122 Intermediate Level (I-Level) Aviation Life Support System(S)

122. I LEVEL ALSSPage 1 of 11

122. INTERMEDIATE LEVEL (I-LEVEL) AVIATION LIFE SUPPORT SYSTEM(S)(ALSS) FUNDAMENTALS

References:

[a] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. I

[b] NAVAIR 13-1-6.2, Emergency Personnel and Drogue Parachute Systems

[c] NAVAIR 13-1-6.4-2, Oxygen Equipment (Regulators)

[d] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. V

[e] NAVAIR 06-30-501, Oxygen/Nitrogen Systems Technical Manual

[f] A6-332AO-GYD-000, ABO Surveillance Program Laboratory and Field Guide

.1 Discuss ALSS pool management. [ref. a, ch. 16]

1. General

a. A pool of ALSS spare assemblies (parachutes, life rafts, SSKs, life preservers, survival radios, and miniature regulators) shall be established by IMA ashore. The spare ALSS assemblies are owned by the station/MALS Aviation Supply Officer and are inventoried, maintained, and stored by the local IMA. This material will be maintained, in a rotatable ALSS pool located in the IMA 800 Division. IMA personnel shall ensure all spare ALSS equipment is properly stored, RFI upon demand by O-level activities, and on hand quantities match those on the activity's supply records.

b. When the deployment site does not have an ALSS pool, the supporting shore-based IMA is responsible for providing RFI Assemblies equal to 10 percent of those required for full outfitting of the deploying squadron or detachment to the deployed site.

c. Deployed shipboard IMAs will be responsible for providing all repair parts and components required to support the embarked squadrons' ALSS equipment.

d. Upon completion of deployment, the shipboard IMA is responsible for returning the same number ofRFI assemblies originally provided by the supporting shore-based IMA. When the deployment site does nothave an established IMA, the deployed site Supply Officer is responsible for the return of all unusedassemblies and adequate documentation on the used material to guarantee proper stock replacement, carcasstracking, and charges.

e. Personal survival equipment, such as helmets, survival vests, gloves, flight suits, or items of squadron equipment which are not normally inducted into the IMA for maintenance, are not to be included in ALSS pools.

.2 Discuss the purpose and use of the SEATS/ICAP Program. [ref. a, ch. 10]

* SEATS/ICAP is a microcomputer based system which provides a standardized method to manage, report and generate hard copy history records on ALSS components and installed explosive devices.

SEATS - Survival Equipment Asset Tracking System

ICAPS - Increased Capabilities

.3 Discuss the unique QA requirements for ALSS equipment. [ref. a, chs. 14, 16]

1. General.

1. Activities having no or only one PR assigned shall designate in writing a properly cross trained QAR or CDQAR to inspect work performed on ALSS equipment maintained by WorkCenter 13A. This does not include parachute or life raft/life preserver packing/repacking or other I-level maintenance functions on ALSS equipment. Cross trained QARs/CDQARs shall use NAVAIR 13-1-6 series manuals for technical guidance. Personnel performing ALSS equipment maintenance and QARs/CDQARs inspecting work performed shall be ordnance certified per OPNAVINST 8020.14.

2. O-level activities supported by contract maintenance shall use only qualified, certified civilian personnel to perform O-level maintenance on ALSS/egress system maintenance.

(1) For WorkCenter 13A, only personnel who are graduates of Navy PR or equivalent Air Force or Army MOS course shall be allowed to perform ALSS system maintenance.

(2) For WorkCenter 13B, only personnel who are graduates of NavyAME"A"School and CNATTU for specific T/M/S or T/M/S factory equivalent training course shall be allowed to perform egress system maintenance.

(3) In addition to paragraphs (1) and (2) above, for contract maintenance personnel to be designated as a QA Inspector on ALSS/egress equipment, a documented working history with ALSS/egress equipment is required.

3. I-level activities using NALCOMIS shall assign SMQ passwords to all personnel designated as QARs, CDQARs, and CDIs. QA stamp numbers shall be required for ALSS inspection records, calibration METER cards, and all non-NALCOMIS maintenance documents, for example, VIDS/MAFs. These open purchased numbered impression stamps, which identify the inspector, will be used as required or as established by local policies. Stamps shall be closely controlled by QA and adequate storage facilities provided. A stamp may not be reassigned within a period of 3 months.

