain to their assigned tasks. The following is a list of supplemental information provided to assist in the completion of the assigned tasks:

A. LPR 1710.16, “Aviation Operations and Safety Manual” B. FAA Advisory Circular 43.13-1B/2B, “Acceptable Methods, Techniques, and Practices, Aircraft

Inspection, Repair and Alterations” C. NPR 8735.2A, “Management of Government Quality Assurance Functions for NASA Contracts” D. LaRC, “Foreign Object Damage (FOD) Program” (see chapter 11 – LPR 5310.1) E. LaRC, “Oil Analysis Program” (see chapter 12) F. LaRC, “Quality Assurance Office Procedures and Documentation Instructions” (see chapter 10) G. LaRC, “Tool Control Program” (see chapter 14) H. “Aircraft Crash Rescue Handbook” I. NASA-STD-8739.3, “Soldered Electrical Connections” J. NASA-STD-8739.4, “Crimping, Interconnecting Cables Harness, and Wiring” K. NASA-STD-8739.7, “Electrostatic Discharge Control” L. NASA Management Information System (NAMIS) M. Langley Management System (LMS)

The following procedures are found in LMS.

NPD 7900.4, NASA AIRCRAFT OPERATIONS MANAGEMENT

NPR 7900.3, Aircraft Operations Management.

NPD 1440.6, NASA RECORDS MANAGEMENT

LMS-TD-0957, Nickel Cadmium Battery Maintenance LMS-TD-0965, Valve Regulated Lead Acid Battery Maintenance Procedures LMS-OP-0911, Review and Implementation of Aircraft Directives LMS-OP-0912, Aircraft Maintenance, Inspection and Flight Release LMS-OP-0913, Simulation Operational Readiness and Remedial Action LMS-OP-0939, Aviation Accident Reporting, Investigation and Site Management Plan LMS-CP-5580, Airworthiness and Safety Review Board (ASRB) LMS-CP-4759, Acquisition of Hazardous Materials LMS-CP-4892, Bonded Storage LMS-CP-0506, Selection, Calibration, Use, Control, Recall, Procurement, and Storage of Measuring and Test Equipment (M&TE) LAPD 1710.1, Langley Research Center Aviation Safety Policy LAPD 1700.1, Safety Program LAPD 1700.2, Safety Assignments and Responsibilities

LMS-OUP-D1, Research Services Directorate Organizational Unit Plan LMS-CP-0902, Unilateral Stop Authority for Flight Operations and Related Activities NPD 8621.1, NASA Procedural Requirements for Mishap and Close Call Reporting, Investigating, and Recordkeeping.

LF 22, Check Log (ESD) LF 44, Hazardous Material - Procurement, Inventory, and Storage Record LF 84, Loan Receipt LF 115, Aircraft Operational Report LF 239, Flight Operations/1244 Complex Incident/Hazard/Close Call Report LF 248, Materials Analysis and Quality Assurance Laboratory (MAQAL) Work Request LF 270, Flight Operations Flight Readiness Review (FRR) Research Services Directorate (RSD) LF 319, Explosives Safety Permit LF 333, Powered Industrial Truck (Forklift and tug) Daily Inspection Checklist LF 781A, NAMIS Aircraft Maintenance Discrepancy Work Request LF 781H, Aircraft Flight Status and Maintenance Record LF 781LB, Aircraft/Engine/APU Flight Record (Rev. Nov. 2005) Informed Version LF 781LC, Experimental Equipment Log (Rev. Oct. 2003) Informed Version LF 781LF, Aircraft Work and Progress Report

1.4 Organization

RSD is responsible for maintenance of and modifications to aircraft as specified in Section 1.2 of this manual. The organizational structure can be found in LMS-OUP-D1.

Chapter 2

Procedure/Authority/Responsibility

2.1 Procedure

All LaRC-assigned aircraft are maintained as public use or as certified aircraft using maintenance criteria published by the manufacturer, FAA, or military services as guidelines. In addition, all aircraft assigned to LaRC are classified as either Research or Program Support. The Lead, Quality Assurance Office, with concurrence by the Head, RSIB, and Director, RSD, is responsible for establishing inspection intervals.

A. Research aircraft, such as prototypes, modified airframe/powerplants, platform, and testbeds are used for research and development.

B. Program Support aircraft are used to support research and development programs, pilot proficiency, chase/photography, and transportation of research personnel.

C. The Director, RSD, following NPR 7900.3 may move aircraft from one classification to another to support Langley Research Center missions.

2.2 Authority

The authority to perform maintenance and to ensure airworthiness of aircraft at LaRC is delegated downward through the Center’s chain of command:

Center Director Associate Director for Operations Director, RSD Head, RSIB, (RSD)

2.3 Responsibilities

A. Director, RSD - responsible for overall safety procedures and policies for maintaining and modifying aircraft assigned to the Center.

