Measurement Process

Objective and binding statement

Definition
Control of Measurement Processes
Metrological Conformation
Material Resources
Purchase description
Metrological Requirement Capture
1. Objective and binding statement
This chapter and associated documents define the measurement processes and measuring
equipment and procedures used for calibration of measuring equipment in accordance ISO10012.
All documents referenced in this chapter are considered as part of the chapter. This chapter is
approved by the undersigned. The undersigned ensure that:

 This chapter including the referenced documents is maintained in conformity with the
Quality Assurance and is used as a basic working document within working station;

 All personnel engaged with calibration of measuring equipment and testing UUT are
thorough knowledge of the processes described in this chapter and associated documents.

 According to design assurance level, measuring equipment in category a send to laboratory.

The laboratory accommodation, facilities and equipment are adequate to comply with
ISO10012.

 This chapter includes requirements for implementation of measurement management

systems, and can be useful in improving measurement activities and the quality of products.

 Organizations have the responsibility to determine the level of controls needed and to
specify the measurement management system requirements to be applied.

 Fuel Nozzle Assembly Tester measurement requirements are determined and converted
into metrological requirements. The measurement management system meets the Fuel
Nozzle Assembly Tester metrological requirements, and compliance to Fuel Nozzle
Assembly Tester -specified requirements can be demonstrated.

Signed by:
Quality Assurance
2. Definition:
2.1 Measurement Management System: Measurement management systems, control measurement
processes and metrological conformation of measuring equipment. See Figure1.

Figure 1. Measurement Management System

2.1 Measurement process:
Applies to physical measurement activities (e.g. in design, test, production, inspection).
2.2 Measuring equipment:
Measuring instrument, software, measurement standard, reference material or auxiliary apparatus,
or a combination thereof, necessary to realize a measurement process.
All measuring equipment necessary to satisfy the specified metrological requirements shall be
available and identified in the measurement management system. Measuring equipment shall have
a valid calibration status prior to being confirmed. Metrological requirements for the measuring
equipment are derived from specified requirements for the product or the equipment to be
calibrated, verified and confirmed.
2.3 Calibration of measuring equipment:
Calibration responsibility for locally manufactured calibration aids; i.e., jigs, fixtures, adapters,
etc., will be determined jointly by the User and Precision Measurement Equipment Laboratories
(PMELs) Chief. Conflicts in determinations will be submitted by organization Quality Assurance.
2.4 Metrological characteristic:
Characteristic of measuring equipment which can influence the results of measurement. Measuring
equipment usually has several metrological characteristics and can be the subject of calibration.
2.5 Metrological requirements:
Metrological requirements derived from
a. Product specification and expressed as range, stability, resolution, environmental conditions or
operator skills.
b. MSDS, Calibration Fluid standard or military standard.
c. Design process, calibration Process and calibration software.
2.6 Metrological confirmation:
Metrological confirmation (see Figure 2.) shall be designed and implemented to ensure that the
metrological characteristics of the measuring equipment satisfy the metrological requirements for
the measurement process. Metrological confirmation comprises measuring equipment calibration
and measuring equipment verification.

Figure 2. Metrological Confirmation

 3. Material Resources
3.1 Fuel nozzle Assembly tester measuring equipment

3.1.1 Flow meter, Gas Turbine

A turbine flow meter is a volume sensing device. As liquid or gas passes through the turbine
housing, it causes the freely suspended turbine blades to rotate. The velocity of the turbine rotor is
directly proportional to the velocity of the fluid passing through the flow meter.
The external pickoff mounted on the body of the flow meter, senses each rotor blade passing,
causing the sensor to generate a frequency output. The frequency is directly proportional to the
volume of the liquid or gas.
Either a magnetic or modulated carrier pickup can be used to sense the rotational speed of the
turbine rotor.
Depending on your flow meter application, there are many types of turbine flow meters to choose
from. And after understanding the application several factors come into effect when choosing a
flow meter, such as:
 Fluid Type
 Viscosity
 Connection
 Pipe Sizing
 Process Temperature (min & max)
 Flow Range (min & max)
 Pressure Range (min & max)
 Accuracy Range
 Specific Application

