MGMT 203 Aircraft Systems and Maintenance – Importance to Management Module 4
THIS DAY IN AVIATION September 27 1913 — Katherine Stinson becomes the first woman in the United States to make an official airmail flight.
THIS DAY IN AVIATION September 27 1922 — Dr. Albert Taylor and Leo Young, scientists at the US Naval Aircraft Radio Laboratory, make the first successful detections of objects by “radio observation.” They use wireless waves to detect objects not visible due to weather or darkness. This insight leads to the advent of radar.
THIS DAY IN AVIATION September 27 1956 — The first piloted airplane to exceed Mach 3 is the rocket-powered Bell X-2.
THIS DAY IN AVIATION September 27 1991 — SAC forces stand down from Alert status.
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Management of Aeronautical Science Learning Objectives – Module 4 (9/26/16 – 10/9/16) Aircraft Systems and Maintenance – Importance to Management Upon successful completion of this module, you will be able to: 1. For a typical aircraft, describe the functions of the flight controls. 2. Examine the components of a typical airframe system such as fuel, landing gear and brakes, oxygen systems, air conditioning systems, pressurization systems, hydraulic systems, deice and anti-ice systems, electrical, and autopilot systems. 3. Explain the formation of shock waves on an aircraft wing. 4. Describe fly by wire primary flight controls and the advantages of this technology. Monday
Management of Aeronautical Science Learning Objectives – Module 4 (9/26/16 – 10/9/16) Aircraft Systems and Maintenance – Importance to Management Upon successful completion of this module, you will be able to: 5. Describe the three areas that most maintenance procedures are based upon. 6. Examine the scope and detail of the 100 hour and annual inspection. 7. Describe the recording and approval of Major Repairs and Alterations. 8. Differentiate between the four options to the inspection program for large turbine powered multi-engine aircraft. 9. Discuss the Continuing Analysis and Surveillance System (CASS) of an air carrier maintenance program. 10. Critique the make or buy decision and outsourcing maintenance. 11. Explain the three primary airline maintenance processes. 12. Examine quality requirements for an airline maintenance program. Tuesday Wednesday
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Discussion: Aircraft Systems: Wed Oct 5 Your post should be a minimum of 300 words with at least, two sources cited. Respond to at least two of your classmates. Your responses to classmates should be at least 100 words and contribute to the continuing conversation.
Discussion: Aviation Maintenance: Wed Oct 5
Module 4 Review Questions (Due Fri Oct 7) Spend quality time responding to the following questions in your own words. 1. Describe the primary flight controls, their movement about each axis, and location. 2. Explain the formation of the wing airfoil normal shock wave during high-speed flight. 3. Examine the scope and detail of the 100 hour and annual inspection. Who has the authority to sign off on each inspection? 4. Differentiate between the four options of the inspection program for large turbine powered, multi-engine aircraft. 5. What is the make or buy decision? Critique both sides for aviation maintenance.
Assignments Due – Module 4 (9/26/16 – 10/9/16) Management of Aeronautical Science Assignments Due – Module 4 (9/26/16 – 10/9/16) Review Module 4 Instructions for the following assignments: Discussion Board Due (Aircraft Systems) (Due - Wed Oct 5) – 2 part (Post and Respond) Discussion Board Due (Aviation Maintenance) Review Questions – Aircraft Systems and Maintenance – Importance to Management (Due - Fri Oct 7) – 5 Questions
September/October 2016 Sunday Monday Tuesday Wednesday Thursday Friday Saturday 25 26 Module 4 Intro Aircraft Systems / Maintenance 27 Module 4 Aircraft Systems / Maintenance 28 29 Beaufort County Airport (ILT) Surprise! 30 Flightline Friday 1 2 3 4 5 Discussion Due 6 7 Review Questions Due 8 9 10 Module 5 Intro Aviation Safety and Security 11 Aviation Safety and Security 12 1st Quarter Grades Due 13 14 Flightline Report Cards Sent Home 15 16 17 18 19 20 21 22
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MGMT 203 Aircraft Systems and Maintenance – Importance to Management Module 4
Autopilot System Also called Auto Flight. Controls aircraft about the three axes of flight. Relieve pilot’s workload. Automatic Flight Control System (AFCS) Consists of Autopilot Flight director Air data sensors Other avionic systems
Landing Gear Supports aircraft on ground, during takeoff, landing, and parking. Must be able to absorb extreme shocks (landing). Two basic arrangements Conventional or tail wheel configuration Lightest weight landing gear. Disadvantage is ground loop on landing. Skid or tail wheel. Nose wheel or tricycle Most popular. Main Landing Gear located behind center of gravity (CG). Nose Landing Gear located forward of CG. Ease of ground handling and landing.
