1. King Fahd University of Petroleum and Minerals Mechanical Engineering Department Presented by Mohammad Hazzazi ID# 997584 19/10/2004

2. WELCOME TO MY CO - OP PRESINTATION

3. Title PROCESSES AND QUALIFICATIONS FOR REPARING AND OVERHULLING AIRCRAFT COMPONENTS

4. OUTLINE : GENERAL BACK GROUND ABOUT THE (AACC) MY COOP PROGRAME PRODUCTION AREA ENGINEERING OFFICE STUDY CASE CONCLUSION

5. GENERAL BACK GROUND ABOUT THE COMPANY : The Aircraft Accessories and Components Company (AACC ltd) is an economic offset company established under the Ministry of Defense and Aviation, to repair and overhaul aerospace accessories and components. (AACC) has 28 million in paid up capital. There are two investors for the (AACC); Operations and Maintenance Company (OMC) with86% and Saudi Arabian Airlines with 14%.

6. The Aircraft Accessories and Components Company (AACC ltd) Building

7. WHAT DOES THE AACC DO? 1-Stripping/Disassembly: C-130 Propellers of Hamilton Standard C-130 Valve Housing C-130 Pump Housing C-130 Reduction Gearbox F-15 Airframe Mounted Accessory Drive Gearbox F-15 Jet Fuel Starter F-15 Fuel Control System Assembly: F-15 Airframe Mounted Accessory Drive Gearbox F-15 Fuel Control System F-15 Shafts C-130 & F-15 Bearing cleaning and assembly. Other……….

8. CO-OP TRAINING ASSIGNMENTS C.O-OP K.F.U.P.M STUDENT NAME:Mohammad Hazzazi CO - OPENGINEER AREA START DATE FINISH DATE TIME PERIOD COMMENTS MACH.SHOP 7/2/2003 18/2/2004 2 WEEKS FUEL CELL 21/2/200425/2/2004 1 WEEK PROCESS 6/3/2004 10/3/20041 WEEK ASSY - TEST 13/3/2004 20/3/2004 3/4/2004 17/3/2004 31/3/2004 7/4/2004 1 week 1 week 1 WEEK BALLSCREW AMAD / C.G.B. R.G.B. INSPECTION 19/4/200421/4/2004 3 DAYS TOTAL 11 WEEKS ENG. OFFICE 24/4/200411/8/2004 17WEEKS MY COOP PROGRAME

9. PRODUCTION AREA INTRODUCTION MACHINE SHOP AREA Fuel Cell PLATING AREA PROCEES AREA ASSEMBLY AND DISASSEMBLY AREA INSPECTION AND NON-DESTRUCTIVE TESTING AREAS (NDI):

10. 1-MACHINE SHOP AREA

11. The purpose of cell repair is to return a cell to a serviceable condition, to restore its ability to carry the maximum load permitted. 2- Fuel Cell The entire procedure for repair and inspections of cells requires knowledge, experience and skill. Repair of fuel cells shall be accomplished in warm, dry place. The temperature should be controlled to maintain 60 to 90 degrees Fahrenheit (15 to 32 C˚)

12. 3- PLATING AREA In this area, treatment by chemical solutions takes place. It serves two purpose : 1- Protect components against corrosion by providing a protection layer on their surfaces. 2- Increase the material size of some items. Blade : hot cleaner  cold swill  chromic anodize

13. 4- PROCEES AREA This area to overhaul, clean and repair the blades and their components. Also called the work area because it do a lot of pre work for the components before it is passes to other areas. This area contains 6 main sections. These sections are : Panting section Breaks repairing sectionBreaks repairing section Measuring sectionMeasuring section Deicing sectionDeicing section Moulding sectionMoulding section Jet water sectionJet water section

14. The station of the blade measurements. The edge alignment measurements. The thickness for each station. The angle. The face alignment. The width. 4-a :Measuring section:

16. 4-b :Jet water section This section is for removing foam from blades beside the lead at the end of the blade using special machine called “ the jet water". This machine can pump water up to 20,000 psi. The necessary pressure to achieve the previous target is 10,000 psi.

17. CGB> 1000 hrs→ overhaul < 1000 hrs→ repair. RGB> 5000-hrs→ overhaul < 5000-hrs→ repair Propeller> 2000 hrs→ overhaul < 2000 hrs→ repair AMAD > 500 F→ overhaul < 500 F→ repair. 5- ASSEMBLY AND DISASSEMBLY AREA In the stripping (disassembly) area, the technician receives the parts and stripes them according to the QPI (Quality Production Inspection Schedule).

19. INSPECTION AREA NDT The magnetic particle NDT method The fluorescent penetrant NDT method 6- INSPECTION AND NON-DESTRUCTIVE TESTING AREAS (NDI):

20. 7- ENGINEERING OFFICE

21. WHAT A MECHANICAL ENGINEER IS DOING Mechanical engineers at AACC have a group of jobs and activities to do. The most important thing of these jobs and activities is the First Article Qualification Projects (FAQ). Whenever a new part that has never been to or reworked at AACC is delivered to company, some procedures have to be followed

22. QPI Standard Replacement List ( SRL ) Scrape / Serviceable Parts View Inspection

23. STUDY CASE:

24. I was asked to do the First Article Qualification (FAQ) Project to develop the capabilities to overhaul and repair for the (Four Inch Diameter Pneumatic Butterfly Shutoff Valve). The engineer responsible for this project asked me to analyze and put procedure for repairing such Butterfly Shutoff Valve. Finally he told me to write my observation on a report and handle it to him to review it.

25. The four-inch diameter pneumatic butterfly shutoff (load control) valve, located on an outlet port on the top right side of the turbine plenum assembly, functions as a bleed-air shutoff and load control valve for compressed air output. The load control valve includes a butterfly valve, a rate control and pneumatic actuator, solenoid valve and a poppet valve along with diaphragm assemblies, linkages and connection. ANALYSIS:

27. 1- Writing the QPI 2-Strip Disassembly 3- P arts Names : Work Step: 1.Body assembly 3. Arm, Linkage 2.Body, Actuator 4. Housing, Actuator 3. Retainer, Piston 6. Link, Intermediate See page 48 QPI

28. Need Special Tools

29. Seal Metal Puller

30. Inspection

31. HELPING THE ENGINEERS M1A2 TANK

32. Design Tools

33. Conclusion FAQ QPI Team work JOP