3.1.2 Flow meter, Liquid Turbine

A turbine flow meter is used for volumetric total flow and/or flow rate measurement and has a relatively
simple working principle. As fluid flows through the turbine meter, it impact upon turbine blades that are
free to rotate about an axis along the center line of the turbine housing. The angular (rotational) velocity of
the turbine rotor is directly proportional to the fluid velocity flowing through the turbine. The resulting
output is taken by an electrical pickoff(s) mounted on the flow meter body.
3.1.3 Frequency Counter
A frequency counter is an electronic instrument, or component of one, that is used for
measuring frequency. Frequency counters usually measure the number of cycles of oscillation, or pulses
per second in a periodic electronic signal.
3.1.4 Level
A Level Transmitter is simply an instrument that provides continuous level measurement. Level
transmitters can be used to determine the level of a given liquid at any given time. This is different to a
level switch which only alarms when the level of material (liquid) reaches a predetermined level.
3.1.5 Power Supply, DC
3.1.6 Pressure Gauge
3.1.7 Pressure Gauge, Compound
A compound gauge is a device that can display both positive and negative (vacuum) pressures.
You need to use a compound gauge when you are measuring a system that is exerting both positive
and negative pressure on the gauge.
3.1.8 Pressure Gauge, Differential
3.1.9 Pyrometer
A pyrometer is a type of remote-sensing thermometer used to measure the temperature of a
surface.
3.1.10 Relief Valve
3.1.11 Pressure Regulator.
Pressure Regulators and associated pressure measuring or indicating devices used with gas
supply bottles or with non-critical piped gas or fluid apparatus, such as air or water lines, do not
require calibration. If the user identifies a critical application, provide the regulator along with
range and accuracy requirements to the PMEL for calibration as a SPECIAL calibration.
3.1.12 Pressure Reducing Valves
In hydraulics, a pressure reducing valve serves the same purpose as a "pressure regulator" valve
in a compressed air system. It can be described as a 2-way, normally open valve which is piloted
from its own outlet. It is one of a variety of pressure control valves available for hydraulic
circuits. It is always used in a branch circuit, never in the full pump flow line. It will reduce the
pressure in one branch while allowing other branches to operate at full system pressure. A knob
or screw allows adjustment of the outlet pressure over the working range of the valve. It will
accept a flow of high pressure oil on its inlet and deliver the same flow from its outlet at a
constant reduced pressure, as long as the inlet pressure is higher than the value set on the
adjustment knob.

3.1.13 Snap Gage

A snap gauge is a form of go/no go gauge. It is a limit gauge with permanently or temporarily
fixed measurement aperture(s) (gaps) which is used to quickly verify whether an outside
dimension of a part matches a pre-set dimension or falls within predefined tolerances.
3.1.14 Sound Level Calibrator
A Sound Level Calibrator or Acoustic Calibrator is a hand-held device that emits an audible tone
of very accurate level and frequency.
3.1.15 Thermometer
3.1.16 Thermometer, Dial
3.1.17 Vacuum Gauge
3.1.18 Voltmeters, AC/DC Analog
3.1.19 Wattmeter’s, RF (Panel Mounted)

3.1.20 Software
Software used in the measurement processes and calculations of results shall be documented,
identified and controlled to ensure suitability for continued use. Software, and any revisions to it,
shall be tested and/or validated prior to initial use, approved for use, and archived.
Software may be in several forms, such as embedded, programmable, or off-the-shelf packages.
Off-the-shelf software might not require testing. Testing may include virus checking, checking of
user-programmed algorithms, or a combination thereof as necessary to achieve the required
measurement result.
Software configuration control can help maintain the integrity and validity of measurement
processes using software. Archiving may be accomplished by creating back-up copies, off-site
 storage, or any other means to safeguard programming, ensure accessibility, and to provide the
level of traceability necessary.

3.1.21 Computer/PC Clock.

Computer/PC Clocks do not require calibration when used for program timing events; i.e., data
printouts, delays, settling time, etc.

3.1.22 Electrical Meter.

The Electrical Meters referred to in the General Calibration TOs are those used for measuring
voltage, current or other properties as an exist and not those incorporated in combination test sets
such as multi meters. General Calibration TOs are being prepared in such a way that calibration
may be accomplished with the standards presently available.
3.2 TYPE OF MAINTENANCE DESCRIPTION CODE
3.2.1 SERVICE: [A]
Includes all units of work associated with servicing, cleaning and movement of equipment
that is not accomplished concurrently with Type Maintenance codes B, C or D.
3.2.2 UNSCHEDULED MAINTENANCE: [B]
Includes all unscheduled maintenance, inspection, calibration, repair and servicing
performed between calibration intervals.
3.2.3 SCHEDULED CALIBRATION OF EQUIPMENT OR COMPONENTS: [C]
Includes all units of work accomplished concurrently with a scheduled calibration.
3.2.4 SPECIAL INSPECTION: [D]
Includes all units of work accomplished during all phases of special inspections.

3.3 WHEN DISCOVERED DESCRIPTION

3.3.1 During Equipment Operation/Caused Equipment Down Time [F Date]
Equipment downtime refers to the amount of time that equipment is not operating, whether
that’s a result of unplanned equipment failure (like a fault or broken part) or planned
downtime (like necessary downtime for preventive maintenance). Typically, the term
“equipment downtime” refers to unexpected downtime that accumulates any time the
production process stops.
3.3.2 During Equipment Operation/Did Not Cause Equipment Down Time [E Date]
3.3.3 Daily Inspection/Shift Verification [S Date]
3.3.4 Operational System Check [J Date]
3.3.5 Special Inspection [K Date]
3.3.6 Quality Control Inspection [L Date]
3.3.7 During Scheduled Calibration [C Date]
3.3.8 Non-Destructive Inspection, includes optical penetrant, magnetic particle, radiographic,
eddy current, ultrasonic, spectrometric oil analysis, etc. [O Date]
3.3.9 During Unscheduled Calibration [B Date]
3.3.10 In-Shop Repair and/or Disassembly for Maintenance [R Date]
3.3.11 Upon Receipt or Withdrawal from Supply Stocks [W Date]
3.3.12 During Initial Equipment Installation [I Date]
4. Purchase description:
4.1 Equipment adjustment control
Access to adjusting means and devices on confirmed measuring equipment, whose setting affects
the performance, shall be sealed or otherwise safeguarded to prevent unauthorized changes. Seals
or safeguards shall be designed and implemented such that tampering will be detected.
The metrological confirmation process procedures shall include actions to be taken when seals or
safeguards are found damaged, broken, bypassed or missing.
Special attention should be paid to write-protection techniques to prevent unauthorized changes to
software and firmware.
The decisions about what measuring equipment should be sealed, the controls or adjustments
which will be sealed, and the sealing material such as labels, solder, wire, paint, are normally left
to the metrological function. Implementation of a sealing programme by the metrological function
should be documented. Not all measuring equipment lends itself to sealing.

