Technical Procedures Manual

Part 2 – Maintenance Procedures

Issue :3
Revision :0 Inspection Standards
Date : 07/05/2004
Resp. Manager : MAM
TPM-02-02-01
Inspection Standards

1. Purpose

1.1 This procedure defines the level of inspection prescribed in the Approved
Maintenance Programmes and associated work documents.

2. Scope and Responsibilities

2.1 It is the responsibility of all Maintenance Section Staff to ensure that inspection
standards are adhered to and complied with at all time.

3. Procedure

3.1 General

3.1.1 All routine inspection requirements are specified in the appropriate

Maintenance Programme and work documents, which currently employ
differing terminology. This procedure rationalizes the differences in
terminology until the various Maintenance Programmes and work
documents are progressively standardized.

3.2 Inspection Levels

3.2.1 The inspection levels defined are listed in ascending order of intensity.
They are all specified in order to detect defects that would impair
airworthiness or cause an unacceptable economic penalty if not corrected
prior to the next routine inspection.

3.2.2 They are intended to provide a substantive degree of guidance but they
do not define the absolute inspection requirements for every requirement.
In many cases the nature of the area or item being inspected and its
location will influence the precise type of inspection carried out. In some
instances Maintenance Programmes will amplify the requirements by e.g.
requiring an aircraft to be in a particular configuration.

1. Walkround Inspection:

A visual inspection from the ground, walking as close as

necessary to detect obvious damage, leaks and other
discrepancies which would impair continued airworthiness.
Performed in the prevailing environment and the only lighting
normally required is a hand torch.

2. General Visual Inspection:

Is a collective term, which includes the following:

(a) A visual inspection normally from the ground, walking as

close as necessary to detect obvious damage, leaks and
other discrepancies which would impair continued
airworthiness. In some instances it is necessary to view
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Part 2 – Maintenance Procedures
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Revision :0 Inspection Standards
Date : 07/05/2004
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from a particular location and this will be stated where,
required. Good environmental conditions necessary to
perform an adequate check are required.

(b) A general Surveillance Inspection (Zonal Inspection) in a

good light of the whole area/zone specified to detect
damage/discrepancies in structure, system/powerplant
installations and components which would impair continued
airworthiness.

The inspection must be of sufficient depth to establish that any

significant deterioration is identified and rectified to ensure that the
general quality/condition of the zone/area is satisfactory until the
next higher inspection becomes due.

The extent of the inspection is defined by the access, identification

of access doors/panels, positioning of surfaces and removal of
linings. The whole of the area/zone is to be inspected as visible
with the relevant access open.

External surveillance may require the use of workstands/steps to

gain the necessary proximity to perform an adequate check.

Internal surveillance will utilise inspection aids in the form of

additional lighting, mirrors and cleaning may be required to gain
the necessary proximity to perform an adequate check.

3. Detailed Visual Inspection:

A close intensive visual inspection with good lighting of a highly

defined structural detail, system detail, component or location to
detect damage/discrepancies, which would impair continued
airworthiness. This inspection may involve the removal of
soundproofing or other equipment and the use of a hand lens.

4. Special Detailed Inspection:

An inspection of a specific location or hidden detail using specified

non-destructive inspection techniques to detect
damage/discrepancies, which would impair continued
airworthiness.

3.3 Non Routine Inspections

3.3.1 Entry Inspection

Must be carried out whenever an area is entered or disturbed in order to

carry out routine servicing, rectification work or a detail inspection within
an area that is not aligned to that area’s surveillance inspection. The
inspection is carried out from the vantage point gained to carry out the
specified task and must ensure that no obvious defects exist.

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Part 2 – Maintenance Procedures
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Revision :0 Inspection Standards
Date : 07/05/2004
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3.3.2 Closure Inspection

Must be carried out when work has been completed in an area just prior to
closure of the area. The inspection must ensure that no obvious defects
exist and in particular freedom from foreign objects.

3.4 Inspection Standards

3.4.1 The inspection standard to be applied to the levels of inspection where the
term “check” or “inspect” are specified will be defined as follows.

3.4.2 Where the term “check” is specified in the programme:

1. That the item is to be inspected (externally and 'in-situ' unless

otherwise stated) to a degree at least sufficient to ensure that it will
remain serviceable until the next scheduled inspection of the item.