Landing Gear Configurations Fixed Landing Gear Non-retractable Light weight Produces some parasite drag Wheel fairing provides streamlining or reduces parasite drag Called wheel pants Retractable Landing Gear Increased speed Reduces parasite drag. More complex and more maintenance Must employ an emergency extension system Brakes are on Main Landing Gear
Landing Gear FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 1. p. 1-36
Fuel Systems Purpose Fuel tanks Fuel strainers and/or filters Storage of fuel on aircraft Delivers proper amount of clean fuel at proper pressure 14 CFR Part 23 has details on fuel system design Fuel tanks Within the wing Integral or wet wing construction Others located in bottom central fuselage area, center wing, horizontal stabilizer, and/or internal and external auxiliary tanks. Usually has boost pumps or fuel pumps Fuel strainers and/or filters Selector valves Transfer fuel from one tank to another Select any tank to feed any engine
Fuel System FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 14-19
Fuel Systems Refueling Fuel Jettison System or Dump System Over the wing Pressure refueling or Single Point Refueling (SPR) SPR adapter for fueling truck hose connection Wing tank Fuel Level Control Valve –controls the level of fuel in tank. Has test functions Selector valves Fuel Jettison System or Dump System Required for transport category aircraft if maximum takeoff weight is 105% of maximum landing weight. Can jettison fuel from left and/or right wing
Oxygen Systems Aviator’s breathing oxygen Prevents hypoxia (lack of oxygen) and aircraft operation at high altitudes. 3 forms of oxygen carried on the aircraft Gaseous Solid or chemical (candle) Liquid (LOX) Flight deck and passenger (PAX) systems Oxygen Cylinders with valves Oxygen regulators and oxygen masks One for each flight crew members One for complete PAX system (masks for each passenger)
Oxygen Systems FAA. (2008). FAA-H-8083-25 Pilot's Handbook of Aeronautical Knowledge. p. 6-35
Air Conditioning Systems Supplies conditioned air for heating and cooling of aircraft compartments. Sources of cabin pressure (air cycle system) Jet engines supply compressor bleed air Engine Driven Compressor (EDC) Vapor Cycle System (Freon) Greater cooling capacity Many different components Beyond scope of this course
Heater Systems Combustion Heaters Electric Heaters Fuel from the aircraft fuel tank is injected into the burner area. Electric Heaters Air duct or electric operated radiant heat blankets. Engine Exhaust Heater or Exhaust Shroud Heater Reciprocating engines Jacket installed around tailpipe Carbon monoxide testers are required in cabin Air cycle air conditioning system Can supply cool or heated air dependent of position of selector valve.
Cabin Pressurization Systems Main purposes Prevents hypoxia (lack of oxygen) Permits operation at high altitudes Outflow Valve Regulates air exit or air outflow from aircraft fuselage Set by cabin altitude controller (in flight deck) Safety Valve May be built into the outflow valve or separate component Backs up the outflow valve Manual depressurization system controlled by emergency switch or handle.
