JPG 5322.

1
(Formerly JSCM 5322)
Revision E

CONTAMINATION CONTROL
REQUIREMENTS MANUAL
Occupational Safety and Quality Assurance Branch
Occupational Safety and Institutional Assurance Division
November 2000

National Aeronautics and Space Administration

Lyndon B. Johnson Space Center
Houston, Texas

CONTAMINATION CONTROL REQUIREMENTS MANUAL

NOTICE

When government drawings, specifications, or other data are used for any purpose other than in
connection with a definitely related government procurement operation, the United States government
thereby incurs no responsibility nor any obligation whatsoever; and the fact that the government may
have formulated, furnished, or in any way supplied the said drawings, specifications, or other data is
not to be regarded by implication or otherwise as in any manner licensing the holder or any other
person or corporation, or conveying any rights or permission to manufacture, use, or sell any patented
invention that may in any way be related thereto.

REVISIONS AND CHANGES

REV LTR CHANGE NO. DESCRIPTION DATE

---- ---- Baseline September 1970

A ---- Revision A December 1974

A 1 Change 1 August 1980

B ---- Revision B November 1982

C ---- Revision C February 1994

C 1 Change 1 (revised Table V, page B-7) September 1995

D Revision D May 2000

E Replaced Section 20, added Table VII November 2000

 NT2 Approval:

Original signed by
Elmer R. Johnson

1.0 INTRODUCTION
1.1 PURPOSE
1.2 APPLICABILITY
1.3 ACRONYMS AND DEFINITIONS
1.4 TRADE NAMES
1.5 WAIVERS AND DEVIATIONS
1.6 QUALITY ASSURANCE
1.7 REVISIONS AND CHANGES
2.0 REFERENCE DOCUMENTS
2.1 FEDERAL STANDARDS AND SPECIFICATIONS
2.2 ASTM STANDARDS AND PRACTICES
2.3 INSTITUTE OF ENVIRONMENTAL SCIENCES PUBLICATIONS
2.4 MILITARY HANDBOOKS, SPECIFICATIONS, STANDARDS, AND TECHNICAL ORDERS (TOs)
2.5 NASA PROCEDURES, REQUIREMENTS, SPECIFICATIONS, AND STANDARDS
2.6 OTHER REFERENCES
3.0 PROCUREMENT
3.1 CONTAMINATION CONTROL PLAN
3.2 CLEANLINESS CERTIFICATION
3.3 REVIEW OF PROCUREMENT DOCUMENTATION
4.0 RECEIVING INSPECTION
4.1 PACKAGING INSPECTION
4.2 PACKAGING REMOVAL
4.3 ITEM INSPECTION
4.4 REPACKAGING
4.5 DOCUMENTATION
5.0 ENVIRONMENTALLY CONTROLLED AREAS (ECAs)
5.1 TYPES AND CLASSIFICATIONS
5.2 ENVIRONMENTALLY CONTROLLED AREA OPERATIONAL REQUIREMENTS
5.3 CLEAN ROOM REQUIREMENTS
5.4 LAMINAR FLOW CLEAN WORK STATION REQUIREMENTS
5.5 CONTROLLED WORK AREA REQUIREMENTS
6.0 CERTIFICATION OF CLEAN ROOMS AND LAMINAR FLOW CLEAN WORK STATIONS
6.1 INSTRUMENT CALIBRATION
6.2 PREPARATION
6.3 INTEGRITY INSPECTION
6.4 DOCUMENTATION
6.5 TESTING REQUIREMENTS
6.6 FLAMMABLE AND TOXIC FLUID FACILITIES
6.7 RECERTIFICATION
6.8 CERTIFICATION DECAL
7.0 SURFACE CLEANLINESS LEVELS
7.1 GENERAL
7.2 GUIDELINES FOR SELECTION AND USE OF VISIBLE CLEANLINESS LEVELS
8.0 PRECISION-CLEANING REQUIREMENTS
8.1 GENERAL CLEANING PROCESS CONTROLS
8.2 PRECLEANING METALLICS
8.3 INSPECTION
8.4 PRECISION CLEANLINESS LEVELS
8.5 PRECISION-CLEANING
8.6 CLEANING FLUID PERFORMANCE REQUIREMENTS, OTHER DESIGN
CONSIDERATIONS, AND CLEANLINESS VERIFICATION
8.7 NONMETALLIC MATERIALS CLEANING METHOD AND RINSE TEST
8.8 FINAL PACKAGING
9.0 PROCUREMENT REQUIREMENTS FOR PRECISION-CLEANED PACKAGING MATERIAL
9.1 PROCUREMENT REQUIREMENTS
9.2 CERTIFICATION
10.0 PACKAGING OF PRECISION-CLEANED PARTS
10.1 PROCEDURES
10.2 PRECISION PACKAGING
10.3 PACKAGING OF SMALL ITEMS
10.4 PACKAGING OF LARGE, HEAVY, OR ODD-SHAPED ITEMS
10.5 PACKAGING OF HOSE AND TUBE ASSEMBLIES
10.6 PROVISIONS FOR TESTING ELECTRICAL AND ELECTRONIC ITEMS
10.7 CERTIFICATION DECALS
11.0 STORAGE OF PRECISION-CLEANED ITEMS
11.1 ENVIRONMENTAL CONTROL
11.2 INSPECTION
11.3 ACCESS CONTROLS
11.4 POSTSTORAGE DECONTAMINATION
12.0 VISUAL CLEANLINESS LEVEL REQUIREMENTS
12.1 VISUAL CLEANLINESS LEVELS
12.2 VISUAL CLEANING PROCESS CONTROLS
12.3 HANDLING
12.4 VISUAL INSPECTION
12.5 PACKAGING REQUIREMENTS
12.6 IDENTIFICATION, CERTIFICATION, AND STORAGE
12.7 FABRICATION, TESTING, ASSEMBLY, AND FIELD OPERATIONS
13.0 CLEAN ROOM GARMENTS
13.1 GENERAL
13.2 LAUNDERING REQUIREMENTS
13.3 INSPECTION
13.4 ACCEPTANCE CRITERIA AND LIMITS
14.0 PERSONNEL TRAINING
14.1 APPLICABILITY
14.2 TRAINING FOR ENVIRONMENTALLY CONTROLLED AREA DISCIPLINES
14.3 QUALIFICATION STATUS
14.4 CERTIFICATE
14.5 RETRAINING AND QUALIFICATION
15.0 SPECIAL CLEANING REQUIREMENTS
15.1 PORTABLE GAS CYLINDER CLEANING
15.2 CLEANING SMOOTH-BORE HOSES AND TUBING
16.0 FLUID SAMPLING
16.1 GENERAL REQUIREMENTS
16.2 SAMPLING APPARATUS PREPARATION
16.3 CONTAMINATION CONTROL DURING SAMPLING
16.4 SAMPLING PROCEDURES
16.5 SAFETY
17.0 CONTAMINATION CONTROL DURING FABRICATION, ASSEMBLY, AND TESTING
17.1 GENERAL REQUIREMENTS
17.2 FABRICATION
17.3 ASSEMBLY
17.4 TESTING
18.0 CONTAMINATION CONTROL DURING REPAIR, REPLACEMENT, AND MAINTENANCE
18.1 OPERATIONS PRECEDING SYSTEM BREAKING
18.2 REPAIR, REPLACEMENT, OR MAINTENANCE OPERATIONS
19.0 ENVIRONMENTAL TEST CHAMBER CLEANLINESS
19.1 GENERAL REQUIREMENTS
19.2 TEST ARTICLE INSTALLATION
20.0 NONAIRBORNE BREATHING AIR SYSTEMS
20.1 PROCEDURES
20.2 SYSTEM CLEANLINESS
20.3 SYSTEM CERTIFICATION
20.4 MAINTENANCE AND SAMPLING
20.5 IDENTIFICATION AND MARKING
20.6 REFERENCES
21.0 AIR, OXYGEN, AND OXYGEN-RICH SYSTEMS REFERENCES

APPENDIX A — ACRONYMS AND DEFINITIONS

APPENDIX B — TABLES

1.0 INTRODUCTION
1.1 PURPOSE
The JSC Contamination Control Requirements Manual establishes the requirements and criteria for
coordinated contamination control activities. This manual provides the minimum controls necessary to
establish and maintain an effective contamination control system.

JSCM 8080, "JSC Design and Procedural Standards Manual," stipulates additional mandatory
contamination control requirements. The latest issue of JSCM 8080 should be reviewed to ensure that
standards relating to contamination control which are issued after publication of this document are also
implemented.

1.2 APPLICABILITY
This manual is applicable to JSC organizations and on-site contractors who are responsible for
designing, developing, manufacturing, inspecting, processing for shipment, and testing of flight or
flight-related equipment. Portions of this document may be specified in JSC contracts as applicable.

1.3 ACRONYMS AND DEFINITIONS

Definitions of and acronyms for terminology used in this manual are contained in appendix A.

1.4 TRADE NAMES

The use of trade names of commercially available products does not constitute an endorsement of
those products by NASA nor does it imply that there are no other suitable products available.

1.5 WAIVERS AND DEVIATIONS

If it is apparent that the requirements of this manual cannot be complied with, the responsible technical
organization initiates a waiver or deviation and submits it in sufficient time to allow for proper
evaluation and disposition. Submit requests by memorandum to the Director, Safety, Reliability, and
Quality Assurance (SR&QA). The Director, SR&QA, has approval authority with concurrence, as
required, by the Director, Space and Life Sciences.

At White Sands Test Facility (WSTF), the manager responsible for contamination control activities
maintains full authority over waivers and deviations to the requirements contained in this document.

1.6 QUALITY ASSURANCE

At JSC, the Institutional Safety and Quality Division is responsible for ensuring compliance with this
manual. Applicable inspection requirements are delineated within the text.

1.7 REVISIONS AND CHANGES

All revisions and changes to this manual must be approved by formal JSC concurrence procedures, as
specified in applicable JSC management documentation. The Director, SR&QA, has approval authority
for editorial changes (e.g., correction of typographical errors) to this manual.

Many American Society for Testing and Materials (ASTM) and Institute of Environmental Sciences (IES)
publications are considered to be "full-consensus" publications and are used by representatives of all
sectors of industry and government. Contamination control requirements should follow ASTM, IES, or
similar guidelines when not specified in this manual.

2.0 REFERENCE DOCUMENTS

The latest revisions of the documents listed below are applicable to the extent specified herein. Refer
any conflicts between the documents referred to herein and the contents of this manual to the
Occupational Safety and Quality Assurance Branch for resolution.

NOTE: References on nonairborne breathing systems and on air, oxygen, and oxygen-rich
systems are listed in sections 20.0 and 21.0, respectively.

2.1 FEDERAL STANDARDS AND SPECIFICATIONS

a. FED-STD-102, "Preservation, Packaging, and Packing Levels"
b. FED-STD-209E, "Federal Standard, Airborne Particulate Cleanliness Classes in Clean Rooms and
Clean Zones"
c. PPP-T-66, "Type I, Class B - Tape: Pressure Sensitive Adhesive Water-Proof - for Packaging and
Sealing"
d. TT-I-735, "Specification, Isopropyl Alcohol"

2.2 ASTM STANDARDS AND PRACTICES

a. ASTM D2109-71, "Nonvolatile Matter in Halogenated Organic Solvents and Their Admixtures"
b. ASTM F51-65T, "Sizing and Counting Particulate Contamination in and on Clean Room Garments"
c. ASTM D1605, "Standard Recommended Practices for Sampling Atmospheres for Analysis of Gases
and Vapors"
d. ASTM D2407, "Standard for Sampling Airborne Particulate Contamination in Clean Rooms for
Handling Aerospace Fluids"
e. ASTM E21.05, "Standard Method for Measurement of Nonvolatile Residue (NVR) on Surfaces"
f. ASTM E 595-20, "Standard Test Method for Total Mass Loss and Collected Volatile Condensed
Materials From Outgassing in a Vacuum Environment"
g. ASTM F24, "Standard Method for Measuring and Counting Particulate Contamination on Surfaces"

2.3 INSTITUTE OF ENVIRONMENTAL SCIENCES PUBLICATIONS

a. "IES Handbook of Recommended Practices, Contamination Control Division"
b. IES-CC-009 -84, "Compendium of Standards, Practices, Methods, and Similar Documents Relating to
Contamination Control"
c. IES-RP-CC-002 -83-T, "Laminar Flow Clean Air Devices"

2.4 MILITARY HANDBOOKS, SPECIFICATIONS, STANDARDS, AND TECHNICAL ORDERS (TOs)

a. MIL-A-18455, "Argon, Technical"
b. MIL-C-10578, "Corrosion Removing and Metal Conditioning Compound (Phosphoric Acid Base)"
c. MIL-P-116, "Preservation, Methods of"
d. MIL-P-27401, "Nitrogen, Grade A, B, or C"
e. MIL-HDBK-406, "Cleaning Materials for Precision-Cleaning and Use in Clean Rooms and Clean Work
Stations"
f. MIL-HDBK-407, "Precision-Cleaning Methods and Procedures"
g. MIL-HDBK-410, "Contamination Control Technology, Logistic Protection of Precision -Cleaned
Material"
h. MIL-M-9950, "Military Specification: Missile Components; Liquid Oxygen, Liquid Nitrogen, Gaseous
Oxygen, Gaseous Nitrogen, Instrument Air, Helium and Fuel Handling Systems; Cleaning and Packaging
for Delivery"
i. MIL-STD-1246, "Product Cleanliness Levels and Contamination Control Program"
j. MIL-STD-1695, "Military Standard: Environment, Working, Minimum Standards"
k. TO 00-25-203, "Contamination Control of Aerospace Facilities, US Air Force"
l. TO 42C-1-11, "Cleaning and Inspection Procedures for Ballistic Missile Systems"

2.5 NASA PROCEDURES, REQUIREMENTS, SPECIFICATIONS, AND STANDARDS

a. JSC-01218, "JSC Standard Procedures for Liquid and Gas Sampling"
b. JSCM 5341, "Requirements for Sampling Atmospheric Gases and Hydrogen"
c. JSCM 8080, "JSC Design and Procedural Standards Manual" (G-5, G-9, G-13, G-20, G-21, E-10, F-
11, F-17, F-20, F-23, F-24, F-25, F-26, F-27, F-28, F-29, and M/P-9)
d. KSC-C-123, "Specification for Surface Cleanliness of Fluid Systems"
e. MSCF-PROC-166D, "Procedures for Cleaning, Testing, and Handling Hydraulic System Detailed Parts,
Components, Assemblies, and Hydraulic Fluids for Space Vehicles"
f. MSFC-SPEC-164A, "Specification for Cleanliness of Components for Use in Oxygen, Fuel, and
Pneumatic Systems"
g. MSFC-STD-246, "Standard Design and Operation Criteria of Controlled Environmental Areas"
h. NHB 53401, "NASA Standard Procedures for the Microbiological Examination of Space Hardware"
i. NHB 5340.2, "NASA Standards for Clean Rooms and Work Stations for the Microbially Controlled
Environment"
j. NHB 8060.1C, "Flammability, Odor, Offgassing, and Compatibility Requirements and Test Procedures
for Materials in Environments That Support Combustion"
k. NSTS 07700, Volume XIV, "Space Shuttle System Payload Accommodations," section 3.6.12,
"Contamination Control"
l. NSTS 08242, "Limitations for Nonflight Materials and Equipment Used in and Around the Shuttle
Orbiter Vehicles"
m. SE-S-0073, "NSTS Specification, Fluid Procurement and Use"
n. SN-C-0005, "Contamination Control Requirements for the Space Shuttle Program"
o. SP-5015, "Advances in Sterilization and Decontamination, A Survey," 1978
p. SP-5076, "Contamination Control Handbook," 1969

2.6 OTHER REFERENCES

a. SAE-ARP-598, "SAE Aerospace Recommended Practice for the Determination of Particulate
Contamination in Liquids by the Particle Count Method"
b. ANSI Z9.2, "Fundamentals Governing the Design and Operation of Local Exhaust Systems"
c. MDC H4070 (Space Station), "Contamination Control Plan"
d. NFPA B93.19, "Method for Extracting Fluid Samples from the Lines of an Operating Hydraulic Fluid
Power System for Particulate Contamination Analysis"
e. NFPA 318, "Standard for Fire Protection in Cleanrooms"
f. Rockwell MA0110-301, "Product Cleanliness"
g. SAE ARP-743, "Procedures for the Determination of Particulate Contamination of Air in Dust
Controlled Spaces by the Particle Count Method"
h. "Spacecraft Cleanliness Control for Particles," 10th International Symposium on Contamination
Control (ICCCS 90), Zurich, Switzerland, September 10-14, 1990

3.0 PROCUREMENT
Include in procurement documents for flight and flight-related equipment, environmental test facilities,
nonairborne breathing systems, facility fluid systems, precision-cleaned packaging materials, and
garment maintenance services appropriate contamination control requirements. Base these
requirements upon the design and application of the procured item and tailor them appropriately for
each procurement.
Select requirements from JSC documents (e.g., SN-C-0005, "Contamination Control Requirements for
the Space Shuttle Program") and this manual. The Occupational Safety and Quality Assurance Branch
will, upon request, assist JSC organizations in the selection of cost-effective contamination control
requirements.

