122. I LEVEL ALSS
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122. INTERMEDIATE LEVEL (I-LEVEL) AVIATION
LIFE SUPPORT SYSTEM(S) (ALSS) FUNDAMENTALS
References:
[a] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. I
[b] NAVAIR 13-1-6.2, Emergency Personnel and Drogue Parachute Systems
[c] NAVAIR 13-1-6.4-2, Oxygen Equipment (Regulators)
[d] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. V
[e] NAVAIR 06-30-501, Oxygen/Nitrogen Systems Technical Manual
[f] A6-332AO-GYD-000, ABO Surveillance Program Laboratory and Field Guide
.1 Discuss ALSS pool management. [ref. a, ch. 16]
1. General
a. A pool of ALSS spare assemblies (parachutes, life rafts, SSKs,
life preservers, survival radios, and miniature regulators) shall be
established by IMA ashore. The spare ALSS assemblies are owned by the
station/MALS Aviation Supply Officer and are inventoried, maintained,
and stored by the local IMA. This material will be maintained, in a
rotatable ALSS pool located in the IMA 800 Division. IMA personnel
shall ensure all spare ALSS equipment is properly stored, RFI upon
demand by O-level activities, and on hand quantities match those on the
activity's supply records.
b. When the deployment site does not have an ALSS pool, the
supporting shore-based IMA is responsible for providing RFI Assemblies
equal to 10 percent of those required for full outfitting of the
deploying squadron or detachment to the deployed site.
c. Deployed shipboard IMAs will be responsible for providing all
repair parts and components required to support the embarked squadrons'
ALSS equipment.
d. Upon completion of deployment, the shipboard IMA is responsible
for returning the same number of RFI assemblies originally provided by
the supporting shore-based IMA. When the deployment site does not have
an established IMA, the deployed site Supply Officer is responsible for
the return of all unused assemblies and adequate documentation on the
used material to guarantee proper stock replacement, carcass tracking,
and charges.
e. Personal survival equipment, such as helmets, survival vests,
gloves, flight suits, or items of squadron equipment which are not
normally inducted into the IMA for maintenance, are not to be included
in ALSS pools.
.2 Discuss the purpose and use of the SEATS/ICAP Program. [ref. a, ch.
10]
* SEATS/ICAP is a microcomputer based system which provides a
standardized method to manage, report and generate hard copy history
records on ALSS components and installed explosive devices.
SEATS - Survival Equipment Asset Tracking System
ICAPS - Increased Capabilities
.3 Discuss the unique QA requirements for ALSS equipment. [ref. a, chs.
14, 16]
1. General.
1. Activities having no or only one PR assigned shall designate in
writing a properly cross trained QAR or CDQAR to inspect work performed
on ALSS equipment maintained by Work Center 13A. This does not include
parachute or life raft/life preserver packing/repacking or other Ilevel
maintenance
functions
on
ALSS
equipment.
Cross
trained
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QARs/CDQARs shall use NAVAIR 13-1-6 series manuals for technical
guidance.
Personnel
performing
ALSS
equipment
maintenance
and
QARs/CDQARs inspecting work performed shall be ordnance certified per
OPNAVINST 8020.14.
2. O-level activities supported by contract maintenance shall use
only qualified, certified civilian personnel to perform O-level
maintenance on ALSS/egress system maintenance.
(1) For Work Center 13A, only personnel who are graduates of Navy
PR or equivalent Air Force or Army MOS course shall be allowed to
perform ALSS system maintenance.
(2) For Work Center 13B, only personnel who are graduates of Navy
AME "A" School and CNATTU for specific T/M/S or T/M/S factory
equivalent training course shall be allowed to perform egress system
maintenance.
(3) In addition to paragraphs (1) and (2) above, for contract
maintenance personnel to be designated as a QA Inspector on ALSS/egress
equipment, a documented working history with ALSS/egress equipment is
required.
3. I-level activities using NALCOMIS shall assign SMQ passwords to
all personnel designated as QARs, CDQARs, and CDIs. QA stamp numbers
shall be required for ALSS inspection records, calibration METER cards,
and all non-NALCOMIS maintenance documents, for example, VIDS/MAFs.