NOTES: Cross training is not permitted into the following: AME areas of egress systems or PR I-level areas of responsibility. Only qualified I-level personnel (graduates of approved PR school) will be permitted to pack, repair, or perform calendar inspections on personnel parachutes, drogue chutes (excluding drogue chutes in nonremovable head boxes), SSKs, and inflatable survival equipment. Cross training under provisions are permissible for PR O-level functions only. ALSS O-level and I-level areas of responsibility are outlined in NAVAIR 13-1-6 series manuals and shall be strictly followed.

.4 Discuss documentation requirements for ALSS equipment. [ref. a, ch. 16]

1. Records and Cards

(1) The following records are designed to document ALSS components:

(a) The Parachute Record (OPNAV 4790/101) is designed to provide the current configuration and inspection record of a parachute assembly and its components. The record is a single copy, single-sided SEATS generated form. The record is designed to be filed in the aircraft logbook or the ejection seat AESR where the parachute system is installed.

(b) The Seat Survival Kit Record (OPNAV 4790/137) is designed to provide configuration and inspection information for an SSK and its components. The record is a single copy, single-sided SEATS generated form. The record is designed to be filed in the aircraft logbook or the ejection seat AESR in which the SSK is installed.

(c) The Aircrew Systems Record (OPNAV 4790/138) is designed to provide a continuous configuration and inspection record of ALSS components, kits, and assemblies. This record is a single copy, single-sided SEATS generated form. Each item of ALSS requiring inspection at the I-level of maintenance shall have a separate Aircrew Systems Record. The record shall be filed in the logbook of the aircraft in which the ALSS component, kit, or assembly is installed. For personnel mounted equipment or other equipment which is not aircraft mounted, the record will be maintained as directed by the MO. For amplifying instructions for this record refer to 4790, VOL I, Chapter 13 and NAVAIR 13-1-6 series manuals.

(d) The Aircrew Personal Equipment Record (OPNAV 4790/159) shall be initiated by the cognizant O-level activity upon the initial issue of personal equipment to the aircrew member. The record provides the current configuration of all personal survival equipment issued to the aircrew member. Only items of ALSS requiring inspection at the O-level shall be documented on this record. The record shall be retained until new equipment can no longer be documented in allotted spaces. As an item is removed from service it will be deleted from the record by drawing a single red line through all information pertaining to that item. Information pertaining to the removed item's replacement will be annotated in the next available line below. When the card is filled, a new record shall be initiated and all current data transcribed to the new record. Upon verification of data, the old record may be destroyed.

(e) When any ALSS equipment has been involved in an aircraft mishap, the records shall be forwarded per OPNAVINST 3750.6 and NAVAIR 13-1-6 series manuals.

(2) Record Retention. Each aircrew member shall have a separate file containing the Aircrew Personal Equipment Record (OPNAV 4790/159) and separate Aircrew Systems Records (OPNAV 4790/138) as needed. The aircrew flight equipment file shall be constructed of a 9 x 12 manila folder. The Aircrew Personal Equipment Record (OPNAV 4790/159) will be firmly attached on the right side of the folder and all applicable Aircrew Systems Records (OPNAV 4790/138) will be placed on the left. All maintenance actions performed on an aircrew member's equipment shall be documented on a MAF. After normal processing of the VIDS/MAF, Copy 3 will be placed in the aircrew member’s flight equipment file beneath the Aircrew Personal Equipment Record (OPNAV 4790/159) until Copy 1 is received from the data services facility. Copy 3 can then be discarded. Copy 1 will be placed beneath the Aircrew Personal Equipment Record (OPNAV 4790/159) and retained for a minimum of 6 months.

NOTE: All aircrew flight equipment records and files shall be maintained as directed by the MO.

(a) When an item of ALSS is due for inspection or maintenance, Maintenance Control shall forward all appropriate records with the MAF or WO to the Aircrew Personal/Protective/Survival Equipment Work Center.

(b) For record entry requirements for ALSS records refer to Chapter 13 and NAVAIR 13-1-6 series manuals.

.5 Discuss special facility requirements for ALSS work centers.

[ref. b, WP 003; ref c, ch. 3]

1. GENERAL.

a. The wet locker and washroom shall be separateareas. The packing area, store rooms, and fabric areasshould be separated if room is available. The packingtables shall be adequately spaced. The fabric area shallbe kept clean. All local fire regulations shall be adhered

to.

b. packing area

c. Fabric area

d. Wet Locker

e. Washroom.

f. Storage facilities.

2. Environmental requirement.

Parachutes should be inspected, repaired andpacked under regulated temperature and humidityconditions. So, these conditions must be controlled inall parachute lofts. In general, the loft shall not beexcessively damp or dusty. It shall be continuously orfrequently ventilated.