3.1 CONTAMINATION CONTROL PLAN

The purpose of a contamination control plan is to ensure product cleanliness. Include in procurements
for spacecraft and spacecraft systems and subsystems the requirements for a contamination control
plan. Procurements for items of lesser complexity may also require a contamination control plan when
stringent cleanliness requirements are specified or when contamination control is important.

3.2 CLEANLINESS CERTIFICATION

Procurement documents for systems, subsystems, and major assemblies shall require that the
contractor submit a certification of cleanliness which identifies the cleanliness level to which the
contract item was cleaned and verified.

3.3 REVIEW OF PROCUREMENT DOCUMENTATION

Submit contamination control provisions of contracts to the Mechanical and Chemical Process
Engineering and GFE Branch, or approved alternate, for review.

4.0 RECEIVING INSPECTION

Inspect items cleaned to precision levels upon receipt to ensure that storage, transit, and handling of
the packaged item have not violated the cleanliness integrity. Requirements applicable to visibly clean
plus ultraviolet (VC + UV), visibly clean (VC), and generally clean (GC) items are stated herein.

4.1 PACKAGING INSPECTION

Visually inspect precision, VC + UV, or VC items for packaging integrity. If the seal integrity is found to
have been violated, return the items to the supplier or route for cleaning and certification.

4.2 PACKAGING REMOVAL

During inspection, remove precision and VC + UV packaging (if removal is necessary) in only a
controlled environment to prevent degradation of item cleanliness.

4.3 ITEM INSPECTION

Visible evidence of item damage from transit, handling, packaging, or other causes shall be reason for
rejection. This requirement is applicable to all items. Inspect GC items for cleanliness and, if
necessary, clean them to the GC level using a hardware-compatible process. Visible contamination on
items cleaned to precision, VC + UV, or VC levels shall be cause for rejection.
4.4 REPACKAGING
If a controlled environment is required, repackage all items (except GC items) before removing them
from the controlled environment and after completing the receiving inspection. In those cases where
item cleanliness cannot be ensured, reclean the item before repacking.

4.5 DOCUMENTATION
Review documentation accompanying precision, VC + UV, or VC items for compliance with applicable
purchase order or engineering requirements, including certification of cleanliness. Maintain such
documentation and/or item certification shall as a permanent record traceable to the item received.

5.0 ENVIRONMENTALLY CONTROLLED AREAS (ECAs)

Areas designated as ECAs include clean rooms, laminar flow clean work stations, and controlled work
areas (CWAs). Control facilities so identified by a documented cleaning and process procedure which,
as a minimum, meets the requirements delineated herein. Certify clean rooms used for final cleanliness
verification, assembly, testing, and packaging of precision, VC + UV, and VC cleaned articles, and all
laminar flow clean work stations used to process flight or flight-related equipment.

5.1 TYPES AND CLASSIFICATIONS

5.1.1 Clean Room Design

FED-STD-209E describes several clean room types which include conventional and laminar airflow
designs. The final filters used in clean rooms shall be high-efficiency particulate air (HEPA) filter
assemblies. The Occupational Safety and Quality Assurance Branch will, upon request, assist JSC
organizations with the selection of an appropriate clean room design.

5.1.2 Selection of Clean Room Class

Cleanliness classes of clean rooms used at JSC shall comply with FED-STD-209E. When selecting the
clean room classes to be used, consider the surface cleanliness level required, the articles to be
processed, and the time required for processing. As the processing time increases, the airborne
particulate control required becomes more stringent; therefore, two articles requiring the same surface
cleanliness level, but greatly different processing times, will also require different clean room classes.
The Occupational Safety and Quality Assurance Branch must concur in the selection of clean room
classes for flight and flight-related equipment (see table I, appendix B).

NOTE: Regardless of clean room class, prolonged exposure of unprotected surfaces will
result in contamination in excess of the allowable cleanliness level; therefore, specify in
operating procedures intermediate packaging of all items when the items are not actually
being processed.

5.1.3 Laminar Flow Clean Work Stations

Use only HEPA filter assemblies for the final filters used in clean work stations. Regardless of the
surrounding environment, clean work stations reflect the efficiency and integrity of the HEPA filter;
therefore, classify and maintain all JSC clean work stations to a Class 100 Level, as a minimum, and to
meet the detailed requirements specified in sections 5.2 and 5.4.

5.1.4 CWA Classification

Laboratories, special workrooms, vacuum chambers, or other facilities that require environmental and
contamination controls, which are not clean rooms but do meet the minimum requirements of sections
5.2 and 5.5, may be identified as CWAs.

5.2 ENVIRONMENTALLY CONTROLLED AREA OPERATIONAL REQUIREMENTS

These are common requirements applicable to all ECAs at JSC. Detailed requirements for each specific
facility type are contained the in subsections below. Table II, appendix B, provides a ready reference
matrix of requirements relating to ECAs.

5.2.1 Garments
a. All personnel using an ECA shall wear approved clean room garments. Minimum garment
requirements for ECAs are listed in table III, appendix B. The Mechanical and Chemical Process
Engineering and GFE Branch approve clean room garment requirements for ECAs.
b. Change garments as required to maintain product cleanliness.
c. Personnel must remove clean room garments in the change area before leaving the ECA. Personnel
wearing clean room garments outside the ECA are barred from reentry until they have changed
garments. Garments worn outside the ECA or worn during contaminant-generating operations are
considered contaminated and must be exchanged for clean garments.
d. Special footwear may be optional, depending upon the type facility; however, mud-caked or dirty
shoes are not allowed in the ECA. Clean shoes with a mechanical shoe cleaner or by other appropriate
cleaning methods before entering the clean room. Use tacky mats or other approved mats (e.g.,
magna mats) at the entry to the ECA.

5.2.2 Personnel Training

ECA personnel shall be trained per section 14.0.

5.2.3 Tools and Fixtures

a. Keep tools and fixtures in drawers or stainless steel wire baskets and cover when not in use. Do not
keep tools in toolkits with felt-lined drawers or leather cases. Tools may be kept on clean polyurethane
foam wipers.
b. Use only tools used in all clean room activities for spacecraft operations, or in work associated with
flight equipment that are corrosion resistant and constructed of minimum particulate-generating
materials.
c. Clean all equipment to a VC condition before its entry into the clean room, clean bench, or CWA.
Examine each tool before each use to verify that the VC condition has been maintained. Remove tools
with cracks, chips, or evidence of corrosion from the area and remedy the discrepancy. Metal-abrading
tools (e.g., pipe wrenches, pliers, and knurled-jaw holding tools such as vise grips) and vises are not
permitted in an ECA.
d. Construct all cabinets, stools, benches, etc. of minimum particle-generating material.

5.2.4 Oil, Grease, and Lubricants

Oil, grease, and lubricants, other than those approved for specific applications, are not permitted in the
ECA.

5.2.5 Grease or Oil Deposits

Operations, equipment, or other sources causing grease or oil deposits are not permitted. Do not allow
equipment that generates hydrocarbons (oil, grease, smoke, etc.) in the ECA. Electrically operated
equipment or other non-hydrocarbon-generating equipment may be used if verified clean by the
appropriate quality organization before use.

5.2.6 Compressed Gas

Supply compressed gas used within the ECA from a source that is equipped with dehydrators and filters
capable of removing all types of contamination. Schedule and record regular maintenance of this
equipment.

5.2.7 Paper Products

All paper products not necessary for operation are excluded from the ECA. Use paper products required
for operation that are treated to prevent particulate generation or enclosed in a plastic bag, except at
times when exposure is required to read or sign off a particular operation.

5.2.8 Wiping Material

Use only approved, clean, low-lint wiping cloths or clean polyurethane wipers for cleaning operations.

5.2.9 Smoking, Food, and Beverages

Smoking, food, and beverages are not allowed in the ECA.

5.3 CLEAN ROOM REQUIREMENTS

Certify clean rooms per section 6.0. Observe the requirements stated below in addition to those
specified in section 5.2.

5.3.1 Clean Room Operational Requirements

Establish clean room operational requirements to ensure effective contamination control of the article to
be processed. Requirements may be selected from, but are not limited to, those contained in the
appendix to FED-STD-209E. The items described below are mandatory for JSC clean rooms.

5.3.1.1 Clean Room Furnishings. Construct clean room furniture of materials that exhibit a minimum
of chipping, flaking, oxidizing, or other deterioration. Paint shall be hard and nonflaking, such as
epoxy. For furniture subjected to abrasion and bumping, choose stainless steel or laminated plastic
surfaces.

5.3.1.2 Work Station Location. Process the most contamination-sensitive articles at work stations
closest to the filter bank or in laminar flow clean rooms, at the worker level. Keep obstructions to the
airflow to a minimum, particularly upstream of critical work.

5.3.1.3 Airborne Particle Monitoring. Determine particulate contamination of the clean room at various
periods during the work cycle to ascertain peak contamination times. Then monitor the clean room at
least once daily during those periods of greatest contaminant generation (normally during those periods
of greatest occupancy). Sample the air with an isokinetic nozzle.

5.3.1.4 Positive Pressure. The minimum positive pressure differential between the clean room and any
adjacent area subject to lesser cleanliness requirements shall be 1.27 millimeters (0.05 in.) of water,
with all entryways closed. When the entryways are open, maintain adequate blower capacity to
maintain an outward flow of air to minimize contaminants migrating into the room.

5.3.1.5 Temperature Range. Maintain temperature in clean rooms at 19.4*C to 23.9*C (67*F to 75*F)
with the exception of those laboratories or work areas for which other temperatures are actually
required by the items being processed. At JSC, the Mechanical and Chemical Process Engineering and
GFE Branch must concur in the selection of temperature ranges other than the above-noted range.

5.3.1.6 Relative Humidity (RH) Range. Maintain the RH in clean rooms at 30% to 50% unless other
ranges are actually required by the articles being processed. Rusting of parts may occur at RHs above
50%. Electrical static charges on dielectric materials or parts may cause problems because of particle
attraction at low RHs.

The above-noted RH maximum of 50% may be increased to 60% for clean rooms that are used solely
for the processing of corrosion-resistant articles. However, such a high humidity level can only be
approved after a careful evaluation of the articles to be processed and of the equipment within the
room. When approved, stipulate this level in the operating procedure for that specific clean room. At
JSC, the Mechanical and Chemical Process Engineering and GFE Branch must concur in the selection of
RH ranges other than 30%-50%.

5.3.1.7 Clean Room Lighting. Provide shadowless, uniform incident lighting of 800 to 1,000 lumens
(75 to 100 ft-candles, 24 to 30 meter-candles) per square meter at all work locations within the clean
room.

5.3.1.8 Shutdown During Nonuse Periods. The shutdown of clean rooms to conserve energy during
periods of nonuse will not invalidate the rooms' annual certification status; however, restore all the
required environmental conditions before beginning work operations. After reestablishing the required
particulate levels, clean all work surfaces and equipment to a VC level using vacuum equipment and
polyurethane wipes dampened with an approved cleaning solution.

Laminar flow rooms usually regain proper airborne particulate populations within a matter of minutes.
Nonlaminar (conventional) rooms, however, have poor "clean-down" capability and sometimes require
several days before acceptable levels are obtained. The reestablishment of proper temperature and
humidity levels has been a problem in both laminar and nonlaminar flow clean rooms. Periods of up to
1 week are sometimes required. Therefore, only by actual testing of each individual clean room can the
net benefit of shutdown be determined. At JSC, the Mechanical and Chemical Process Engineering and
GFE Branch will, upon request, assist with these evaluations.

5.3.2 Operating Procedures

Documented operational procedures are required for all classes of clean rooms. Describe in the
procedures clean room monitoring, personnel discipline, and clothing requirements. Submit procedures
for review and approval to the Mechanical and Chemical Process Engineering and GFE Branch.

5.4 LAMINAR FLOW CLEAN WORK STATION REQUIREMENTS

Certify laminar flow clean work stations as specified in section 6.0. In addition to ECA requirements
specified in section 5.2, observe the requirements stated below for the maintenance, use, and operation
of laminar flow clean work stations.

5.4.1 Maintenance and Use

Provide a protective screen in front of the filters. Clean the screen to remove any particles before work
begins. A vacuum device with a plastic intake nozzle is recommended for this cleaning. Remove from
the station or properly cover all sensitive material during this operation. To avoid the premature
loading of prefilters, maintain the floor area surrounding the air intake GC.

5.4.1.1 Work Surfaces. After the screen has been cleaned and the air supply is operating, wipe the
work surface thoroughly with a clean polyurethane wiper dampened with filtered isopropyl alcohol.
Wipe the work surface at least once each shift to maintain a VC level; and as often as necessary to
remove contamination generated by the task performed.

5.4.1.2 Personnel Discipline. Proper personnel operating techniques are required to control
contamination which may be carried into the work station on hands, tools, fixtures, and other
materials. When work stations are operated in an uncontrolled ambient environment, there is a greater
possibility of contaminants being introduced.

Take care to ensure that hands and clothing are clean and free from loose dirt and lint before they are
placed inside the clean work station. Use smocks with snug fitting wristbands, caps, and gloves, as
necessary, to maintain the required cleanliness. Clean gloves used to handle parts must not be used to
handle material outside the clean work station and then returned to the station. If close inspection of
the workpiece requires the worker to lean over the part, wear a headcovering which adequately covers
facial and head hair.

5.4.1.3 Equipment and Materials. Clean all materials (workpieces, tools, containers, and jigs) before
placing them in the station. Place only the items actually required for the task in the work station.
Keep the area between the filter and the precision, VC + UV, or VC item being processed free of all
equipment. Never allow high particulate-generating materials, such as paper and wood, in the station.

5.4.1.4 Shutdown During Nonuse Periods. The shutdown of laminar flow clean work stations during
periods of nonuse will not invalidate the work stations' annual certification status. Use the following
procedures for the powerdown and restart of laminar flow clean work stations:

a. Powerdown. Remove all tools, processing hardware, and flight-related hardware from
the laminar flow clean work station before cutting off power.
b. Restart. Operate the laminar flow clean work station for a minimum of 15 min. before
cleaning work surfaces. Then clean as specified in section 5.4.1.1. Do not begin operations
until at least 5 min. after the completion of work surface cleaning.

5.4.1.5 Monitoring Laminar Flow Clean Work Stations. After recertification, inspect clean work station
filters quarterly. More frequent inspection may be conducted for special applications or when it is
determined to be necessary by the operating organization or the Mechanical and Chemical Process
Engineering and GFE Branch. Post the due dates for yearly certification on the exterior of the flow
bench. Use the following procedures to monitor laminar flow clean work stations:

a. Prefilters. Vacuum clean or replace prefilters. Replace prefilters which are damaged or
structurally unsound.
b. Sampling. Consider each clean work station to have four equal-sized work areas: left,
left center, right center, and right. Take samples at each of the four work areas, midway
between the final filter face and the forward exhaust area. Use an automatic particle
counter having current calibration status and a sampling rate of at least 0.003 m3 (0.1 ft3)
per minute.
Sample air with an isokinetic nozzle. Operate the particle counter in the bench area until
stable readings are obtained. Then take a 0.028-m3 (1.0- ft3) sample at each of the four
work areas, as defined above. Do not use diocytal phthalate (DOP) smoke to challenge the
filter when monitoring clean work stations. The particulate count of the sample shall not
exceed the limits of a Class 100 station.
c. Records. Maintain monitoring and maintenance records for each laminar flow clean work
station.

5.5 CONTROLLED WORK AREA REQUIREMENTS

The requirements stated below are in addition to ECA requirements specified in section 5.2 and may be
used where a high degree of shop cleanliness is required. Applicability of these requirements includes,
but is not limited to, such facilities as any suitably enclosed room, environmental test chamber, or
immediate vicinity of a spacecraft. Specify housekeeping procedures, personnel controls, and
contaminant-generation constraints to obtain and maintain an acceptable level of work area cleanliness
and to protect, as applicable, workpiece cleanliness. Although annual certification is not required,
observe the minimum requirements stated below.