Pressurization Systems FAA. (2008). FAA-H-8083-25 Pilot's Handbook of Aeronautical Knowledge. p. 6-32
Electrical Power Systems Direct current (DC) system Battery DC generator and control system Transformer Rectifier (Change AC to DC) Alternating System (AC) Alternator and controls Inverter (change DC to AC) Main electrical bus system for providing electrical power to all aircraft and engines systems. Auxiliary Power Unit (APU), Ram Air Turbine (RAT), and hydraulic motors may drive electrical generators.
Hydraulic Systems Provide pressure to operate many systems Landing gear Main Landing Gear (MLG) brakes Anti-skid brake system Nose landing gear steering system Flight controls Horizontal stabilizer trim system Doors (cargo and passenger doors) Hydraulic motors to operate emergency systems
Hydraulic Systems FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 12-7
Main Landing Gear (MLG) Brakes FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 13-49
Hydraulic Systems Components Hydraulic tanks or reservoirs Filters Boost pumps Engine driven hydraulic pumps Selector valves Actuators Motors Accumulators Stores fluid under pressure (Emergency MLG brake accumulator example) Acts as a surge damper or shock absorbing device Supplements pump when it is under peak loads
Hydraulic Systems Components Hydraulic Systems Components Hydraulic Systems Components FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 12-23
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Deice and Anti-Ice Systems There are many types of systems available Deicer boots or pneumatic deice system Boots normally installed at leading edge of wings and/or stabilizers. Weeping wing uses small holes in leading edge that allow antifreeze solution to weep out the holes. Anti-ice using exhaust heaters Thermal anti-icing and deicing systems Uses jet engines bleed air Operates whenever icing conditions are first encountered or expected to occur. Windshield Ice Control Systems Most common is electrically heated element window windshield panels.
Wing Deicer Boots FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 15-13
Wing Anti-icing Turbine compressor bleed air Wing Anti-Icing FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 15-5
Deice and Anti-Ice Systems There are many types of systems available Pitot Tube Heat System Rain Elimination System Wipe it off (Wiper system) Blow it off (Blast system) Windshield Rain Repellent (chemical removal) system Not common due to issues with hazards and corrosion
Pitot Tube and Static Ports FAA. (2008). FAA-H-8083-25 Pilot's Handbook of Aeronautical Knowledge. p. 7-2
Deice and Anti-Ice Systems There are many types of systems available Jet Engine Anti-icing System Anti-ice of inlet guide vanes, nose dome, and nose cowl Bleed air from compressor is used mostly. Fuel Deicer Operates as a heat exchanger Uses bleed air Prop Anti-icing System Ice causes a loss of blade efficiency and vibration May use fluid system Electric deicing/anti-icing system Reciprocating engines and turboprop
Ice and Rain Protection FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 15-3
High Speed Flight 4 areas of flight Below 0.75 Mach = Subsonic 0.75 to 1.2 Mach = Transonic 1.2 to 5 Mach = Supersonic Above 5 Mach = Hypersonic Speed of sound varies with changes in temperature of the air as speed of sound is a function of temperature.
High Speed Flight Shock Wave Formation (Fixed wing aircraft) Depends upon airfoil design and wind tunnel testing at different parameters. Always forms on the top of the wing first because air stream is accelerated here first. Called Critical Mach Number At flight speed of Mach 0.77, a normal shock wave develops on top of wing. Drag results aft of the shock wave Boundary layer separation At flight speed Mach 0.82, top of wing shock wave moves toward trailing edge and a normal shock wave develops on bottom of wing.
High Speed Flight Shock Wave Formation (Fixed wing aircraft) At flight speed Mach 0.95, normal shock waves move to trailing edge. At flight speed Mach 1.05, a shock wave is formed at the leading edge and is called a bow wave.