1. REQUIREMENTS.

a. The temperature and relative humidity inpacking loft and dry locker shall be maintained withinlimits indicated in (Figure 3). Ideal conditions are a temperature of 24 C (75 F) and a relative humidity of

60%.

b. The shaded area on temperature-humidity chart,shown in (Figure 3), outlines the allowable environmentallimits inside parachute loft and illustratesfavorable and unfavorable conditions. Parachutes shouldnot be packed when conditions are in the unacceptablezone. These limits are affected by two variables:relative humidity and temperature. Recordings of thesevariables shall be taken at least 3 times daily, using therelative humidity and temperature indicator to ensure that favorable conditions are maintained.

NOTE:Do not pack parachutes when conditions are outsideacceptable conditions.

c. Relative humidity is ratio between amount ofwater vapor in air and amount the air could hold at agiven temperature. Relative humidity is usually writtenas a percentage. Specific humidity is the weight of thewater vapor found in a given volume of air. Relativehumidity limits must be maintained to prevent condensationin actuators and other metal parts. Specifichumidity limits must be maintained to prevent staticelectricity in canopy cloth.

d. Given any two of these variables, it can bedetermined, by using the chart, if the packing loft anddry locker have safe environmental conditions.

.6 Discuss training/qualification requirements for working on ABO equipment.[ref. c, ch. 3, Glossary-2; ref. d, ch. 5; ref. e, ch. 2]

1. General

Shop supervisors shall be responsible for conducting a continuing training program stressing thesignificance of oxygen system cleanliness, personalcleanliness and the oxygen safety program. Conscientious adherence to all cleanliness requirements andsafety regulations shall be observed at all times.

2. ABO analyzing equipment operators shall be:

(1) Trained by one of the following:

(a) Aviators Breathing Oxygen (ABO) Test Site Operator/Analyst course (Course C-670-2018).

(b) Aircrew Survival Equipmentman Class A1 course (Course C-602-2010).

(c) Aviators Breathing Oxygen Contaminant Analyzer Intermediate Operator Maintainer course (Course C-750-3217).

(d) ABO qualified NATEC (Code 3.1/3.2) personnel.

(2) Actively involved with ABO analysis. Personnel who do not interpret sample scans within a two-year period shall be required to complete all initial certification requirements.

(3) Knowledgeable with ABO sampling procedures and analyzing requirements of NAVAIR A6-332AO-GYD-000 and NAVAIR AG-115-SL-OMP-000.

3. Program manager shall Ensure ABO Surveillance Program indoctrination and follow-on training is provided to personnel. All personnel associated with the ABO Surveillance Program shall have a thorough knowledge of the characteristics of LOX/gaseous oxygen, hazards of contamination, and need for quality standards. They shall be familiar with and comply with procedures outlined in NAVAIR 06-30-501, NAVAIR 13-1-6.4-1, NAVAIR A6-332AO-GYD-000, NAVAIR AG-115-SL-OMP-000, NAVAIR 06-20-2, MIL-HDBK-1028/1C, NAVAIR 17-15-98, MIMs, and MRCs (as applicable) to the oxygen servicing/maintenance tasks they perform. Training shall include personnel responsibilities and shall be documented on the NAMP Indoctrination Training sheet in the individual's qualification/certification record.

.7 Discuss special tools required for working on ABO equipment. [ref. c, ch. 3]

1. General.

All tools and equipment shall be maintainedfree of grease, oil and other combustible materials. Tools used on oxygen equipment shall not beused for any other purpose. Tools shall be markedOXYGEN USE ONLY, or other suitable methods ofidentification may be used.

2. Example of a special tool for AIRCRAFT DILUTER DEMAND OXYGEN REGULATORSTYPE AN6004-1, SERIES 2858-A1,2858-A1A, 2858-B1, AND 2858-C1

1. Aircraft Diluter Demand Oxygen Regulators Pioneer Type AN6004-1, Series 2858 (figures 4-1)are manufactured by Pioneer Central Division of BendixAviation Corp (CAGE 06840 and 19315). They are designed to regulate breathing oxygen to the aircrewmember during flight. Table 4-1 contains the leading particulars for the regulators.

3. REQUIRED SPECIAL TOOLS: Table 4-9 list special tools and test equipment required in connection with the work prescribed for disassembly and assembly procedures.

