SISCAL Outsourcing

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SGCP Operator Training and Portable Pressure
Calibrator Outfitting Update
Kathy Saunders NAVSEA TMDE
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OVERVIEW

• Course Description
• Proposed Master Course Schedule
• Training Improvement Process
• Work to Date
• Schedule
• Current Efforts for PPC Fielding
• PPC Outfitting Metrics
• Outfitting Issues

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SGCP OPERATOR COURSE CIN A-652-0500X

• COURSE DESCRIPTION
• Course Mission Statement
• The Surface Shipboard Gage Calibration Operator
  course is designed to provide selected naval and
  other authorized personnel with the knowledge and
  skills to operate Surface Shipboard Gage
  Calibration Standards.

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Master Course Schedule (proposed)

• Training to include use of PMS MIP Series
  9802/XXX (9802/001 for 1127 9802/004 for 3666
  9802/PPC for 3731 9802/002 for 3604 9802/003
  for 3605 9802/006 for TSD 650)
• Planned inclusion to course curriculum is
  Differential (Barton) Gages and Detroit Style
  Switches. Modifications will include the
  addition of knowledge material to Topic 2.1
  (Pressure Principles) and Topic 3.1 (Temperature
  Principles). Development of practical
  application Job Sheets for pressure and
  temperature calibration of these gages and
  switches are required in Labs 1-4. The technical
  manual reference is S700-B4-PRO-010.

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Training Improvement Process

• PPC, Torque, SGCP TECH Data will be added to
  current curriculum
• In order to update Current Training
• Navy Systems Training Plan (NSTP) must be updated
  
• Draft is complete (pending approval/final course
  rev)
• Torque and Portable Pressure Calibrator to be
  included
• Legacy equipment retained
• 1040C is not included in the current POI per
  TYCOMs
• Front End Analysis (FEA) must be completed
• Gaps identified have been incorporated into the
  POI
• CRL, 9802 MRCs, Safety, Barton Gages, Detroit
  style switches, New pressure and torque standards
  added.
• Business Case has been developed, pending review
• Proposed Course length extended to 7 days review
  by CNET, TYCOMS
• Standards Repair Course at Corry Station - Not
  reviewed

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WORK TO DATE

• Updated NTSP, BCA and FEA
• Changes pending final COI review and update
• PPC OEM delivered training incorporated into
  waterfront training
• Provided to CNE Norfolk 3 instructors
• CNE has reviewed courseware provided by NAVSEA 04
  
• Waterfront training is in place and on-going
• Developed initial outfitting strategy to support
  PPC delivery to ships
• TYCOMS coordinating
• Completed rewrite of modules 1.1, 1.2, 4.1, 4.2
• Staffed to SYSCOM Subject matter experts
• Legacy Course material converted to WORD Format
• To aid in material review comments/track change
  process

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SCHEDULE 2009
Event Comp Feb Mar Apr May Jun Jul Aug Sep
Review Requirements 100
Receive OEM Training Material 100
Draft FEA / Task Analysis 100
Draft BCA 80 X F
Draft NTSP 80 X F
COI Revisions 50 X X X X
SME TYCOM Review 30 X X X F
Conduct Pilot TBD X
X Activity C draft due F
document finalized
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CURRENT EFFORTS For PPC Fielding

• Two Step approach near term
• Initial outfitting training support (IN PLACE)
• Major basins
• Sustainment Training long term
• Provided by CNE sites as Surface Ship training
• TYCOMS and Subject Matter Experts to review COI
• Master Schedule, Modules 1.1, 1.2 and 4.1, 4.2
  under review now.
• Temp, Pressure, Barton and Detroit switch modules
  to follow

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PPC Outfitting Metrics
BASIN BAHRAIN EVERETT GAETA GROTON GUAM MAYPORT NORFOLK PEARL HBR SAN DIEGO SASEBO YOKOSUKA SCN
                         
ACU             2   2      
AS   1     1              
CG           4 6 3 7   2  
DDG   2       4 21 6 10   7 6
FFG   3       12 6 2 7      
LCC     1               1  
LCS                 1      
LPD             2   4 1   3
LSD             6   4 2    
MCM 3               9 2    
MST             4   1      
SSN   4   15 3   8 15 5     5
                         