Airfoil Shock Waves Normal Shock Wave forms turbulence or possible separation From Bill Teeple SFTY 330 Course M = .77
Airfoil Shock Waves Normal Shock Wave turbulence or possible separation From Bill Teeple SFTY 330 Course Normal Shock Wave forms M = .82
Airfoil Shock Waves Normal Shock Wave Supersonic airflow turbulence From Bill Teeple SFTY 330 Course Supersonic airflow Normal Shock Wave M = .95
Airfoil Shock Waves Bow Wave Normal Shock Wave starts to form Supersonic airflow turbulence From Bill Teeple SFTY 330 Course Supersonic airflow Normal Shock Wave M = 1.05
Airfoil Shock Waves Bow Wave compresses Normal Shock Wave Supersonic airflow turbulence From Bill Teeple SFTY 330 Course Supersonic airflow Normal Shock Wave M = above 1.05
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Understand management perspective of aviation maintenance
Maintenance Maintenance is a must when considering aircraft designs or modifications. Modifications to existing aircraft are being accomplished in lieu of aircraft redesign and development. Avionics modification Aging fleet problems High cycle aircraft can result in initial fatigue cracking of the complete airline fleet . Most aircraft designs include redundancy Backup systems Prevents effects of failure on safety
Maintenance Practices Good and reliable maintenance assures an item stays as reliable as initially designed. Reliability = safety Good maintenance practices provide Reliability and safety Insure customer satisfaction Insures equipment utilization Increases confidence in the public's eyes
Maintenance Procedures Most maintenance procedures are based on Hours or Time Cycles Landing gear retractions and extensions Engine starts and operation Chronological time/calendar Accomplished in accordance with Title 14 CFR(s) and manufacturers’ procedures. Adequate inspection is a must
Title 14 CFR Requirements Aircraft, rotorcraft, engine, and propeller Airworthiness Regulations and 14 CFR Part 39: Airworthiness Directives (AD) (previously discussed) 14 CFR Part 21 Certification Procedures for Product and Parts Provides requirements for replacement parts and approvals Part 21.303 replacement and modification parts require all replacement parts used on an aircraft must be produced under a Parts Manufacturer Approval (PMA). 4 exceptions Parts approved under a type or production certificate. Parts produced by an owner or operator for maintaining or altering his own product. Parts produced under a Technical Standard Order (TSO). Standard parts such as fasteners, safety wire, etc.
Title 14 CFR Part 43 Title: Maintenance, Preventive Maintenance, Rebuilding, and Alteration. Aircraft having a U.S. Airworthiness Certificate Includes airframe, engines, and propellers Logbook Entries for inspections and repairs Appendix A: Lists Major repairs Major alterations Preventive maintenance
Title 14 CFR Part 43 Appendix B Recording of Major Repairs and Major Alterations FAA Form 337 Person performing repair completes form Form completed by the A&P Approved by person with an Inspection Authorization (IA) Appendix D Scope and Detail of Annual and 100 hour Describes the inspection requirements
Title 14 CFR Part 43 Appendix E Altimeter System Test and Inspection Appendix F ATC Transponder Tests and Inspections Note Aircraft manufacturer may perform alterations, maintenance, and inspections. If special tools or testers are required by aircraft manufacturer you must use them.
Title 14 CFR Part 91 Title: General Operations and Flight Rules Has maintenance requirements Includes the requirements for maintenance, inspection, and record keeping. General Aviation Inspections Each aircraft must undergo an annual inspection once during each 12 calendar months. Inspector Authorization (IA) Scope and detail in Part 43 In addition to above requirement aircraft that are used for hire must be inspected each 100 hours of operation. A&P
Title 14 CFR Part 91 Progressive Inspection An alternative to the 100 hour/annual inspection Breaks up and change the 100 hour/annual inspection into smaller/shorter inspections for compliance at a different hourly or calendar time basis. Complete inspection must be accomplished in 12 calendar months. Supervisory requirement IA Certified repair station Aircraft manufacturer
Title 14 CFR Part 91.409 Large Turbine Powered Multi-engine Aircraft Provides 4 options to the inspection program Continuous Airworthiness Program Part 121 (airlines or air carrier) Air Taxi Operator Program (Part 135) Aircraft with more than 10 passenger seats. Manufacturer's Inspection Program Owner-Operator Developed Inspection Program approved by FAA.
