Maintenance Program Development: Structure MSG3 Analyses

Maintenance Program Development
Structure MSG3 analyses Definitions
Environmental Deterioration
…result of chemical interaction with its climate or environment…
Page 41
Fatigue Damage
…cracks due to cyclic loading and subsequent propagation.
Page 42
Wear Damage
Physical deterioration of the surface of an item due to relative motion
between two parts in contact.
Page 43
Structure MSG3 analyses

IN-SERVICE
EXPERIENCE
INFORMATION
DESIGN
FATIGUE
& DAMAGE
TOLERANCE
TEST RESULTS EVALUATIONS
Page 44
Structure MSG3 analyses AIRCRAFT

STRUCTURE
Significant YES NO Other

SELECTION Significant?
Structure Structure
Document the Significant

DOCUMENTATION
Structure (SSD)
Identify Strutural
IDENTIFICATION
Significant Items (SSI)
Perform SSI
ANALYSIS
MSG-3 Analysis
Resulting
RESULTS
Requirements
Structure To be considered
by Zonal WG
MPP
Page 45

DAMAGE SOURCES
ACCIDENTAL ENVIRONMENTAL FATIGUE
DAMAGE DETERIORATION DAMAGE
SUSCEPTIBILITY
EVALUATION
DAMAGE
DETECTABILITY
EFFECT ON
CONTINUING
AIRWORTHINESS
Page 46

individual SSI Analysis
Each type of deterioration/damage is analysed separately:
METALLIC NON-METALLIC METALLIC & NON-METALLIC
ACCIDENTAL DAMAGE ACCIDENTAL DAMAGE ACCIDENTAL DAMAGE ACCIDENTAL DAMAGE

ANALYSIS ANALYSIS ANALYSIS ANALYSIS
ED/CPCP ED (“Aging”) ED/CPCP ED (“Aging”)

ANALYSIS ANALYSIS ANALYSIS ANALYSIS
FATIGUE DAMAGE FATIGUE DAMAGE

ANALYSIS ANALYSIS
Page 47

Corrosion Prevention Control Programme (CPCP)
ATA MSG-3
Operator/Manufacturer
Scheduled
Maintenance
Development
Revision 2
April 1988
November 1993
Objective of CPCP: “control corrosion to Level 1 or better”
Level 1 Corrosion
Corrosion damage that does not require structural reinforcement or replacement,
Or
Corrosion occurring between successive inspections that exceeds allowable limits but is local
and can be attributed to an event not typical of operator's usage of other aircraft in the same
fleet (e.g. mercury spillage).
Page 48

Consolidated ED / CPCP Requirement
ED INSPECTION CPCP
REQUIREMENT REQUIREMENT
• INSPECTION LEVEL • INSPECTION LEVEL
• THRESHOLD • CPCP THRESHOLD
• INTERVAL • INTERVAL
• Sampling (Y/N) • TPS Application (Y/N).
ED/CPCP CONSOLIDATED
MAINTENANCE REQUIREMENT
• INSPECTION LEVEL
SAMPLING
• THRESHOLD (Y/N)
• INTERVAL
• TPS Application (Y/N)
• CPCP THRESHOLD (100% Threshold)
Page 49

SIGNIFICANT SIGNIFICANT
SSI
STRUCTRURE STRUCTURE
ANALYSIS
SELECTION DOSSIER
FORMS
FORMS FORMS
Page 50

SSD SSI SSI SSI
AD AD AD
ANALYSIS ANALYSIS ANALYSIS
ED/CPCP ANALYSIS ED/CPCP ANALYSIS ED/CPCP ANALYSIS
ED (“Aging”) ED (“Aging”) ED (“Aging”)

FATIGUE DAMAGE FATIGUE DAMAGE FATIGUE DAMAGE

REQUIREMENTS REQUIREMENTS REQUIREMENTS
CONSOLIDATION TASKS
Page 51
Zonal MSG3 analyses
Page 52
Zonal MSG3 analyses
General Principles
The Zonal Inspection Requirements = General Visual Inspection