B. Head, RSIB - responsible for:

Establishing and implementing procedures for the maintenance, alteration, and servicing of all aircraft and associated ground support equipment Designating, evaluating, and administering certification of personnel within the Branch Assuring that all assigned Crew Chiefs and other personnel perform maintenance in a safe and efficient manner Ensuring that each person is qualified for his or her particular task and that his or her certification records are current C. Senior Maintenance Technician of the Research Systems Integration Branch - responsible for:

Team assignments and the movement of personnel as workloads fluctuate Guidance and leadership of junior level technicians Assisting the Branch Head in formulating and implementing procedures and instructions

D. Senior Electronics Technician of the Research Systems Integration Branch - responsible for:

All maintenance and modifications on avionics and electronic equipment Maintenance of aircraft batteries for all assigned RSIB aircraft Experimental system interface with basic aircraft wiring Maintenance of the personal survival equipment

E. Site Supervisor for the Support Aircraft Team - responsible for:

Maintenance and modifications to assigned aircraft Ensuring that all assigned personnel are qualified or being trained under qualified personnel and that all certification records are current

F. Crew Chiefs, technicians, and mechanics assigned to RSIB - responsible for:

Performing all assigned functions safely and efficiently Performing only those duties for which a current certification is on file, for which training is in progress, or which has been approved by the functional supervisor Keeping up-to-date on the latest technical and safety publications in the assigned area of expertise

G. Operations and Engineering Branch - responsible for:

Providing pilots support for aircraft/simulation programs for RSD Tactical planning and implementation of flight research missions Flight Operations Support Center operations and maintenance Providing meteorological services for flight operations and emergency weather information

H. Airworthiness Engineers & Configuration Management - Airworthiness and Configuration Management is provided by RSD Airworthiness Engineers and are the focal point for aircraft and research systems modification and operational airworthiness assurance. Airworthiness responsibilities include, but are not limited to:

Reviewing engineering designs, aircraft modifications, and equipment installations Maintaining configuration management of baseline LaRC aircraft and research system integrations Reviewing and signing of program initiations and change requests, work orders, and hazard analyses J. Quality Assurance Office - responsible for:

Oversight of aircraft maintenance, inspections, and provide Audits I/A/W NPR 7900.3C, NPR 8735.2A and directed by Chief of flight operations/Director RSD using NASA 7900.3 and LMS-OP-

Ensure safe integration of research equipment using LMS-OP-0910 Review directives as received from other governing bodies using LMS-OP-0911 Ensure that the configuration of aircraft and components are correct Provide trend analysis Conduct Parts and Hardware Certification of all items procured Monitor FAA Suspected Unapproved Parts Program (SUP) and Governement – Industry Data

Exchange Program (GIDEP) Maintain Weight and Balance records for assigned aircraft Review, maintain, and provide oversight of NAMIS current documentation and historical records Maintain a technical library that will aid in the maintenance of the aircraft and systems and notify

Head, RSIB when updates are available See Chapter 4 for additional information

Chapter 3

Qualification and Certification Requirements

3.1 Flight Crews

Refer to LPR 1710.16 for the qualification and certification of flight crews.

3.2 Maintenance

The Senior Maintenance Technician and the Senior Electronics Technician of RSIB are responsible for making all maintenance personnel job assignments based on the experience and skill level(s) of the individuals.

Experience and skill level(s) is based upon:

Previous employment Education Level and type of certification or license held Level of on-the-job training completed

All civil service maintenance positions are filled either internally NPR 3335.1 or via outside hiring using

LMS-CP-4303.

3.3 Quality Assurance

The Lead, Quality Assurance Office is responsible for making all job assignments based on the experience and skill level(s) of the individuals. All civil service positions within the Quality Assurance Office are filled either internally using NPR 3335.1 or via outside hiring using LMS-CP-4303.

3.4 Training

The Senior Maintenance Technician is responsible for working with the RSD Training Coordinator in assessing training needs and updating the RSD Required Training Needs and Record Form for RSIB and coordinating the training of assigned personnel.

The Lead, Quality Assurance Office is responsible for working with the RSD Training Coordinator in assessing training needs and updating the RSD Required Training Needs and Record Form and coordinating the training of assigned personnel.

Approved training is received in the following methods:

Formal commercial or military maintenance training courses on aircraft, engines, systems, and/or related components

On-the-job training under more experienced personnel On-site training using LMS-CP-4316 for related items such as lifting procedures, forklift, crane, highlift vehicles, and fuel truck operation On-site/in-house periodic training on safety related items such as the hangar fire system, fire extinguishers, FOD prevention, chemicals, emergency response, and hearing conservation Formal commercial or military training courses or on-the-job training on airframes, engines, systems, test equipment, and/or related components

3.5 Certification/Re-Certification/Qualification Cycle

The Head, RSIB is responsible for ensuring all certification/re-certification requirements are met by civil service personnel and for updating the RSD Record Form and the Required Training Needs and Record Form when this training is complete.