5.5.1 Facility Requirements

a. Air condition the CWA or the environment surrounding the CWA, and filter the air supply. Use
cleanable or throw-away filters with an efficiency rating of 90%, and clean or change as required.
b. Temperature may be controlled for personnel comfort; however, humidity shall be controlled to the
extent necessary to prevent condensation or corrosion on all surfaces (50% RH or less) or to preclude
buildup of electrical static changes (minimum of 30% RH). At JSC, the Mechanical and Chemical
Process Engineering and GFE Branch must concur in the selection of RH ranges other than 30%-50%.
c. Provide a space at the entrance to the CWA for storage of clean room garments and for dressing.
Separate this area from the enclosed rooms by an enclosed anteroom or by a partition. This
partitioning may consist of flame-retardant plastic curtains.
d. Protect CWAs from overhead operations; e.g., crane, high-lift, or facility maintenance. A flame-
retardant plastic covering may be used for this purpose.

5.5.2 Maintenance of the CWA

a. Sweeping and sweeping compounds will not be permitted in CWAs.
b. Vacuum floors at least once each 8-hr shift, or more frequently if required, to maintain a GC
condition. (This is not required during test preparations which require more than 8 hrs for operation;
however, vacuum once each 24-hr period.) Locate the vacuum source either outside the CWA or equip
it with absolute type filters on the exhaust. As an alternative, vent the vacuum exhaust outside the
CWA.
c. Damp mop with water floors, walkways, and other walking surfaces at least weekly. Clean walls and
other surfaces at least monthly, or more frequently if required, to maintain a GC condition. Clean by
vacuuming; clean room adhesive roller; wiping with clean, low-lint cloths; or wiping with polyurethane
wipers dampened with water, as required. A water solution with a suitable detergent; e.g., trisodium
phosphate, may be used for stubborn soils, but shall be followed by water-rinse mopping or wiping.
Alternative cleaning solutions must be approved by the appropriate operating or surveillance
organization.

5.5.3 CWA Operations

a. Records of particulate population or fallout are not required for CWAs; however, visual or wipe
evidence of dust, dirt, or oils shall be reason for ceasing operations in the immediate area and cleaning
the affected area to a VC condition. Upon completion of cleaning and acceptance by the appropriate
quality group, the operations may proceed. Inspect articles subjected to out-of-control conditions to
verify a VC condition.
b. Clean all parts, equipment, tools, test fixtures, and apparatuses before placing them in the CWA.
The responsible quality group shall verify that these are VC before they're placed in the CWA.
c. Perform assembly, disassembly, modification, or repair to systems or subsystems which require that
a system cleanliness level be maintained under localized clean conditions, as specified in sections 17.0
and 18.0.
d. PROTECT ALL SURFACES, LINES, OR PARTS OPENED BECAUSE OF PART OR ASSEMBLY REMOVAL OR
SYSTEM BREAK-IN WITH STANDARD CLOSURE (METAL PLUGS, CAPS, BLIND FLANGES) OR COVER
WITH CERTIFIED CLEAN INNER PACKAGING FILM AS SPECIFIED IN TABLE V, APPENDIX B. SECURELY
SEAL OR TAPE FILM COVERS TO THE UNIT.
e. Do not perform contaminant-generating operations; e.g., sanding, grinding, chipping, drilling,
welding, and painting, in the CWA unless specifically approved by the responsible quality organization.
Then exercise controls and monitor as follows:

1) Securely cover areas and portions of the assembly adjacent to the contaminant-
generating operation to prevent accumulation or entrapment of particles.
2) Place plastic or other approved material of sufficient size to catch particles generated
below the contaminant-generating operation.
3) Upon completion of the contaminant-generating operation, thoroughly vacuum and then
remove the cover below the operation. Vacuum the surfaces and areas exposed by removal
of the covers. Then vacuum all adjacent areas, including walls and floors, to the extent
required to provide a GC work area. Verify cleanliness before further operations.
4) Personnel who performed the contaminant-generating operation must leave the CWA
and must change garments before performing other operations within the CWA.
6.0 CERTIFICATION OF CLEAN ROOMS AND LAMINAR FLOW CLEAN WORK STATIONS
Certify and recertify clean rooms and laminar flow clean work stations per the minimum requirements
stated below.

6.1 INSTRUMENT CALIBRATION

All instruments and applicable equipment, including permanent clean room monitoring equipment, used
during the certification process shall have current calibration status.

6.2 PREPARATION
Before certification begins, clean all clean room equipment and furniture and properly locate them in
the room. Choose locations to effect the least interference with the airflow within the room, to provide
protection for "downstream" operations, and to locate the heaviest contaminant-generating operations
closest to the room exhaust area.

Operate laminar flow clean work stations at least 15 min. before beginning certification procedures.
Evaluate the immediate surroundings. Although the clean work station is designed to operate in an
uncontrolled ambient environment, particles generated around the station may penetrate the laminar
airstream or may follow the worker's arms into the station. Also check the area for any other
operations producing high-velocity air, particles, or vapors which could be introduced into, interfere
with, or penetrate the airstream.

6.3 INTEGRITY INSPECTION

Vacuum clean or replace prefilters, and vacuum clean the internal blower motor areas. Inspect motors
for excess lint, evidence of overheating, and worn or damaged drive belts. Inspect all internal wiring
for damaged insulation, evidence of heating, and general condition.

6.4 DOCUMENTATION
Prepare a documented procedure or test preparation sheet (TPS) for the certification process. The
Occupational Safety and Quality Assurance Branch will, upon request, help prepare the certification
procedure. Before implementation, the procedure shall be approved by the Occupational Safety and
Quality Assurance Branch.

6.5 TESTING REQUIREMENTS

The certification procedure shall, as a minimum, consist of the tests described below.

6.5.1 Clean Room Testing Requirements

6.5.1.1 Filter Particulate Leak Test. Scan the final HEPA filter bank to verify the absence of leaks with
a calibrated automatic particle counter that samples at a rate of about 0.03 m3/minute for a reasonably
accurate sampling and fast sampling time.

Sample the air with an isokinetic nozzle. Scan slowly; i.e., approximately 2 meters (6 ft) per minute
with the probe held 8 to 15 centimeters (3 to 6 in.) from the filter protection screen. Do not use DOP
smoke to test the HEPA filter. Undamaged HEPA filters will normally pass less than 15 particles per
0.028 m3 (1.0 ft3). Any reading in excess of 30 particles indicates a leak.

In vertical laminar flow rooms having high ceilings, the sampling of numerous locations at the
workbench level may be conducted in lieu of the filter leak check.

If a leak is detected, determine if the leak is in the filter or around the filter (indicating a poor seal).
Small pinhole leaks in the filter may be repaired with room-temperature vulcanized silicone on the
upstream side of the filter. Tightening filter clamps may correct poor seals or seat sealing gaskets
properly. If these corrections do not correct the leak, replace the filter.

6.5.1.2 Room Particulate Sampling. Subsequent to a successful filter leak check, determine
particulate concentrations at selected locations within the room. Carefully select the sample locations
to ensure evaluation of major work locations and representative areas of the room. In vertical laminar
flow clean rooms, sample at approximately 1 m (30 to 40 in.) above the floor surface. A minimum
sample is 0.084 m3 (3 ft 3) per sample location. Determine the concentration of particles per 0.028 m3
(1 ft 3) of 0.5 micron and greater and 5.0 microns and greater (see table I, appendix B). The evaluation
procedure or TPS must include a sketch of the room which shows the selected sampling locations.
6.5.1.3 Temperature and Humidity. Determine temperature and humidity values within the clean
room. Normally, temperature and humidity are uniform in laminar flow facilities, but may vary
significantly in nonlaminar facilities. More locations, therefore, should be checked in nonlaminar flow
facilities. For convenience, some of the same locations selected for airborne particulate sampling may
be used.

6.5.1.4 Static Pressure. Determine and record the static pressure within the clean room and adjacent
rooms or areas.

6.5.1.5 Light Intensity. Using a calibrated light intensity meter, record incident illumination for major
work locations.

6.5.1.6 Consistent Performance. Perform and record the airborne particulate sampling, temperature
checks, and humidity checks for 3 consecutive days, unless rooms are monitored daily. Note
recertification requirements, section 6.7.

6.5.2 Laminar Flow Clean Work Station Testing Requirements

Use requirements specified in section 6.5.1.1 for laminar flow clean work stations with one exception:
scan at a distance of 5 to 10 centimeters (2 to 4 in.) from the filter by overlapping horizontal passes.
Operate stations at least 15 min. before testing.

6.6 FLAMMABLE AND TOXIC FLUID FACILITIES

The JSC Medical Operations Branch and the Test, Operations, and Institutional Safety Branch evaluate
and approve clean rooms and laminar flow clean work stations which contain cleaning facilities using
flammable and/or toxic fluids before certification.

6.7 RECERTIFICATION
Recertify clean rooms annually. Evaluation for recertification shall include all items required for initial
certification. The airborne particle sampling, temperature checks, and humidity checks may be done
only once, provided daily monitoring records for these items are available for the 2 workdays preceding
the recertification evaluations of the clean room.

Recertify laminar flow clean work stations annually. Inspect laminar flow clean work station prefilters
quarterly. If the prefilters are maintained properly, a laminar flow clean work station will function
properly unless a mechanical breakdown (e.g., a fan belt breakage) occurs. More frequent
recertification may be performed for special applications or when requested by the using organization.

6.8 CERTIFICATION DECAL

Affix a certification decal to all clean rooms and work stations that specifies the environment
classification and the date of certification and recertification. Decals for JSC clean work stations shall
include JSC Institutional Safety and Quality approvals.

7.0 SURFACE CLEANLINESS LEVELS

7.1 GENERAL
The responsible design or using organization selects cleanliness levels from table IV, appendix B. The
following two categories of cleanliness levels are available for use in providing uniform and cost-
effective contamination control applicable for a wide range of cleanliness needs:
a. Precision cleanliness. Precision cleanliness levels may be described as "quantitative," since
particulate counts, with or without nonvolatile residue (NVR) or other suitable film/nonparticulate
method limits, are required. These levels are usually specified for internal surfaces of fluid systems.
b. Visible cleanliness. Visible cleanliness levels (see section 7.2) may be described as "qualitative," in
that verification and/or inspection of these levels is visual. However, these levels are not considered to
be inadequate, since the application of these levels must be viewed with respect to hardware design
and operation. These levels represent a cost-effective alternative to precision cleanliness levels and
offer greater flexibility for the appropriate design or using organizations. Visible cleanliness levels may
be used as either interim or final cleanliness levels.

All aspects of cleaning, certification, packaging, storage, and field operations for precision cleanliness
levels are addressed in sections 8.0, 9.0, 10.0, 11.0, 17.0, and 18.0. Visible cleanliness requirements
are detailed in section 12.0, and in some instances refer to applicable precision cleanliness
requirements for brevity. Section 7.2 is provided to aid in the selection of visible cleanliness levels.
7.2 GUIDELINES FOR SELECTION AND USE OF VISIBLE CLEANLINESS LEVELS
As a point of reference, the human unaided eye (corrective lenses are acceptable) can detect particles
as small as 40 to 50 microns under ideal conditions.

7.2.1 VC + UV
This level provides a surface condition free of all visible contamination (particulate and nonparticulate)
augmented by UV (UV light of 3,200 to 3,800 angstroms wavelength) inspection. UV inspection will
detect some, but not all, hydrocarbon film matter. This level is usually specified for hardware that
cannot tolerate buildup of hydrocarbons between uses or operations.

NOTE: Quantitative (gravimetric) hydrocarbon detection is provided by NVR or other

suitable film/nonparticulate measurement.

The VC + UV level requires (1) mandatory cleaning and (2) heat-sealed double bagging for
preservation.

7.2.2 VC
This level provides a surface condition similar to VC + UV except that UV inspection is not a
requirement. This level is usually designated for (1) hardware that requires removal of surface
particulate and nonparticulate contamination for operation or use; or (2) hardware for which recleaning
would be difficult and/or time-consuming, therefore making continuous packaging protection desirable.
This level requires mandatory cleaning and protection by heat-sealed bagging.

7.2.3 GC
This level is similar to VC but differs in the following significant areas:
a. Cleaning is only required if the item does not pass inspection. If the item has ever been inspected;
i.e., is acceptable "as is," it does not need to be cleaned.
b. Inspection is not as rigorous as VC in that clumps or agglomerations of contamination are removed
instead of individual particles.
c. Heat-sealed bagging protection is not required; but normal protection is required for handling,
shipping, and storage.
The GC level should therefore be specified for hardware that is not sensitive to contamination and is
easily and quickly cleaned or recleaned.

8.0 PRECISION-CLEANING REQUIREMENTS

The intent of this section is to specify those general requirements applicable to precision-cleaning
processes. Precleaning precedes final or precision-cleaning. Since the characteristics of the assemblies
or components being cleaned vary, this section does not describe the many methods of precleaning.
These methods can be found in detailed procedures written for that purpose. Because of the nature of
the materials, nonmetallic precleaning methods vary markedly from those used for metallic parts and
are each covered separately in section 8.6.

NOTE: The requirements in this section are also applicable to visual cleanliness levels to the
extent specified in section 12.0.

8.1 GENERAL CLEANING PROCESS CONTROLS

For all fluids, equipment, and facilities used for precision-cleaning, observe the following minimum
requirements for contamination control. These requirements are designed to avoid the inadvertent
introduction of contaminants into parts, components, and subsystems during the cleaning, assembly,
functional testing, and packaging processes.

8.1.1 Cleaning Fluids

For all cleaning fluids, establish, document, and implement requirements that control fluid composition,
purity, cleanliness, and use. Control the cleaning fluids selected for use as precleaning solutions during
use by analysis, solution replacement, or adjustment to maintain cleaning effectiveness and
compatibility with the type of material being cleaned. Analyze final flush and verification fluids for
precision cleanliness before using to determine compliance with the stipulated specification
requirements.

8.1.2 Solution Control Records

Maintain records indicating the scheduled analysis, analysis results, and any solution replacement or
adjustment activities.
8.1.3 Special Cleaning Processes
Control special cleaning processes, such as ultrasonic cleaning and surge cleaning, by documented
procedures.

8.1.3.1 Ultrasonic Cleaning. Test ultrasonic cleaning equipment to verify that adequate cavitation
turbulence for good cleaning action is maintained. Conduct such tests using the manufacturer's
recommended test method.

8.1.3.2 Ultrasonic Fluid. The fluid used in ultrasonic cleaning equipment should be as recommended
by the manufacturer. However, if an alternative fluid is used, perform tests to verify that the
alternative fluid does, indeed, perform the proper cleaning action and is compatible with articles to be
cleaned.

8.1.3.3 Surge Cleaning. Subject surge or pressure and vacuum cycle cleaning of components and
systems to specific pressure or flow controls to prevent damage to the item from pressure or vacuum.
Do not clean items such as pressure vessels, which are sensitive to pressure cycle fatigue, using a
surge cleaning procedure.

8.2 PRECLEANING METALLICS

Preclean (rough clean) each item requiring precision-cleaning to the VC level before placing it in a clean
room or clean work station. Control the precleaning by detailed procedures that have been approved
by the responsible agency. At JSC, the Mechanical and Chemical Process Engineering and GFE Branch
has approval authority.

8.2.1 Precleaning Process Controls

Preclean parts to remove all visible contaminants without removing or changing the characteristics of
the base materials. Remove all traces of precleaning materials from parts at the completion of the
precleaning process to prevent the future formation of mineral salts and corrosion products. Use tests,
such as pH testing, to verify removal of all residuals.

8.2.2 Work Flow

All steps in precleaning procedures must progress in an uninterrupted work flow through the final rinse
and drying operation. If the work flow is unavoidably interrupted, specify a recycling operation in the
precleaning procedure. Precleaning procedures shall include, as a minimum, protection of the item by
interim packaging or other approved means to prevent recontamination through all subsequent
operations.

8.3 INSPECTION
Before precision-cleaning, inspect items to the VC level as described below.

8.3.1 Visual Inspection

Make a visual observation with the unaided eye (corrective lenses are acceptable) under a white light of
sufficient intensity to well illuminate the surface being inspected. Borescopes, mirrors, or other devices
may be used to increase accessibility during inspection, but magnifying lenses may be used only to
further identify visible contaminants. Where configuration, color, or other item characteristics interfere
with visual observation, the tests described below are to be used to augment visual inspections.

8.3.1.1 Wipe Test. Wipe the surface to be inspected with a lint-free, item-safe, and fluid-safe
medium, and observe the medium for the presence of contaminants. Do not wipe too hard, since soft
metals; e.g., aluminum, will abrade and soil the medium, giving an erroneous indication of
contamination. Subject the wiping medium to the blacklight test specified in section 8.3.2.

NOTE: When the wiping medium is subjected to further tests, such as blacklight or
hydrocarbon evaluation, a baseline reading of the blank medium must be determined and
accounted for in subsequent evaluations.

8.3.1.2 Water Break Test. Place the surface to be inspected in the horizontal, face-upward position, if
possible. Then spray the surface with distilled purified water, such as distilled water from an atomizer,
so as to completely cover the area of interest. The presence of droplets or breaks in the water film will
be an indication of possible oily hydrocarbons.

