PROCESS AND MATERIAL SPECIFICATION

PROCESS SPECIFICATION

01-01-11

Final cleaning and drying of metallic

oxygen pipes, fittings and other
components of oxygen systems

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PROCESS AND MATERIAL SPECIFICATION

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PROCESS AND MATERIAL SPECIFICATION

AIPS
Airbus Process Specification
"Final cleaning and drying of metallic oxygen pipes, fittings and other
components of oxygen systems

Published and distributed by :

AIRBUS S.A.S.
ENGINEERING DIRECTORATE
31707 BLAGNAC Cedex
FRANCE

Copyright reserved
Ref. no.AIPS09-01-013
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Contents

Scope

Normative references

Definition, applicability and limitations

Requirements

Process qualification

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1 Scope
This Airbus Process Specification defines the requirements for "Final cleaning and drying of metallic oxygen pipes,
fittings and other components of oxygen systems".
The purpose of this specification is to give design and quality requirements to manufacturers. Although the
essential requirements of a process will be defined, the specification does not give complete in-house operating
instructions, these shall be given in the manufacturers detailed process instruction and supporting work
instructions.
This specification shall not be used as an inspection document unless parts of assemblies have been
manufactured according to this specification.
It shall be applied when required by the relevant standard, material specification or drawing or the item is identified as
pipes, fittings or other components of the oxygen system.

2 Normative references
This Airbus specification incorporates by dated or undated reference provisions from other publications. All
normative references cited at the appropriate places in the text are listed hereafter. For dated references,
subsequent amendments to or revisions of any of these publications apply to this Airbus specification only when
incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred
to shall be applied.
National standards should be applied if Airbus standards are not available.
AIMS 09-01-000
AIMS 09-03-000
AIMS 09-03-001
AIMS 09-04-000
AIMS 09-04-001
SAE ARP 1176
TDD 35D001
ISO 9227
RTCA/DO-160-E

Technical specification - Liquid cleaning agents-General requirements

Technical specification - Liquid non-aqueous cleaning agents
Material specification - Liquid non-aqueous cleaning agents
Technical specification - Aqueous cleaning agents
Material specification - Aqueous cleaning agents
Cleaning and packing of oxygen components
Oxygen system
Corrosion tests in artificial atmospheres
Environmental Conditions and test procedures for Airborne Equipment

3 Definition, applicability and limitations

3.1 General description of process
Pipes, fittings and other components of the oxygen system shall be cleaned before assembly and shall achieve the
required cleaned status. The final process shall conform to the requirements.
3.2 Definitions
Pre-cleaning:

Cleaning after the bending-process for removal of oils, grease, etc.

Final cleaning:

Last cleaning step to reach the required cleanliness level of parts and assemblies

Drying:
Pipes:

After final cleaning, residues of the cleaner in the pipe shall comply with the limits given in this
specification
All existing diameters and part dimensions of pipes (length, diameter)

Components:

Fittings, sleeves, elbow, unions

Fitting:

T-, elbow-and cross fittings

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Cleaning agent:
Analysis solvent:

Page 4

Any compound or substance, suitable to remove all contaminants by chemical action, may be
called a cleaning agent.
Solvent, which allows solving all residual contamination on the surface; used to evaluate
surface cleanliness by subsequent measurement of NVR and particles in the solvent

3.3 Applicability
This Airbus specification is applicable when invoked by the drawing directly or through another document for the
purpose given in the scope. When processing to AIPS09-01-013 is required, it shall be invoked on the drawing by
the words "Final cleaning and drying of metallic oxygen pipes, fittings and other components of oxygen systems"
according to AIPS09-01-013.
3.4 Limitations
This process shall follow the pre-cleaning and shall be used for final cleaning of pipes, fitting and other components
of the oxygen system. The final cleaning process is applicable after attachment of sleeves and unions.
The process is limited to cleaning of pipes, fitting and components made from aluminium alloy or steel.