All certification and re-certification requirements shall meet Center guidelines and RSIB requirements.

Copies of all formal training received by civil service employees are maintained in personnel folders maintained at branch level with original to Office of Human Capital Management for inclusion in the official personnel folder. Certification of all contract employees' formal training is maintained in a manner and location as specified by their employment office.

A computer file is maintained on particular tasks such as egress system maintenance, jacking, towing, servicing oxygen systems, servicing fuel, engine run up, operation of various ground support equipment, operation of specialized electronic equipment, and soldering of electrical connections that require annual certification.

The Senior Maintenance Technician, the Senior Electronics Technician, and the Site Supervisor for the Support Aircraft Team of RSIB are responsible for:

Ensuring individual qualification records are current Ensuring individuals are re-certified as required Notifying the RSD Training Coordinator of formal training requirements

The Lead, Quality Assurance Office is responsible for:

Ensuring Quality Assurance individual qualification records are current Ensuring Quality Assurance individuals are re-certified Notifying the RSD Training Coordinator of formal training requirements for Quality Assurance individuals

Chapter 4

Quality Assurance/Inspection

4.1 System

The Quality Assurance Office of RSD shall:

Accomplish technical inspections and audits for RSD assigned or project related: aircraft, experimental system installations or modifications, aircraft or equipment modifications, life support, service bulletins, technical orders, airworthiness directives, advisory circulars, and other pertinent information is accomplished in accordance with all appropriate commercial or military standards LMS-OP-0912

Validate aircraft airworthiness by accomplishing aircraft inspections: in-process and final inspections on modifications, repair of aircraft and related equipment, installation or modification of NASA or operator owned research equipment regardless of operator and geographical location as required (LMS-CP- 0910)

Verify and maintain required records for all aircraft assigned to, or under the control of LaRC, have been maintained, inspected, and/or modified according to engineering drawings, applicable standards, service bulletins, technical orders, airworthiness directives, advisory circulars, and other pertinent information LMS-OP-0911

Initiate special inspection requirements or maintenance practices affecting the airworthiness of research aircraft or operations for specific research programs with concurrence of Head, RSIB

Monitor and provide oversight on Aircraft Maintenance and Inspection programs Conduct acceptance inspections of all aircraft and aircraft related parts/hardware received at LaRC including raw materials used on research projects Evaluate other aircraft not assigned for physical condition and maintenance records when requested by the ASO or Aviation Director. (Commercial Aircraft Services) Review mechanical and electrical drawings of proposed research equipment, designs, and installations preferably prior to fabrication and/or aircraft installations, all as built or redline drawings and analysis will be completed and attached in NAMIS prior to completion and sign off of the Work Order. Track redline changes on drawings and analysis using NAMIS. Update project Work Order records with finalized documentation.

Maintain a technical library for all assigned aircraft, to include airframe, power plant, and accessories;

and notify RSIB when revisions to the manuals have been updated on the publication server

Maintain a file of specifications, standards, drawings, Advisory Circulars, Service Bulletins, Technical Directives, Airworthiness Directives and other documentation required for supporting the assigned aircraft and research programs either as hardcopies or in NAMIS

Maintain weight and balance control on all assigned aircraft, including the weighing of aircraft, calculating changes, calculating forward and aft center of gravity, gross weight limits, and zero fuel limits, and providing the appropriate forms to the crew chief and attaching in NAMIS

Alert the Head of RSIB and the ground and flight crews of possible problems Report major safety-related quality assurance discrepancies to the Safety and Mission Assurance

Office Provide Trend analysis to assist in the investigation of recurring problems / maintenance issues

4.2 Government Mandatory Inspection Points. (GMIP)

GMIP Inspections will be completed by NASA Quality Assurance upon completion of Maintenance defined as safety critical which, in turn, could result in Loss of Life or Loss of Mission. Ref NPR 8735.002A22

Safety Critical Maintenance Areas include but are not limited to:

1. Flight Controls/ Control Surfaces

2. Flight Control System Rigging

3. Landing Gear system/ Rigging

4. Engine Systems

5. Engine Control System Rigging

6. Propeller System

All above maintenance will be document in NAMIS with a Down Arrow Status, and will require NASA Quality Assurance signature prior to closing the NAMIS work Request.

4.3 Designated Inspectors

The Director, RSD; the Head, RSIB; or the Senior Maintenance Technician, RSIB have the authority to clear "Red X" conditions if a Quality Assurance Specialist is not available. Note: The Head, RSIB can request that a contractor or NASA personnel act as designated inspector as required by mission needs.

The contractor has authority to use designated inspectors in the maintenance task order. The QA Office will then designate by letter.

Designated Inspector Training requirements o Must have had training provided by Quality Assurance office on NAMIS, duties, requirements, and expectations required as a Designated Inspector within the preceding 12 months of requested dates by Head, RSIB o Must be current and trained on the airplane that Designated Inspector is being requested o GMIP clearance authority for Designated LARC Aircraft maintenance contract personnel will be addressed on a case by case basis and approved by the Head of RSIB and Head of RSD Flight QA office.