Preflight Inspections Requirements can be found in Approved Flight Manual Pilot's Operating Handbook Maintenance Manual Additional inspection requirements Mandatory inspections 14 CFR Part 91 - Pilot is responsible for determining the airworthiness of the aircraft before flight Pilot must conduct inspection 14 CFR Part 135 and Part 121 have requirements for inspection Check company procedures For an example maintenance personnel may perform an in-depth preflight Flight crew may perform a preflight walk around visual and check of equipment
Special Inspections Detailed in aircraft maintenance manuals 3 common types Hard or overweight landing inspection Severe turbulence inspection Lightning strike inspection
14 CFR Part 121 Airlines Maintenance Title: Certification and Operations: Domestic, Flag, and Supplemental Air Carriers and Commercial Operators of Large Aircraft. Continuous Airworthiness Program (airlines or air carrier) FAA approves the air carrier's maintenance program and any changes to the program Time limitations Inspections Overhauls Effectiveness of preventive maintenance
14 CFR Parts 121 Airlines Maintenance Part 121.131 Manual Requirements Often called Air Carrier Manual. For use and guidance of flight and ground operations personnel. Both operational specification and manual are laws to follow after accepted by FAA. Part 121.135 Provides detailed requirements for manual contents. Part 135 also has a manual requirement
14 CFR Part 121 Operator's Maintenance Manual Part of the air carrier manual or may be a separate manual. Define the continuous airworthiness maintenance program. Prescribes the authorizations, methods, standards, and procedures of maintenance. Has 3 general categories Policies and Procedures. Detailed Instructions for accomplishment of the scheduled inspection program. Technical manuals for maintenance standards and methods. Part 121 and 119 specifies the time limitations for overhaul, inspections, and checks set forth in the operations specifications.
14 CFR Part 119 Operations Specification (OpSpec) Issued to air carriers Lists authorizations and specifications Legally binding and has 8 broad categories General Enroute authorizations and limitations Airport authorizations and limitations Maintenance Weight and Balance Schedules Equipment interchange Aircraft leasing
Airlines Maintenance 3 Primary Maintenance Processes Hard Time (HT) (Time Changes) Overhaul time limits or part life limit. Dates back to the origin of aviation. On-Condition Maintenance (OC) Repetitive inspections or tests must be accomplished, at specific intervals. Requires periodic inspected for serviceability. Condition Monitoring (CM) Depends upon data collection and analysis. Analysis of failures to improve performance.
5 Types of Maintenance Inspection Unscheduled Maintenance Tasks performed at specific intervals Routine and non-routine Unscheduled Maintenance Basically a discrepancy and corrective action process Maintenance or flight crew discrepancies Major Repair and Overhaul Sometimes called Depot Repair Shop operations Preventive Maintenance Directed to the prevention of failure Proactive in nature Required Item Inspection (RII) 2 A&Ps must sign maintenance documents
AC 120-16F Air Carrier Maintenance Program Explains the meaning, scope, and content of the maintenance program. 10 Elements of the air carrier program Airworthiness responsibility Air carrier maintenance manual Air carrier maintenance organization Accomplishment and approval of maintenance and alterations Maintenance schedule Required Item Inspection (RII) Usually 2 A&Ps will sign off the maintenance task Maintenance recordkeeping system Contract maintenance Personnel training Continuing Analysis And Surveillance System (CASS)
Airline Maintenance Checks Airlines undergo periodic checks from simple, routine examinations to detailed inspections. Specifically stated by airline in their procedures. The information below is an example only A Check The shortest and simplest work Performed every 300 hours of operation
Airline Maintenance Checks B- Check Incorporates "A" check requirements Often is 600-hour intervals or every 6 months More detailed examinations May require some disassembly of airframe over the one-to two-day process C- Check Performed every two to three years Includes all elements of “A" and "B" checks Some disassembly Detailed aircraft & engine examinations Often lasts a week or longer
Airline Maintenance Checks D-Check Every 6 years Requires complete structural and systems examination and testing including engine removals. Several weeks to months depending upon aircraft condition. Equivalent to Military Depot level maintenance.