8.3.2 Blacklight (UV) Inspection

Make a visual observation of the item with the unaided eye (corrective lenses are acceptable) under UV
light (3,200 to 3,800 angstroms wavelength) for the presence of hydrocarbons. Where the surface to
be inspected is inaccessible, perform a wipe test, and inspect the wiping medium under UV light.

NOTE: Any contamination detected by the visual inspection or blacklight inspection shall be
cause for recleaning. If recleaning fails to remove fluorescent indications, investigate to
determine if the item material is naturally fluorescent.

8.4 PRECISION CLEANLINESS LEVELS

Select precision cleanliness levels from table IV, appendix B. The responsible design or using
organization specifies the level of cleanliness. Personnel trained in accordance with section 14.0 of this
manual perform sampling and certification tasks to attain specified cleanliness levels.

8.5 PRECISION-CLEANING
Precision-clean in a clean room environment, following precleaning operations described herein. Flush
or wipe the items to be precision-cleaned with a suitable cleaning solution or solvent and/or vacuum
clean or blow off with clean dry air to prevent the entry of gross contaminants into the clean room
environment.

Precision-cleaning using a precision-cleaning agent. Document all precision-cleaning processes and

have authorized personnel approve them. At JSC, the Mechanical and Chemical Process Engineering
and GFE Branch has this authority.

8.6 CLEANING FLUID PERFORMANCE REQUIREMENTS, OTHER DESIGN

CONSIDERATIONS, AND CLEANLINESS VERIFICATION

8.6.1 Cleaning Fluid Performance Requirements

The cleaning fluid used in a cleaning method or procedure should be capable of assisting to clean the
component, product, etc., to the required cleanliness level. The cleaning methods and procedures
should be well understood. Additionally, the cleaning fluid should be:
a. Nontoxic (not harmful if inhaled or spilled on the skin) and nonpoisonous.
b. Nonexplosive.
c. Noncorrosive under normal use.
d. Nonflammable. This does not limit potential cleaning fluids only to nonflammable fluids. Flammable
cleaning agents, such as isopropanol, should be used with care in cleaning oxygen systems or
equipment that may combust flammable materials. Fuel systems may allow limited and careful usage
of isopropanol or other flammable cleaning agents. In general, combustible cleaning agents should be
used with care to clean systems or products that may combust the cleaning agent during cleaning; or
even at a later time such as when the system or product is packaged, stored, used, etc.
e. Environmentally sound. Minimize waste streams. The cleaning agent should be recoverable and/or
disposable. A good disposal system is one whose discharge passes no contaminants to the
environment; a better system is one that has no discharge at all.
f. Compatible with the system or product materials. The cleaning fluid purity and composition should
be to a level that is demonstrated to allow the desired level of cleanliness to be achieved without
adversely affecting the product. The cleaning fluid should not react with, combine with, etch, or
otherwise cause immediate or later degradation of the system or product being cleaned.

8.6.2 Other Design Considerations

a. If cleaning must be performed, consider using tap water or detergents/soaps with tap water first. If
tap water is not acceptable, consider distilled or deionized water. Dry without heat if possible.
Consider mechanical cleaning and drying methods as well.
b. To avoid the reaction under heat and subsequent production of toxic compounds, do not clean
breathing air and breathing oxygen systems that use metal hydroxides for rebreathing with
halogenated substances.
c. Do not use CFC-113 to clean the Orbiter reaction control system subsystem fuel components because
of the potential reactivity of the CFC-113 with monomethylhydrazine.
d. Design systems with filters that require changing or systems with components that require servicing
or cleaning so that changeout, cleaning, and reassembly are easily performed.
e. Aluminum, magnesium, and other porous materials may not be suitable for ultrasonic cleaning.

8.6.3 Cleanliness Verification

Following precision-cleaning, unless otherwise specified, rinse each item using 100 milliliters of unused
precision-cleaning solvent for each square ft of critical surface. Rinse by agitation, sloshing, or by
spraying the test solvent over the critical surface in such a manner as necessary to obtain a reliable
test solution. Drain the test solvent immediately to prevent particle redeposition on the test surface.
Place clean components in the inner packaging wrap (not sealed) during the particle/NVR determination
to preclude contaminating the component. Particulate determination shall be made in accordance with
the requirements of SAE-ARP-598. Determine NVR in accordance with ASTM D2109-71.

8.7 NONMETALLIC MATERIALS CLEANING METHOD AND RINSE TEST

For the purpose of this document, nonmetallic materials include natural rubber, Teflon, nylon, Kel-F,
polytetrafluoroethylene, polyethylene, polycarbonates, and other plastic or synthetic rubber materials.
Take care to ensure that the cleaning solution used in the method will not adversely affect the
materials; i.e., cause external damage or absorption of the cleaning solution and consequent
outgassing. Also take care to ensure that nonmetallic materials are compatible with the use fluid.

8.7.1 Cleaning Method

The following method or its equivalent is acceptable for cleaning nonmetallic materials:
a. Decontaminate materials using a cold tap water flush until the pH of the effluent is within one-half a
pH unit of the influent.
b. Detergent-clean the materials with a biodegradable non-ionic detergent using nylon brushes as
necessary.
c. Spray rinse the materials with 65.5* to 82*C (150* to 180*F) tap water, followed by a rinse with
deionized water that has a minimum specific resistance of 50,000 ohm-centimeter.
d. Use nitrogen gas, as specified in MIL-P-27401, grade B (at approximately 48*C [102*F]), for drying.

8.7.2 Rinse Test

When a final flush is required for cleaning verification, perform it in accordance with section 8.6.3,
except that the solvent medium shall be high-purity water.

8.8 FINAL PACKAGING

Package all precision-cleaned items in accordance with section 10.0 of this document immediately after
cleaning and drying.

9.0 PROCUREMENT REQUIREMENTS FOR PRECISION-CLEANED PACKAGING MATERIAL

The material cleanliness and packaging requirements for the procurement of packaging materials used
for the packaging of precision-cleaned components are specified in this section. Materials shall be of
the type specified in table V, appendix B.

NOTE: The requirements in this section are also applicable to visual cleanliness levels to the
extent specified in section 12.0.

9.1 PROCUREMENT REQUIREMENTS

All packaging procurement documentation shall reflect the requirements stated below.

9.1.2 Cleanliness Level

Clean outer packaging material to the VC level. Precision-clean inner packaging material to the
appropriate precision cleanliness level in accordance with hardware requirements.

NOTE: Procurement of inner packaging materials precision-cleaned to levels stricter than

Level 100 (e.g., Level 50 or Level 25) requires the concurrence of the Occupational Safety
and Quality Assurance Branch.

Double-bag bags, sheeting, tubing, roll stock, and other cleaned film as specified in section 10.0 and
table V, appendix B. The inner bag shall be constructed of the same material as the one being
packaged (e.g., nylon film packaged in nylon). Roll stock shall be wound on clean cores made from
nondusting plastic or metal.

9.1.3 Environmental Control

Perform all processing and inspections within an environment compatible with the required cleanliness
level for the packaging material being processed. Wear clean, white, nylon (or equivalent) gloves for
handling packaging materials.

NOTE: Plastic films generate large electrostatic charges when handled. These charges may
cause attraction of large quantities of airborne particles to the surfaces of such film unless
 precautions are taken to minimize exposure of clean film surfaces to the clean room
atmosphere before testing for verification of the cleanliness level.

9.1.4 Visual Inspection Requirements

Do not allow evidence of oil, grease, water, solvents, paints, ink, dirt, metal chips, labels,
preservatives, or other foreign matter on the external surfaces or the internal surfaces of intimate
packaging materials nor on the internal surfaces of the overwrap packaging when inspecting with the
unaided eye.

9.1.5 Rinse Test

Test a minimum sample of 1% of the procured bags and a minimum of one sample per roll of sheet or
tubing stock. Use the procedure set forth below, or an equivalent procedure approved by the
responsible personnel, to verify compliance with the required cleanliness level.

9.1.5.1 Preparation. Heat-seal the bag across the open end. Using surgical scissors or another
extremely sharp blade (to minimize particle generation when cutting), cut off one corner of the bag so
that an opening not over 2 centimeters (0.75 in.) in length is created. Seal plastic tubing for precision
packaging applications at both ends of a length to give an inside test area of approximately 0.1 m2 (1
ft2) and sample by rinse testing. Cut plastic film (flat roll stock) carefully with surgical scissors or
another sharp blade to a length of 30 centimeters (12 in.). Fold the section in half, seal it into a bag
form in such a manner as to minimize exposure of the interior to airborne particles, and sample by
rinse testing.

9.1.5.2 Rinsing. Through the opening, introduce 100 milliliters of solvent for each 0.1 m2 (1 ft2) of
interior surface from a wash bottle or similar apparatus. Consider a bag having less than 0.1 m2 (1
ft2) of interior surface to be 0.1 m2 (1 ft2). Hold the opening shut by a practical means. Then rinse
down the exterior of the bag with the same agent to prevent exterior particles from being picked up
when the bag is decanted. Agitate the rinsing agent within the bag with a gentle but rapid sloshing.

9.1.5.3 Collection of Sample. Pour out the rinsing agent within the bag through the same opening
that was held shut during rinsing, and pour through a microporous membrane filter.

9.1.5.4 Testing. Examine the effluent of the rinse test for particulate matter by the particle count
method per the requirements of SAE-ARP-598. Determine the purity of the solvent rinse per ASTM
D2109-71, or an appropriate substitute procedure which will effectively measure nonparticulate
contamination. The material used in this test shall not be subsequently used to package precision-
cleaned items.

9.2 CERTIFICATION
The supplier furnishes certification showing evidence of compliance with these requirements, as
specified in the procurement documents, with each package.

10.0 PACKAGING OF PRECISION-CLEANED PARTS

Packaging methods and the packaging sealing requirements for parts and components that have been
precision-cleaned are specified in this section.

NOTE: The requirements in this section are also applicable to visual cleanliness levels to the
extent specified in section 12.0.

10.1 PROCEDURES
Package precision-cleaned parts and components per documented procedures. At JSC, the Mechanical
and Chemical Process Engineering and GFE Branch approves these procedures before their
implementation.

10.2 PRECISION PACKAGING

NOTE: Items cleaned to levels stricter than Level 100 (e.g., Levels 50 and 25) should be
assembled as soon as possible after cleanliness verification. Packaging of such items may
degrade item cleanliness.

10.2.1 Environment
Accomplish all packaging operations within a clean room or laminar flow clean work station.
10.2.2 Equipment
Maintain heat-sealing devices in a clean condition at all times. Inspect daily to determine condition of
the sealing bars. Replace damaged, burned, or worn sealing bars. Determine temperature and timing
cycle adjustments by sample sealing exercises to prevent "under" or "over" heat conditions during
sealing operations. Test seal strength per section 10.2.5.c.

10.2.3 Handling of Components

Persons handling precision-cleaned components during the packaging operations must wear clean, low-
lint, white, non-contaminant-generating gloves whose materials are compatible with cleaning fluids.
Handle items cleaned to visual cleanliness levels per section 12.3.

NOTE: Handle liquid oxygen (LOX) and gaseous oxygen (GOX) components with exposed
critical surfaces with gloves constructed of an approved, compatible material only.

10.2.4 Garments
Wear clean room attire as specified in table III, appendix B, during packaging operations.

10.2.5 Packaging Techniques and Materials

Package items to be cleaned to a precision cleanliness level using the double-bagging technique.
Materials used for double bagging must conform to the requirements of section 9.0 and table V,
appendix B. Double bagging of precision-cleaned parts is required to provide redundancy if one bag is
damaged. Double bagging also enables removal of the outer bag before placement of the parts in the
clean room, spacecraft, or test chamber to maintain area cleanliness requirements. Materials used for
the outer bag may differ from those used for the inner bag in order to obtain overall slough resistance
and moisture barrier qualities. Table V, appendix B, provides a ready reference to applicable bagging
techniques and materials for component cleanliness requirements. Characteristics of the bags shall be
as follows:

a. LOX compatibility. Protect LOX parts, components, subsystems, and systems by an inner
bag of LOX-compatible film, as specified in table V, appendix B, unless surfaces which will
be in contact with oxygen are effectively sealed (capped or plugged) from particles which
may slough from the inner bag.
NOTE: LOX-compatible bags must be sealed on all sides, never center-folded.
b. Size. The size of the bag to be used must be determined in relation to the part. Allow
adequate room within the inner bag so the part is easily encapsulated.
c. Strength. Determine the strength of the bag to be used in relation to the part
contained. Many bags used have three sides sealed, as contrasted to the end sealing of
tubing. When a seal test is to be performed, use the method described by MIL-P-116.

10.2.6 Sealing Orifices

Where parts have many orifices, it may be necessary to seal each one. During assembly, do not
expose parts to the environment more than one at a time, to retard the entry of particulate
contamination. Cut squares of appropriate inner packaging material and tape in place to cover critical
surfaces. (Use fluid-approved tape or at least noncontaminating tape.) Exercise care to ensure the
tape adhesive does not contact critical surfaces. Use a polyester tape (e.g., Mylar) with low-adhesive
and low-residue properties.

For male fittings and tube ends, wrap the protrusion with film and the film drawn over the critical
portions of the part or over the film itself by stretching the tape. The tape used shall be a
polyvinylchloride type conforming to PPP-T-66, type I, class B. Restrain connector nuts with tubing by
taping over the clean film to secure the nut tightly.

10.2.7 Plastic Closures

When plastic closures (e.g., caps, plugs, and heat-shrinkable sleeves) are specified to seal openings of
precision-cleaned internal surfaces, the closures shall be of suitable size and type so as not to generate
particulate matter or otherwise be detrimental to the item.

10.2.8 Metallic Closures

When closure plates are specified to close flanged items, use materials precut and/or drilled like metal
of the flanges being cleaned. Examine the external and internal surfaces of metallic closures for
evidence of fluorescence under UV light. Reclean fluorescent areas.
10.2.9 Film Cushioning
Overwrap heavy items or items having threads, sharp points, or sharp edges, which may puncture or
otherwise damage the barrier bags, with a sufficient amount of the appropriate inner packaging
material to form a cushion. Small, light items which, if dropped, would not cut or otherwise damage
the barrier bags need not be film cushioned. Secure the cushioning film with an approved tape (PPP-T,
type I, class B, unless otherwise specified) whose adhesive shall not come in contact with the body of
the precision-cleaned item.

10.2.10 Inner Bag Purging Gases

When purging is specified, the purging material shall be a precleaned, dry, inert gas (e.g., argon),
conforming to MIL-A-18455; or nitrogen, conforming to MIL-P-27401, grade A, or equivalent. Prefilter
gases to meet the cleanliness level of the item being precision packaged. Purge by directing a stream
of inert gas into the inner bag and over the contents for a sufficient length of time to replace the
entrapped air with inert gas. Then pull a partial vacuum on the bag before sealing.

10.2.11 Dissimilar Metals

To prevent galvanic corrosion, do not place metals dissimilar to the item in contact with the item.

10.2.12 Preservatives
Do not use preservative materials on items which have been precision-cleaned.

10.2.13 Sealing Techniques

Bag sealing techniques shall ensure that the volume of gas sealed in the bag is the minimum possible,
thus permitting room for expansion of entrapped gas during air shipment.

10.3 PACKAGING OF SMALL ITEMS

A sandwich package is an acceptable alternative for packaging light, regular, or symmetrical items;
e.g., O-rings, seals, and gaskets. A sandwich package consists of a number of identical items that are
heat sealed between two film sheets of appropriate inner packaging material. Each item must be in a
separate, purged, heat-sealed compartment so that each compartment may be separated from the
others by cutting with scissors without degrading the integrity of the remaining compartments. Then
identify the sandwich package with evidence of cleaning and placed into a bag of appropriate outer
packaging material. Purge the bag and heat-seal.

10.4 PACKAGING OF LARGE, HEAVY, OR ODD-SHAPED ITEMS

Items which cannot normally be heat-sealed in a transparent film bag because of size, weight, or
configuration and have precision-cleaned interior surfaces may be prepackaged as specified below.

10.4.1 Capped or Plugged Closures

Cap, plug, or otherwise seal all fittings or other openings leading to precision-cleaned inner surfaces.
Mate closures with sealing surfaces and tighten to preclude breathing of the sealed item. Cap or plug
material shall be compatible with system fluids and cleanliness levels.

10.4.2 Film Sheet Closures

Items containing openings leading to precision-cleaned inner surfaces, which cannot be sealed with
caps or plugs, shall have each opening overlaid with two sheets or bags of the appropriate inner and
outer packaging material. Secure each sheet or bag in place by at least two tight wraps of tape. The
tape shall not contact the item.

10.4.3 Film Overwrap

For each item with sealed openings, completely overwrap with an appropriate outer packaging
material. Secure the overwrap with tape or heat-seal where practicable. In any case, sealing of items
that may be exposed to temperature variations during transport and storage shall be adequate to
prevent the internal volumes of the item from breathing.