4.4 Clearance Authority

All Quality Assurance Office clearances shall be by signature, acceptance stamp, electronic signature in NAMIS or a combination of the them.

Chapter 5

Aircraft Maintenance

5.1 Civil Service Support

The Head, RSIB is responsible for all maintenance performed on aircraft assigned to LaRC by both civil service and contract personnel. Civil service employees are certified by job description only, although some may hold FAA or FCC licenses. See chapter 2, Section 2.3 for details concerning the responsibilities assigned to the Head, RSIB.

5.2 Contract Support

Contract support is supplied as follows:

A. Performance Based Contractors (PBC) work within the structure of RSIB to complete specific assignments to include:

Maintenance and modifications to aircraft covered under the Task Order issued by the Site Supervisor

Support to research programs as requested by the Head, RSIB Maintenance of personal equipment controlled by RSIB Quality Assurance Inspection for all basic aircraft maintenance covered under the Task Order issued by the Task Monitor Assist and or provide flight line support during flight operations

B. Services and Support Contractors work with RSD personnel from designated off-site locations to supply the following:

Heavy maintenance Procurement Aircraft inspections Component overhaul/repair Repair and/or maintenance of engines and propellers

All Services and Support Contractors shall have a current FAA Certificate to qualify as a repair station or be a Department of Defense (DoD) facility. Those contractors performing as a qualified repair station for the DoD shall have a quality system conforming to DoD regulations. Those contractors performing under general service and support shall use a quality control system that conforms to FAA regulation, Part 121 or

145. Service and Support Contractors are not permanently assigned to LaRC but supply support on an as-needed basis with services/support delivered to a specified location.

5.3 Center Support

Specialized skills, such as nondestructive testing, welding, machining of parts, heat treatment, and material processing, may be secured from other implementing organizations throughout the Center. In the event that implementing organizations opt to use contractor personnel in the performance of these functions, all received articles shall be inspected using appropriate receipt and inspection procedures. Documentation of all inspections and quality assurance checks performed within the implementing organization shall be supplied to the Quality Assurance Office, RSD for final approval.

Specific modifications made to aircraft shall be classified as flight-critical or non-flight-critical. All flight-critical items require quality assurance be performed by the Quality Assurance Office as well as within the implementing organization. All inspections shall be documented and a copy supplied to the Quality Assurance Office, RSD for final approval.

5.4 Flight Readiness Review(s) and Maintenance Test Flight(s)

A Flight Readiness Review (FRR) shall be convened after a major inspection or modification and prior to the aircraft being released for flight. The FRR is used to inform all interested individuals of maintenance actions or modifications performed on the aircraft and to ensure that all have been completed and the aircraft is ready for flight.

A functional check flight is required for all aircraft where maintenance or modification(s) have been performed on a system that cannot be completely certified through ground based testing or is required by the particular maintenance manual, Time Compliance Technical Order, or Maintenance Work Order. Use of a test flight as a method to aid in the diagnosis of a discrepancy of a newly installed system is acceptable.

Chapter 6

Servicing/Cleaning/Corrosion Control

6.1 Fuel Storage, Transportation and Servicing

RSIB uses two methods of fuel storage: tanker trucks and above ground storage tanks. Jet fuel (JP-5) is stored and serviced from tanker trucks; aviation fuel (100LL) is stored and serviced from above ground tanks; motor vehicle gasoline is stored and serviced in above ground tanks. RSIB is responsible for maintaining the fuel trucks and the fuel tank as well as providing routine maintenance and filter changes on the storage tank at specified intervals. These maintenance functions shall be performed using the approved manufacturer's specifications and NASA guidelines. All fuel trucks shall be parked inside a spill containment pad that meets Environmental Protection Agency (EPA) standards for reducing the impact of fuel spills when not in use.

6.2 Safety Requirements for Refueling/Grounding

Personnel performing fuel servicing operations shall be thoroughly familiar with the applicable portions of the POH. The transient flight crew shall supervise fuel servicing operations to be performed on transient aircraft that are unfamiliar to RSIB personnel. The Senior Maintenance Technician, RSIB shall supervise the servicing when transient aircraft personnel are not available for this function.