Make or Buy Decision Make is company does their own maintenance Buy is company outsources or contracts out Called 3rd party maintenance Maintenance, Repair, and Operations facilities Consider 4 key areas for make or buy decisions Comparative costs Labor relations Quality of work Flexibility
3rd Party Maintenance Contracting out decision Most 3rd party facilities are well established and expanding Services performed Modifications Overhauls Letter checks Especially C & D (Heavy maintenance) Corrosion control and painting Avionics upgrades Cargo conversions Maintenance away from company base or line stations
14 CFR Part 145 Repair Stations Considered 3rd party maintenance Discussed previously in course Repairman certified under Part 65 Many different types and classifications of repair stations
3rd Party Types of Contracts Maintenance Labor only agreement Labor and parts agreements Preventive maintenance Complete maintenance management Complete major repair, modification, and alterations
Maintenance Costs Some examples Maintenance personnel and support Spare/repair parts Test and support equipment maintenance Maintenance training Maintenance facilities Technical data changes Technical manuals/data Transportation and handling
Managers’ Perspective Understand the basics of Maintenance Management Considerations Minimum Equipment List (MEL) Deferred Maintenance Items (DMI) Maintenance personnel duty time limitations Physical fatigue can lead to mistakes, incidents, and accidents. See 14 CFR Part 121 for air carrier maintenance personnel.
Maintenance Planning and Controlling Maintenance planning is coordinated with the flight department or operations. Scheduling is very important to verify the following are available Parts Personnel for shifts Special equipment (jacks, engine change equipment, etc.) Inspection work cards, types, and frequencies Airworthiness Directives (ADs) Life limiting or time change parts Corrections of deferred maintenance items (parts and processes) Corrosion control and painting
4 Categories of Inventory Aircraft-on-ground (AOG) waiting parts is another critical management responsibility. 4 Categories of Inventory Raw materials Work in Progress (WIP) Finished goods Parts, components, engines, etc. Maintenance, Repair, and Operating (MRO) Stock Bench stock Bolts, washers, nuts, gaskets, and rivets, etc.
Inventory Costs Unlimited inventory Minimum inventory Financial drain on the company Minimum inventory Aircraft grounded Parts canned (removed) from another aircraft Growth of deferred maintenance items (DMI)
Inventory Costs Inventory Carrying or Holding Costs Ordering Costs Considered warehousing and material handling. Costs of maintaining and handling materials and inventory for a specific period of time. Ordering Costs Considered purchasing and transportation costs Costs of placing and receiving an order Total Costs = carrying costs + ordering costs
Conformance to customer requirements Quality Conformance to customer requirements Conformance to specifications or standards Airlines 14 CFR Part 121.373 requires the operator to provide a system of continuous analysis and surveillance. Repair Stations require a quality program under 14 CFR Part 145.
Quality Control Process of Consists of Measure actual performance Compare it with specifications Take action if difference Consists of Inspection Acceptance Reporting or Feedback Evaluation of personnel and procedures
Quality Assurance (QA) Oriented to prevent quality problems Emphasis on feedback and corrective actions Evaluates such functions as Reliability reports Audits Component tear-down reports Inspection procedures and results Tool calibration program Cause of any recurring discrepancy Investigation of FAA write-ups
ISO 9001:2008 ISO = equal or uniform International Organization for Standardization (IOS) Headquartered in Geneva Requires quality manual, process, procedures and work instructions. New spec is ISO 9001:2015 ISO 9001:2008 is still being used
ISO 9001:2008 Provides guidance for an effective quality management system (QMS) Company must manage the process Process control Top management support Documentation is a key factor Continuous improvement
AS9100 Aerospace Standard Aerospace Industry Specification Follows requirements of ISO 9001 by requiring specific requirements for the aerospace industry quality and safety. Released in 1999 by Society of Automotive Engineers (SAE) and European Association of Aerospace Industries.
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