10.5 PACKAGING OF HOSE AND TUBE ASSEMBLIES

Internally purge precision-cleaned hose and tube assemblies whose external surfaces do not require
critical or visual cleanliness, and seal to preserve their cleanliness. Seal each end fitting with
appropriate inner packaging material and cover with an outer packaging material.

10.5.1 Film Sleeve

Place each purged, sealed, and identified hose or tube assembly into a sleeve of appropriate outer
packaging material, and then purge and heat-seal.

10.5.2 Flanged Items

Close flanged items with only cleaned internal surfaces by placing at least two precut gaskets of the
appropriate inner packaging material over the flange face. Apply a metallic closure plate over film
gaskets, and insert attachment hardware through all flanged holes and tighten to recommended torque
value for the type and size attachment bolt used.

10.6 PROVISIONS FOR TESTING ELECTRICAL AND ELECTRONIC ITEMS

Prepackage electrical and electronic items which will require testing upon arrival at destination and
during storage in a manner that will permit access to the leads, pigtails, etc., without degrading the
integrity of the unit package.

NOTE: Exercise caution when processing electrical or electronic hardware that is sensitive to
electrostatic discharge (ESD) damage. Special materials and techniques may be necessary
to control ESD. Use materials used for both contamination and ESD control only if
approved by the Occupational Safety and Quality Assurance Branch. Contamination control
packaging shall not be placed inside ESD-control packaging.

10.7 CERTIFICATION DECALS

Identify the bagged item with a decal containing identification, inspection, and certification of
cleanliness information. Decals procured to meet the requirements of this section are not intended for
direct application to parts or equipment; therefore, the decals need not be compatible with fuels or
oxidizers. Apply decals to the outside of the inner bag and over the ends of tape-sealed closures.

11.0 STORAGE OF PRECISION-CLEANED ITEMS

Remove completely precision-cleaned and -packaged items from the clean room and place in an
appropriate container or storage area to protect the plastic bags and contents.

NOTE: The requirements in this section are also applicable to visual cleanliness levels to the
extent specified in section 12.0.

11.1 ENVIRONMENTAL CONTROL

Store all precision-cleaned items in an enclosed, controlled area where temperature and humidity are
maintained within limits compatible with the item and its packaging material. Filter the air supply
through an industrial-grade filter. Maintain the enclosed area in a manner consistent with good
housekeeping practices. Establish and document periodic cleaning schedules.

11.2 INSPECTION
Inspect stored precision-cleaned items periodically, at least once every 2 years, for the integrity of the
outer bag and, on a sample basis, for corrosion or other degradation of the packaged item. To inspect,
remove the outer bag and visually inspect the item through the inner wrap. Any discoloration, visible
contamination, etc., shall be cause for rejection and recleaning of the lot sampled. If no cause for
rejection is found, apply a new outer bag and reseal in the normal manner.

11.3 ACCESS CONTROLS

Establish adequate controls to limit access to storage areas for precision-cleaned items to personnel
specifically trained in the handling of precision-cleaned items.

11.4 POSTSTORAGE DECONTAMINATION

Items removed from the storage area shall have the outer packaging vacuum cleaned before opening to
remove any possible accumulation of dust or other contamination.

12.0 VISUAL CLEANLINESS LEVEL REQUIREMENTS

This section describes the various visual surface cleanliness levels. Methods of attaining these levels
vary and those methods used to preclean surfaces before precision-cleaning procedures are acceptable
and recommended. Cleaning with an approved, compatible solvent (e.g., solvent wipe), however, is
mandatory for VC and VC + UV items, unless other methods are required by the hardware in question.
Specific packaging requirements are also included. Refer to section 7.2 for further information.

12.1 VISUAL CLEANLINESS LEVELS

Definitions of the visual cleanliness levels are stated below.
12.1.1 VC + UV
VC (as defined in paragraph 12.1.2) and inspected with the aid of a UV light of 3,200 to 3,800
angstroms wavelength.

NOTE: Any evidence of fluorescence shall be cause for recleaning. If recleaning does not
reduce the fluorescence, investigate to determine whether the fluorescing material is a
contaminant or the basic material.

12.1.2 VC
VC is free of all particulate and nonparticulate visible to the normal unaided eye (corrective lenses are
acceptable). Particulate is identified as matter of miniature size with observable length, width, and
thickness. Nonparticulate is film matter without definite dimension. Borescopes, mirrors, or other
devices may be used to increase accessibility during inspection, but magnifying lenses may be used
only to further identify visible contaminants.

12.1.3 GC
Free of manufacturing residue, dirt, oil, grease, processing debris, or other extraneous contamination.
Achieve this level by washing, wiping, blowing, vacuuming, brushing, or rinsing. Do not designate the
GC level for hardware that is sensitive to contamination. This level may be attained in any area where
the cleanliness integrity of the article being processed would not be jeopardized.

12.2 VISUAL CLEANING PROCESS CONTROLS

All fluids, equipment, and facilities used for cleaning to the VC or VC + UV cleanliness levels shall be
subject to the same minimum requirements specified for precleaning procedures (sections 8.1, 8.2, and
8.6). Cleaning with an approved, compatible solvent (e.g., solvent wipe) is mandatory for VC and VC +
UV items, unless other methods are required by the hardware in question. GC items do not require
cleaning before inspection; cleaning is required only if the item does not pass GC inspection. Use a GC
cleaning process compatible with the hardware materials.

12.3 HANDLING
Handle items cleaned to the VC + UV, VC, and GC levels as follows:
a. VC + UV level. Handle items cleaned to the VC + UV level the same as precision-cleaned items
(i.e., with gloves, forceps, or tweezers).
b. VC level. Handle items cleaned to the VC level with gloves if so specified by the responsible design
or using organization.
c. GC level. Gloves are not required for the handling of GC items.

12.4 VISUAL INSPECTION

Accomplish non-UV visual inspection under a white light of sufficient intensity to adequately illuminate
the surface being inspected. Perform the inspections as follows:
a. VC and VC + UV levels. Inspect as specified in sections 8.3, 12.1.1, and 12.1.2.
b. GC level. Inspect as specified in section 12.1.3; pay particular attention to those locations with
cracks, crevices, holes, etc., which may trap or retain contamination.

12.5 PACKAGING REQUIREMENTS

Unique packaging requirements exist for items cleaned to visual cleanliness levels. The requirements
stated below supplement packaging requirements delineated in sections 9.0 and 10.0. Procurement
documents shall reflect specific packaging requirements selected from this section when visual
cleanliness levels are specified.

12.5.1 VC + UV Level
The VC + UV cleanliness level requires the use of the double-bagging technique as specified in section
10.0 and table V, appendix B. Section 9.0 is applicable with the following exceptions: (1) Clean inner
packaging materials and verify to the VC + UV level as a minimum; and (2) perform visual inspection
verification of the VC + UV levels instead of rinse testing. Accomplish packaging operations within a
Class 100,000 ECA or better.

12.5.2 VC Level
The VC cleanliness level requires packaging only in a single bag as specified in table V, appendix B.
Section 9.0 is applicable with the following exceptions: (1) Clean packaging material and verify to the
VC level as a minimum; and (2) perform visual inspection verification of the VC level instead of rinse
testing. Section 10.0 is applicable, except for the double-bagging requirements. Accomplish packaging
operations, as a minimum, within a CWA.

12.5.3 GC Level
The GC cleanliness level has no specific contamination packaging requirements. This does not preclude
protective packaging of the article for handling, shipping, and storage activities. Process items
scheduled for shipment for subsequent spaceflight and package in an area where the cleanliness
integrity of the article being processed is not jeopardized.

At JSC, environmentally protect GC hardware in transit between facilities. Acceptable means of

protection include plastic boxes with snug-fitting covers or reusable plastic, non-heat-sealable bags.
Use hardware-compatible foam or other acceptable means of cushioning, if necessary. Do not use
deteriorated or contaminated boxes or bags.

12.6 IDENTIFICATION, CERTIFICATION, AND STORAGE

12.6.1 VC and VC + UV Levels

Identify items processed to the VC or VC + UV cleanliness levels with a decal containing identification,
inspection, and certification of cleanliness information, per instructions contained in paragraph 10.7 of
this manual. Since VC items are single-bagged, place identification/ certification decals on the outside
of the single bag. Storage, environmental control, inspection, access controls, and poststorage
decontamination requirements shall be as specified in section 11.4.

12.6.2 GC Level
This level does not require a cleanliness certification decal, since protective packaging for contamination
control is not required. Establish nominal storage requirements as necessary, and consider such
parameters as length of storage and fungus growth.

12.7 FABRICATION, TESTING, ASSEMBLY, AND FIELD OPERATIONS

Field operations include, but are not limited to, repair, replacement, and maintenance.

12.7.1 VC + UV Levels
Requirements specified in sections 17.0 and 18.0 are applicable to items cleaned to the VC + UV level.

12.7.2 VC and GC Levels

Requirements detailed in sections 17.0 and 18.0 may be applied to VC or GC items if so specified by the
responsible design or using organization.

13.0 CLEAN ROOM GARMENTS

The minimum requirements for the materials, construction features, laundering processes, and controls
for clean room garments and accessories, including biologically clean garments, are stated below.

13.1 GENERAL

13.1.1 Garment Construction

The garment shall cover the body adequately and shall incorporate adjustable collars and cuffs to give a
snug fit. It may be fastened by either snaps, ties, or zippers and shall not have pockets. Garments
selected must have been tested and proven to exhibit limited linting characteristics. Flame-retardant
materials may be used for personnel protection; however, such materials shall comply with the
requirements contained in this section and must be approved by the Mechanical and Chemical Process
Engineering and GFE Branch.

Where antistatic garments are required, select garments having surface resistivity approaching 11.0 log
R units (log of resistivity per square unit of surface). This may be achieved by addition of an antistatic
agent to the material.

13.1.1.1 Fabric. Garments shall be of a 100% synthetic textile fiber, such as Dacron or nylon, of a
white or pastel color, and have a taffeta or herringbone twill weave.

13.1.1.2 Thread. The thread shall be a continuous filament, stranded, 200 denier, 100% polyester,
and of the same color as the garment.
13.1.1.3 Seams. Seams shall be closed, double stitched, and free of loose threads.

13.1.1.4 Style. All smocks and coats shall be at least knee length, and all coveralls shall have full -
length legs.

13.1.2 Accessory Construction

13.1.2.1 Head Coverings. Head coverings may be any of the types described below provided hair is
fully covered:
a. Surgeon caps for short hair styles.
b. Snood caps with drawstring or bouffant style caps for long hair styles.
c. Hoods and face covers. Hoods shall completely cover head and neck, except for face. Hoods should
also cover the nose when necessary. Hoods shall fit inside the neck of the coverall. A face mask shall
completely cover beards or mustaches.

13.1.2.2 Shoe Coverings. The tops of the shoe covers shall be made of the same material as the
basic garment, be high enough to cover the coverall pants legs, and be secured to the pants legs by
either a tie or snaps. Turn all seams inside and double stitch. The soles shall be made of skid-resistant
plastic or other acceptable material.

13.1.2.3 Shoe Socks. Shoe socks shall be made of stretch nylon, or equivalent material, one-size
design, with coverage of leg to midcalf. The use of other types of shoe coverings shall be subject to
approval by the Mechanical and Chemical Process Engineering and GFE Branch.

13.1.2.4 Gloves. Gloves shall be a form-fitting, one-size design, and shall provide complete
coverage. Each using organization should determine the least contaminant-generating material for its
particular application.

13.1.2.5 Wiping Cloths. Reusable cloths shall be lint free and constructed of a synthetic, low
particulate-generating fiber. Single-use or throw-away cloths may be used for specific applications if
they are compatible for precision-cleaning use.

13.2 LAUNDERING REQUIREMENTS

13.2.1 Processing
Conduct all laundering in facilities that provide airborne particulate control compatible with the
cleanliness required for the garments.

13.2.2 Cleaning Techniques

Clean by water washing or dry cleaning using approved clean room techniques. Either method or a
combination of the two is acceptable as long as particulate content is held within acceptable limits.

13.3 INSPECTION
Inspect clean room garments as described below.

13.3.1 Sampling
Check 2% of each shipment to ensure that garments meet particulate requirements listed in 13.4.
Conduct particulate determination in an environment equal to or better than the environment wherein
the garment was cleaned, if possible. Check points of garments per a method, or a method similar to
that, established by ASTM F51-65T or TO 00-25-203.

13.3.2 Visual Inspection

Inspect each garment and accessory for needed repairs, missing snaps, and broken zippers. This
inspection shall be the responsibility of the user. Reject any garment or accessory showing breakdown
of fabric, as evidenced by loose fiber ends protruding from the surface.

13.4 ACCEPTANCE CRITERIA AND LIMITS

13.4.1 Particulate
The maximum permissible concentration of particles and fibers per square ft of fabric surface shall not
exceed 5,000 particles of 5 microns and larger, with a maximum of 25 fibers. Use a method of
sampling in accordance with or equivalent to ASTM F51-65T or T.O. 00-25-203. Alternative methods
with higher flow rates and particle and fiber concentrations may be used if approved by the procuring
agency.

13.4.2 Particle Counting Method

Use suitable counting techniques of particles in accordance with a method, or a method similar to that,
established by ASTM F51-65T or TO 00-25-203.

13.4.3 Hydrocarbons
Sample garments shall have no visible hydrocarbons, such as oil stains or grease, as determined by UV
light.

13.4.4 Packaging
Package all garments individually in a polyethylene bag and hermetically seal in the clean room before
exposure to an uncontrolled environment.

13.4.5 Certifications
The supplier submits certification showing evidence of compliance with these requirements with each
shipment.

14.0 PERSONNEL TRAINING

This section defines the minimum training requirements for operational, technical, and management
personnel.

14.1 APPLICABILITY
The requirements of this section are applicable to all operational, quality, technical, and management
personnel.

14.2 TRAINING FOR ENVIRONMENTALLY CONTROLLED AREA DISCIPLINES

Personnel training for individual ECA operations is required and shall be accomplished by the successful
completion of a formal training program in each unit operation (as applicable).

ECA disciplines are individual operations required in a listed ECA to permit flexibility in personnel
training. In addition to ECA disciplines, personnel need only be trained and qualified in the operations
that encompass their particular job responsibilities. Individual clean room operations and personnel
required to be trained are as shown below.

OPERATION PERSONNEL REQUIRING TRAINING

ECA discipline All personnel (see note)

Precision-cleaning and packaging Personnel cleaning parts and handling cleaned parts

Part/item sampling Sampling personnel

NOTE: Personnel requiring entry to the ECA on a visit or on a temporary basis must be
knowledgeable in the basic ECA disciplines or shall be instructed before entering. An escort
qualified for ECA entry must escort and be directly responsible for such personnel. The
appropriate ECA supervisor controls entry of visitors or temporary personnel to prevent
overpopulation and compromise of ECA integrity.

14.3 QUALIFICATION STATUS

Acquire qualification status as specified below.

14.3.1 Previous Qualifications

Personnel previously trained for individual ECA operations must furnish the responsible training officer
with copies of training results, certificates, or any other data requested for proof of qualification.

14.3.2 New Employees

Newly employed personnel may be issued temporary permits for entry into the ECA room for periods
not to exceed 90 days. New employees granted temporary permits for ECA entry shall only be granted
such permits after they have been verbally indoctrinated in ECA entry procedures, garment donning
procedures, and ECA rules and regulations.

Personnel having temporary permits shall be assigned to and be the direct responsibility of a qualified
operations, quality, technical, or supervisory person. These personnel must receive formal training in
specific ECA unit operations. Provide new employees (1) a minimum of 2 hrs' formal training, including
an introduction to contamination control disciplines, the applicable governing requirements, and the
unit operations applicable to the individual assignment; or (2) on-the-job training.

14.3.3 Janitorial Services

Personnel performing janitorial services may be granted temporary permits after thorough verbal
indoctrination in ECA entry procedures, garment donning procedures, and ECA rules and regulations. A
qualified operational or supervisory person must be directly responsible for janitorial personnel.

14.3.4 Training Records

The ECA operating organization maintains records listing all employees and the specific operations for
which they are qualified.

14.4 CERTIFICATE
Upon successful completion of the appropriate qualification requirements, a certificate of training may
be issued. This certificate shall bear the signature and title of the authorized training officer.

14.5 RETRAINING AND QUALIFICATION

The authorized training officer or the responsible division, branch, or section chief may require a person
to be retrained any time there is reason to question the proficiency of the individual.

15.0 SPECIAL CLEANING REQUIREMENTS

15.1 PORTABLE GAS CYLINDER CLEANING

As a minimum, clean portable cylinders (metal only) used for breathing oxygen and breathing air shall,
per the following or equivalent procedure. Perform cleanliness and gas purity tests regardless of the
procedures used. A portable cylinder is defined as a cylinder that contains a 5- to 30-minute supply of
oxygen or air for emergency use.