The following safety provisions are to be observed as a minimum when performing fuel servicing:

When positioning the fuel truck:

1. maintain 10-foot minimum distance between the aircraft and servicing vehicle

2. do not park with vehicle facing aircraft

3. always use chocks as well as setting parking brakes on servicing vehicle

Provide a LaRC authorized, three point static grounding in the following order using only approved grounds that are identified with a valid test date:

1. static ground to the aircraft

2. servicing vehicle to static ground

3. servicing vehicle to aircraft

Ensure that the single point nozzle is grounded and that the nozzle is connected to the aircraft (some hoses have ground wires)

Ensure that a 150-pound halatron fire extinguisher or an approved substitute is available and positioned

Wear only cotton, non-static producing clothing that provides personal protection; do not wear nylon clothing during servicing

Disconnect grounds in reverse order when servicing is complete Return the servicing vehicle to the designated storage area and make appropriate log entries

6.3 Defueling/Grounding

The following procedures shall be used when defueling aircraft:

Observe all requirements listed for refueling Drain all water from aircraft sumps and check for contamination Determine the type and grade of fuel in the aircraft and ensure that the correct truck or storage tank is used for defueling Pump the fuel from the aircraft into the truck or storage tank Draining fuel tanks:

1. drain all fuel that cannot be pumped from the fuel tanks into approved containers

2. ground the containers and then bond them to the aircraft

3. Caution: DO NOT allow fuel being drained from sumps to free-fall

4. Caution: DO NOT use plastic or polyethylene buckets or pails for collecting or storing fuel

A fire/crash vehicle shall be on the scene during all defueling operations. Only the Head, RSIB is authorized to waive this requirement.

A person will be stationed on top of the defuel truck during the operation.

Use the following procedure when defueling operations involve an RSIB assigned fuel truck:

Remove the fuel truck from service and attach to the ignition key a red aircraft parts tag specifying the reason the truck is out of service and the aircraft that was defueled

Analyze a fuel sample for contamination by forwarding to Langley AFB Fuel Lab or by other suitable means

Return the truck to service if the fuel sample is acceptable (Note: The fuel truck will remain out of service if the sample is unacceptable, and the aircraft that was defueled will be placed on a Red X condition and corrective maintenance actions initiated)

6.4 Contamination Checks

Drain all fuel trucks prior to first use of the day to check for water and visually check for contamination.

Physically sample all fuel trucks for contamination on a monthly basis and send the samples to Langley

AFB Fuel Lab for analysis.

Drain all aircraft fuel sumps on a daily basis prior to flight or 3 hours after servicing to check for contamination.

6.5 Off Base Refueling

The flight crew is responsible for ensuring that:

aircraft away from LaRC are serviced with the correct type and grade of fuel aircraft away from LaRC are serviced with all the additives listed in the operational requirements sumps away from LaRC are drained to check for contamination

6.6 Oil Service

Oils currently in use fall into two classifications: mineral or synthetic. Each class consists of several different types and grades. Special care shall be taken not to mix classes, grades, and types of oils:

Store oils in marked dispensing units or containers furnished by vendors Separate the various types and grades of oil while stored in the same area Exercise extreme caution when handling synthetic oils to avoid absorption through the skin or damage to painted surfaces, rubber, and other materials (Note: Clean up all spills immediately)

Dispose of all drained or contaminated oil immediately using designated containers (Note:

Dispose of the various types of fuels and oils separately)

Refer to Section 6.11 for additional information on hazardous waste disposal.

6.7 Oxygen Service

Oxygen in gaseous form is not flammable; however, it will support rapid combustion of most materials. It reacts violently to petroleum products if fire or a spark from static electricity is present.

The following safety precautions will be observed at all times during servicing operations:

Only fully trained and certified personnel shall handle or service oxygen systems Service according to manufacturer instructions and the applicable portions of the aircraft maintenance manual As a minimum, two persons are required to service gaseous systems: one individual to watch the aircraft gages and the other to operate the gaseous system servicing cart All power sources shall be off and the aircraft shall be parked 50 feet from any structure or spark-producing source and clear of oil and fuel spills Clothing, hands, and tools shall be clean and free of oil and grease Wear protective face shield when servicing gaseous systems Ensure that a 150-pound halatron or equivalent fire extinguisher is available DO NOT service oxygen systems simultaneously with other servicing operations Ground the aircraft and the servicing cart; the cart requires grounding to the aircraft unless steel braided hose is used for servicing

6.8 Tire Inspection/Storage/Servicing

Inspect all tires for serviceability in accordance with the applicable aircraft maintenance manuals Use only new tires as replacements. Note: Only the Head, RSIB has the authority to approve the use of recap tires.

Ensure that tires with the correct speed and ply rating are installed upon the aircraft.

Store new tires in a standing position.

Use the tire safety cage for initial servicing of and standing time for high-pressure tires. Note:

Appropriate tire inflation kits are furnished for each aircraft. For aircraft with tire pressures above 70 PSI, the kits shall contain a pressure relief valve and a gage; for lower pressures, the kits contain a gage only. All kits shall be maintained in accordance with LMS-CP-0506.

Comply with specific instructions and safety precautions prescribed by the aircraft being serviced.

Wear safety goggles or a face shield.

Use only nitrogen for servicing aircraft tires with landing speeds above 100 knots.

Use the calibrated tire inflation kit furnished for that aircraft, which has the specified relief valve setting.

Stand forward or aft of the tire, well out of the explosion area.