These open purchased numbered impression stamps, which identify the
inspector, will be used as required or as established by local policies.
Stamps shall be closely controlled by QA and adequate storage
facilities provided. A stamp may not be reassigned within a period of 3
months.
NOTES: Cross training is not permitted into the following: AME areas of
egress systems or PR I-level areas of responsibility. Only qualified Ilevel personnel (graduates of approved PR school) will be permitted to
pack, repair, or perform calendar inspections on personnel parachutes,
drogue chutes (excluding drogue chutes in nonremovable head boxes),
SSKs,
and
inflatable
survival
equipment.
Cross
training
under
provisions are permissible for PR O-level functions only. ALSS O-level
and I-level areas of responsibility are outlined in NAVAIR 13-1-6
series manuals and shall be strictly followed.
.4 Discuss documentation requirements for ALSS equipment. [ref. a, ch.
16]
1. Records and Cards
(1) The following records are designed to document ALSS components:
(a) The Parachute Record (OPNAV 4790/101) is designed to provide
the current configuration and inspection record of a parachute assembly
and its components. The record is a single copy, single-sided SEATS
generated form. The record is designed to be filed in the aircraft
logbook or the ejection seat AESR where the parachute system is
installed.
(b) The Seat Survival Kit Record (OPNAV 4790/137) is designed to
provide configuration and inspection information for an SSK and its
components. The record is a single copy, single-sided SEATS generated
form. The record is designed to be filed in the aircraft logbook or the
ejection seat AESR in which the SSK is installed.
(c) The Aircrew Systems Record (OPNAV 4790/138) is designed to
provide a continuous configuration and inspection record of ALSS
components, kits, and assemblies. This record is a single copy, singlesided SEATS generated form. Each item of ALSS requiring inspection at
the I-level of maintenance shall have a separate Aircrew Systems Record.
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The record shall be filed in the logbook of the aircraft in which the
ALSS component, kit, or assembly is installed. For personnel mounted
equipment or other equipment which is not aircraft mounted, the record
will be maintained as directed by the MO. For amplifying instructions
for this record refer to 4790, VOL I, Chapter 13 and NAVAIR 13-1-6
series manuals.
(d) The Aircrew Personal Equipment Record (OPNAV 4790/159) shall
be initiated by the cognizant O-level activity upon the initial issue
of personal equipment to the aircrew member. The record provides the
current configuration of all personal survival equipment issued to the
aircrew member. Only items of ALSS requiring inspection at the O-level
shall be documented on this record. The record shall be retained until
new equipment can no longer be documented in allotted spaces. As an
item is removed from service it will be deleted from the record by
drawing a single red line through all information pertaining to that
item. Information pertaining to the removed item's replacement will be
annotated in the next available line below. When the card is filled, a
new record shall be initiated and all current data transcribed to the
new record. Upon verification of data, the old record may be destroyed.
(e) When any ALSS equipment has been involved in an aircraft
mishap, the records shall be forwarded per OPNAVINST 3750.6 and NAVAIR
13-1-6 series manuals.
(2) Record Retention. Each aircrew member shall have a separate file
containing the Aircrew Personal Equipment Record (OPNAV 4790/159) and
separate Aircrew Systems Records (OPNAV 4790/138) as needed. The
aircrew flight equipment file shall be constructed of a 9 x 12 manila
folder. The Aircrew Personal Equipment Record (OPNAV 4790/159) will be
firmly attached on the right side of the folder and all applicable
Aircrew Systems Records (OPNAV 4790/138) will be placed on the left.
All maintenance actions performed on an aircrew member's equipment
shall be documented on a MAF. After normal processing of the VIDS/MAF,
Copy 3 will be placed in the aircrew member’s flight equipment file
beneath the Aircrew Personal Equipment Record (OPNAV 4790/159) until
Copy 1 is received from the data services facility. Copy 3 can then be
discarded. Copy 1 will be placed beneath the Aircrew Personal Equipment
Record (OPNAV 4790/159) and retained for a minimum of 6 months.