4.2 Gage Block Packing

All Gage Block sets will be pre-packaged before they leave the laboratory to avoid damage of the
Gage Blocks. The packaging includes oiling the Gage Blocks and placing packing inside the case
to hold Gage Blocks in position. The case will then be taped shut both lengthwise and widthwise.
4.3 Filter level
If applicable provide filter module with 3 μ filter element and clogging indicator micro switch or
clogging indicator gage.
Test fluid, calibration fluid, MIL-PRF-7024, Type II, or equivalent, must be filtered to pass
contamination examinations every other month as set forth in APR4865 to an ISO level of 16/13 or
better (5 microns or better). The fluid must be maintained at 80° F ± 2° F (27° C ± 1° C).

4.4 Permanent noise emission

Max. 75dB (A) in 1m (39.4in) distance is permissible.
4.5 Control settings
The control settings shall be determined by the approved equipment test procedure.
4.6 Test equipment
Test equipment used for inspections and tests shall be as specified by approved equipment test
procedure. The test equipment shall be properly maintained and calibrated.
4.7 Calibration interval
Calibration interval specified in the page……
Metrological Confirmation:
a. To ensure that the metrological characteristics of the measuring equipment satisfy the
metrological requirements for the measurement process.
b. Metrological confirmation comprises measuring equipment calibration and measuring
equipment verification.
c. Metrological confirmation procedures include methods to verify that measurement
uncertainties and/or measuring equipment errors are within permissible limits specified in
the metrological requirements.
Metrological Requirement (characteristic):
Measuring equipment usually has several metrological characteristics. The measurement management
system shall ensure that specified metrological requirements are satisfied.
Specified metrological requirements are derived from requirements for the product. These
requirements are needed for both measuring equipment and measurement processes. Requirements
may be expressed as maximum permissible error, permissible uncertainty, range, stability, resolution,
environmental conditions or operator skills.
Metrological characteristics can be the subject of calibration. Examples of characteristics for
measuring equipment include:

 Range,
 Bias,
 Repeatability,
 Stability,
 Hysteresis,
 Drift,
 Effects of influencing quantities,
 Resolution,
 Discrimination (threshold),
 Error,
 Dead band.
Metrological Requirement Capture
No. 0009 Identification Code: 1901-C-01-0009
Subject:
Operating and Maintenance instructions are supplied with each facility
Description (Quantity/Quality)
NA
Preliminary Solution
1. Operating and Maintenance instructions explained in the Fuel Nozzle ASSY Tester Maintenance
manual.

No. 0014 Identification Code: 1901-C-02-0014

Subject:
Calibration by software
Description (Quantity/Quality)
NA
Preliminary Solution
1. Definition

No. 0021 Identification Code: 1901-C-02-0021

Subject:
Filter level
Description (Quantity/Quality)
3 μ filter
Preliminary Solution
1. Provide 5-micron filter element commercially available.

No. 0037 Identification Code: 1901-C-05-0037

Subject:
Rel. air humidity
Description (Quantity/Quality)
10 to 90% (non-condensing)
Preliminary Solution
1. Definition

No. 0038 Identification Code: 1901-C-05-0038

Subject:
Permanent noise emission
Description (Quantity/Quality)
Max. 75dB (A) in 1m (39.4in) distance
Preliminary Solution
1. Definition

No. 0054 Identification Code: 1901-C-09-0053

Subject:
Mass flow
Description (Quantity/Quality)
1.5 - 550g/h, ±2% range
Preliminary Solution
1. Definition

No. 0055 Identification Code: 1901-C-09-0054

Subject:
Volume flow fuel
Description (Quantity/Quality)
±0.75% of full scale
Preliminary Solution
Calibration System
1. Definition

No. 0063 Identification Code: 1901-S-01-008

Subject:
3. TEST CONDITION
3.2 Filtration
Description (Quantity/Quality)
The minimum acceptance Beta ratio for
MIL-C-7024-II filtration systems shall be as shown in Equation 1:
β 6/11/15 = 2 / 20 / 75
a. β6 = 2 (50.0% efficient @ 6 μm)
b. β11 = 20 (95.0% efficient @ 11 μm)
c. β15 = 75 (98.66% efficient @ 15 μm)
Preliminary Solution
1. Determined the beta ratio of filter element before assembly by laboratory testing.
2. Use delta pressure switch to generate signal for filter element clogging indicator.
3. Installation of filter module at upper point of test stand decrease fuel waste in every filter element
change and easy maintenance.