15.1.1 Recommended Procedure

15.1.1.1 Inspection. Using a light source with an intensity level of 1,000 to 1,600 lumens (30 to 45
meter-candles, 100 to 150 ft-candles) per square meter, inspect the internal surfaces of the gas bottles
for the presence of scale, slag, oxide, or grease.

15.1.1.2 Degreasing. When the visual inspection dictates the need, degrease the gas bottles by
flushing them with solvent. Make another visual inspection and repeat the process as required. When
cleanliness is achieved, dry the gas bottle with nitrogen gas.

15.1.1.3 Sand or Grit Blasting. Remove scale, slag, and oxides by sandblasting, using a 20- to 30-grit
silicone sand at a minimum nozzle pressure of 95 PSI. Ensure that the sandblast air is free of oil and
moisture. Exercise care to avoid blasting threaded areas of the bottle. Ground blast hoses and nozzles
to dissipate static charges.

15.1.1.4 Flush Cleaning. When sand or grit blasting is performed, follow by a flush cleaning with
solvent. If scale, slag, oxides, or grease are still visible, resandblast and reflush as necessary. When
cleanliness is achieved, dry the bottle with nitrogen gas.

15.1.1.5 Hydrostatic Testing. Following degreasing, sandblasting, and flush cleaning, hydrostatically
test the bottles as applicable according to Department of Transportation regulations.

15.1.1.6 Final Cleaning. Subsequent to hydrostatic testing, subject the bottle to a final cleaning.
Using phosphoric acid as specified in MIL-C-10578 (or other cleaning agents that are compatible with
the gas bottle), flush or immerse the bottle for a period of 25 to 30 min. and then flush with water until
the pH is within 0.5 pH of the influent water and dry with nitrogen gas.

NOTE: For water-flushing operations, invert the bottle and flush as quickly as practical to
 prevent excessive flash corrosion on the interior surface.

15.1.2 Mandatory Verifications

15.1.2.1 Cleaning Verification. Verify final cleanliness by a solvent flush. Immediately after flushing,
position the bottle upside down and purge thoroughly with filtered nitrogen per MIL-P-27401, grade B.
Analyze the flush fluid for NVR content. Allow a maximum film/nonparticulate contamination of 1.0
milligram per 0.1 m2 (1 ft2) of bottle internal surface area if NVR, equivalent total organic carbon
(TOC), or use another film-verification method.

15.1.2.2 Gas Purity Verification. After it has been verified that the NVR level is acceptable, pressurize
the bottle with the required amount of oxygen or air from a certified clean source and cap. Draw a
sample of the gas from the bottle and analyze. If the gas sample meets the applicable gas specification
requirements, refill the bottle from a certified source. If the sample fails because of excessive solvent
fumes, a vacuum purge may be required. The bottle may have to be simultaneously heated and
vacuum purged for adequate cleaning. After the vacuum purge, repeat the gas sampling and analysis
until an acceptable sample is obtained.

15.2 CLEANING SMOOTH-BORE HOSES AND TUBING

Clean smooth-bore hoses and tubing as specified below.

15.2.1 Precleaning
Examine hoses or tubes for evidence of kinks, bends, or thread damage and decontaminate by
immersion or flush rinsing with cold tap water until pH of effluent is within one-half pH unit of influent.

15.2.2 Detergent Cleaning

Perform detergent cleaning as follows:
a. Clean exterior surfaces of hoses or tubing with non-ionic biodegradable detergent cleaner using nylon
brushes as required. Exposure time, temperature (not to exceed 62.7*C [145*F]), and concentration
shall conform to the manufacturer's recommended procedures.
b. Rinse the cleaned surfaces with tap water and dry with hot (49* to 60*C [120* to 140*F]) nitrogen
gas (MIL-P-27401, grade A, or equivalent).
c. Carefully clean end fittings of hoses and tubes with solvent using nylon brushes as required. Care
must be taken to ensure that the solvent does not contact the hose.
d. Install the adapter fitting and connect the hose or tube to be cleaned to the pump discharge line.
e. Install a restricter fitting in the downstream end of the hose or tube being cleaned. This provides
backpressure so that cleaning and rinsing solutions will contact all interior surfaces.

15.2.3 Cleaning of Hose Assemblies

Cleaning of hose assemblies shall proceed as follows:
a. Flush the hose with a non-ionic biodegradable detergent cleaner (or suitable cleaner/rinsing fluid) for
5 to 15 min. (or for however long it takes).
b. Change the flush pump suction to deionized water that has a minimum specific resistance of 50,000
ohms and flush the hose for 1 to 2 min..
c. Detach the hose from the flush pump discharge hose, and remove all adapter fittings. Thoroughly
rinse end fittings of the hose with the deionized water.
d. Dry the hose with hot (49 to 60*C [120 to 140*F]) nitrogen gas (MIL-P-27401, grade B, or
equivalent). Dry in heated (49 to 60*C [120 to 140*F]) vacuum chamber for 25 to 30 min. at
maximum vacuum.

15.2.4 Final Rinse and Cleaning

Perform the final rinse and cleaning as follows:
a. Flush rinse small hoses or tubes with 0.8-micron-filtered rinse fluid.
b. Fill and drain large hoses or tubes with 0.8-micron-filtered rinse fluid.
c. Use deionized water to rinse nonmetallic items.
d. Restrict the flow of fluid at the downstream end of the hose or tube as necessary to provide fluid
contact with all interior surfaces of the hose or tube.
e. After completion of the final rinse, continue the rinse and collect 100 milliliters of water per square ft
of interior surface of the hose or tube.
f. Dry interior surfaces and end fittings with 10-micron absolute filtered hot (49* to 60*C [120* to
140*F]) nitrogen gas (MIL-P-27401, grade B, or equivalent).
16.0 FLUID SAMPLING
This section defines general requirements for sampling liquids and gases. All phases of sampling (e.g.,
equipment cleaning and handling) instructions are the responsibility of the operating organization and
are not within the scope of this document. JSC-01218 details the preferred methods of sampling and
may be used as a guide in establishing detailed procedures. the Occupational Safety and Quality
Assurance Branch approves sampling procedures used at JSC.

NOTE: The use of liquid-borne particle counters requires Mechanical and Chemical Process
Engineering and GFE Branch concurrence.

16.1 GENERAL REQUIREMENTS

16.1.1 Sample Points

Sample system test points (identified as the "most severe" locations; i.e., the bottom of propellant
tanks, just upstream of engines, etc.) only when specifically required by controlling documentation.

16.1.2 Samplers
Sampler configurations and materials differ because of the pressures of the gases supplied. Materials
for construction of samplers must be compatible with the sampled fluids and shall contribute a
minimum of contaminants to the sample. Samplers shall be serialized and identifiable as to the
material sampled and the sample source. Other requirements are cited below.

16.1.2.1 Sample Bottles for Breathing Systems. After its initial cleaning and certification for use in
sampling breathing systems, do not use the sample bottle for sampling any other fluid. Recleaning is
not required for each sampling, provided the bottle remains sealed (except when in use) and a
preceding sample has not failed. Heat, purge, and/or evacuate the bottle to remove residual
contaminants prior to reuse. Seal the bottle with AN-type caps or plugs.

16.1.2.2 Cryogenic Samplers. Maintain liquid cryogenic samplers in a clean condition during storage
because of the rigid purity requirements for the fluids they contain. In cleaning before storage, the
samplers may be heated and/or vacuum purged to remove absorbed impurities. Purge gases shall be
those of the material normally sampled and shall be of sufficient purity to preclude contaminating the
sampler. Storage configuration (e.g., positive pressure or vacuum) of liquid cryogenic samplers shall
be in accordance with JSC-01218.

16.2 SAMPLING APPARATUS PREPARATION

16.2.1 Cleaning of Sampling Apparatus

Clean all sampling apparatuses to a level consistent with the operations being performed. If particulate
contamination of the sampler is suspected, run "blank" rinses, using a specified cleaning solvent filtered
through a membrane filter (0.2 to 0.8 micron), to determine the contaminant level of the sampler.
Limit cleaning of samplers to a particulate level to those instances in which the particle count is
required. Clean sampling apparatuses, as a minimum, as follows:
a. Wash each part of the disassembled sampling apparatus (filter holder, sample bottle, fittings, hoses,
etc.) with a hot detergent and water solution.
b. Rinse or flush thoroughly with distilled water, tap water, or deionized water, as needed.
c. Rinse or flush thoroughly with isopropyl alcohol as specified in TT-I-735, or appropriate water.
d. Rinse or flush thoroughly.
e. Certify by liquid sample that the required cleanliness of the sampling apparatus has been met.
f. Purge dry with filtered nitrogen, as specified in MIL-P-27401, grade B.

16.2.2 Sampling Hoses, Tubing, and Fittings

After cleaning and drying, seal hoses and tubing with clean AN-type plugs and then package with an
appropriate outer packaging material as specified in table V, appendix B. Individually double-bag
fittings as specified in section 10.0.

16.2.3 Preparation and Assembly of Filter and High-Pressure Filter Holder

Prepare and assemble high-pressure filter holders, as a minimum, as follows:

NOTE: Prepare the high-pressure filter holder and the particulate sample analysis in at least
a Class 10,000 clean room or work station.
a. Using clean forceps, remove the filter from its container.
b. Pressure rinse the grid side of the filter with a stream of filtered solvent compatible with and
approved for the system being sampled.
c. Microscopically examine the filter for holes, gouges, or other damage. Also size and count all
particles over 10 microns in size. This particle count shall be known as the sample "blank" and shall be
recorded.
d. Place the filter with grid side up on the lower half of the filter holder.
e. Immediately place, do not slide, the upper half of the filter holder containing the O-ring into position.
f. Install and torque the bolts and closures.
g. Double bag the assembled high-pressure filter holder as specified in section 10.0 and table V,
appendix B.

16.3 CONTAMINATION CONTROL DURING SAMPLING

Take reasonable precautions to prevent contaminating the sampling apparatus, fluid, or system before,
during, and after extracting the sample. Flush the sample port on the line (container) to be tested
immediately before connecting the sampler. Flush with a specified precision-cleaning solvent that is
compatible with the system being sampled. When cleaning the sample ports, exercise care, even when
using a compatible solvent, that the cleaning solvent does not contaminate the sampler. Properly cap
and/or package sample ports.

16.4 SAMPLING PROCEDURES

General procedural requirements applicable to fluid sampling are as stated below.

16.4.1 Agitation
When containers of liquids to be sampled have been at rest for a time during which particles in the
liquids may have settled, agitate the liquids before sampling to ensure a representative sample. Do not
agitate liquids in stationary (e.g., permanently installed) containers and/or pressurized containers.
Take gas samples for particulate with the sampling system operating at the design mass flow rate or, in
the event this is not practicable, at a flow rate producing turbulence.

16.4.2 Gas Particulate Sampling

Sample gases for particulate by connecting to a system or storage test point and directing the flow of
the gas through a membrane filter. Filters must show a complete O-ring indentation on the membrane,
or else resampling is required. Use a high-pressure gas membrane filter assembly with an
appropriately sized membrane filter. When attaching the sampler assembly to the sample port, take
extreme care to prevent the generation of particles. Hold the filter assembly vertically so that the
particles impinge on the horizontal filter membrane in a downward, vertical flow.

16.4.3 Dynamic Samples

Whenever possible, use a closed system (i.e., one not exposed to the atmosphere) for sampling. For
samples taken during a fill operation, use a flowthrough sampler at the same flow rate as the system
being serviced.

16.4.4 Static Samples

Where flowthrough cannot be realized, fill the sampler and drain twice before retaining a sample.
Whenever safety or other constraints demand, evacuate the sampler before use. The fill-and-drain
methods, however, provide the least representative samples and should be used only when no other
choices are available.

16.4.5 Filter Handling

After sampling, place the loaded filter in a precision-cleaned petri dish. Do not open the petri dish until
the particles have been counted.

16.5 SAFETY
Safety requirements are not delineated in this section. These shall be included in detailed operating
procedures which respond to the requirements of the responsible safety organization.

17.0 CONTAMINATION CONTROL DURING FABRICATION, ASSEMBLY, AND TESTING

This section establishes the minimum contamination controls necessary to prevent the recontamination
of precision-cleaned items.

NOTE: The requirements in this section are also applicable to visual cleanliness levels to the
 extent specified in section 12.0.

17.1 GENERAL REQUIREMENTS

Protect precision-cleaned items from airborne contaminants during processing performed after cleaning,
including the use of temporary packaging or covering. Upon completion of all required processing,
double-bag the cleaned item per table V, appendix B.

17.2 FABRICATION
Completely evaluate the fabrication operations for each component and establish and document
appropriate cleanliness requirements for each phase of the operation. Determine environmental and
personnel controls considering such factors as the complexity of the fabrication or item and whether
required cleanliness can be satisfactorily accomplished at a later level of assembly. Implement
environmental and contamination controls for, but not limited to, such processes as soldering, welding,
plating, bonding, and application of lubricants. These controls shall be sufficient to ensure the
cleanliness and purity required for process and product reliability.

17.3 ASSEMBLY
Assemble precision-cleaned items in an appropriate class clean room or laminar flow clean work station.

NOTE: Final assembly operations in which only small areas of critical surface are exposed
(e.g., connections and fittings) may be performed in a CWA upon approval from the
Mechanical and Chemical Process Engineering and GFE Branch. It may be necessary,
however, to monitor airborne particulate in the CWA during such operations.

Protect certified clean parts from recontamination by interim packaging or other protection before and
during assembly operations. Establish process controls, including use of clean rooms, laminar flow
clean work stations, purge gases, dry box enclosures, and strict personnel controls, as required to
ensure that no contaminants are introduced into the component being assembled.

Perform visual inspections frequently during the assembly process to ensure that cleanliness has not
been degraded. Reject parts and components if visible contaminants are detected during the assembly
process.

Assembly techniques and subsystem assembly controls are as stated below.

17.3.1 Assembly Techniques

Typical techniques to prevent the contamination or recontamination of the items being assembled are
listed below. Develop additional techniques or improvement of the listed techniques as required for the
particular assembly operation being performed.

a. Handle precision-cleaned items only with clean forceps, tweezers, or gloved hands during assembly.
Handle items cleaned to visual cleanliness levels per section 12.3.

NOTE: Use gloves for the handling of LOX or GOX components with exposed critical surfaces
that are constructed of an approved, compatible material.

b. Align lines, hoses, and components with B-nut type fittings with the mating part and rotate only the
threaded fitting to prevent the generation of particulate and the subsequent contamination of the item.
Keep movement of mating surfaces to an absolute minimum.
c. To prevent the generation of packaging material contaminants, open packaging materials using a
sharp instrument.
d. Use purges in all possible instances to prevent the entry of contaminants into precision-cleaned
items.
e. Maintain strict personnel controls to minimize contamination in assembly areas.
f. Maintain assembly work areas, benches, tools, and aids in a clean condition to prevent the contact
transfer of contaminants.

17.3.2 Subsystem Assembly Controls

Reject components and subassemblies if contaminants are detected during the assembly process. If a
subsystem is contaminated, appropriate authorities shall determine whether to disassemble and clean
the subsystem or perform in-place cleaning to meet the appropriate cleanliness levels.
17.4 TESTING
The functional testing of precision-cleaned items is governed by test procedures delineating the test
methods and acceptance criteria. When specific contamination control requirements are not stipulated
by the governing document, implement the requirements stated below.

17.4.1 Component Functional Testing

Protect components, such as valves, which require functional testing from particulates and other
contaminants during testing. When feasible, perform all functional testing inside a laminar flow work
station. Sample all functional testing equipment, such as pressurization consoles and connecting
hardware, and certify to meet the required cleanliness level. Reject Components contaminated beyond
the acceptable level during the process, then disassemble and reclean.

17.4.2 Test Facility/Equipment

Verify the test facility and test equipment by inspection and/or sampling as required to ensure that the
facility or the test fluid to be used will not contaminate the precision-cleaned item.

17.4.3 Fluid Line Connections

Seal fluid line connections when not in use to ensure equipment cleanliness integrity.

17.4.4 Mechanical Connections

Mechanically connect lines, parts, and fittings of cleaned items and test equipment with a minimum of
slide fitting to reduce the generation of particles.

17.4.5 Item Protection

For components that have been tested using liquid, drain and seal leak tight with clean caps or plugs at
all ports. Then wipe the exterior surfaces with non-lint-producing material moistened with approved,
compatible solvent and dry.

18.0 CONTAMINATION CONTROL DURING REPAIR, REPLACEMENT, AND MAINTENANCE

This section establishes the minimum contamination control requirements for repair and replacement of
or maintenance operations performed on systems which have previously been precision-cleaned. The
cleanliness of precision-cleaned, contaminant-critical systems may be compromised by improper
contamination control techniques during any operation. Localized clean operations may be conducted
in a number of ways, any of which are acceptable provided the general requirements stated below are
met.

