PROCESS AND MATERIAL SPECIFICATION

PROCESS SPECIFICATION

01-01-12

Final Cleaning of hydraulic pipes

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PROCESS AND MATERIAL SPECIFICATION

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PROCESS AND MATERIAL SPECIFICATION

AIPS
Airbus Process Specification
Final Cleaning of hydraulic pipes

Published and distributed by:

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

Copyright reserved
Ref. no. AIPS09-01-014
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Contents list

Scope

Normative references

Definition, applicability and limitations

Requirements

Process qualification

Appendix

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1 Scope
This Airbus Process Specification defines the requirements for final cleaning and drying of metallic hydraulic
pipes.
The purpose of this specification is to give design and quality requirements to manufacturers of hydraulic
pipe assemblies for AIRBUS aircraft. Although the essential requirements of a process will be described in
detail, the specification does not give complete in-house operating instructions. These shall be given in the
manufacturers supporting work instructions. The details of the successfully qualified process shall be
specified by means of a process instruction.
This specification shall not be used as an inspection document unless parts of assemblies have been
manufactured according to this specification. It shall be applied when required by the relevant standard,
material specification or drawing or the item is identified as pipes of the hydraulic system.

Normative references

This Airbus specification incorporates by dated or undated reference provisions from other publications. All
normative references cited at the appropriate places in the text are listed hereafter. For dated references,
subsequent amendments to or revision of any of these publications apply to this Airbus specification only
when incorporated in it by amendment of revision. For undated references, the latest issue of the publication
referred to shall be applied.
National standards should be applied if airbus standards are not available.
AIMS09-01-000
AIMS09-03-000
AIMS09-03-001
AIMS09-04-000
AIMS09-04-001
AITM6-3002
SAE AS 4059
AIPS03-01-015
AIPS09-01-010
AIPS09-01-003

Technical specification - Liquid cleaning agents-General requirements

Technical specification - Liquid non-aqueous cleaning agents
Material specification - Liquid non-aqueous cleaning agents
Technical specification - Aqueous cleaning agents
Material specification - Aqueous cleaning agents
Measurement of cleanliness of hydraulic distribution components
Cleaning and packing of hydraulic components
Blanking of pipes, hoses and components
Cleaning of pipes with liquid non aqueous agents
Cleaning with aqueous cleaning agents

3 Definition, applicability and limitations

3.1

General description of process

Pipes of the hydraulic system shall be cleaned before assembly and shall achieve the required cleaned
status. The final process shall conform to the requirements.
3.2

Applicability

This Airbus specification is applicable when invoked by the drawing directly or through another document for
the purpose given in the scope. When processing to AIPS09-01-014 is required, it shall be invoked on the
drawing by the words "Final cleaning and drying of metallic hydraulic pipes of hydraulic systems" according
toAIPS09-01-014.
3.3

Limitations

This process shall follow the pre-cleaning, which can be done according to AIPS09-01-010 or AIPS09-01003. This process shall be used for final cleaning of pipes of hydraulic system. The final cleaning process is
applicable after attachment of sleeves and unions.
The process is limited to cleaning of pipes and fittings installed on the pipes made from aluminium alloy,
stainless steel or titanium.

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Definitions

Pre-cleaning:

Cleaning after the bending-process for removal of oils

Final cleaning:

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

Drying:

After final cleaning, residues of the cleaner in the pipe shall comply with the limits given
in this specification

Pipes:

Tubes equipped with swaged fittings (union, sleeve and nut). All existing diameters and
part dimensions of pipes (length, diameter)

Cleaning agent:

Any compound or substance, suitable to remove all contaminants by chemical action,

may be called a cleaning agent.

Analysis solvent

Solvent, which dissolves all residual contamination on the surface; used to evaluate
surface cleanliness by subsequent measurement of particles in the solvent

