1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2012 SAE International All rights reserved. No part of this pub
3、lication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/ARP6196AEROSPACERECOMMENDEDPRACTICEARP6196 Issued 2012-05 Gas Turbine Engine Test Fa
5、cility Audit Process RATIONALETest facilities are frequently audited by various authorities, regulatory bodies, gas turbine engine OEMs and customers. The main purpose of the audit process is to ensure that the test cell operator/owner provides evidence that the facility is maintained in such a way
6、that it meets the requirements set by the OEM and authorizing bodies and that the test cell meets the conditions set in the correlation process. This document describes guidelines and criteria to audit a test facility both from an auditor perspective in addition to the user/owners perspective. SAE A
7、RP6196 Page 2 of 10 TABLE OF CONTENTS 1. SCOPE 32. REFERENCES 32.1 Applicable Documents 32.1.1 SAE Publications . 32.2 Other References 32.3 Definitions and Abbreviations . 33. AUDIT PROCESS IN GENERAL 43.1 General Information 43.2 Audit Intervals . 43.3 Repeat Audits 43.4 Corrective Actions . 44. S
8、PECIFIC AREAS OF ATTENTION . 54.1 Correlation and Test Equipment . 54.2 Manuals and Documentation 64.3 Procedures 64.4 Storage of Parts and Consumables 64.5 Training . 64.6 Safety 74.6.1 Facility . 74.6.2 Operation 74.7 Housekeeping . 74.8 Fuel . 74.9 Slave Equipment . 84.10 Software Maintenance 94.
9、10.1 Engine operating software (FADEC controlled engines) 94.10.2 Test Cell Operating Software (Data Acquisition System) . 95. MAINTAINING THE TEST CELL IS AUDIT PROOF 95.1 Configuration Control 95.2 Performance Trend Analysis . 95.3 Facility Maintenance and Inspection Plan 106. NOTES 10SAE ARP6196
10、Page 3 of 10 1. SCOPE This SAE Aerospace Recommended Practice provides recommendations for: the audit process in general; a list of specific areas of attention to be audited; maintaining the test facility in such a manner that it meets audit requirements. 2. REFERENCES 2.1 Applicable Documents The f
11、ollowing publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document a
12、nd references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0
13、001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.ARP741 Turbofan and Turbojet Gas Turbine Engine Test Cell Correlation ARP5758 Trend Analysis for Maintaining Correlation of Gas Turbine Engine Test Cells ARP6028 Configuration Control for Maintaining Correlatio
14、n of Gas Turbine Engine Test Cells 2.2 Other References FAA Advisory Circular AC 43-207 Aviation Maintenance Management: McGraw - Hill, ISBN:0-00714251-X Jurans Quality Handbook McGraw - Hill, ISBN 0-07-034003-X ATA Specification 103, Standard for Jet Fuel Quality Control at Airports ISO 9001, Quali
15、ty management Chapter 4.0 Quality management system 2.3 Definitions and Abbreviations AUDIT: An independent, objective assurance activity, designed to assess both the effectiveness and efficiency of an organizations operations. FACILITY OPERATIONS MANUAL: Manual that describes the test cell layout,
16、organization, and operation. SLAVE EQUIPMENT: Equipment installed to the engine, solely for testing purposes, is removed after completion of test. A4A: Airlines for America formerly known as ATA: Air Transport Association of America, Inc. SAE ARP6196 Page 4 of 10 FADEC: Full Authority Digital Engine
17、 Control FOM: Facility Operations Manual OEM: Original Equipment Manufacturer PMD: Precision Measurement Devices 3. AUDIT PROCESS IN GENERAL 3.1 General Information Test facilities can be audited by: quality assurance or control from the maintenance organization; environmental, health, and safety or
18、ganizations, both from the maintenance provider as well as from the local authorities; regulatory bodies of the local government; regulatory bodies of the customer governments; customers; OEMs. 3.2 Audit Intervals The general interval for audits is 1 year, however, random audits are possible. 3.3 Re
19、peat Audits In case of findings requiring immediate follow up, repeat audits to monitor compliance of the corrective actions can be carried out. 3.4 Corrective Actions Findings by the auditor are reported by a findings report submitted within a period of 4 weeks. The findings are filed in the local
20、quality defect reporting system and a process owner/responsible person is identified. The quality defect reporting system requires: root cause identification; corrective action plan; action for related areas; preventative actions to avoid reoccurrence. SAE ARP6196 Page 5 of 10 4. SPECIFIC AREAS OF A
21、TTENTION This section provides an overview of attention areas. 4.1 Correlation and Test Equipment Date of last correlation. Current correlation books status. Type of engines the test cell is correlated for and as necessary confirming the engines being tested at the facility. All the precision measur
22、ement devices (PMDs) per the applicable engine manuals present to perform all tests and measurements required to assure conformance to specifications. All PMDs included in the calibration program. All PMDs traced to standards of which they were calibrated. Examples of such PMDs: load cells thermocou
23、ples pressure probes vibration sensors speed sensors For instrumentation calibrations in house: the necessary standards available. Standards include the OEM or vendor instrumentation calibration requirements such as test procedures, test equipment, limits and accuracy requirements. Specified calibra
24、tion intervals established for each PMD, related to the engine manual requirements or test equipment vendor requirements. In case of deviations to the engine manual requirements, approved alternate means of compliance. Records of calibrated PMDs containing repairs and accuracy tracking being maintai
25、ned and available. All PMDs serialized and assigned to the facility. Responsible person/department responsible for calibration. Sample audit to prove that the facility is monitoring for compliance. Records showing performance data trending since last correlation(s) monitoring that the engine test ce
26、ll and engine performance data is within correlation tolerances. SAE ARP6196 Page 6 of 10 4.2 Manuals and Documentation Facility operations manual in place and updated, to comply with current standards. Written correlation documentation on file. Document on site that describes calibration maintenanc
27、e and slave equipment maintenance. All manuals current and conforming to the latest revision status, hardcopies as well as digital documentation. Responsible person on site and organization identified for documentation/manual control. All checklists being used and conformation to current revision st
