Contents Introduction .................................................................................................................................................. 2 SISCAL Sweep definitions .............................................................................................................................. 2 Policy SISCAL Sweep...................................................................................................................................... 3 SISCAL 534 Roles ........................................................................................................................................... 3 SISCAL Lab 4NG/4NH/4NP/4NV Roles ...................................................................................................... 3 Types of Sweep Assignments ........................................................................................................................ 4 Sweep Engineer............................................................................................................................................. 5 Pre-Sweep ................................................................................................................................................. 6 During Sweep ............................................................................................................................................ 6 Post Sweep ................................................................................................................................................ 7 Sweep Team Lead ...............................................................................Ошибка! 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Sweep Technician ......................................................................................................................................... 5 Report Cal Status Acronym ........................................................................................................................... 7 General Points ............................................................................................................................................... 8 In Brief and Out brief .................................................................................................................................... 9 In Brief ....................................................................................................................................................... 9 Out Brief .................................................................................................................................................... 9 Sweep Emails Pre and Post ......................................................................................................................... 10 pre ........................................................................................................................................................... 10 Post – Fi8nal ............................................................................................................................................ 10 Introduction • “Calibration is the comparison of a measurement system or device of unverified accuracy with a measurement system of known and greater accuracy to detect any deviation from required performance specifications of the unverified measurement system or device.” NAVSEAINST 4734.1B para 5.C • NAVAIR and NAVSEA agree • Calibration is the verification of measurement accuracy of an instrument (with or without signal chain) using a calibrated standard. SISCAL Sweep definitions • • SWEEP • Defined as Calibration Effort to perform calibration on Ship’s CRL Calibration Activity 2 instrumentations (includes sensors, signal chains, displays etc..) over one continuous scheduled period. Some SISCAL lab may deviate from one continues time frame. • Scheduled as 10 or 15 working day Window for 4NG, 4NH, 4NV. 4NP will have separate windows dependent on scheduling. • All calibrations performed on site/in place. Split Sweep • Effort to perform Sweep but over two separate scheduled periods. • All calibrations performed on site/in place. • • • Callback • Request driven effort to perform calibration on instruments identified in a sweep as NOT CALIBRATED. Typically to address various instruments left uncelebrated following a SISCAL Sweep. • Callback events for <100 instruments per AWR/2-kilos • SISCAL II events for 100+ instruemnts per AWR/2-Kilos • All calibrations performed on site/in place. SISCAL Sweep teams are • • 4NG: based in Philadelphia, PA, Supports Surface and Carriers homeported in Norfolk, San Diego, Mayport, Everett, Bremerton, Bahrain, Rota and CVN in Yokosuka., Japan., • 4NH: Based