4 Requirements
4.1

Engineering requirements

4.1.1 Requirements concerning the cleaning process

The cleaning process used shall not damage the cleaned pipes, the material, the surface protection and
the swaging interfaces or the dry lubricant of the fittings.
4.1.2 Requirements concerning the cleaning agents
The cleaning process and agents used during the cleaning process shall be qualified.
The cleaning agents shall meet the Cleanliness level of AS4059 Class 7 or better.
4.1.3 Requirements concerning purging fluids
The purging fluids shall achieve the requirements of the AS 4059. In order to achieve this requirement, all
purging fluids shall achieve AS4059 Class 7.
4.1.4 Requirements concerning the analysis solvent
The analysis solvent shall achieve the required AS4059 Class 6 or better.
4.1.5 Requirements concerning the Cleanliness level of pipes of the hydraulic system
For hydraulic pipes the required Cleanliness level has to be met. The Cleanliness level of hydraulic pipes is
defined on the drawing. AS4059 Class 7 or better is required for all pipes in the hydraulic system.
4.1.6 Requirements concerning the dryness of the hydraulic pipes
After drying no residues of the cleaner are allowed on the inner surface of the components of the hydraulic
system. The drying parameters temperature, drying time and flow conditions shall be controlled and recorded
during the drying process.
4.1.7 Requirements concerning the caps and plugs
The caps and plugs shall be conforming to the requirements of AIPS 03-01-015.
4.1.8 Requirements concerning the packing material
The packing material shall be of such cleanliness that items are not contaminated.

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Technical requirements

4.2.1 Before starting the cleaning process

The process qualified according to this document is to be considered as a final cleaning process for single
parts. If the fittings have seals that cannot be removed prior to cleaning then the compatibility and the
influence of the cleaning process on the seal and the effect on the cleanliness of the bath (if applicable) must
be verified.
4.2.2 During the cleaning process
The total inner surface must be cleaned during the cleaning process. That means the complete inner surface
of the component must be wet.
4.2.3 After the final cleaning process
It shall be ensured that the components are free of residual dirt and cleaner residues before packing. The
dryness shall be ensured. All assemblies, parts or tubing shall be taken from the work area and kept clean by
using cleaned caps and plugs. After this the parts shall be sealed in transparent visible clean polyethylene
wraps.
4.3

Quality requirements

4.3.1 Cleaning process

After cleaning of the components a visual inspection is to be applied to confirm that the cleaning process has
caused no damage upon the materials and the surface protection.
4.3.2 Cleaning agents
A verification of the cleaning agents shall be undertaken prior to the cleaning procedure. A verification of
particles shall be done according to the methods named in the AS 4059. The cleaning agent shall have
fewer particles than required to meet Cleanliness level AS4059 Class 7 or better.
4.3.3 Purging fluids
A verification of particle shall be done according to the methods named in the AS 4059. The purging fluid
shall have fewer particles than required to meet Cleanliness level Class NAS 7 of the AS 4059.
4.3.4 Analysis solvent
Regular verification shall be done for particles according to the methods named in the AS 4059. It shall be
verified that the analysis solvent is suitable for the contamination base of the parts.
4.3.5 Cleanliness of hydraulic pipes
The verification of particle levels shall be done according to the procedure described in AITM6.3002 and
according to the particle measuring methods named in AS 4059 after final cleaning of the pipes. The
verification of the finally cleaned hydraulic pipes shall be performed several times during the daily production.
4.3.6 Dryness of the hydraulic pipes
The drying parameters temperature, drying time and flow rate shall be controlled and recorded during the
drying process.
4.3.7 Cleanliness level of the caps and plugs
The cleanliness level of the caps and plugs has to be verified according to AITM6.3002 using the particle
measuring method in AS 4059.
4.3.8

Cleanliness level concerning the packing material

The packing material has to be visually inspected.

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4.3.9 Verification tests during qualified cleaning process

All verification tests shall be done according to AS 4059 summarised in table 1 below. In the chapter
cleanliness inspection and tests are all named tests are described. These test methods are applicable. If
another test method is used only specified and qualified test methods are allowed and the reason for
changing the test method shall be explained.
Table 1 -Verification tests during qualified cleaning process

5 Process qualification
5.1

Process qualification procedure

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

Process qualification

5.2.1 General
The general process qualification, the qualification of industrial facilities and Airbus quality assurance are
described in prevailing procedure documents.
The process qualification is given and maintained only on condition that the qualified workshop complies with
the cleaning and inspection documents formally approved by Airbus.
The qualification is limited to a specific issue of any process specification of the developer. Any modification
needs reapproval or re-qualification. Users need to be qualified in accordance with the relevant Airbus quality
requirements. Airbus reserves the right to audit the use of qualified processes to check conformity with the
agreements.
5.2.2 Screening Phase
In the first step a screening of process parameters shall be done. The process parameters shall be recorded
and then defined.
The final cleaning process must be stable and reproducible before the technical qualification procedure is
launched, so that a selected set of process steps and parameters is taken for the qualification. This selected
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set of process steps shall deliver a reproducible cleanliness level of the cleaned pipes and shall comply with
the all requirements, also take respect to corrosion resistance. When the screening is finished a first draft of
the production work instruction shall be issued and the qualification can start.
The general process qualification, the qualification of industrial facilities and quality tasks shall be described
in prevailing procedure documents.
5.2.3 Start of qualification
The process qualification shall be done by qualified and authorized personal.
The process qualification shall be performed using the materials (cleaning agents and hydraulic system
components (material) and cleaning procedures/equipment to be used in serial production. All affected
materials, all surface coatings (galvanic coatings and painting), all kind of parts and assemblies shall be
tested with the cleaning process. The production shop must use its facilities under serial production
conditions during the qualification tests.
The process qualification shall be done with a qualified cleaning agent according to Category III of AIMS 0901-000. The non-aqueous cleaning agents shall be qualified according to AIMS 09-03-000, with aqueous
cleaning agents in accordance with AIMS 09-04-000.
5.3