TOTALS 3 10 1 15 4 20 55 26 50 5 10  
FIELDED TO DATE 0 0 0 2 1 9 31 1 16 5 10 14
Total sets outfitted to date OPN 75 sets SCN
14 sets
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PPC Phosphate ester issue

• From Naval Ships Technical Manual 556
• 556-5.1.3 SYNTHETIC FIRE RESISTANT FLUIDS
  (PHOSPHATE ESTER BASE). Tertiary butylated
  triphenyl phosphate fluids per MIL-H-19457 have
  been used in aircraft elevators and other surface
  ship hydraulic systems where a fire resistant
  fluid is required. The current formulation,
  MIL-H-19457 Revision C and later is not toxic and
  less irritating than earlier formulations. The
  improved formulation is recognized by its blue
  color while the earlier formulations were green
  in color. Use only fluids in containers marked
  MIL-H-19457 Rev C, or later. Care is required in
  handling MIL-H-19457 fluid. See paragraph 556-5.2
  for handling precautions and protective
  equipment.

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PPC Phosphate ester issue

• From TAMS Executive Board meeting March 24, 2009
• NAVSEA TMDE will establish a engineering study to
  evaluate the viability of the proposed Heavy Duty
  Exception Trap for use with fluids as identified
  by NAVSEA/NAVAIR used in conjunction with
  aircraft and ammunition elevators onboard
  air-capable vessels.
• Testing to be accomplished at two sites NSWCCD
  Philadelphia and NSWC Corona
• To date request into King Nutronics on part
  ordering information on four traps for testing.

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Outfitting Issues to Date

• Use of Teflon tape on the hand pump output
  fitting. These are AN fittings and Teflon thread
  tape should NOT be used when making AN
  connections.
• Additional priming to overcome the lack of
  humidity within the hand pump. Priming required
  to re-moisturize internal seals to minimize
  pressure leaks.
• During outfitting in Pearl Harbor, contaminants
  have been found during initial priming in several
  of the sets recently delivered to Navy. Report
  with findings has been sent to King Nutronics who
  is working with their suppliers to determine
  source of debris.

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POC LIST

• NSWCCD-SSES 953 SISCAL ISEA
• Ed Gormley [phone]
• SISCAL.NSWCCD.FCT_at_navy.mil
• NAVSEA
• Kisan Pandit SEA 04RM3 [phone]
• Technical Warrant Holder
• Dave Young SEA 04RM32 [phone]
• SISCAL Program Manager
• Kathy Saunders SEA 04RM34 [phone] ext 131
• TMDE Program Manager 9acting) PPC Initial
  Outfitting, ILS
• Jeff Anderson SEA 04RM34 [phone] ext 127
• TMDE Deputy Program Manager PPC Calibration
  logistics
• Contractor Support
• Mike Litwin CACI [phone]

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Questions ?
Email me at Kathleen.saunders_at_navy.mil
Ideas, comments and suggestions ?
Call me at 757-396-0248 ext 131
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Backup Slides
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SGCP Training Backup Slide

• STUDENT THROUGHPUT
• AFLOAT TRAINING GROUP, MID PACIFIC 72
• CENTER FOR NAVAL ENGINEERING, NORFOLK 225
• CENTER FOR NAVAL ENGINEERING, SAN DIEGO 126
• GROTON 64
• TRAINING SUPPORT, WEST PACIFIC 108
• BANGOR 144
• KINGS BAY 144
• KINGS BAY MTT 48
• RMCs ?
• Guam ?
• ATTRITION 0
• LENGTH
• LENGTH 5 DAYS
• CLASS HOURS 23
• LAB HOURS 17