in Yokosuka Japan, Supports surface homeported in Yokosuka, Sasebo. Also supports local Carrier for callbacks and Singapore for Surface callbacks. • 4NP: based in Pearl Harbor, Hawai. Supports Surface homeported in Pearl Harbor • 4NV: Based in Camp Pendleton, California. Supports LCACs homeported in ACU5. Documents: • CRL subset of Cal Activity 2 instruemnts • System calibration procedures (SCP)s Policy SISCAL Sweep • Data sheets for SISCAL Sweeps and SISCAL IIs to be scanned and sent to SISCAL EA with sweep reports for archived • • • • Data sheets for SISCAL Sweeps and SISCAL IIs to be scanned and archived with sweep reports on branch drive SISCAL 534 Roles • 534 Branch Manager – Responsible for personnel and financial management of NSWCPD code 534. • SISCAL Engineering Agent (EA) – Responsible for technical decision making within the SISCAL program, such as SCP and CRL development and maintenance. • 534 Quality Manager – Responsible for developing and enforcing the Quality Management Systems for code 534 activities, including 4NG. • 534 Document Control Specialist - Responsible for SCP management for all ship classes. • Ship Class Manager – Responsible for technical decision making, CRL and SCP management for their assigned ship class. SISCAL Lab 4NG/4NH/4NP/4NV Roles • SISCAL Lab 4NP/4NH/4NV • Sweep Engineer – Responsible for the overall operation and reporting or their assigned SISCAL effort. Independent of ship class responsibility • • Sweep team Technician – Performs physical calibrations in accordance with appropriate procedures. SISCAL Lab 4NG • 4NG Lab Manager – Responsible for operation of 4NG calibration lab, and the execution of 4NG calibration efforts. • Sweep Engineer – Responsible for the overall operation and reporting or their assigned SISCAL effort. Independent of ship class responsibility • Fleet Scheduler – Coordinates with the fleet to create the schedule of SISCAL efforts. • 4NG CTR TEAM • CTR Program Manager - Responsible for personnel and financial management of SAIC contractors for NSWCPD branch 534. • SAIC Logistician – Coordinates SAIC personnel assignments to SISCAL efforts. • SAIC Team Lead – Coordinates the daily operation of the SAIC technicians on their Sweep • SAIC Technician – Performs physical calibrations in accordance with appropriate procedures. Types of Sweep Assignments • Shipboard • • Remote • • Sweep Engineer remains in Philadelphia but maintains contact with Team Lead to track Sweep progress and provide guidance and communication with ship. SISCAL II • • Sweep Engineer travels to location and manages the Sweep from onboard ship May be treated as Remote sweep, overseen by the Ship Class Manger or Sweep Engibneer Callback • No Sweep Engineer need be assigned Sweep Engineer/Team Lead • Need to maintain Situational Awareness during the Sweep • What has been calibrated? (system/equipment terms) • What has been rejected? (specific instruments) • What are the exceptions? (system/equipment terms) • What is remaining? (system/equipment terms) • What is SISCAL’s plan of the day/next day/visit? (system/equipment terms) • What support requirements are needed for remaining? • What support has the ship been unable to provide? • When Shipboard, Sweep Engineer should have this knowledge in real time • When Remote, Sweep Engineer should have this knowledge on a daily basis • Sweep technician should have this knowledge in real time • Sweep Engineer and Sweep technician should be in agreement in this knowledge • • • Maintain Inventory of Calibration Standards in use during sweep • Communicate any issues with Sweep Engineer as they occur • Need for technical information • Any procedure or datasheet discrepancies • Problems with ship’s force support Provide 534 Engineer and Ship with status updates on rejected and exception instruments Sweep Technician • Perform Calibrations IAW provided SCPs • Record calibration results on data sheets • Return data sheets to Sweep Team Lead upon completion or at end of day • Report any issues to the Sweep Team Lead • Rejections or Exceptions to calibration • Need for additional technical support • Note any discrepancies in procedures and datasheets Pre-Sweep • Contact ship via email prior to sweep • Provide support requirements needed, Energized but NON operational. • Provide tentative schedule, daily list of equipment scheduled • CC the Sweep Lab Manager, SISCAL Ship Class manager/EA • Verify with SISCAL Ship Class Manager that Sweep team the latest SCPs • Assemble information for use on the Sweep • Sweep Macro file • Working CRL for ship (work with Ship class manager) • Possible? Working CRL for other hulls of the same class/configuration (work with Ship class manager) During Sweep • Maintain communication