4 Requirements
4.1 Technical requirements
4.1.1 Before starting the cleaning process
During establishment of the final cleaning process it shall be considered that only components without lubrication
film shall be cleaned. If the fittings have sealing adapted the function, the compatibility and the influence of the
cleaning process on the sealing must be verified. Additionally the influence of the lubrication on the bath
cleanliness must be verified.
4.1.2 During the cleaning process
The total inner surface must be cleaned during the cleaning process. That means the complete inner surface of the
component must be wetted. If water-soluble cleaning agent is used the rinsing and drying requirements of the ARP
1176 shall be considered.
4.1.3 After the final cleaning process
The components shall be handled and packed according to the ARP1176. It shall be ensured that the components
are free of residual dirt to the level required by ARP 1176 and cleaner residues. The dryness shall be ensured
according to the ARP 1176. All assemblies, parts or tubing shall be taken from the work area and kept clean by
using cleaned caps and plugs. After this the parts shall be sealed in transparent visible clean polyethylene wraps.
4.2 Engineering requirements
4.2.1 Requirements concerning the cleaning agents
The cleaning process and agents used during the cleaning process shall be qualified and shall be conform with the
ARP 1176.
The cleaning agents shall meet the Cleanliness level of category 1C of the ARP 1176. In category 1C of the ARP
1176 a defined particle class and Non-Volatile Residue (NVR) is allowed.
If a non-aqueous cleaning agent is used it shall be qualified according to AIMS 09-03-000 and the requirements
shall be in accordance with AIMS 09-03-001.
The amount of Non-Volatile Residue (NVR) shall be less than 10 mg/l if the cleaning agent is solvent-based (see
also ARP 1176).
If an aqueous cleaning agent is used it shall be qualified according to AIMS 09-04-000 and the requirements shall
be in accordance with AIMS 09-04-001.

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4.2.2 Requirements concerning the cleaning process

The cleaning process used shall not damage the cleaned components, the material or the surface protection.
4.2.3 Requirements concerning purging fluids
The purging fluids shall achieve the requirements of the ARP 1176. That means all purging fluids used shall
achieve cat. 1C of the ARP 1176 including the required particle level.
4.2.4 Requirements concerning the analysis solvent
The analysis solvent shall achieve the required Cleanliness level category 1 C of the ARP 1176. The analysis
solvent shall have fewer particles than required by Cleanliness level 300. The amount of Non-Volatile Residue
(NVR) shall be less than 5 mg/l. The analysis solvent shall be chosen with respect to the contamination base and
with respect to ARP 1176.
4.2.5 Requirements concerning the Cleanliness level of pipes, fittings and other components of the oxygen
system
For oxygen pipes a certain Cleanliness level has to be met. In TDD 35D001 the Cleanliness level of oxygen pipes
is defined. In TDD 35D001 category 1C of ARP 1176 is required for all oxygen components in the oxygen system.
In category 1C of ARP 1176 a defined particle class and Non-Volatile Residue (NVR) is allowed on the inner
surface of the components of the oxygen system. Refer to ARP 1176 for oxygen system component categories.
4.2.6 Requirements concerning the dryness of the oxygen pipes
After drying in general no residues of the cleaner are allowed on the inner surface of the components of the oxygen
system. The drying parameters temperature, drying time and flow rate shall be controlled and recorded during the
drying process.
If 2-Propanol or Ethanol is used for cleaning, the residue of 2-Propanol or Ethanol after drying shall be less than 30
ppm defined in the TDD 35D001.
4.2.7 Requirements concerning corrosion resistance
The cleaning process shall not influence the corrosion resistance of the components after cleaning the
components. That means no decrease of the corrosion resistance is allowed after the salt spray.
4.2.8 Requirements concerning the caps and plugs
The caps and plugs shall be conform to the requirements of the TDD35D001. That means the category 1C of the
ARP1176 is required.
4.2.9 Requirements concerning the packing material
Approved clean polyethylene plastic wrap shall be used for packing according to ARP1176. The packing material
shall be of such cleanliness that items are not contaminated again.
4.2.10 Requirements concerning clean room
The clean room shall be designed with respect to the requirements of cat. 1C of the ARP 1176. In this room only
cleaning and packing tasks are allowed.
All assemblies, parts or tubing shall be taken from the work area and kept clean by using cleaned caps and plugs.
After this the parts shall be sealed in transparent visible clean polyethylene wraps.
4.3

Quality requirements

4.3.1 Cleaning agents

A verification of the cleaning agents shall be undertaken prior to the cleaning procedure. A verification of particle
and the Non Volatile Residue levels shall be done according to the methods named in the ARP 1176. The cleaning
agent shall have fewer particles than required to meet Cleanliness level 300.