No. 0064 Identification Code: 1901-S-01-009

Subject:
3. TEST CONDITION
3.3 Fuel Contamination Testing
Description (Quantity/Quality)
The acceptance level shall conform to the requirement MIL-C-7024 Type II fluid. The recommended
contaminant testing method is the International Standards Organization Solid Contaminant Code
(ISOSCC). The recommended ISOSCC rating acceptance level for all fuel nozzle test stands is 16/13(see
Appendix B). It is recommended that the fluid contaminant level be checked at intervals of 60 days.
Preliminary Solution
1. The fluid contaminant level be checked at intervals of 60 days.
2. Provide sampling port at upstream of circulation pump.
3. Route sample of fuel to laboratory.

No. 230 Identification Code: 1901-S-04-007

Subject:
3. REQUIREMENTS
3.1 Materials
Description (Quantity/Quality)
The fluids shall consist completely of hydrocarbon compounds, except as otherwise specified herein
Preliminary Solution
1. Calibrating fluid used in the calibration of aircraft fuel system components has MIL-C-7024 TYPEII.
2. Stoddard solvent is a mixture of numerous hydrocarbons derived by refining crude oil. It is a petroleum
distillate with a boiling range of 154-202°C and a flashpoint of 38-60°C.
3. The hydrocarbon chain length ranges from C7 to C12 although a form of Stoddard solvent called 140
flash contains C5 and C6 hydrocarbons as well.
4. PMEL report shall determine status of the
4.1 Homogeneous
4.2 Free from water
4.3 free from sediment or suspended matter
4.4 Clear and bright @ ambient temp 21° C (70° F).

No. 0408 Identification Code: 1901-S-08-086

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.1 Conditions and control settings.
Description (Quantity/Quality)
Conditions and control settings shall be as specified in 4.5.1.1 through 4.5.1.2.
Preliminary Solution
1. Definition.

No. 0409 Identification Code: 1901-S-08-087

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.1 Conditions and control settings
4.5.1.1 Test conditions.
Description (Quantity/Quality)
Unless otherwise specified in the detailed test herein, the inspection of 4.5 shall be performed under the
conditions of a through e. Ambient conditions within the specified ranges need not be controlled. For
equipment having a specified warm up or stabilization period after turn-on, formal measurements and
observations shall be made only after the specified interval (see 3.8.1.1).
a. Temperature: 25° ±10°C.
b. Humidity: 20 to 70 percent RH.
c. Altitude: 0 to 4600 m.
d. Power: Nominal or alternate power source specified for the equipment,
e. Attitude: Normal operating position.
4.5.1.1.1 Measurements of test conditions. All measurements of the test conditions shall be made with
instruments of the accuracy specified in 4.5.1.1.3.
4.5.1.1.2 Tolerance of test conditions. The tolerance of test conditions shall be as specified in a through e:
a. Temperature. The test item shall be totally surrounded by an envelope of air (except at necessary
support joints). The temperature of the test section measurement system and the temperature
gradient
throughout this envelope, that is measured close to the test item, shall be within ±2°C of the test
temperature and shall not exceed 1°C per m or a maximum of 2.2°C total (equipment not
operating).
b. Pressure. Pressure shall be measured with an accuracy of ±5 percent of the measured value.
c. Humidity. Relative humidity at the chamber control sensor shall be ±5 percent RH of the
measured value.
d. Acceleration. Acceleration shall be measured to within ±10 percent.
e. Time. Elapsed time shall be measured with an accuracy of ±1 percent.
4.5.1.1.3 Accuracy of test instrument calibration. The accuracy of instruments and test equipment
used to control or monitor the test parameters shall be verified prior to and following each test and
then calibrated at predetermined intervals.

Preliminary Solution
1. Definition.

No. 0410 Identification Code: 1901-S-08-088

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.1 Conditions and control settings
4.5.1.2 Control settings.
Description (Quantity/Quality)
The control settings shall be as determined by the approved equipment test procedure (see 6.5.2.2) or the
purchase description.
Preliminary Solution
1. Definition.

No. 0411 Identification Code: 1901-S-08-089

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.2 Performance of test.
Description (Quantity/Quality)
Tests shall be performed in accordance with 4.5.2.1 through 4.5.2.6.
Preliminary Solution
1. Definition.

No. 0412 Identification Code: 1901-S-08-090

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.2 Performance of test
4.5.2.1 Pretest qualification.
Description (Quantity/Quality)
Prior to proceeding with the environmental tests, the test item shall be operated under standard ambient
conditions (see 4.5.1.1) to evaluate the performance characteristics of the equipment, defined in the
purchase description. This test is used to establish the level of performance of the equipment at the outset
of testing, prior to any environmental tests. This test is performed before, during, and after the
environmental tests, whenever a satisfactory operational test is required. Degradation of the equipment
performance shall be noted if it exceeds any bound established in the purchase description.
Preliminary Solution
1. Definition

No. 0414 Identification Code: 1901-S-08-092

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.2 Performance of test
4.5.2.3 Performance check during test.
Description (Quantity/Quality)
When operation of the test item is required during the test exposure, suitable tests shall be performed to
determine whether the test exposure is producing changes in performance when compared with pretest
qualification.
Preliminary Solution
1. Definition