.8 Discuss the requirements and equipment for testing liquid oxygen and liquidnitrogen. [ref. e, ch. 3; ref. f, ch. 2]

1. General.

This section establishesproceduresandrequirements for the quality control of oxygenthat is procured, generated, stored, transferred,and used at Naval and Marine Corps AirStations or aboard aircraft carriers for breathingpurposes by aircrews. This section is applicableto all personnel who are responsible forsupervising or performing the operationsassociatedwith receipt, generation,storage,andtransferring of, and servicing aircraft withaviators breathing oxygen.

2. OUALITY CONTROLREOUIREMENTS OF AVIATORS LIOULDBREATHING OXYGEN.

1. Procurement Limits, Aviators liquid andgaseous breathing oxygen, whether it isgenerated by Navy and Marine activities orprocured from commercial sources, must meetthe purity and contamination requirements asshown in table 2- 1.

2. Use limits are applicable to receiving/storage tanks, servicing equipment andconverters in service shown in table 2- 1.

3. Emergency Use Limits. Followingguidance is provided concerning use of ABOunder emergency conditions when liquid ABOcontains a greater concentration of contaminantsthan the use limit or has a low purity. Inemergency situations where an immediatedecision is essential, local commands may usethe following guide for making on-site decisionson the use of such oxygen. The risk in usage isminor if nitrous oxide (in the total absence ofacetylene), methane, and ethylene, do notexceed three times their respective use limitsFor example, if an analysis of LOX from astorage tank indicates that methanecontamination is 150 ppm (3 times normal uselimits), only minor risk would be involved in itsusage in an emergency situation. However,LOX is not recommended for use when any ofthe following apply: nitrous oxide (in thepresence of acetylene at any concentration)exceeds 4 ppm, carbon dioxide exceeds 20 ppm,acetylene exceeds 0.2 ppm, or highhydrocarbons (ethane equivalent) exceed 8 ppm.In the instance that gaseous aviators breathingoxygen is being tested, the following will alsoapply: Carbon dioxide and moisture may exceedtheir use limits by three times. It is imperativethat the source of excessive contamination bedetermined and alleviated. Thus, if the LOXsampled at the aircraft converter outlet is foundto contain excessive amounts of a particularconstituent, not only should the converter beinvestigated for problems, but so should theservice cart, transfer lines used, and any otherpossible sources until the fault is uncovered andcorrected.

3. SAMPLING AND TESTING.

Sampling and testing of LOX atspecified intervals and points in the supplysystem provide the continuous monitoring ofcontamination that is essential to the qualitycontrol of ABO. However, if the sample takendoes not truly represent its source, then testresults cannot serve the intended purpose.Careful observationof operating instruction forLOX samplers is important to ensurerepresentative samples.

1. ON-BASE TESTING.

1. Navy and Marine Corps Activitieswhich produce liquid oxygen shall sample andtest the contents of the generator in accordancewith paragraph 2-14.1. Receipt of aviatorsbreathing oxygen from a contractor shall also betested in accordance with this paragraph, and bythe following test for particulate matter, beforeunloading is permitted. Periodic surveillance ofstorage tanks, servicing trailers and aircraftconverter systems shall be made. Table 2-2 lists the testing andsampling equipment required to perform theparticulate test:

Note:Test for particulate is only required whencontamination is suspected.

2. Particulate Test. Approximately 200mils of the sample shall be poured into a clean400 ml beaker or similar container, without afilter paper in the bottom. A watch-glass coveror some other means of partially covering thetop of the beaker shall be used as the 200 milsof liquid evaporate to dryness. When the froston the outside of the beaker has melted, theoutside of the beaker shall be wiped with aclean dry cloth and the beaker placed on cleanwhite paper. The interior of the beaker shall bevisually examined, without the aid of

magnification for the presence of particles.

4. EOUIPMENT.

Addition of contaminants fromequipment shall be reduced or prevented byoperating and maintaining generators, storagetanks, servicing carts, and aircraft oxygensystems in accordance with applicable technicalmanuals.

5. SAMPLER.

1. The function of a good cryogenic liquid batch sampler is to extract and hold a representative, unmodified sample for analysis. Ensure the sample is not modified in the course of progressing from the original sample point to the analytical instrument. Liquid oxygen is more volatile than the contaminating constituents are. There is a tendency for liquid oxygen to at least partially vaporize during the sampling process, increasing the apparent contamination level of the residual fluid. The higher contamination level may be high enough to result in the sample being rejected. Good sampling procedures and techniques are very important when drawing a sample to ensure that the sample is representative of the contents of the equipment.