Ensure that the tire is deflated prior to removing the axle nut when removing the wheel from the aircraft.

Use extreme caution when working around an overheated tire. Approach from the front or from the rear. While injuries can still occur, this will give the best protection from an exploding tire.

6.9 Exterior/Interior Aircraft Cleaning

Cleaning of aircraft is required to remove deposits that lead to damage of parts and/or corrosion, to facilitate inspection, and to preserve appearance. Cleaning materials shall be of a manufacturer's approved specification for the job. All safety precautions published for the product shall be observed. If doubt exists, do not use the product.

Exercise care to cover pitot/static openings and any other areas that can be damaged by cleaning products or water when cleaning the exterior of the aircraft

Do not spray cleaning agents directly on such items as wheel bearings, rod end bearings, electrical components, and hydraulic actuator pistons

Clean interior materials of plastic, leather, or vinyl with mild soap and water; use only manufacturer's approved cleaning agents for stain removal or other cleaning of upholstery

Use a foam type cleaning agent for cleaning carpets not removed from the aircraft; only the Head, RSIB has the authority to approve any substitutions in cleaning agents

Clean windows and canopies with soap and water or an approved cleaner only; verify the type of material prior to cleaning in order to select the best method

6.10 Corrosion Control

Corrosion control consists of the following specific preventive measures:

Maintaining cleanliness of equipment Treatment as corrosion occurs and restoration of protective finishes Lubricate exposed areas of struts, cables and hydraulic cylinders according to manufacturer's specification Spray corrosion inhibiting compounds according to manufacturer's specifications Assuring that all drains are open and clear of debris and accumulated moisture is removed

Consult with LaRC personnel or the manufacturer's representative for evaluation and recommended treatment procedures in cases where severe corrosion is found.

6.11 Hazardous Waste Disposal

All hazardous waste that is discarded by RSD personnel shall be disposed of in accordance with LaRC Hazardous Waste Disposal Practices. Any violation shall be reported to the Head, RSIB.

Chapter 7

Ground Handling of Aircraft

7.1 Taxiing

Only qualified flight crews are authorized to taxi aircraft assigned to LaRC. The Director, RSD has the authority to authorize other individuals to perform this function.

7.2 Towing

A tow director will be used when moving large aircraft or aircraft located in a congested area. The director will be positioned in a manner that allows the tow motor operator continuous visual contact with the director. The director is selected by the tow motor operator prior to starting the move. The director is responsible for ensuring that the tow motor operator, wing walkers, and brake rider are in position and ready to start the move. For towing a/c during non-standard duty hours, the requirement for wing walkers may be deleted, on a case by case basis, by the Head, RSIB or designate.

Note: Wing walkers are used when towing aircraft in congested areas or when the tow director has any doubt about proper clearance from any object.

On smaller aircraft or in non-congested areas when a tow director is not appointed, the tow motor operator directs the towing operation.

All personnel involved in an aircraft move will have whistles (issued by RSIB) which will be blown when an emergency stop is required during the move.

Only maintenance or flight crew personnel certified on a particular aircraft by the Senior Maintenance Technician or Contractor Site Supervisor are authorized to perform towing operations while acting as the tow motor operator.

The tow motor operator is responsible for ensuring that:

The tow bar is the specified type for the aircraft, that it is in a serviceable condition, and that it is connected The tow motor is rated (draw bar rating) for the aircraft that is being repositioned The specified gear locks are installed and the landing gear scissors are positioned Towing speed does not exceed walking rate for ramp (5 MPH) or lower as appropriate considering weather conditions The aircraft is chocked, the tow bar is disconnected, the scissors are repositioned, and the aircraft is statically grounded after positioning

7.3 Arrivals/Departures

Each Crew Chief or maintenance unit is responsible for launching and recovery, servicing, and repositioning of assigned aircraft. The Head, RSIB; Senior Maintenance Technician; or Contract Site Supervisor has the authority to assign personnel to perform these functions in the absence of assigned crew.

The Head, RSIB or the Senior Maintenance Technician assigns teams/units on a monthly basis to handle transient aircraft arrivals and departures. Only the Head, RSIB or the Senior Maintenance Technician has the authority to transfer personnel to supplement assigned teams/units when the need arises. Personnel meeting arriving transient aircraft determine from the flight crew if servicing is required, the expected departure time, and if hangaring is required and direct the flight crew toward the flight planning room.

7.4 Engine Run Ups and Power Checks:

Only qualified flight crews or maintenance personnel currently certified for a given aircraft are authorized to operate engines during maintenance checks.

Perform engine runs in designated areas only.

High power turns on jet aircraft shall be conducted on the trim pad or designated Air Force area, using tie downs and/or restraints as directed by the original equipment manufacturer or NASA Langley policy.