NOTE: All aircrew flight equipment records and files shall be
maintained as directed by the MO.
(a) When an item of ALSS is due for inspection or maintenance,
Maintenance Control shall forward all appropriate records with the MAF
or WO to the Aircrew Personal/Protective/Survival Equipment Work Center.
(b) For record entry requirements for ALSS records refer to
Chapter 13 and NAVAIR 13-1-6 series manuals.
.5 Discuss special facility requirements for ALSS work centers.
[ref. b, WP 003; ref c, ch. 3]
1. GENERAL.
a. The wet locker and washroom shall be separate areas. The packing
area, store rooms, and fabric areas should be separated if room is
available. The packing tables shall be adequately spaced. The fabric
area shall be kept clean. All local fire regulations shall be adhered
to.
b. packing area
c. Fabric area
d. Wet Locker
e. Washroom.
f. Storage facilities.
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2. Environmental requirement.
Parachutes should be inspected, repaired and packed under regulated
temperature and humidity conditions. So, these conditions must be
controlled in all parachute lofts. In general, the loft shall not be
excessively damp or dusty. It shall be continuously or frequently
ventilated.
1. REQUIREMENTS.
a. The temperature and relative humidity in packing loft and dry
locker shall be maintained within limits indicated in (Figure 3). Ideal
conditions are a temperature of 24 C (75 F) and a relative humidity of
60%.
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b. The shaded area on temperature-humidity chart, shown in
(Figure 3), outlines the allowable environmental limits inside
parachute loft and illustrates favorable and unfavorable conditions.
Parachutes should not be packed when conditions are in the unacceptable
zone. These limits are affected by two variables: relative humidity and
temperature. Recordings of these variables shall be taken at least 3
times daily, using the relative humidity and temperature indicator to
ensure that favorable conditions are maintained.
NOTE: Do not pack parachutes when conditions are outside acceptable
conditions.
c. Relative humidity is ratio between amount of water vapor in
air and amount the air could hold at a given temperature. Relative
humidity is usually written as a percentage. Specific humidity is the
weight of the water vapor found in a given volume of air. Relative
humidity limits must be maintained to prevent condensation in actuators
and other metal parts. Specific humidity limits must be maintained to
prevent static electricity in canopy cloth.
d. Given any two of these variables, it can be determined, by
using the chart, if the packing loft and dry locker have safe
environmental conditions.
.6 Discuss training/qualification requirements for working on ABO
equipment. [ref. c, ch. 3, Glossary-2; ref. d, ch. 5; ref. e, ch. 2]
1. General
Shop supervisors shall be responsible for conducting a continuing
training
program
stressing
the
significance
of
oxygen
system
cleanliness, personal cleanliness and the oxygen safety program.
Conscientious adherence to all cleanliness requirements and safety
regulations shall be observed at all times.
2. ABO analyzing equipment operators shall be:
(1) Trained by one of the following:
(a) Aviators Breathing Oxygen (ABO) Test Site Operator/Analyst
course (Course C-670-2018).
(b) Aircrew Survival Equipmentman Class A1 course (Course C-6022010).
(c) Aviators Breathing Oxygen Contaminant Analyzer Intermediate
Operator Maintainer course (Course C-750-3217).
(d) ABO qualified NATEC (Code 3.1/3.2) personnel.
(2) Actively involved with ABO analysis. Personnel who do not
interpret sample scans within a two-year period shall be required to
complete all initial certification requirements.
(3) Knowledgeable with ABO sampling procedures and analyzing
requirements of NAVAIR A6-332AO-GYD-000 and NAVAIR AG-115-SL-OMP-000.
3. Program manager shall Ensure ABO Surveillance Program indoctrination
and follow-on training is provided to personnel. All personnel
associated with the ABO Surveillance Program shall have a thorough
knowledge of the characteristics of LOX/gaseous oxygen, hazards of
contamination, and need for quality standards. They shall be familiar
with and comply with procedures outlined in NAVAIR 06-30-501, NAVAIR
13-1-6.4-1, NAVAIR A6-332AO-GYD-000, NAVAIR AG-115-SL-OMP-000, NAVAIR
06-20-2, MIL-HDBK-1028/1C, NAVAIR 17-15-98, MIMs, and MRCs (as
applicable) to the oxygen servicing/maintenance tasks they perform.