No. 0417 Identification Code: 1901-S-08-095

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.2 Performance of test
4.5.2.6 Test equipment.
Description (Quantity/Quality)
Test equipment used for inspections and tests shall be as specified in the purchase description or approved
equipment test procedure (see 6.5.2.2). The test equipment shall be properly maintained and calibrated.
Preliminary Solution
1. Definition

No. 0420 Identification Code: 1901-S-08-098

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.5 Group C tests.
Description (Quantity/Quality)
The Group C tests shall be performed as specified in 4.5.5.1 through 4.5.5.7 and in the purchase
description or approved equipment test procedure (see 6.5.2.2). These tests shall be performed under the
test conditions of 4.5.1.1.
4.5.5.1 Temperature and humidity tests. The temperature and humidity tests shall be performed in
accordance with 4.5.5.1.1 through 4.5.5 .1.1.2. Figures 3 and 4 show the T/H tests for Class 1. Figures 5
and 6 show the T/H tests for Class 2. Figures 7 and 8 show the T/H tests for Class 3. Figures 9 and 10
show the T/H tests for Class 4. No rust or corrosive contaminants shall be imposed on the test item by the
test facility (T/H chamber).
4.5.5.1.1 Procedure T/H. Install the test item in the test facility in accordance with 4.5.2.2. During the tests
specified in 4.5.5.1.1.1 the RH need not be controlled. RH of 95 percent (with the applicable tolerance)
does not include conditions of precipitation. The rate of temperature change shall be 1 °C to 5 °C per
minute. The temperature limits and RH are specified by class in Table 11. Precipitation is not authorized
during the T/H test.
Preliminary Solution
1. Definition
2. Figures 9 and 10 show the Temperature and Humidity tests for Class 4.
3. TABLE 11.indicate Temperature limits.

No. 0421 Identification Code: 1901-S-08-099

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.5 Group C tests
4.5.5.1.1.1 Temperature test procedure.
Description (Quantity/Quality)
The temperature test procedure consists of a five independent tests (a through e) that can be performed in
any sequence, except as indicated for test a.
The profiles provided in Fig. 3 (for Class 1), Fig. 5 (for Class 2), Fig. 7 (for Class 3), and Fig. 9 (for
Class 4) demonstrate only one possible sequence of testing. The detailed test procedure at the time of
testing shall define the actual test sequence. The humidity during the test is uncontrolled for all tests
except test (d), where the humidity shall be controlled within the range of 5 to 20 percent relative humidity
(with the applicable tolerance), to simulate an arid environment. The testing maybe interrupted after any
test, a through e. Performance of the satisfactory operation test shall occur at the end of each temperature
test period, adding whatever time is required to perform the satisfactory operation test. (This means that
the total time required to perform the temperature testing will be the cumulative total consisting of: the
time required for each temperature test, the time required to perform a satisfactory operation test at each
temperature test, and any interruption period).
Test (a). Place the test item in the test chamber in accordance with 4.5.2.2. This testis the initial
operation verification test. With the temperature at the room ambient the equipment is operating
for 2 hours, after which the satisfactory operational test is performed. Test (a) shall always be
performed
first in the test sequence.
Test (b). The temperature is maintained at -40 °C (for Class 1), -10 °C (for Class 2), and 0 °C (for Class
3), or 10 °C (for Class 4). The equipment is not operating for 4 hours. Operate the test item for the
Warm up period recommended by the manufacturer. Perform the satisfactory operation test and
compare the results with test (a) in accordance with 4.5.2.1. No alignment or adjustment of other
than the operating controls shall be permitted throughout the test specified.
Test (c). The temperature is maintained at -51 °C (for Classes 1 and 2), or -40 °C (for Classes 3 and
4). the equipment is not operating for 4 hours. Following the 4 hour cold storage soak, the
temperature is raised to 23 °C. For an additional 4 hours the equipment is maintained at these
conditions. Operate the test item for the warm-up period recommended by the manufacturer.
Perform the satisfactory operation test and compare the results with test (a) in accordance with
4.5.2.1. No alignment or adjustment of other than the operating controls shall be permitted
throughout the test specified.
Test (d). The humidity during this test is controlled at within the range of 5 to 20% (with the applicable
tolerance). The temperature is maintained at 55 °C (for Classes 1 and 2), 50 °C (for Class 3), or 40
°C (for Class 4). The equipment is operating for 4 hours. Following the 4 hour arid heat operating
soak, perform the satisfactory operation test and compare the results with test (a) in accordance
with 4.5.2.1. No alignment or adjustment of other than the operating controls shall be permitted
throughout the test specified.
Test (e – Class 1). The temperature is maintained at 71 °C. The equipment is not operating for 4
hours. The equipment is then turned on and operated for 20 minutes after the required warm-up
period. The temperature is maintained at 71 °C. During the 20 minute operating period perform the
satisfactory operation test (shortened as necessary to fit in the 20 minute operation period) and
compare the results with test (a) in accordance with 4.5.2.1. No alignment or adjustment of other
than the operating controls shall be permitted throughout the test specified.
Test (e – Classes 2, 3, and 4). The temperature is maintained at 71 °C. The equipment is not operating for
4
hours. Following the 4 hour hot storage soak, the temperature is lowered to 23 °C. For an
additional 4 hours the equipment is maintained at these conditions. Operate the test item for the
warm-up period recommended by the manufacturer. Perform the satisfactory operation test and
compare
the results with test (a) in accordance with 4.5.2.1. No alignment or adjustment of other than the
operating controls shall be permitted throughout the test specified.
4.5.5.1.1.2 Procedure, humidity cycle. The humidity cycle testing follows immediately after the testing of
4.5.5.1.1. This procedure consists of 5 days of temperature humidity cycling, with each days cycle
consisting of the profile displayed in Fig. 4 (for Class 1), Fig. 6 (for Class 2), Fig. 8 (for Class 3), or Fig.
10 (for Class 4). Satisfactory operational tests are performed at the times indicated on the figures with a
diamond symbol, noted as (a), (b), and (c) (as applicable). The following Notes 1 through 4 apply:
Note 1. A satisfactory operational test (at normal room ambient conditions) shall be conducted prior
to and at-the-conclusion of the five-day humidity test.
Note 2. During the humidity cycle, the equipment is only operating during the warm-up period and
the satisfactory operational test.
Note 3. The Satisfactory Operation Tests (SOT), as annotated by (a), (b), and (c) shall each be
performed at least once each during the 5 days of humidity cycling, at the indicated times. SOT (a)
and (b), as appropriate, shall be performed at any of cycles 2, 3, 4, or 5. SOT (c) shall be
performed at least at Cycle 5. SOT’s may also be performed at any, or all cycles at the indicated
times.
Note 4. To accommodate varying times for completing satisfactory operational tests, the cycle
timing after a test maybe adjusted to allow a return back to the regular profile timing.
However, a minimum 4-hour dwell time prior to period of operation should be observed.