NOTE: The requirements in this section are also applicable to visual cleanliness levels to the
extent specified in section 12.0.

18.1 OPERATIONS PRECEDING SYSTEM BREAKING

18.1.1 Area Cleanup

The area in which the repair, replacement, or maintenance is to be performed shall undergo a stringent
housecleaning process, before which all loose or extraneous equipment shall be removed from the area.

18.1.2 Controlled Environment Enclosures

Construct a temporary enclosure around the portion of the system to be opened to prevent
contaminating the open system (or replacement part) by exposure to the normal working environment.
The air source used shall furnish filtered air to provide an environment equivalent to or better than the
environment required for the initial assembly of that particular system. Depending on the size of the
components or the complexity of the repair operation, the enclosure may be a small "dry box" design or
a large, walk-in, tent-type configuration as described below.

18.1.2.1 Small "Dry Box" Enclosure. This enclosure, normally made of a polyethylene sheet, shall be
large enough to admit the hands. Wipe the inside of the enclosure VC and then open the system to
admit a flow of dry filtered inert gas from the system. The gas flow pressure shall be such that no dust
or other environmental contaminants can enter the enclosure. When purging the system is not feasible
(e.g., small tubing in liquid system), establish a purge of filtered air through the "dry box."

18.1.2.2 Walk-in Enclosures. The nature of the operation may necessitate the construction of a large
walk-in enclosure. Make this enclosure of a polyethylene sheet, suitably reinforced (if necessary), and
wipe VC before use. Pump air into the enclosure so as to provide a controlled environment required for
the system components, by properly operating a HEPA filter assembly and temperature and humidity
controls as required. The rate of airflow into the enclosure shall be sufficient to preclude dust or other
environmental contaminants from entering the enclosure; however, the influent airflow shall not be so
great as to force contaminants into the opened system. A good method is to install the filtered air
blowers onto the enclosure and pressurize the entire enclosure to 1 or 2 in. (water psig).

NOTE: The JSC Test, Operations, and Institutional Safety Branch, and the Mechanical and
Chemical Process Engineering and GFE Branch must approve the design, configuration, and
operation of all walk-in enclosures.

18.1.3 System Purge

In operations on nonliquid systems or systems which have been drained, establish a purge with inert
gas in the system before opening. The gas shall meet or exceed system cleanliness level
requirements. The gas flow rate shall be such that a positive pressure from the system to the
environment shall prevail upon opening the system. Continue the purge until the repair, replacement,
or maintenance operation is completed and the system is closed. When a gas purge is not used,
protect the open system lines by a bag (constructed of an appropriate inner packaging material as
specified in table V, appendix B) secured around the open port, or sealed by an approved method to
prevent the entry of contaminants.

18.2 REPAIR, REPLACEMENT, OR MAINTENANCE OPERATIONS

18.2.1 Garments
Personnel in the enclosure during repair, replacement, or maintenance operations shall wear clean
room attire as required to maintain the cleanliness requirements of the system components. Use table
III, appendix B, as a guide in establishing garment requirements. Handle items cleaned to visual
cleanliness levels per section 12.3.

NOTE: Handle precision-cleaned items with clean forceps, tweezers, or gloved hands only.
When gloves are used for the handling of LOX or GOX components with exposed critical
surfaces, they shall be constructed of an approved, compatible material.

18.2.2 Enclosure Operations

Do not conduct operations in the enclosure unless the system purge and filtered air inputs are "on."
"Operations" shall include the unwrapping of precision packaged components or tools, opening or
closing of the system, installation or removal of components, etc., by properly clothed personnel.

18.2.3 Removed Parts

Handle all contamination-sensitive parts removed from assemblies as specified below.

18.2.3.1 Local Clean Area. Protect all surfaces, lines, ports, etc., opened or exposed because of part
removal or system breaking with caps, covers, or plugs to prevent contamination of the exposed
system. Close critical surfaces or tube openings of removed components, parts, or system with clean
protective plugs or caps, or cover with a clean plastic bag constructed of an appropriate inner
packaging material per table V, appendix B.

In addition, place a clean plastic bag (constructed of an appropriate outer packaging material as
specified in table V, appendix B) over the plugged, bagged, or capped area. Immediately after
removal, completely cover the item with a plastic bag (constructed of an appropriate outer packaging
material per table V, appendix B) for transporting to the clean room.

18.2.3.2 ECA. Conduct all subsequent operations involving parts, systems, etc., which are to be
reinstalled on the spacecraft in an ECA of a level meeting the cleanliness requirements established for
the specific item. Upon completing final cleaning, before being removed from the ECA, protectively
package the item per section 10 before returning for reinstallation. Remove all protective coverings
inside the localized clean areas. When returning the item to a contractor for repair, double-bag it (per
table V, appendix B) in the ECA before shipment.

18.2.3.3 Cleaning and Sampling. Repair, replacement, or maintenance operations which may result
in the contamination of interfacing items shall be cause for cleaning and sampling of the contaminated
items to ensure the cleanliness integrity of the assembly being serviced.
18.2.4 Fluid Spills
Clean up all fluids spilled in or upon the system per approved documented procedures. JSC
Institutional Safety and Quality personnel witness the cleanup operations and adequately document it
for corrective action traceability.

19.0 ENVIRONMENTAL TEST CHAMBER CLEANLINESS

This section establishes the minimum cleanliness requirements for environmental test chambers. It
also includes requirements for maintaining cleanliness standards while components are being removed
or replaced. Cleanliness levels of subsystems shall be as established in the applicable subsystem
specification.

19.1 GENERAL REQUIREMENTS

Environmental test chambers shall be designated as CWAs as a minimum. Other requirements are
stated below.

19.1.1 Personnel Access

Restrict access to the immediate vicinity of the test article or work area to those personnel essential to
the operation. The responsible test organization and the operating organization, the contractor, or the
responsible JSC representative jointly establish details of control.

19.1.2 Garments
Personnel working in or visiting the CWA must wear clean room garments. Personnel entering the test
article shall wear clean coveralls or smocks, foot covers or approved shoe socks, and hoods or caps. All
garments shall be donned at the test article entrance or appropriate location before entry.

NOTE: Handle items cleaned to visual cleanliness levels per section 12.3.

19.1.3 Access to Test Article

Restrict entry to the test article to personnel who must enter to perform necessary tests, checkouts,
maintenance, inspections, and/or repair functions.

19.1.4 Systems/Subsystems Assembly or Rework

Perform maintenance or parts replacement under localized clean operational conditions ("dry box" or
walk-in enclosure per section 18.0) when the specifications for the systems indicate that more rigid
contamination controls are required than provided by the surrounding CWA.

19.1.5 Checklist
Provide an accountability checklist for all items (parts and tools) taken into environmental chambers.
There shall be no exceptions. Verify installed hardware by the responsible quality group and account
for removed parts. Locate any item not accounted for or determine its disposition before continuing
testing and/or maintenance.

19.1.6 Training Requirements

Properly train all personnel having access to the test article work area before their entering. This
training shall be sufficiently extensive to enable these persons to fully implement the intent and
requirements of this specification.

19.1.7 Test Article Cleanliness

19.1.7.1 Interior Cleanliness. Clean the interior of the test article (i.e., vacuum and/or wipe down) at
the end of each working period. Locate the vacuum source outside the work area with a well-cleaned
hose and pickup attachment inside. If this is impractical, use an approved industrial-type vacuum
cleaner with filtered exhaust.

19.1.7.2 Exterior Cleanliness. Perform the vacuuming and wipe-down of the outside of the test
article, as required, per applicable specifications. Do not wipe down where damage to protective
coatings may result.

19.1.8 Fluid Spills

Clean up spills per paragraph 18.2.4.

19.1.9 Access Openings to Test Article or Chamber

During nonoperational periods, keep all entrances to the test article or chamber closed.

19.1.10 Contaminant-Generating Operations

Do not permit contaminant-generating operations (e.g., sanding, grinding, chipping, soldering, and
drilling) in the chamber unless specifically approved by the operating organization. When such
operations are approved, clean the work area to its original cleanliness condition before work continues.

19.2 TEST ARTICLE INSTALLATION

19.2.1 Preparations
Before installing the test article, clean the interior of the chamber per an effective, approved cleaning
procedure. Clean, as required, to maintain the required cleanliness.

19.2.2 Installation of Test Article

Before installing the test article, completely vacuum and wipe down its exterior, if needed, to remove
all visible soil. Do not wipe down if damage to protective coatings may result.

19.2.3 Postinstallation of Test Article

After the test article is positioned and all electrical and mechanical connections are completed,
thoroughly vacuum the chamber. Remove all visible film matter before operations continue.

20.0 NONAIRBORNE BREATHING AIR SYSTEMS

This section establishes the minimum cleanliness requirements and gas purity requirements for both
portable and permanently installed nonairborne breathing systems. Also included are the sampling
requirements to be met during operational and nonoperational periods.

20.1 PROCEDURES
Develop, document, and approve procedures for system operation, maintenance, preventive
maintenance, servicing, sampling, certification, and safety. The JSC Medical Sciences Division, Mail
Code SD and the Occupational Safety and Institutional Assurance Division, Mail Code NT approve
procedures prepared for JSC on-site breathing systems.

20.2 SYSTEM CLEANLINESS

Clean parts, components, subassemblies, and assemblies, as a minimum, to Level 300A of table IV,
appendix B. Use a more stringent cleanliness level when required to ensure system safety and
functional integrity. Other requirements are stated below.

20.2.1 Cleanliness Maintenance

Close all openings into the breathing system (e.g., ports, open ended lines, and interconnecting fittings)
and protect with fittings or covers of a material which is compatible with the system fluids.

20.2.2 Periodic Cleanliness Evaluation

The organization responsible for the integrity of a breathing system shall document procedures for
periodic evaluation of system cleanliness. The procedures establish the frequency of these evaluations
as is agreed necessary.

Perform this evaluation, including particulate matter determination and NVR or other suitable
film/nonparticulate matter (e.g., TOC) determination, as is agreed necessary.

20.3 SYSTEM CERTIFICATION

Certify systems used for breathing purposes as stipulated below. The responsible safety and medical
officers determine the disposition of systems failing the required purity levels, when analyzed in
accordance with applicable requirements and this section, before testing. This requirement is
applicable to all vacuum chambers, facilities, and hazardous testing operations.

20.3.1 System Certification Sampling Requirements

Sample new systems and systems modified or contaminated subsequent to certification initially and
once each 24 hrs for the following 48 hrs. If the samples, when analyzed, meet the applicable
specification, system and test requirements, the system may be considered certified. A system shall be
considered contaminated as specified in sections 17.0 and 18.0 or if routine sampling procedures reveal
particulate or nonparticulate matter exceeding specified requirements.
 NOTE: Check new breathing air systems initially for mercury contamination as specified in
applicable medical and safety requirements.

20.3.2 Breathing Source Supply Certification

20.3.2.1 General. Analyze fluids (liquid and gas) and certify them to applicable requirements before
supplying them to a breathing system.

20.3.2.2 Mixed-Gas Systems. For mixed-gas systems, analyze each constituent gas before the
blending process. After the blending process, the synthesized gas must be sampled (at the farthest use
point) and analyzed to ensure compliance with the applicable specification or test requirements.

NOTE: Because of the difference in boil-off temperatures between liquid oxygen and liquid
nitrogen, liquid air systems require strict analysis sampling schedules to preclude a
breathing system from becoming nitrogen rich.

20.4 MAINTENANCE AND SAMPLING

Maintain cleanliness in systems and fluids certified per paragraph 20.3 and sample them per table VI,
appendix B. Maintain gas purity in systems and fluids certified per paragraph 20.3 and sample them
per table VII, appendix B. Whenever more stringent controls and sampling frequencies are required to
ensure system integrity and safety, reflect these controls and frequencies in the applicable operating
procedures.

NOTE: Schedule and perform maintenance on system and fluid supply filtration equipment
(i.e., particulate, oil, moisture, activated carbon) to ensure system safety and reliability.

20.5 IDENTIFICATION AND MARKING

Identify use-point outlets by displaying a sign, tag, or label that reads "Compressed Gas for Breathing
Purposes" or a similar statement that clearly indicates the contents of the breathing gas.

20.6 REFERENCES

a. FED-SPEC BB-A-1034, "Compressed Air, Breathing"

b. MIL-A-27420, "Air, Liquid, for Breathing Purposes"
c. MIL-O-27210, "Oxygen, Aviator's Breathing, Liquid, Gas"
d. MIL-STD-1622, "Cleaning of Shipboard Compressed Air Systems"
e. NASA SD-B-0023-A, "Helium/Oxygen Breathing Mixtures"
f. NASA JSC TSD QI 1760.1, "Procedure for Cleaning Breathing Air and Oxygen Systems"
g. NASA JSCM 1700, "JSC Safety Manual and Health Handbook"
h. NASA JPG 8080.5, "JSC Design and Procedural Standard Manual," Standard F17,
"Cleanliness of Flowing Fluids and Associated Systems"; F27, "Liquid or Gas Containers -
Verification of Contents"; M/P-9, "Breathing Systems - Requirement to Test for Mercury
Contamination"
i. NASA SP-3006, "Bio-Astronautic Databook"

21.0 AIR, OXYGEN, AND OXYGEN-RICH SYSTEMS REFERENCES

Contamination control is important regarding oxygen systems. Contaminants in oxygen systems can be
fire hazards. Particulate matter in oxygen systems can become ignition sources if the particles move
through the system and impact various components. Films, nonparticulate matter, NVR, oils, greases,
etc., may be flammable to some degree and act as a fuel source for a fire.

Engineers, technicians, and other people who work with oxygen systems should be aware of the
hazards (fire hazards, specifically) related to oxygen systems. These hazards are addressed in the
references listed below. The ASTM Technology Training Course regarding oxygen systems is also useful
for anyone dealing with oxygen systems and the minimization of fire hazards.
a. ASTM Standard Technology Training Coursebook, G4.05, "Fire Hazards in Oxygen Systems," 1990
b. NSS 1740.15, "Safety Standard for Oxygen and Oxygen Systems"

APPENDIX A:
 ACRONYMS AND DEFINITIONS

ACRONYMS

ANSI American National Standards Institute

ASTM American Society for Testing Materials
CWA Controlled Work Area
DOP Dioctyl Phthalate
ECA Environmentally Controlled Area
ESD Electrostatic Discharge
ft foot (feet)
FEP Fluorinated Ethylene Propylene
GC Generally Clean
GFE Government-Furnished Equipment
GOX Gaseous Oxygen
HEPA High Efficiency Particulate Air
IES Institute of Environmental Sciences
JSC Lyndon B. Johnson Space Center
LOX Liquid Oxygen
m meter
MSFC George C. Marshall Spaceflight Center
NASA National Aeronautics and Space Administration
NVR Nonvolatile Residue
psi pounds per square inch
psig pounds per square inch gauge
RH relative humidity
SAE Society of Automotive Engineers
SR&QA Safety, Reliability, and Quality Assurance
TOC Total Organic Carbon
TPS Test Preparation Sheet
ULO Ultra Low Outgassing (trademark of Cleanfilm, Inc.)
UV Ultraviolet
VC visibly clean
VC + UV visibly clean plus ultraviolet
WSTF White Sands Test Facility

DEFINITIONS

Airborne Particulate Matter: Particulate matter suspended in the ambient atmosphere

Clean Room: An enclosed area employing control over the particulate matter in air with temperature,
humidity, and pressure control, as required

Clean Work Station: A work bench or similar working enclosure having its own filtered air or gas supply

Cleanliness Level: (1) An established maximum of allowable contaminants based on size, distribution,
or quantity on a given area or in a specific volume or (2) absence of particulate and nonparticulate
matter visible under white light and/or UV illumination

Contaminant: Any unwanted matter which could be detrimental to the required operation, reliability, or
performance of a part, component, subsystem, or system

Controlled Work Area (CWA): An area maintained to a high degree of shop cleanliness

Critical Surface: A surface which requires precision cleanliness or requires contamination control

Dioctyl Phthalate (DOP): A chemical used for filter efficiency testing

Environmentally Controlled Area: A classification which includes clean rooms, laminar flow clean work
stations, and CWAs
Electrostatic Discharge: A transfer of electrostatic charge between bodies at different electrostatic
potentials caused by direct contact or induced by an electrostatic field

Fiber: A particle whose length-to-width ratio is in excess of 10:1 (If not visible it may be referred to as
a microfiber)

Fluid: A liquid or gaseous material

Flush: A rinsing of a part, component, subsystem, or system, using a liquid as the rinsing medium

Generally Clean (GC): Free of manufacturing residue, dirt, oil, grease, processing debris or other
extraneous contamination. This level can be achieved by washing, wiping, blowing, vacuuming,
brushing, or rinsing

High Efficiency Particulate Air (HEPA) Filter: A filter with minimum efficiency of 99.97% determined by
the homogeneous DOP or other equally sensitive method at airflows of 20% and 100% of the rated flow
capacity of the filter

Micrometer/Micron: A unit of measurement equal to one-millionth of a meter or approximately

0.00003937 in. (e.g., 25 microns are approximately 0.001 in.)