Training shall include personnel responsibilities and shall be
documented
on
the
NAMP
Indoctrination
Training
sheet
in
the
individual's qualification/certification record.
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.7 Discuss special tools required for working on ABO equipment. [ref. c,
ch. 3]
1. General.
All tools and equipment shall be maintained free of grease, oil and
other combustible materials. Tools used on oxygen equipment shall not
be used for any other purpose. Tools shall be marked OXYGEN USE ONLY,
or other suitable methods of identification may be used.
2. Example of a special tool for AIRCRAFT DILUTER DEMAND OXYGEN
REGULATORS TYPE AN6004-1, SERIES 2858-A1,2858-A1A, 2858-B1, AND 2858-C1
1. Aircraft Diluter Demand Oxygen Regulators Pioneer Type AN6004-1,
Series 2858 (figures 4-1) are manufactured by Pioneer Central Division
of Bendix Aviation Corp (CAGE 06840 and 19315). They are designed to
regulate breathing oxygen to the aircrewmember during flight. Table 4-1
contains the leading particulars for the regulators.
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3. REQUIRED SPECIAL TOOLS: Table 4-9 list special
equipment required in connection with the work
disassembly and assembly procedures.
tools and test
prescribed for
.8 Discuss the requirements and equipment for testing liquid oxygen and
liquid nitrogen. [ref. e, ch. 3; ref. f, ch. 2]
Created by LTJG KyungNho "TACO" Kim
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1. General.
This section establishes procedures and requirements for the quality
control of oxygen that is procured, generated, stored, transferred, and
used at Naval and Marine Corps Air Stations or aboard aircraft carriers
for breathing purposes by aircrews. This section is applicable to all
personnel who are responsible for supervising or performing the
operations
associated
with
receipt,
generation,
storage,
and
transferring of, and servicing aircraft with aviators breathing oxygen.
2. OUALITY CONTROL REOUIREMENTS OF AVIATORS LIOULD BREATHING OXYGEN.
1. Procurement Limits, Aviators liquid and gaseous breathing oxygen,
whether it is generated by Navy and Marine activities or procured from
commercial sources, must meet the purity and contamination requirements
as shown in table 2- 1.
2. Use limits are applicable to receiving/storage tanks, servicing
equipment and converters in service shown in table 2- 1.
3. Emergency Use Limits. Following guidance is provided concerning
use of ABO under emergency conditions when liquid ABO contains a
greater concentration of contaminants than the use limit or has a low
purity. In emergency situations where an immediate decision is
essential, local commands may use the following guide for making onsite decisions on the use of such oxygen. The risk in usage is minor if
nitrous oxide (in the total absence of acetylene), methane, and
ethylene, do not exceed three times their respective use limits For
example, if an analysis of LOX from a storage tank indicates that
methane contamination is 150 ppm (3 times normal use limits), only
minor risk would be involved in its usage in an emergency situation.
However, LOX is not recommended for use when any of the following apply:
nitrous oxide (in the presence of acetylene at any concentration)
exceeds 4 ppm, carbon dioxide exceeds 20 ppm, acetylene exceeds 0.2 ppm,
or high hydrocarbons (ethane equivalent) exceed 8 ppm. In the instance
that gaseous aviators breathing oxygen is being tested, the following
will also apply: Carbon dioxide and moisture may exceed their use
limits by three times. It is imperative that the source of excessive
contamination be determined and alleviated. Thus, if the LOX sampled at
the aircraft converter outlet is found to contain excessive amounts of
a particular constituent, not only should the converter be investigated
for problems, but so should the service cart, transfer lines used, and
any other possible sources until the fault is uncovered and corrected.
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3. SAMPLING AND TESTING.
Sampling and testing of LOX at specified intervals and points in the
supply system provide the continuous monitoring of contamination that
is essential to the quality control of ABO. However, if the sample
taken does not truly represent its source, then test results cannot
serve
the
intended
purpose.