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4.3.2 Cleaning process

After cleaning the components a visual inspection is to be applied to confirm that the cleaning process has caused
no damage upon the materials and the surface protection.
4.3.3 Purging fluids
Regular verification shall be done for particles and Non Volatile Residue according to the methods named in the
ARP 1176.
4.3.4 Analysis solvent
Regular verification shall be done for particles and Non Volatile Residue according to the methods named in the
ARP 1176. It shall be verified that the analysis solvent is suitable for the contamination base of the parts and shall
comply with the ARP1176 requirements.
4.3.5 Cleanliness level of pipes and fittings and other components of the oxygen system
The verification of particle and Non-Volatile Residue (NVR) levels shall be done according to the methods named in
the ARP 1176 after final cleaning of the components. The verification of the finally cleaned oxygen pipes and
fittings shall be performed several times during the daily production. The cleaned components should be rinsed
with a certain analysis solvent with respect to ARP1176.
4.3.6 Dryness of the oxygen pipes
The drying parameters temperature, drying time and flow rate shall be controlled and recorded during the drying
process. After drying the residue of the final cleaning agent in the pipe shall be measured.
If 2-Propanol or Ethanol is used for cleaning, the residue concentration after drying shall be measured with a gas
analysis device. The residue after drying shall be less than 30 ppm as defined in the TDD 35D001.
4.3.7 Verification of the corrosion resistance
The corrosion resistance must be verified after final cleaning by using the salt spray test according to RTCA/DO160E "Enviromental Conditions and Test Procedures for Airborne Equipment, Section 14/Salt Fog", Para 14.3.6.6
Performance of Normal Salt Fog Test (Category S). Using a reference component is mandatory.
4.3.8 Cleanliness level of the caps and plugs
The cleanliness level of the caps and plugs has to be verified according to ARP 1176 (NVR and particle test).
4.3.9 Verification of the packing material
The packing material has to be visually inspected according to ARP 1176.
4.3.10 Verification of the clean room and cleaning plant
The cleanliness level of the clean room and cleaning plant has to be checked/measured/determined regularly
according to ARP 1176.
4.3.11 Verification tests during qualified cleaning process
All verification tests shall be done according to ARP 1176 summarised in table 1 below. In the chapter cleanliness
inspection and tests are all named tests are described. These test methods are applicable. If another test method is
used only specified and qualified test methods are allowed. The reason for changing the test method shall be
explained and shown that it is equal to the required test method.

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Table 1 - Verification tests during qualified cleaning process

5 Process qualification
5.1

Process qualification procedure

For technical qualification: Refer to AIRBUS qualification procedure for Manufacturing Process.
5.2

Process qualification

5.2.1 General
The general process qualification, the qualification of industrial facilities and Airbus quality assurance are described
in prevailing procedure documents.
The process qualification is given and maintained only on condition that the qualified workshop complies with the
cleaning and inspection documents formally approved by Airbus.
The qualification is limited to a specific issue of any process specification of the developer. Any modification needs
reapproval or re-qualification. Users need to be qualified in accordance with the relevant Airbus quality
requirements. Airbus reserves the right to audit the use of qualified processes to check conformity with the
agreements.
5.2.2 Screening Phase
In the first step a screening of process parameters shall be done. The process parameters shall be recorded and
then defined.
The final cleaning process must be stable and reproducible before the technical qualification procedure is
launched, so that a selected set of process steps and parameters is taken for the qualification. This selected set of
process steps shall deliver a reproducible cleanliness level of the cleaned pipes and shall comply with all
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requirements, also take respect to corrosion resistance. When the screening is finished a first draft of the
production work instruction shall be issued and the qualification can start.
The general process qualification, the qualification of industrial facilities and quality tasks shall be described in
prevailing procedure documents.
5.2.3 Start of qualification
The process qualification shall be done by qualified and authorized personal.
The process qualification shall be performed using the materials (cleaning agents and oxygen system components)
and cleaning procedures/equipment to be used in serial production. All affected materials, all surface coatings
(galvanic coatings and painting), all kind of parts and assemblies shall be tested with the cleaning process. The
production shop must use its facilities under serial production conditions during the qualification tests.
The process qualification shall be done with a qualified cleaning agent according to Category III of AIMS 09-01000. The non-aqueous cleaning agents shall be qualified according to AIMS 09-03-000, with aqueous cleaning
agents in accordance with AIMS 09-04-000.
5.3 Standard qualification test program (QTP)
This chapter provides the details of the standard test program, which shall be taken into account for the definition of
the specific qualification test program (QTP) for the technical qualification of a shop.
The QTP shall show the compliance with the engineering, technical and quality requirements defined in this AIPS
(chapter 4). In addition to the acceptance criteria, specific test requirements are defined as amendment and/or
deviation. This means the qualification test program (QTP) includes the standard qualification test defined by this
AIPS hereinafter (chapter 5.4) as well as any amendment or deviation.
Any change to the cleaning process/cleaning agent shall be submitted for technical assessment to the appropriate
Airbus authority, which shall decide whether new verification tests are required.
5.4 Verification during qualification testing of the required performance and quality level
Testing of at least 60 components of each fitting supplier - at least 6 different types of fittings, with respect to
smallest and biggest diameters.
Testing of at least 50 pipes - at least 8 different types of pipes, with respect to the smallest and biggest diameters
and the maximum length and maximum number of bends.
5.4.1 Cleaning agents
The cleaning agent should be chosen in accordance with ARP1176.
The cleaning agent shall be verified with respect to category 1C of ARP 1176. A verification of particle and the Non
Volatile Residue levels shall be done according to the methods named in the ARP 1176. The cleaning agent shall
have fewer particles than required to meet Cleanliness level 300.
The degree of cleanliness of the cleaning agent should be checked and documented during the qualification.
5.4.2 Cleaning process
After cleaning the components a visual inspection is to be applied to confirm that the cleaning process has caused
no damage upon the materials and the surface protection. Each surface shall be visual examined.
5.4.3 Purging Fluids
The used purging fluids shall be verified before starting the qualification process. Verification shall be done for
particles and Non Volatile Residue according to the methods named in the ARP 1176.
5.4.4 Analysis solvent
Before verification of the components it shall be proved that the analysis solvent is suitable for solving the residual
contamination base (oils and manufacturing auxiliaries). The degree of the cleanliness level of the analysis solvent
should be checked and documented in accordance with ARP1176. Verification shall be done for particles and Non
Volatile Residue according to the methods named in the ARP 1176. The Cleanliness level shall be better category
1C.
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5.4.5 Cleanliness level of oxygen pipes and fittings