2. That the item is, at the time of inspection, free from any observed
defects, likely to affect airworthiness.

3.4.3 Where the term “inspect” is specified in the programme:

1. That the Zone/System/item/Component Inspection is of sufficient

depth to establish that any significant deterioration/defect is
identified and rectified to ensure the airworthiness will be
maintained until the next higher scheduled inspection is due

3.4.4 The inspection/check must comply with the minimum standards set out
hereunder having regard to the environment of the material which the
Zone/System/Item Component is constructed. The depth or degree of
application being at the discretion of the signatory.

3.4.5 Metal Parts

All structural members, honeycomb bonded structure, bodies or castings,

or units in systems, instruments, electrical and radio installations, metal
pipes, ducting, tubes, rods, levers, etc.

Inspect for:

Cleanliness, external evidence of damage, leaks, overheating, or

discharge, including obstruction of drainage or vent holes or of overflow
pipes and orifices. Aerodynamic smoothness of fairings and serviceability
of fasteners/security of attachment fasteners and visible connections,
locking and bonding

Freedom from:

Cracks (visual) distortion, scores, chafing, evident wear, pulled or missing

fasteners, e.g. rivets, bolts, screws. Separation of bond, failure of welds

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Revision :0 Inspection Standards
Date : 07/05/2004
Resp. Manager : MAM
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and spot welds. Deterioration of protective treatment and corrosion,
sealing of fairings and fluid ingress.

3.4.6 Rubber, Fabric, Fibre Glass/Composites And Plastic Parts

Honeycomb bonded structures, composite skin sections, control surfaces,

frames, fairings and radomes. Ducting pipes, flexible mountings, seals,
windows and the insulation of electrical cables.

Inspect for:

Cleanliness, external evidence of damage, obstruction of drainage or vent

holes. No evidence of fluid soakage/ingress; or failure of joints. Protective
treatment or finish intact.

Freedom from:

Splits, cracks, scores, disbond, delamination, distortion or crushing. Cuts,

chafing, kinking, twisting, contraction and sufficient free length.
Deterioration, crazing, loss of flexibility, overheating, fluid seepage and
contamination. Security of attachments (supports, packings and electrical
bonding correctly positioned, serviceable and secure), connections and
locking. Distortion of attachment holes if dismantled.

3.4.7 Control System Components

Inspect for:

Correct alignment - no fouling. Free movement, distortion, evidence of

bowing, scores, fraying, kinking, evidence of wear flattening, cracks and
loose rivets. Deterioration of protective treatment, corrosion. Electrical
bonding correctly positioned, undamaged and secure. Attachments,
connections and locking secure.

3.4.8 Electrical Motors, Alternators, Generators and Actuators

Inspect for:

Cleanliness, obvious damage, evidence of overheating, corrosion and

security-of attachments and connections. If protective covers are required
to be removed:- Cleanliness, scoring, pitting, brushes free in holders, not
excessively worn and correct bedding. Adequate spring tension,
overheating and fluid ingress.

3.4.9 Relays, Solenoids and Connectors

Inspect for:

Cleanliness, obvious damage, corrosion, evidence of overheating, security

of attachments and connections. If protective covers are required to be
removed:- Cleanliness, pitting, or burning of contacts, evidence of
overheating and security of contacts exposed.
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Part 2 – Maintenance Procedures
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Revision :0 Inspection Standards
Date : 07/05/2004
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3.4.10 Batteries

Inspect for:

Corrosion, spilt electrolyte, security and cleanliness, attachment of

terminals, condition of case and vent system.

3.5 Inspection Frequencies

3.5.1 The inspection frequencies are detailed in the Approved Maintenance

Programme.

3.5.2 It is necessary to know when the next routine inspection is due so that a
judgement can be made on whether an observed level of deterioration will
develop into a positive defect before the next inspection and to determine
whether any degree of rectification is required.

3.5.3 All inspection Maintenance Programme references are cross referenced

on work documents, hence the inspection frequency can be readily
established.

3.6 Removal Of Parts

3.6.1 All the above inspection requirements are intended to be carried out
without the removal of any parts except where specifically required in
Maintenance Programme or task card. However, this does not preclude
the removal of parts on an unscheduled basis should the circumstances
dictate a more searching inspection.

3.7 Control Systems

3.7.1 It is necessary, particularly with engine and flying control systems, to

ensure that the total length of cables, rods etc. entering and leaving a
specified area are inspected over the full control movement The system
should also be moved to reveal potentially hidden wear points, e.g. where
a cable changes direction around a pulley.

4. References and Associated Procedures

4.1 Aircraft Maintenance Manuals

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 Technical Procedures Manual
Part 2 – Maintenance Procedures
Issue :3
Revision :0 Inspection Standards
Date : 07/05/2004
Resp. Manager : MAM
TPM-02-02-01

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