28、atus. Proof that the engine serial numbers of engines in process are related to the bill off work/work order. All paperwork completed and the correct entries made. 4.3 Procedures All personnel to have proper work instructions (not working under verbal instructions). Work is being accomplished in agr
29、eement with work instructions and manuals. The test cell procedures manual available to the test cell personnel. Operators aware and instructed to have no shadow toolboxes left In the test cell and no material in pockets or pocket protectors when entering the test cell while engine is operating. 4.4
30、 Storage of Parts and Consumables Parts materials properly stored and identified. Lubrication and preservation fluids traceable by batch to supplier and delivery dates. Lubrication and preservation fluids properly stored in accordance with supplier and engine OEM requirements, separated from dust an
31、d debris, and supplied with filter elements, in the supply lines, tracked for replacement intervals.4.5 Training All personnel trained in accordance with maintenance facility and local authority requirements. Operators licensed for the applicable engine types. SAE ARP6196 Page 7 of 10 4.6 Safety 4.6
32、.1 Facility All entrance and exit doors free from obstructions and in proper condition. All flammable and hazardous materials labeled/identified and stored properly . All ventilation systems operating properly. The test cell inspected periodically for integrity of critical mounting systems, thrust f
33、rame flex plates, thrust frame cone bolts, bolt support brackets, engine mounts and bolts, including slave equipment, intake and exhaust, electrical cables, hand cuffs and harnesses for chafing, hoist systems, engine saddle cables, oil and fuel lines for chafing. Fire extinguishers placards/identifi
34、cation clearly visible. Fire extinguishers in proper condition and inspection current. Engine fire suppression systems in proper condition and inspections current. Material data sheets information available to all personnel. First aid kit procedures and kit allocations available and up to date. 4.6.
35、2 Operation All personnel aware of safety and emergency procedures and aware of emergency telephone numbers. Emergency procedure for engine operation in place, current and known to the operators. 4.7 Housekeeping Overall condition of the facility to be neat and orderly. Waste containers available an
36、d used. Preparation room as well as test cell free of debris. Cleaning schedule in place. Eating and drinking restricted to dedicated areas. 4.8 Fuel An identified standard like ATA 103 and/or local standard to monitor the fuel handling and fuel condition of the fuel used in the test cell. Identifie
37、d responsible people/organization for fuel loading process. Loaded fuel of the proper grade. SAE ARP6196 Page 8 of 10 System in place to confirm the loaded fuel in the storage tank(s) is in compliance with OEM requirements. General condition of fuel storage area, tankard(s) and leakage including con
38、tainment. Required safety, security and fire measures in place and current. Compliance with local safety and environmental requirements. Periodic white bucket (or equivalent) checks on fuel supply vessel. Periodic white bucket (or equivalent) checks on tank sumps. Fuel filter differential pressure m
39、easurement system in place and operational, proof of traceability. Filters/separators equipped with all required equipment. Millipore downstream of filter checks in place of the fuel/water coalescer system. Free water test down-stream of filter in place. All required placards and correct color codin
40、g in place. Check on operation of water defense system and emergency fuel shut off system. Verification that records are: current; complete; meets ATA 103 or equivalent alternative Training records available for personnel involved with fuel loading, storage and handling. 4.9 Slave Equipment Overview
41、 of all current test cell slave equipment available. Slave equipment properly stored and identified as slave equipment. Maintenance and calibration program in place with records on file. Records of nacelle equipment including current records of serial numbers, repair history and flow path areas. SAE
42、 ARP6196 Page 9 of 10 4.10 Software Maintenance 4.10.1 Engine operating software (FADEC controlled engines) Procedure in place to assure that engine performance test is conducted with required engine operating software of correct configuration and revision status. 4.10.2 Test Cell Operating Software
43、 (Data Acquisition System) Procedure In place to assure that the operating software is current and in compliance with: OEM engine manual requirements for each particular engine model; test cell vendor manual requirements; approved by engineering or other approved authorities; quality assurance manua
44、ls. 5. MAINTAINING THE TEST CELL IS AUDIT PROOF Maintenance of the test cell to assure audit compliance. To assure the test cell is constant in compliance with all audit requirements, a configuration control system, performance trend analysis plan as well as a frequent maintenance and inspection pla
45、n must be in place. 5.1 Configuration Control Configuration control is the process that assures that the test cell remains in the condition at time of the correlation(s). To assure this, the test cell configuration during correlation must be well documented, hardware locations in the test cell ident
46、ified and positions marked. Any changes to the test cell layout which may have effect on the configuration like maintenance, repair and alterations should be investigated and if required, verified by back to back tests. For further information regarding configuration control refer to ARP6028. All ch
47、anges must be documented in the facilty operations manual or any other documents like maintenance logs. 5.2 Performance Trend Analysis In order to assure that measured and calculated performance is still within correlation tolerances an active performance trend analysis system that conducts active t
48、rending of the specified performance parameters must be in place. For further information regarding trend analysis methods refer to ARP5758. SAE ARP6196 Page 10 of 10 5.3 Facility Maintenance and Inspection Plan A facility maintenance and inspection plan assures the overall condition of the facility remains correct and the facility: meets all technical requirements; complies with safety and environmental requirements; correlation status is maintained. In order to achieve this: the organization must have a periodic inspection and