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Master Course Schedule

• Day 1
• Topic Curriculum Time (Hrs)
• 1.1 Course Indoctrination and Orientation 1
• 1.2 Navy Metrology and Calibration (METCAL)
  Shipboard
• Instrumentation
  and Systems Calibration (SISCAL) 2 (orig is 3)
• 2.1 Pressure Calibration Concepts and Principles
  3 (orig is 4)
• 2.2 Principles of Operation and Application of
  1127 Pressure Unit 2 (orig is 1)
• Day 2
• Exam Lab Safety Demonstration (includes written
  knowledge test) 1
• Lab 1 Demonstration and Trainee use of 1127
  Pressure Unit 3 (orig is 2)
• 2.3 Principles of Operation and Application of
  3666 (series) Pressure Unit 2
• Lab 2 Demonstration and Trainee use of 3666
  (series) Pressure Unit 2 (orig is 2)
• Day 3
• Lab 2 (cont) Trainee use 3666 (series)
  Pressure Unit 1
• 2.4 Principles of Operation and Application of
  3721 (series) PPC Units 3
• Lab 3 Demonstration and Trainee use of 3721
  (series) PPC Units 4

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Master Course Schedule

• Day 4
• Topic Curriculum Time (Hrs)
• Lab 3 (cont) Trainee use of 3721 PPC
  Units 4
• 3.1 Temperature Calibration Concepts and
  Principles 1 (orig is 2)
• 3.2 Principles of Operation and Application of
  3605/3604 Thermo Unit 2
• Lab 4 Demonstration and Trainee use of
  3605/3604 Thermo Unit 1 (orig is 4)
• Day 5
• Lab 4 (cont) Demonstration and Trainee use of
  3605/3604 Thermo Unit 2
• 4.1 Torque Calibration Concepts and Principles
  2
• 4.2 Principles of Operation and Application of
  TSD 650 Torque System 1
• Lab 5 Demonstration and Trainee use of TSD 650
  Torque System 3 (orig is 2)
• Day 6
• Exam Knowledge test (written) 2
• Exam Performance (Lab) 6
• Day 7 (TBD)
• Introduction to Calibration of Barton
  Gages 1.5
• Introduction to Calibration of Detroit
  Switches 1.5

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Heavy Duty Exception Fluid Kit

• Kit will be contained in a Pelican type transit
  case of approximate dimensions 16" x 13" x 6".
• Kit Contents
• 1/ea. 3ft test hose
• 1/ea. 6ft. test hose
• 1/ea. Heavy Duty Exception Fluid trap (see
  attached photo) Constructed of stainless steel,
  EPDM o-rings and borosilicate armored glass.
• 1/ea. Adapter fittings kit
• 1/ea. Exception trap adapter kit (45 and 90
  degree elbow fittings, stainless steel) 1/ea.
  Exception trap o-ring kit
• Volume of trap is 3.7 oz., much larger than the
  standard trap provided with the 3731 (1.5 oz.)
• Total Price per kit 4,056.00

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PPC HEAVY DUTY EXCEPTION KIT
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PPC HEAVY DUTY EXCEPTION TRAP
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OEM Testing Report
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Configuration
For Fresh (potable) Water, Air and Refrigerants
Part number 3731-2-1 SCAT 5089 NSN 7Z
6625-01-550-3898
For Hydraulic oil, Seawater and Exception Fluids
Part number 3731-3-1 SCAT 5090 NSN 7Z
6625-01-550-4306
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Configuration

• Model 3731 Portable Pressure Calibrator
• Kit is comprised of
• One Druck Hand pump part PV411A
• Four Crystal Engineering Digital Pressure Gages,
  part
• 3731-31-30 3731-31-300 3731-31-3000
  3731-31-6000
• Hose kit assembly
• Hydraulic Reservoir assembly
• Hydraulic exception fluid trap assembly
• Accessory Kit
• Adapter Fittings Kit

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METRL Entries
3731-2-1Pneumatic Portable Pressure Calibrator
CAGE 13859 (listed as SR) 3731-3-1 Hydraulic
Portable Pressure Calibrator CAGE 13859 (listed
as SR) 3731-31-30/300/3000/6000 Pressure Head
CAGE 1PS62 (listed as 24 months) PV411A
Portable Pressure Hand Pump CAGE 1CE49 (listed
as NCR) Note ALL entries to be reflected by JUNE
2009 METPRO