Preliminary Solution
1. Definition
2. Fig. 9 (for Class 4) demonstrate only one possible sequence of testing.

No. 0446 Identification Code: 1901-S-08-124

Subject:
4. VERIFICATION
4.5 Examination and test methods
4.5.9 Calibration interval verification.
Description (Quantity/Quality)
Calibration interval verification shall be as specified in the purchase description.
Preliminary Solution
1. Definition

No. Identification Code: 1901-M-01-016

Subject:
TESTING AND FAULT ISOLATION
4. Test Conditions
Description (Quantity/Quality)
A. Test fluid, calibration fluid, MIL-PRF-7024, Type II, or equivalent, must be filtered to pass
contamination examinations every other month as set forth in APR4865 to an ISO level of 16/13 or
better (5 microns or better). The fluid must be maintained at 80° F ± 2° F (27° C ± 1° C).
B. It is recommended that the spray test chambers be illuminated with 75 watt collimated under lighting
And /or 300-watt external indirect lighting.
Preliminary Solution
1. PMEL report the ISO level per 100 ml of sample fluid.
2. Refer to ISO 4406 and ISO 11171. (ISO 4402 revised by 11171)
3. The ISO cleanliness code (per ISO4406-1999) is used to quantify particulate contamination levels per
milliliter of fluid at 3 sizes 4m, 6m and 14m. The ISO code is expressed in 3 numbers (example:
19/17/14). Each number represents a contaminant level code for the correlating particle size. The code
includes all particles of the specified size and larger.
4. ISO 16/13 represent Particles per Milliliter from more than 320 up to or including 640 for particle size
6m and more than 40 up to or including 80 for particle size 14m respectively.
5. ISO 18/16/13 target World Wide Fuel Charter cleanliness standard for diesel fuel delivered from the
filling station nozzle. High quality reliable systems general machine requirements
7. If Particle Count Falls between 32000-64000 report range 16 for 6m filter.
8. If Particle Count Falls Between 4000-8000 report range 13 for 14m filter.

No. Identification Code: 1901-M-01-017

Subject:
TESTING AND FAULT ISOLATION
5. Equipment Calibration
Description (Quantity/Quality)
A. Fuel nozzle test stand must be calibrated on each day of production using program master orifice set
6775211M6. an orifice is provided for each test condition. Connecting each orifice in turn to the fluid
outlet hose; apply pressure as marked on each individual orifice and record the flow. Measured flow
must be within 0.5% of values specified for the orifice. If flow readings are not within limits, calibrate
fuel nozzle test stand to meet these requirements and retest.
B. Pressure measuring taps shall indicate the true static pressure at a location approximately 6 in.
(152mm) from fuel nozzle inlet in a smooth tube having an internal diameter equal to or greater than that
of the fitting to which it is attached. Flow measurement equipment shall be accurate to within ±0.5% of
reading at all test points, except that flow measurement equipment for flows less than 10 pph shall be
accurate to within ± 0.05 pph. Pressure measurement equipment shall be accurate within ± 0.5% at all test
points. Airflow measurement equipment shall be accurate within ± 1% of reading at all tests points for air.
Preliminary Solution
1. PMEL Report flow pass from orifice master plate one time before installation on Fuel nozzle ASSY
tester.
2. Use orifice master plate for calibration of mass flow meter in each test procedure.