with Sp and Sweep team lead WRT Situational Awareness guidance • Perform in-brief/out-brief as requested (if shipboard) • Work with Sweep Team to set priorities for day/week/visit • Sweep Engineer has final say on priorities • Coordinating with Ship’s Force for Sweep Team support • Provide Sweep Team with additional technical guidance as required • • Track any CRL Cal activity 2 adds/deletes/changes on both the MACRO file and your copy of the ship’s working CRL • • • Coordinate with ship class manager for assistance with updates 4NG: Investigate any tech authority Add/Delete/Change requests and annotate your working CRL • • Document guidance provided for potential revision of SCP, using SCP change request Inform class manager of findings Communicate any issues with SISCAL Lab Manager as they occur • Need for technical information • Problems with ship’s force • Problems with sweep team Review SCP data sheets and update Sweep Macro daily • Every Friday send SF/ SISCAL 534 POCs a status report with: %calibrated, %exceptions, a list of rejects and a rundown of any major roadblocks (i.e. HPAC2 under maintenance, diesel inspectors working on engine, unable to shift standby generator) Post Sweep • Compile final reports and send to ship and SISCAL Lab manager • 4NG: Archive data on 534 Branch Drive in SISCAL director, Sweep results • Coordinate with Ship class manager to ensure any CRL changes in Working CRL/MAcro • • Update sweep dates and statuses in MCMS or MeasureWeb • • Ship class manager will published via MCMS or MeasureWeb within 5 working days after Sweep/Callback compltetyion Have short debrief with SISCAL Lab Manager to discuss Sweep results • • • Report Cal Status Acronym 2A.1 In Tolerance - Able to hook up and perform calibration as directed by the procedure, all test points came within tolerance on the first run. 2A.2 Adjusted - Able to hook up and perform calibration as dictated by the procedure, but one or more parts of the signal chain had to be adjusted to bring all test points into tolerance. 2B Special Cal - Able to hook up and perform calibration as dictated by the procedure, but were unable to verify signal calibration by SCP, therefore need to deviate by other means i.e. only calibrating a certain range, single point verification, etc. Also used for radar TLIs where we do not test the TLI mechanism and cannot call the TLI fully calibrated. 2C Calibrated/replaced - Able to hook up and perform calibration as directed by the procedure, all test points came within tolerance after replacement/repair of instruments during initial sweep. 3A Rejected - Able to hook up and perform calibration as dictated by the procedure, but even with available adjustments could not bring the test points into tolerance. The key difference between Reject and any other of the exception statuses is that we were able to perform the calibration but the results didn't come within our tolerances. Other Notes used to distinguish ways we were hindered from performing the calibration. 3B Previous Reject - Part of the signal chain still bears the rejected sticker from a previous calibration attempt. 3C Not Installed - Unable to hook up and perform calibration due to Instrument should be in place but is not there, such as: panel meter removed from mounting, pressure transducer removed, but gage line and cabling still in place. 3D Not done due to Ship's Operations - Unable to hook up and perform calibration due to Ship's operations prevent testing, i.e. ship was running HPAC, LPAC or AC for the entire visit. 3E Not done at ship's request - Unable to hook up and perform calibration due to Ship's force has formally requested we do not calibrate specific instruments. This is a rare one as normally there is a previous request for ship to sign off on not performing the calibration. 3F Not done due to shipyard activity - Unable to hook up and perform calibration due to Tagouts for outside activity prevents calibration. Examples include HPAC, LPAC, AC tagged out for repair, Diver activity preventing shifting of equipment, or other maintenance activity. 3G Cannot Isolate - Unable to hook up and perform calibration due to Instrumentation cannot be properly isolated or connected to perform test, such as leaking hoke or root valves on pressure systems, damaged threading on pressure transducers, poor shorting switches inside switchboards. This has also been used when pressure transducers or TLIs are mounted in places which cannot be safely accessed after contacting SF for Assitance. 