Careful
observation
of
operating
instruction for LOX samplers is important to ensure representative
samples.
1. ON-BASE TESTING.
1. Navy and Marine Corps Activities which produce liquid oxygen
shall sample and test the contents of the generator in accordance with
paragraph 2-14.1. Receipt of aviators breathing oxygen from a
contractor shall also be tested in accordance with this paragraph, and
by the following test for particulate matter, before unloading is
permitted. Periodic surveillance of storage tanks, servicing trailers
and aircraft converter systems shall be made. Table 2-2 lists the
testing and sampling equipment required to perform the particulate test:
Note: Test for particulate is only required when contamination is
suspected.
2. Particulate Test. Approximately 200 mils of the sample shall
be poured into a clean 400 ml beaker or similar container, without a
filter paper in the bottom. A watch-glass cover or some other means of
partially covering the top of the beaker shall be used as the 200 mils
of liquid evaporate to dryness. When the frost on the outside of the
beaker has melted, the outside of the beaker shall be wiped with a
clean dry cloth and the beaker placed on clean white paper. The
interior of the beaker shall be visually examined, without the aid of
magnification for the presence of particles.
4. EOUIPMENT.
Addition of contaminants from equipment shall be reduced or
prevented by operating and maintaining generators, storage tanks,
servicing carts, and aircraft oxygen systems in accordance with
applicable technical manuals.
5. SAMPLER.
1. The function of a good cryogenic liquid batch sampler is to
extract and hold a representative, unmodified sample for analysis.
Ensure the sample is not modified in the course of progressing from the
original sample point to the analytical instrument. Liquid oxygen is
more volatile than the contaminating constituents are. There is a
tendency for liquid oxygen to at least partially vaporize during the
sampling process, increasing the apparent contamination level of the
residual fluid. The higher contamination level may be high enough to
result in the sample being rejected. Good sampling procedures and
techniques are very important when drawing a sample to ensure that the
sample is representative of the contents of the equipment.
2. The USAF TTU-131/E LOX Sampler is based on the shielded cup
principle of operation. Liquid oxygen flows through the hollow shell of
the internal sample cup, cooling and finally discharging through the,
vent port. After the sample compartment is sufficiently cooled to
prevent boiling when the sample is introduced, the inlet valve is
opened and the cup begins to fill. When full, liquid again issues from
the vent port and the inlet valve is closed, trapping an exactly
measured liquid sample.
The sample vaporizes into the outer sampler
cavity; and the pressure increases to 450 psi due to evaporation. This
provides the sample for analysis.
The sampler can produce various
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contamination values for a given sample because of a separation process
that occurs in the sample cup. During the evaporation procedure, high
boiling point contaminants such as nitrous oxide and solvent chemicals
tend to remain in the liquid oxygen retained in the cup, while the low
boiling point contaminants like methane evaporate nearly as fast as the
oxygen. The passageway between the sample cup and the larger
surrounding vapor cavity is rather narrow, a higher concentration of
contaminants can be expected in the cup than in the cavity, what is in
the cavity is not representative of the extracted sample. One remedy
for this situation is to turn the sampler upside down immediately after
filling, an action that causes the liquid oxygen and contaminants to
flow out of the cup and into the cavity where the liquid oxygen
vaporizes as a homogeneous mixture.
3. The MODEL FCS 2001 Cryogenic Sampler employs the same basic
principals of the USAF TTU-131/E LO2 Sampler. The charging manifold of
the sampler consists of two cups, one inside the other. The inner cup
is a high-pressure vessel. During operation, the cryogenic liquid being
sampled is allowed to flow between the shielding cup (outer) and the
sampling cup (inner) until the sampling cup has been cooled to the
temperature of the cryogenic liquid. Once the inner cup has been cooled
to the temperature of the liquid, the inlet valve is opened to fill the
inner sampling cup. The inlet valve is closed to retain a known volume
of liquid in the cup.
The charging manifold and sample cylinder are
inverted. The pressure in the sample cylinder is allowed to build to
1300 - 1800 psig. The sample extraction valve on the cylinder assembly
is then closed and the charging manifold vented. The use of a sample
cylinder alleviates the weight problem mentioned with the previous
sampler. The sample bottle is removed from the charging manifold and
delivered for analysis.