No. Identification Code: 1901-M-01-029

Subject:
TESTING AND FAULT ISOLATION
7. Test Procedures
K. Wear sleeve qualification (6840023 series nozzles)
Description (Quantity/Quality)
A Wear sleeve (175, IPL Figure 1 and 125, IPL Figure 2) shall be within the diameter specified in Figure
1014 and have no one area with a wear point greater than 0.015 in. (0,813 mm) in depth.
(See Figure 1014 "GRAPHIC-73-11-42-99B-841-A01" on page 1027.).
Preliminary Solution
1. Definition

No. Identification Code: 1901-M-01-030

Subject:
TESTING AND FAULT ISOLATION
7. Test Procedures
L. Secondary body qualification
Description (Quantity/Quality)
(6810184 series nozzles). Secondary body (150, IPL Figure 1) shall be within the diameter specified in
Figure 1015 and shall have no one area with a wear point greater than 0.015 in. (0,381 mm) in depth on
surface A, nor any area with a wear point greater than 0.010 in. (0,254 mm) in depth on surface B.
(See Figure 1015 "GRAPHIC-73-11-42-99B-842-A01" on page 1028.)
NOTE: If wear point area on the secondary body (150) is greater than 0.025 in. (0,635 mm) in depth,
the secondary body must be removed and replaced. Refer to REPAIR, Repair No. 21. If the secondary
body wear point area is between 0.015 and 0.025 in. (0,381 and 0,635 mm) deep, the metering set may be
removed, and replaced per REPAIR, Repair No. 9 and ASSEMBLY section. For fuel nozzle configuration
refer to Table 2 in DESCRIPTION AND OPERATION section 101.
Preliminary Solution
1. Definition

No. Identification Code: 1901-M-01-031

Subject:
TESTING AND FAULT ISOLATION
7. Test Procedures
M. Final assembled nozzle qualification
Description (Quantity/Quality)
NOTE: All overhauled fuel nozzles successfully completing flow and pressure tests and meeting end point
requirements are fully qualified to be returned to service or held as spares. Prior to returning to
service or placing in storage, these nozzles should be visually inspected for handling damage that
may have occurred during the testing sequences. For nozzles meeting these requirements, but not
overhauled, inspect visual and dimensional requirements; refer to items in brackets, per CHECK,
Table 5003.
(1) Inspect nozzle end point requirements using final inspection fixture, 6877020M2. See Figure 1016.
(See Figure 1016 "GRAPHIC-73-11-42-99B-843-A01" on page 1030.)
(2) Check radial position of the support nozzle tip using final inspection fixture, 6877020M2. See Figure
116. Straightening permitted if fuel nozzle is out of position up to 0.080 in. (2,032 mm). If out of position
beyond 0.080 in. (2,032 mm), stress relieve support at 1000o to 2000o F (538o to 1093o C) for 1-hour
minimum after straightening.
NOTE: After straightening tip, the fuel nozzle must be completely disassembled to the support level for
stress relief.
(3) Visually inspect entire nozzle for handling damage.
NOTE: Reinstall color band (170, IPL Figure 1 or 120, IPL Figure 2) if nozzle was ultrasonically cleaned.
(4) Mount flange protector (5, IPL Figures 1 and 2) and all protective caps (10, 15, and 20) or equivalent.
(5) For storage instructions, refer to ASSEMBLY.
Preliminary Solution
1. Definition

No. Identification Code: 1901-M-03-015

Subject:
FUEL NOZZLE AND SUPPORT ASSEMBLY − TESTING & TROUBLESHOOTING
1. Testing and Troubleshooting Test Fluid
Description (Quantity/Quality)
Calibrating Fluid for Aircraft Fuel Systems Components.
Preliminary Solution
1. Definition

No. Identification Code: 1901-M-03-015

Subject:
FUEL NOZZLE AND SUPPORT ASSEMBLY − TESTING & TROUBLESHOOTING
2. Calibration
Description (Quantity/Quality)
See Table 102.
(A) General
1. Flow limits specified in Table 102 are actual test fluid flows. Observed flows must be corrected for
flow meter errors.
2. Test fluid temperature at primary and secondary connections must be kept at 79° − 81°F (26° − 27°C).
3. Fuel nozzle assembly must be mounted so as to permit full inspection of spray cone.
4. Calibrate flow bench. Use HT−000059 Orifice Master.

(b) Testing
1. Install the HT−000321 Flow Adapter or PN 759420 Transfer Tube on both the primary and secondary
connections and connect the assembly to the test stand.
2. Set test points in sequence by Table 102. Gradually increase pressure from one test point to the next.
Fluid flows must be in limits specified for each point.
3. Visually examine spray pattern along full calibration range on test Point 1 while you slowly rotate the
nozzle about its axis. There must be no visible spray pattern streaks or voids. Nozzle is acceptable if treaks
or voids can be eliminated by external cleaning of orifice.
4. Use direct reading protractor to measure spray angle, in plane through nozzle axis, at two positions on
test Point 1, 90 degrees apart. Spray cone must be in specified limits and must be symmetrical about
nozzle axis within five degrees.
Preliminary Solution
1. Definition
Intervals between Metrological confirmations

GENERAL CALIBRATION TECHNICAL ORDERS AND CALIBRATION INTERVAL.

The intervals shall be reviewed and adjusted when necessary to ensure continuous compliance with the
specified metrological requirements.