The following safety practices shall be adhered to during engine runs:

(1) Check emergency access area around aircraft for clearance

(2) Perform walk around inspection; check intake for FOD and check inlet screen installation if applicable

(3) Check ramp for FOD and intakes or propellers for clearance

(4) Check that brakes are set, wheels are chocked, and aircraft is secured if required

(5) Check that a qualified fireguard is positioned and either a fire/crash truck or fire extinguisher is available

(6) Observe danger zones of operation; remain clear of intakes and exhaust areas, rotating propellers, and plane of rotation of propellers and turbine wheels

(7) Adhere to check lists and operating instructions during all engine runs

7.5 Aircraft Marshaling

Use the radio intercom for communication between the pilot and marshaler pertaining to operation of the aircraft systems on aircraft equipped with external intercoms. Use standard aircraft hand signals in cases of aircraft not equipped with external intercom capability. (See Figures 7-1 and 7-2 and Table 7.1) Pilot and marshaler shall be constantly alert to ensure that no action is taken prior to a signal being given and acknowledged. Standard aircraft signals will be used.

Table 7.1: Specific signals

Signal Pilot Marshaler Apply external power to aircraft

Hands above the head; left fist partially clenched; right hand moved in the direction of left hand, with two fingers inserted into circle made by left hand

Respond with like signal

Disconnect external power from aircraft

Reverses apply external power signal by withdrawing fingers of right hand from partially clenched left fist

Respond with like signal when power has been removed

Apply external air to aircraft

Left hand cupped; right fist fully clenched; fist moved in direction of left hand and inserted into cup made with left hand

Respond with like signal when completed

Disconnect external air from aircraft

Reverses apply external air signal by removing right fist from cupped left hand

Respond with like signal when completed

OK Thumb and forefinger form a circle Thumb and forefinger form a circle

Speed brake operation Hands cupped; then open; then closed

Repeat signal prior to operation and gives OK signal when operation is completed

Wing flaps down Hands in front; palms together horizontally; then opened at wrists

Repeat signal prior to operation and gives OK signal when operation is completed

Wing flaps up Reverses wing flaps down signal Repeat signal prior to operation and gives OK signal when operation is completed

Nose gear steering Hands at head level; palms towards marshaler; moves hands back and forth simulating movement of rudder pedals

Repeat signal prior to movement and gives OK signal when operation is completed

Pitot heat check Grasps extended forefinger of left hand with right hand

Give OK signal if system is operating

Chapter 8

General

8.1 Flight Request Procedures

The Director, RSD has the authority to issue flight request authorization according to criteria expressed in LPR 1710.16 and LMS-CP-0905.

8.2 Maintenance Release Procedures

Use the Flight Preparedness Report as the final maintenance release documentation.

The Crew Chief is responsible for ensuring that all required entries on the Flight Preparedness Report are completed prior to each flight and for initialing the preflight completion. Items to be included are:

1. Experimental

2. DAS (Data Acquisition System)

Note: Leaving a line blank for an item that is not included on the aircraft or is not operational during a given flight is NOT acceptable. Write N/A where appropriate.

The Head, RSIB; the Senior Maintenance Technician; designated Senior level technician; or Senior Electronics Technician shall review the form for completeness and sign the Flight Preparedness Report in the designated area.

8.3 Life Support and Personal Equipment

The Crew Chief and the Senior Electronics Technician are responsible for maintenance of life support and personal equipment maintenance. Responsibilities include:

Crew Chief:

Reviewing all aircraft forms in NAMIS each week to ensure that all items are inspected according to schedule Removal and installation of all aircraft items requiring inspection or maintenance

Senior Electronics Technician:

Ensuring that all items are inspected, certified, and documented prior to returning the item to the Crew Chief for re-installation

Tracking, performing, and documenting inspections of equipment not normally stored in the aircraft

8.4 Aircraft Fire and Evacuation Procedures

The Aircraft Crash Rescue Handbook details the fire, rescue, and evacuation procedures for each aircraft assigned and operated by LaRC. Periodic training and evacuation drills are mandatory for LaRC personnel that are required to fly on aircraft assigned and operated by LaRC. Flight Systems Safety is responsible for ensuring that all LaRC personnel have received the mandatory training and that the training is documented.

Training records are stored under the direction of the Director, RSD and archived according to the RSD Record Form. The Operations and Engineering Branch is responsible for ensuring that non-LaRC personnel flying aboard LaRC aircraft receive a safety briefing prior to flight and that the briefing be documented.

8.5 Hangar Fire and Evacuation Procedures

Building 1244 hangar, Building 1244 admin, Building 1244C, and Building 1244D are equipped with a fire warning and a fire protection system. A High Expansion Foam System protects the hangar area while a Water Deluge System protects the 1244D area. Building 1244 admin and 1244C areas are protected by a sprinkler system throughout.

The warning system in ALL areas is activated automatically or by the individual discovering the fire. The High Expansion Foam System is activated automatically by IIIR/video detection system using a cross-zoning method to lessen the possibility of erroneous alarms as well as erroneous releases. Cross-zoning requires detection by sensors in two different zones to allow automatic operation of the High Expansion Foam System. The hangar area is divided into 4 zones and each zone is equipped with a manual dump as well as a manual override station. The manual override system is installed so that in the event of an erroneous alarm, personnel may prevent the system from dumping.