6. ANALYSIS.
1 The acquisition of a representative sample by one of the methods
in the previous section provides us now with material for analysis. NAAG-332AO-GYD-000 sets the contamination limits, and most procurement
specifications stipulate that these limits must be met without
detailing the analytical techniques that may be used to determine
conformance with the specification. Depending on the constituent or
family of constituents being investigated, more than one method of
analysis may be feasible. NA-A6-332AO-GYD-000 provides a list of
contaminates which are of The interest. The sample should also be
inspected for moisture, and total percentage of oxygen in the sample.
There are several methods used to arrive at the percentage of oxygen in
a sample.
2. Oxygen Volumetric (Orsat type) analysis with a suitable oxygen
absorbing agent is the recommended method in this application.
Paramagnetic analyzers. because of their simplicity in field operations,
may be of some use although they are of marginal precision +I percent
at almost 100 percent oxygen concentrations. Direct gas chromatographic
analysis for oxygen is of marginal precision.
3. The Servo Mex is designed to continuously monitor the content of
a sample gas stream, which is clean, dry and non-corrosive. Oxygen
content of the sample gas is determined by measuring the relative
magnetic susceptibility The paramagnetic susceptibility of the oxygen,
is significantly greater than that of other common gases.
This means
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that oxygen molecules are attracted much more strongly than are
molecules of other gases, most of which are slightly diamagnetic,
repelled by a magnetic field. The test Cell measures the force
developed by a strong non-uniform magnetic field on a diamagnetic test
body suspended in the sample gas. The oxygen molecules are attracted to
the magnetic field enhancing the magnetic fields affect on the
diamagnetic body, two nitrogen filled quartz spheres. This causes the
spheres to move in the field. By measuring the movement of the spheres
the amount of oxygen in the sample can be determined.
4. The 8220A Analyzer is used to measure trace contaminants in
oxygen. The system gauges these contaminants by measuring the intensity
and frequency of infrared energy after it has passed through an oxygen
sample. Every chemical functional group absorbs frequencies of infrared
radiation uniquely. A plot of radiation intensity versus frequency
would fingerprint an identifiable chemical group that had polluted an
oxygen sample. The 8220A Analyzer is a modularized, bench-mounted unit
used to support flight operations. This unit is capable of scanning
aviators breathing oxygen samples for up to 15 contaminates, only 11 of
these contaminates are monitored. The unit provides an output of the
quantitative results within the limits of an established table. The
analysis shall be performed on oxygen samples at 16 psi.
5. Contaminant analysis time is IO minutes, The comparison library
has a built-in system for unknown substance composition analysis. The
system modulates radiation from an infrared source. The modulated beam
is directed into a gas cell that contains the oxygen to be sampled. A
detector monitors the gas cell and recovers information over the range
of the infrared spectrum to which the detector is sensitive. The data
that is collected is passed to data processing components for analysis
and reporting.
Infrared frequencies enter through the compartment window . Reflecting
mirrors
route and focus the energy into the gas cell containing the
gas sample during analysis. The cell is a multi-pass cell. A beam of
infrared light, entering through the gas cell input window is reflected
back and forth between the mirrors within the gas cell to achieve a
greater path length, and is passed through the output window
to a
elliptical mirror and reflected to the detector.
With increased path
length there is no requirement for a larger gas cell.
The cell has a IO-meter path length. The detector element is sensitive
to IR energy and produces an output in proportion to the energy
striking the element. The sample has absorbed some of the energy
produced by the source, depending on the chemical make up of the sample.
The absorption produces “absorption bands” that allow the data station
to identify sample contaminates.
The IR detector produces an analog
voltage output. An analog to digital converter is used to translate the
signal into a digital signal. This allows the computer to process the
data. This information is converted to a spectrum, which completes the
analysis process. The sample analysis is sent to the system printer or
stored on the hard drive or floppy disk.
Created by LTJG KyungNho "TACO" Kim
Reviewed by ENS Carol Yeiser