3H Out of Commission - Unable to hook up and perform calibration due to Instrument cannot be calibrated due to non-functioning of equipment. Examples: No power to transducer, HPAC, LPA, AC, etc. tagged out for reasons other than an outside activity. General Points • • • • Technical Issue chain of communication • SAIC Technician -> SAIC Team Lead ->534 Engineer->Class Manager-> EA SAIC General Issue chain of communication • SAIC Technician -> SAIC Team Lead -> SAIC Program manager 4NG General Issue chain of communication • SAIC Technician -> SAIC Team Lead ->534 Engineer->4NG Lab Manager -> 534 Branch Head AND EA 534 Engineer and SAIC Team Lead work together to achieve maximum items calibrated • • 534 Engineer has ultimate responsibility, and ultimate say during the sweep 534 Engineer decisions can be overridden by 4NG Lab manager In Brief and Out brief In Brief • In brief should have similar content and email sent before the sweep • Time frame i.e. 10/4/21 to 10/15/21 • General support requirements • Need equipment Energized and NON Operational • All HMI display needs power • For high voltage system (SWBD or EP monitor) it needs electrical isolation and possibly live work authorization while we test it • Equipment operation and Standby generator status will need to be shifted as the SISCAL effort progresses • No filling or transfers while we work on Tank Level Indicators • Monitor diver activity • Ask about potential interference • Maintenance • Inspection • Drills • Underway • Events • Schedule: Provide a general workflow of how the calibration will proceed. Use template from Shipa class maamnger but may deviste if issue are known ahead of time Review In brief and Out Brief Notes document/Check Lists Out Brief • Out brief and final email should contain similar information • Final reports • Break down of Calibrated and NOT Calibrated percentages • List of NOT Calibrated instruments for Callbacks • “Cheat Sheet” Version listing only rejected parts of the signal chain • Note to submit an AWR for corrected exceptions to initiate a callback Send AWR Guidance docuemnt Draft Report status Sweep Emails Pre and Post pre -> EA Draft Email CHENG, MPA - Surface CHENG, MPA AIMD POC, AIMD chief/1st class – LHA/LHDs SMM, AIMD POC, AIMD chief/1st class - CVNs USS RUSSELL is scheduled for a SISCAL sweep during timeframe 6/18 to 6/29 2018. Support requirements are as follows: (or as detailed in SISCAL Sweep Instrumentation system distinct requirements document) Need equipment Energized and NON Operational Gas Turbines need to be tagged out IAW personnel entering the module. Consoles and Engine controllers need to be online. AC plants and compressors need to be offline with power to their controllers while under test. A Live work chit is required for calibration of switchboard electrical meters, unless any of the boards are powered down. Enclosed is our recommend schedule with start on Monday with Arrival, Invbbrief and XX and starting calibartions with power supplies and a few other preliminary checks, and then start on whichever engine room is available to us with the goal of moving through all the gas turbines in the course of the first week. The switchboard calibration will be tentatively planned for Tuesday of the second week. Auxiliary equipment will be calibrated throughout as the equipment is available. I will be traveling Monday, however the Sweep team will be onboard to load equipment and begin the calibration checks. If necessary, I'll be available to in brief on Tuesday morning for further clarification of our requirements. I require DISS information for my travel visit request, if you could please forward this to the appropriate security personnel or provide the SMO code and POC information that would be most helpful. Post – Final CHENG, MPA - Surface CHENG, MPA AIMD POC, AIMD chief/1st class – LHA/LHDs SMM, AIMD POC, AIMD chief/1st class - CVNs Attached are the reports from the SISCAL sweep of USS MAKIN ISLAND. Reports are as follows: Status Final - Numerical totals of calibration statuses. Final result was 92% calibrated (1583 of 1715 CRL items). Rejected- Items rejected OOC- Items received out of commission, i.e no power at transducer, etc. CNI - Cannot isolate- Items which could not be isolated, such as seized isolation valves, corroded cannon plugs, etc. Also includes TLIs for which we could not find tank top connections. WRT these connections, since returning to Philadelphia I have tracked down the appropriate documentation to locate intermediate junction boxes in order to calibrate the remaining TLIs, these can be accomplished during a callback visit. With the exception of the TLI tank tops, the remaining issues we encountered were also on the lists provided to CHENG, AIMD and the WC during the Sweep. When the issues are rectified/resolved, an AWR can be submitted to schedule the calibration team come back and calibrated those items. AWR guidance has been enclosed