The deluge system in Building 1244D is activated automatically by high temperature sensors, rate of rise sensors, or manually at one of the riser stations and is divided into 2 zones. A single zone or a combination of zones shall be activated as needed to suppress the fire.

These systems are inspected on a periodic basis, and the appropriate safety personnel maintain documentation of the inspection.

ALL RSIB personnel are trained annually on the proper operation of the systems in 1244 hangar as well as 1244D.

The Head, RSIB is responsible for documenting and maintaining records of this training according to the RSD Record Form. Only RSD personnel are assigned to fire fighting squads.

In case of fire:

• Shout "FIRE" and activate the nearest pull station

• Dial 911 to report the fire

• Evacuate the area of non-essential personnel and do not re-enter until notified by the fire department of an "All Clear"

• Report to assigned squads, perform all safety and evacuation procedures assigned to the squad, and assist the fire department if requested

8.6 Ground Support Equipment Maintenance

A performance-based contractor is responsible for maintenance of ground support equipment. All equipment is inspected or serviced at predetermined intervals. Unscheduled maintenance is performed with support from the LaRC Vehicle Maintenance personnel or support contractor. Inspection records or logbooks shall be maintained to schedule and document work.

For Vehicle Maintenance maintained vehicles, all logbooks and inspection records are maintained in Vehicle Maintenance and updated by the personnel performing the maintenance activity.

Training in the use of ground support equipment includes:

Use of maintenance stands Use of compressors Use of hydraulic machines and safety precautions to be observed Use of rectifiers and safety precautions to be observed Use of jacks and safety precautions to be observed Operation and licensing of motor vehicles such as fuel trucks, tow motors, forklifts, and high-reach vehicles or cranes

Training records are maintained by the Head, RSIB according to the RSD Record Form.

8.7 Housekeeping

Good housekeeping is an important requirement for an effective maintenance operation. Good housekeeping enhances fire prevention, safety, and appearance in the work area.

Housekeeping includes:

Do not store flammable liquids in open containers. Use approved safety cans or small plastic bottles only and place in flammable storage lockers. Note: Mark all containers clearly as to contents using appropriate labels.

Smoking is prohibited in all areas of the hangar, hangar annex, and within 50 feet of any fuel truck, fuel storage tank, or aircraft.

Ensure that all fire protection equipment and fire lanes are clear of obstructions at all times.

Keep parked aircraft and equipment clear of hangar doors.

Use static grounds on all hangared aircraft and on all aircraft left on the ramp for extended periods of time.

Use drip pans to prevent spills in the hangar area and ramp. Immediately clean up all fuel, oil, grease, and similar material spills. Note: Use the hazardous material spill unit for cleaning up spills.

Clearly mark with a streamer or protective device all instrumentation booms, wing tips, flight control surfaces, tail surfaces, antennas or other areas of the aircraft that pose a hazard to personnel.

Ensure that all areas immediately adjacent to, and particularly under, all aircraft are kept clear of equipment.

Unplug and disconnect all electrical equipment, extension cords, power units, power cables, and air hoses at the end of the workday.

Cover all air hoses, electrical cords, hydraulic hoses, and cables that traverse walkways with a clearly marked metal cover.

Remove all equipment from the work area and store in the designated area when no longer in use.

Do not leave tools, parts, or other items on maintenance stands or aircraft in an unsafe manner.

Keep all workbenches and toolboxes in a clean and orderly fashion.

Keep the floor and ramp clean and FOD-free.

8.8 Personal Protective Equipment

Use safety glasses, goggles, or face shields when grinding, cutting or sawing metals, plastics or wood and while handling volatile, corrosive, or pressurized fluids.

Wear gloves appropriate to the material being handling when handling acids or other materials that cause burns or can be absorbed through the skin.

Wear approved hearing protection at all times when noise conditions are extreme. Note:

Hearing protection is made readily available at the entrance to the hangar.

Wear hard hats in designated areas at all times. Note: Hard hats are available at the RSIB stockroom.

Wear shoes with non-slip soles. Note: Safety shoes are suggested but not required.

Do not wear loose fitting clothing that could become entangled in rotating or reciprocating machinery.

Avoid wearing jewelry when possible while working hot electrical systems. Bind rings that cannot be removed with tape when working around batteries or energized electrical equipment or when working in confined areas.

Wear a safety harness when working out of high reach equipment or on scaffolding. Note:

Safety harnesses are available in the RSIB stockroom.

8.9 Safety Precautions

Use explosion proof or vapor proof lights in and around the aircraft. Note: The Lead, Quality Assurance Office is responsible for approval of fluorescent light fixtures Verify correct revision before use by checking the LMS Web site

Explosion…