Nonparticulate Matter: Matter (usually film) with no definite dimension

Nonvolatile Residue: Soluble (or suspended) material and insoluble particulate matter remaining after
controlled evaporation of a filtered volatile solvent, usually measured in milligrams. Filtration is
normally through a 0.45-micrometer or 0.8-micrometer membrane filter before evaporation

Particle: Matter with observable length, width, and thickness usually measured in microns; this
definition includes fibers

Particle Counters: Automatic electronic devices designed to separate, size, and count individual
particles

Particulate Matter: The general term applied to matter with observable length, width, and thickness (as
contrasted to nonparticulate film matter without definite dimensions)

Precision-cleaning: Final or fine cleaning accomplished in a controlled environment to achieve precision

cleanliness. Surface cleaning with an approved, compatible solvent (e.g., solvent wipe) is satisfactory
for VC + UV and VC items

Precision Cleanliness: A degree of cleanliness which requires special equipment and techniques for
determination; precision cleanliness levels normally include limits for particulate sizes and quantities

Precision-Cleaning: Agent Any solvent used in precision-cleaning that has been filtered or otherwise
cleaned to a specified cleanliness level. Precision-cleaning agents must be specified for a process or
system application to ensure compatibility of fluids and materials

Precision-Clean Packaging: Packaging or protection used to preserve precision cleanliness for a specific
period and condition

Purge: To flow a gas through a system (or pipeline, tube, tank, etc.) for the purpose of removing
residual fluid or for providing a positive flow of gas from some opening in the system

Total Solids: The residue from a known volume of liquid which has been evaporated to dryness in an
oven

Visibly Clean (VC): Free of all particulate and nonparticulate matter visible to the unaided eye
(corrective lenses are acceptable)

Visibly Clean Plus Ultraviolet (VC + UV): Visibly clean (as defined above) and without fluorescent
matter detectable with a UV light (blacklight) of 3,200 to 3,800 angstroms wavelength
Visual Cleanliness Levels: A category which includes VC, VC + UV, and GC cleanliness levels

APPENDIX B

Table I Clean Room Classes by Particulate Distribution

Table II ECA Requirements Matrix
Table III ECA Garment Requirements
Table IV Surface Cleanliness Levels
Table V Packaging for Cleanliness Protection
Table VI Particulate Sampling Frequency Requirements for Nonairborne Breathing Systems
Table VII Gas Purity Sampling Frequency Requirements for Nonairborne Breathing Systems

TABLE I

CLEAN ROOM CLASSES BY PARTICULATE DISTRIBUTION (NOTE 1)

MAXIMUM PARTICLE COUNT PER 0.028 CUBIC METER (1.0 CUBIC FT)
CLASS
(NOTE 2) SIZE > 0.5 MICRON SIZE > 5.0 MICRONS

100 100 < 10 (NOTE 3)

1,000 1,000 < 10 (NOTE 3)

10,000 10,000 65

100,000 100,000 700

NOTES:
NOTE 1 Particle size distribution curves may be found in FED-STD-209. Other counting methods for
particle distributions are acceptable if appropriate.
NOTE 2 Other classifications (i.e., 400, 8,000, 30,000, etc.) may be used for particle count levels
where unique situations dictate their use. The Occupational Safety and Quality Assurance
Branch must concur in the selection and use of classifications that are not baselined in this
table.
NOTE 3 Counts below 10 particles per cubic ft (0.028 m3 ) are unreliable except when a large
number of samplings are taken.

TABLE II

ECA REQUIREMENTS MATRIX

LAMINAR
FLOW
CLEANROOM: CLEANROOM: CLEAN
LAMINAR NON-LAMINAR WORK REFERENCE
AREA REQUIREMENTS (NOTE 1) FLOW FLOW STATIONS CWAs PARAGRAPHS

ANNUAL CERTIFICATION X X X --- 6.7

CONTROLLED BY APPROVED X X X X 5.0, 5.3.2

DOCUMENTED PROCEDURES

HEPA FILTER SYSTEM X X X --- 5.1.1, 5.1.3

POSITIVE PRESSURE X X --- --- 5.3.1.4

AIRBORNE PARTICLE X X X 5.3.1.3,

MONITORING (NOTE 2) 5.4.1.5

TEMPERATURE CONTROL X X X --- 5.3.1.5

RH CONTROL X X --- X 5.3.1.6,

5.5.1.b

LAMINAR FLOW CRITICAL X --- X --- 5.1.1, 5.1.3

ROOM AIR CHANGE CRITICAL --- X --- --- 5.1.1

SPECIAL TOOL CONTROLS X X X X 5.2.3

SPECIAL GARMENTS X X X X 5.2.1, 5.4.1.2

CONTAMINANT-GENERATING --- --- --- X 5.5.3.e

OPERATIONS MAY BE
AUTHORIZED

STRICT PERSONNEL X X X X 5.4.1.2

DISCIPLINE

FORMAL PERSONNEL TRAINING X X X X 5.2.2, 14.0

NOTES:

NOTE 1 — The intent of this matrix is to provide a quick-look comparison of significant requirements
for clean rooms, laminar flow clean work stations, and CWAs. It should not be inferred that this
matrix represents all requirements necessary for the design, operation, maintenance, and use of
ECAs.

NOTE 2 — Airborne particulate monitoring may be necessary as specified in section 17.3.

TABLE III

ECA GARMENT REQUIREMENTS

ECA

CLASS 100 CLASS CLASS

(NOTE 1) 10,000 100,000
GARMENT M3.5 M5.5 M6.5 CWA

COVERALLS REQUIRED REQUIRED OPTIONAL OPTIONAL

HOODS REQUIRED REQUIRED (NOTE 2) (NOTE 2)

SMOCKS ------ REQUIRED REQUIRED

------ ------ REQUIRED REQUIRED

CAPS
(NOTE 2)

BOOTIES REQUIRED OPTIONAL OPTIONAL OPTIONAL

------ REQUIRED REQUIRED OPTIONAL

SLIP-ON SHOE COVERS
(NOTE 4) (NOTE 4)

HAND COVERINGS (NOTE 5) (NOTE 5) (NOTE 5) (NOTE 5)

NOTES:
NOTE 1 — Laminar flow clean work stations: Garments are required only for those parts of the body
that are extended into the clean work area (i.e., hands, arms, upper torso, facial and head hair, etc.).

NOTE 2 — Hoods shall be worn when caps do not fully cover facial and head hair.

NOTE 3 — Smocks may be used in lieu of coveralls in Class 10,000 vertical laminar flow clean rooms
provided applicable airborne particulate requirements are met.

NOTE 4 — Shoe coverings may be deleted from use in these classes of vertical laminar flow clean
rooms provided applicable airborne particulate requirements are met.

NOTE 5 — The use of hand coverings (e.g., gloves) is dependent upon the type of operation being
performed. Hand coverings are mandatory for handling exposed critical surfaces of precision or VC +
UV cleaned items. When hand coverings are used in the handling of LOX/GOX components with
exposed critical surfaces, they shall be constructed of an approved, compatible material.

TABLE IV
SURFACE CLEANLINESS LEVELS

VISUAL CLEANLINESS LEVELS

Generally Clean (GC) (NOTE 1). Free of manufacturing residue, dirt, oil, grease, processing debris or
other extraneous contamination. This level can be achieved by washing, wiping, blowing, vacuuming,
brushing, or rinsing. The GC level shall not be designated for hardware that is sensitive to
contamination.
Visibly Clean (VC) (NOTE 2). Free of all particulate and nonparticulate visible to the normal unaided
eye ( corrected vision acceptable). Particulate is identified as matter of miniature size with
observable length, width, and thickness. Nonparticulate is film matter without definite dimension.
This level requires precision-cleaning methods, but no particle count.
Visibly Clean Plus Ultraviolet (VC + UV) (NOTE 2). VC (as defined above) and inspected with the aid
of an ultraviolet light (blacklight) of 3,200 to 3,800 angstroms wavelength. This level requires
precision-cleaning methods, but no particle count.

NOTE — Any evidence of fluorescence shall be cause for recleaning. If recleaning does not reduce the
fluorescence, an investigation shall be made to determine whether the fluorescing material is
contamination or the basic material.

NONVOLATILE RESIDUE (NVR) LEVELS

MAXIMUM QUANTITY NVR PER 0.1M 2 (1 FT 2)

LEVEL (SEE NOTES 3 AND 6)

A 1 milligram

B 2 milligrams

C 3 milligrams

D 4 milligrams

PRECISION PARTICULATE LEVELS

 PARTICLE SIZE RANGE

LEVEL MICROMETERS (NOTES 3, 4, AND 6)

1000 < 500 UNLIMITED (NOTE 5)

500 thru 750 34
> 750 thru 1000 5
> 1000 0

750 < 250 UNLIMITED (NOTE 5)

250 thru 500 209
> 500 thru 750 9
> 750 0

500 < 100 UNLIMITED (NOTE 5)

100 thru 250 1,075
> 250 thru 500 27
> 500 0

300 < 100 UNLIMITED (NOTE 5)

100 thru 250 93
> 250 thru 300 3
> 300 0

250 < 100 UNLIMITED (NOTE 5)

100 thru 200 39
> 200 thru 250 3
> 250 0

200 < 50 UNLIMITED (NOTE 5)

50 thru 100 154
> 100 thru 200 16
> 200 0

150 < 50 UNLIMITED (NOTE 5)

50 thru 100 47
> 100 thru 150 5
> 150 0

100 < 25 UNLIMITED (NOTE 5)

25 thru 50 68
> 50 thru 100 11
> 100 0

50 < 10 UNLIMITED (NOTE 5)

15 thru 25 17
> 25 thru 50 8
> 50 0

25 <5 UNLIMITED (NOTE 5)

5 thru 15 19
> 15 thru 25 4
> 25 0

EXAMPLE: Level 300 would be particulate Level 300. Level 300C would be particulate Level 300 plus
NVR Level C.

NOTES
NOTE 1 — GC items do not require cleaning before inspection; cleaning is required only if the item
does not pass GC inspection.

NOTE 2 — Surface cleaning with an approved, compatible solvent (e.g., solvent wipe) is mandatory
for VC and VC + UV items, unless other methods are required for the hardware in question.

NOTE 3 — Particulate and NVR allowables are based on 0.1 m2 (1 ft2) of surface area. Flush fluid
quantity for sampling shall be 100 milliliters per 0.1 m2 (1 ft2) of surface area. Small parts should
be grouped together to obtain 0.1 m2 (1 ft2) of surface area.

NOTE 4 — Maximum quantity per 1.0 standard cubic meter (35 standard cubic ft) of effluent gas
when systems are being evaluated by purging. If feasible, the sampling must be accomplished at the
maximum system operation flow rate.

NOTE 5 — "Unlimited" means particulate in this size range is not counted; however, if the
accumulation of this silt is sufficient to interfere with the analysis, the sample shall be rejected.

NOTE 6 — Other precision particulate levels or residual analyses (i.e., Levels 80, 400, 800, etc., or
total hydrocarbon content analysis) may be specified when design requirements dictate their use.
The Occupational Safety and Quality Assurance Branch must concur in the selection and use of
classifications that are not baselined in this table.

TABLE V

PACKAGING FOR CLEANLINESS PROTECTION

CLEANLINESS REQUIREMENT PACKAGING TECHNIQUE AND MATERIAL REQUIREMENTS

All precision-cleaning except (1) LOX Double-bagging technique required. Inner bag of nylon 6,
service or (2) GOX service > 800 psi. 2 mils thick. Outer bag of antistatic polyethylene film, 6
mils thick. Aclar 22A, FEP Neoflon, and FEP Teflon films
may be used instead of nylon 6 for the inner bag.

Precision-cleaned for (1) LOX service Double-bagging technique required. Inner bag of Aclar
or (2) GOX service > 800 psi. 22A, approximately 1.5 mils thick. Outer bag of antistatic
polyethylene film, 6 mils thick. FEP Neoflon and FEP Teflon
may be used instead of Aclar 22A for the inner bag film.

Cleaned to VC + UV. Double-bagging technique required. Inner bag of nylon 6,

2 mils thick. Outer bag of antistatic polyethylene film, 6
mils thick (NOTE 4).

Cleaned to VC. Shall be single-bagged. Bag shall be antistatic

polyethylene film, 6 mils thick (NOTE 1).

GC. No precision packaging is required. Protective packaging

as required for storage, shipping, and preservation
(NOTES 2, 3).

NOTES

NOTE 1 — The cleanliness certification decal is applied to the outside of the single bag.

NOTE 2 — At JSC, GC hardware in transit between facilities shall be environmentally protected.

Acceptable means of protection include plastic boxes with snug-fitting covers or reusable, non-heat-
sealable plastic bags. Hardware-compatible foam or other acceptable means of cushioning may be
used if necessary. Deteriorated or contaminated boxes or bags shall not be used.

NOTE 3 — The GC level does not require a cleanliness certification sticker, since protective
contamination control packaging is not required.

NOTE 4 — Antistatic polyethylene film (pink polyethylene, purple polyethylene, etc.) shall not
contain tertiary amine compounds which may cause metal corrosion. Antistatic agents may affect
sensitive optical surfaces.

TABLE VI

PARTICULATE SAMPLING FREQUENCY REQUIREMENTS

FOR NONAIRBORNE BREATHING SYSTEMS

• FLUID SOURCE SUPPLIES

(Include K-bottles, tube trailers, compressors, etc. Can be either offsite-procured or on-site-
generated fluids) (NOTE 1).

• Maintain positive pressure of container during periods of nonuse.

• Particulate/NVR (nonparticulate) analysis required prior to initial services.

• NONEMERGENCY BREATHING SYSTEMS (NOTES 2, 3, 4, 5, 6)

• Maintain positive pressure during periods of nonuse.

• Particulate analysis required prior to first human operation.

NOTES

NOTE 1 — Requirements for approved compressed air breathing sources are handled on a case-by-
case basis.

NOTE 2 — Sampling must be accomplished at each use point or at the downstream use point in a
series of adjacent use points.

NOTE 3 — A continuous test series, using the same gas supply, is considered as one human
operation.

NOTE 4 — Used for emergency and therefore cannot be sampled prior to each human operation.

NOTE 5 — The first human operation is the first human use after fabrication, modification, or
recleaning. If sampling or use depletes the supply, recharge from a certified source.

NOTE 6 — The systems downstream of primary and secondary source supplies shall be sampled
and analyzed within 1 working day before beginning human operation.

TABLE VII
 GAS PURITY SAMPLING FREQUENCY REQUIREMENTS
FOR NONAIRBORNE BREATHING SYSTEMS

FLUID SOURCE:

A. LARGE COMPRESSED GAS BOTTLES (Compressed gas cylinders containing greater than or
equal to 150 standard cubic ft of gas at maximum allowable operating pressure, MAWP, also
commonly referred to as K-BOTTLES):
All large compressed gas bottles used for breathing on-site at JSC must each be individually tested
as approved by the Medical Sciences Division, SD, and inspected and certified as approved by the
Occupational Safety and Institutional Assurance Division, NT, before use.

B. SMALL COMPRESSED GAS BOTTLES (Compressed gas cylinders containing less than 150
standard cubic ft of gas at MAWP, commonly referred to as SCUBA cylinders, SCBA cylinders, small
emergency cylinders, etc.):
Due to their small size, as a minimum, all SCBAs and small emergency breathing gas bottles shall
have either the gas fill source analyzed as approved by the Medical Sciences Division, SD, and the
Occupational Safety and Institutional Assurance Division, before use, or each individual bottle may
be tested similar to the large compressed gas bottle requirement listed above.

C. CRYOGENIC SUPPLIED AVIATOR'S BREATHING OXYGEN (ABO):

All cryogenic supplied ABO must be inspected by a member of the Occupational Safety and
Institutional Division, NT, or a delegation of the U.S. government as approved by NT.

D. COMPRESSED AIR SYSTEMS:

All on-site compressed air systems gas purity requirements must be approved by the Medical
Sciences Division, SD, and the Occupational Safety and Institutional Assurance Division, prior to
operations. Normally as a minimum, a fail-safe, in-line calibrated carbon monoxide system is
required that complies with CFR 1910.134.

NOTES

Note: In general, the following source testing requirements are intended to assure that all gases
used for breathing on site at JSC are analyzed by JSC approved personnel and assured to meet the
gas purity requirements before breathing the gas.

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