Standard qualification test program (QTP)

This chapter provides the details of the standard test program, which shall be taken into account for the
definition of the specific qualification test program (QTP) for the technical qualification of a shop.
The QTP shall show the compliance with the engineering, technical and quality requirements defined in this
AIPS (chapter 4). In addition to the acceptance criteria, specific test requirements are defined as amendment
and/or deviation. This means the qualification test program (QTP) includes the standard qualification test
defined by this AIPS hereinafter (chapter 5.4) as well as any amendment or deviation.
Any change to the cleaning process/cleaning agent shall be submitted for technical assessment to the
appropriate AIRBUS authority, who shall decide whether new verification tests are required.
5.4

Verification during qualification testing of the required performance and quality level

Testing of 50 pipes - at least 6 different types of pipes, implicitly with smallest and biggest diameters with
maximum number of bends.
5.4.1 Cleaning process
It should be ensured that the components especially the surface coating are not damaged during the final
cleaning process.
5.4.2 Cleaning agents
The cleanliness of the cleaning agent shall be verified that it complies with AS 4059 Class 7 or better.
The degree of cleanliness of the cleaning agent should be checked and documented during the qualification.
5.4.3 Purging fluids
The purging fluids shall achieve the requirements of the AS 4059. In order to achieve this requirement, all
purging fluids shall achieve AS4059 Class7.
5.4.4 Analyze solvent
The degree of the cleanliness level of the analyze solvent should be checked and documented.
5.4.5 Cleanliness level of hydraulic pipes
Each surface shall be visual examined. The verification of the cleanliness level according to AS 4059 shall
be done.
An investigation of process parameters with respect to the influence on the achieved levels of cleanliness
shall be done.
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5.4.6 Dryness of the hydraulic pipes

Dryness of the components of the hydraulic systems is to be checked after the cleaning operation. The
influence of drying parameters on the achieved levels of dryness is to be studied and documented.
5.4.7 Cleanliness of the caps and plugs
Cleanliness of caps and plugs shall be verified according to AITM 6.3002 and shall comply with AS 4059
Class 7 or better during the qualification process.
5.4.8 Cleanliness level concerning the packing material
The packing material has to be visually inspected according.
5.4.9 Standard qualification test program
All verification tests shall be done according to AS 4059 summarised in table 2 below. In the chapter
cleanliness inspection and tests are all named tests are described. These test methods are applicable. If
another test method is used only specified and qualified test methods are allowed and the reason for
changing the test method shall be explained.
Table 2 - Test selection for the standard qualification test program

Test results of the qualification test program of the process qualification shall be recorded in a qualification
test report (QTR), which may include results from the sub-contractors.
5.5

Qualification test report (QTR)

The basis of the qualification/approval of a specific process to the AIPS is a detailed test report about all
tests and procedures that have been performed (adding details and values).
Prior to any production cleaning run the complete test report shall be submitted and approved by
Engineering.
The test report has to be established and signed by the developer and its quality assurance department.
The test report shall give at least all the following information:
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Name and address of the production shop

Process instruction
Flow of the plant
Description of all used specifications and test methods
Description of the type of cleaning agent
Detailed description of pre-treatment steps
Description of hydraulic system components, including materials and coatings
Justification of the representatively of the chosen components and materials for the process
qualification
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Influence of the process on the corrosion resistance

Cleaning results achieved using the investigated process parameters and Cleanliness levels
Detailed description of process steps with all methods of cleaning and description of the work
instruction sequence
Verification method used to investigate the Cleanliness level of the pipes
Discussion of the results with respect to the qualification test program (QTP) and achievement of the
requirements
Any incident that may have affected the results and any deviation from this AIPS

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RECORD OF REVISIONS

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