The verification of particle and Non-Volatile Residue (NVR) levels shall be done according to the methods named in
the ARP 1176 after final cleaning of the components.
An investigation of process parameters with respect to the influence on the achieved levels of cleanliness shall be
done.
5.4.6 Dryness of the oxygen pipes
Dryness of the components of the oxygen systems is to be checked after the cleaning operation. The influence of
drying parameters on the achieved levels of dryness is to be studied and documented. The drying parameters
temperature, drying time and flow rate shall be controlled and recorded during the drying process.
After drying the residue of the final cleaning agent in the pipe shall be measured. If 2-Propanol or Ethanol is used
for cleaning, the residue concentration after drying shall be measured with a gas analysis device.
5.4.7 Verification of the corrosion resistance
The influence of the cleaning process on the corrosion resistance shall be investigated. The corrosion resistance
must be verified after final cleaning by using the salt spray test according to RTCA/DO-160E "Enviromental
Conditions and Test Procedures for Airborne Equipment, Section 14/Salt Fog", Para 14.3.6.6 Performance of
Normal Salt ForgTest (Category S). Using a reference component is mandatory.
5.4.8 Cleanliness of the caps and plugs
Cleanliness of caps and plugs shall be verified according to category 1C of ARP 1176 during the qualification
process.
5.4.9 Verification of the packing material
The packing should be done according to the ARP 1176. The packing material shall be approved according to
ARP 1176.
5.4.10 Verification of the clean room and cleaning plant
In general the room should be of adequate size, isolated from oil, grease paper and lint particles and other airborne
contaminants. The walls, ceiling and floors should be designed with a surface that is non-dusting and also
minimizes the collection of dust. The requirements of the ARP 1176 shall be fullfilled.
The cleaning plant must be designed in a way that the surfaces are not damaged during the cleaning operation.
The cleanliness level of the clean room and cleaning plant has to be checked/measured/determined regularly
according to ARP 1176.
5.4.11 Standard qualification test program
All verification tests shall be done according to ARP 1176 summarised in table 2 below. In the chapter cleanliness
inspection and tests are all named tests described. These test methods are applicable. If another test method is
used only specified and qualified test methods are allowed and the reason for changing the test method shall be
explained.

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Table 2 - Test selection for the standard qualification test program

Test results of the qualification test program of the process qualification shall be recorded in a qualification test
report (QTR), which shall include results from the sub-contractors.
5.5 Qualification test report (QTR)
The basis of the qualification/approval of a specific process to the AIPS is a detailed test report about all tests and
procedures that have been performed (adding details and values).
Prior to starting a production run, the complete test report shall be submitted to and approved by the appropriate
Airbus authority.
The test report has to be established and signed by the developer and its quality assurance department.
The test report shall give at least all the following information:
-

Name and address of the production shop

Process instruction
Flow chart of the plant
Description of all used specifications and test methods
Description of the type of cleaning agent
Detailed description of pre-treatment steps
Description of oxygen system components, including materials and coatings
Justification of the representatively of the chosen components and materials for the process qualification
Influence of the process on the corrosion resistance
Cleaning results achieved using the investigated process parameters and Cleanliness levels
Detailed description of process steps with all methods of cleaning and description of the work instruction
sequence
Verification method used to investigate the Cleanliness level of the pipes and fittings
Any incident that may have affected the results and any deviation from this AIPS
Discussion of the results with respect to the qualification test program (QTP) and achievement of the
requirements

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