IND Equipment T.O. Reference CAL Interval

01 Flow meter, Gas Turbine T.O. 33K6-4-1708-1 12 months

02 Flow meter, Liquid Turbine T.O. 33K6-4-900-1 6 months

03 Frequency Counter T.O. 33K3-4-53-1 6 months

04 Level T.O. 33K6-4-54-1 12 months

T.O. 33K1-4-25-1 or
05 Power Supply, DC 12 months
T.O. 33K1-4-1000-1
06 Pressure Gauge T.O. 33K6-4-427-1 12 months

07 Pressure Gauge, Absolute T.O. 33K6-4-1121-1 12 months

08 Pressure Gauge, Compound T.O. 33K6-4-428-1 12 months

09 Pressure Gauge, Differential T.O. 33K6-4-557-1 12 months

10 Pyrometer T.O. 33K5-4-75-1 12 months

11 Relief Valve T.O. 33K6-4-278-1 12 Months

12 Snap Gage T.O. 33K6-4-1678-1 12 months

13 Sound Level Calibrator T.O. 33K3-4-2961-1 12 months

14 Thermometer T.O. 33K5-4-42-1 24 months

15 Thermometer, Dial T.O. 33K5-4-28-1 12 months

16 Vacuum Gauge T.O. 33K6-4-430-1 12 months

17 Voltmeters, AC/DC Analog T.O. 33K1-4-1586-1 6 months

18 Wattmeter’s, RF (Panel Mounted) T.O. 33K4-4-69-1 6 months

ACTION TAKEN DESCRIPTION BY LABORATORY

WARRANTY ITEM:
Repair not authorized, item under warranty. Items that are adjusted or repaired at laboratories
(manufacturers, etc.) should have the appropriate action taken code entered when processed back into the
PMEL.
REPAIR NOT AUTHORIZED:
Shop is not authorized to accomplish the repair. This code shall only be used when the repair required to
return an item to serviceable status is not possible due to reason of 2.4.2.1 through 2.4.2.6.
LACK OF EQUIPMENT, TOOLS OR FACILITIES:
Repair is authorized but cannot be accomplished due to lack of authorized equipment, tools or facilities.
LACK OF TECHNICAL SKILLS:
Repair cannot be accomplished due to lack of technically qualified people.
LACK OF PARTS:
Parts are not available to accomplish repair.
SHOP BACKLOG:
Repair cannot be accomplished due to excessive shop backlog.
LACK OF TECHNICAL DATA:
Repair cannot be accomplished due to lack of maintenance manuals, drawings, etc., which describe
detailed repair procedures and requirements.
CONDEMNED:
Item cannot be repaired and is to be processed for condemnation, reclamation or salvage. This code will
also be used when a "condemned" condition is discovered during field maintenance disassembly or repair.
SERVICEABLE-NO REPAIR REQUIRED
DEFERRED OR POSTPONED:
Use when Bench Check is deferred to indicate item is being held awaiting for parts, a standard, or
necessary technical data.
REPAIRED
CALIBRATED - NO ADJUSTMENT:
Item is calibrated and no adjustment was made.
CALIBRATED - ADJUSTED:
Item is adjusted and calibrated (includes adjustments to optimize/nominalize)
RETURNED TO CUSTOMER:
Returned to customer un-calibrated.
TEST/INSPECT - NON CALIBRATION
TEST/INSPECT:
Item is tested and/or inspected (other than bench checked) upon being returned from Calibration
laboratory. May also be used for other in-house laboratory inspections.

CALIBRATION CONDITION RETURNED DESCRIPTION

IN-TOLERANCE:
Item was calibrated and ALL calibration authority parameters were verified and returned with EACH
parameter meeting the calibration authority specifications. The item may or may not have been adjusted.
Includes TO directed limitations.
CUSTOMER APPROVED LIMITED CALIBRATION:
Item was calibrated, may or may not have been adjusted, and did not meet all OEM specifications and/or
TO requirements, but met customer calibration requirements.
NOT CALIBRATED:
Item returned to the customer not calibrated.

Records of the metrological confirmation process

These records shall be maintained and available.

Calibration Informal Memo

Form.No.: VST-FRM-207-0 Tracking No.: EAR-XXXXX Date: mm/dd/yyyy

Equipment Manufacturer, Identification
Type: ID code No. Serial No.
Metrological Requirement: Raised by: Approved by:
Sign/Date: Sign/Date:

TYPE OF MAINTENANCE:
SERVICE: [A]
UNSCHEDULED MAINTENANCE: [B]
SCHEDULED CALIBRATION: [C]
SPECIAL INSPECTION: [D]

INTERVAL:
WHEN DISCOVERED DESCRIPTION:
[I Date]
[O Date]
[J Date]
[K Date]
[R Date]
[F Date]
[E Date]
[C Date]
[W Date]
[L Date]
[L Date]
[S Date]
[B Date]
ACTION TAKEN DESCRIPTION BY LABORATORY:
[AT WI]
[AT RN/A]
[AT C]
[AT S]
[AT P]
[AT R]
[AT CN/A]
[AT CA]
[AT RTC]
[AT TNC]
[AT T]
DESIGNATED MAXIMUM PERMISSIBLE ERROR:

STATEMENT ABOUT RELEVANT ENVIRONMENTAL CONDITIONS:

UNCERTAINTIES:

LIMITATIONS:
CALIBRATION CONDITION:
IN-TOLERANCE
CUSTOMER APPROVED LIMITED CALIBRATION
NOT CALIBRATED