(GVI) requirements for each aircraft zone to check system and
power plant installations , wiring (EWIS- Electrical Wiring
Interconnection Systems) for security and general condition and
structure for general condition
Page 53
Zonal MSG3 analyses
The Aircraft is sub-divided into major zones:
e.g A380: 8 Major Zones (External)
100 Lower half of fuselage to rear pressure bulkhead
200 Upper half of fuselage to rear pressure bulkhead
200
300 Fuselage tail section and stabilizers 500
400 800
400 Power Plant, Nacelles and Pylons 800

100
500 Left Wing 400

300
600 Right Wing 800
600
800
700 Landing Gear & Landing Gear Doors 800
800
800 Doors
Major Sub-Zones (Internal)
Sub-divisions of the Major Zones, e.g. 100 is divided into 110, 120, 130,..
Zones
Sub-divisions of Major Sub-Zones, e.g.
120 is divided into 121, 122, 123,..
Page 54
Enhanced Zonal (EZAP)

wiring and wiring installations within
the Zone
Zonal Analysis Procedure
Page 55
Zonal Maintenance Requirements
GVI: General Visual Inspection

Visual examination to detect obvious unsatisfactory
conditions and discrepancies in the zone
DET: DETailed Inspection

Full examination of a specific component,
installation or assembly to find damage, failure or
defect.
RST: ReSToration tasks (e.g. cleaning, discard)
Bring the Wiring and Wiring Installation conditions
back to their original Standard
FNC: FuNCtional check

Quantitative test (continuity check-Impedance
loop) to determine if one or more functions of an
item performs within specified limits.
Page 56
Standard Zonal
To detect degradation of
the whole zone (Structure,
equipment, wiring, L/HIRF
protection, bonding leads,
grounding points, ...)
4 major parameters to be considered

•Accidental Damage exposure
GVI
•Environmental Deterioration Exposure
•Zone Density
•Importance of the components installed in the zone
Page 57
Enhanced Zonal
•Detect wiring
degradation Æ
G Route to electrical ignition
Engine
Generator source
•Avoid combustible
material accumulation
P Route with increased wiring
Crossover related risk of fire
Note: appropriate attention
M&S is given to safety related
Routes to deterioration of wiring and
Engine etc.
wirings installation (Electrical
Wiring Interconnection
4 major parameters to be considered Systems, EWIS)

•Environmental Deterioration Exposure
•Zone Density (EWIS Inspect ability) GVI DET RST
•Potential fire effect on adjacent Wiring and Systems
Page 58
L HIRF
(Lightning) (High Intensity Radiated Fields)
MRB
and
Aircraft certification
offices
manufacturer to identify an appropriate method capable to confirm that in-

service operation will not reduce the HIRF and Lightning protection to a level
that is inadequate to maintain Type Certification objectives
1.Identification of dedicated maintenance tasks if needed Æ MRBR

2.Identification of a ‘Lightning/HIRF protection Assurance Plan’ Æ specific
tests on a representative sample of the world fleet at specified intervals
Page 59
L/HIRF maintenance tasks

To detect L/HIRF protection degradation
Aircraft Structure continuity, metal to metal contact
, bonding leads and Metallic networks for Composite
Structures.
Electrical wiring protection Raceways and Braided
conduits -Individual shielding for engine cables in
exposed areas.
Equipment protection clamping and filtering devices
at inputs/outputs prevent damage from
voltage/current resulting from Lightning and HIRF in
addition to the inherent equipment protection.
Systems architecture increasing the non-
susceptibility of Systems to HIRF and Lightning
effects by Segregation of electrical wiring routes
2 major parameters to be considered

•Environmental Deterioration Exposure FNC
Page 60 GVI DET
L/HIRF assurance plan

Objectives
1. Scheduled maintenance program is adequate to keep the

electromagnetic protection at a satisfactory level.
2. Design of the electromagnetic protection is robust and not susceptible
to any systematic degradation.
The tests carried out in the frame of the Assurance Plan consist in measuring the loop
impedance made by the protection element (e.g. a braided conduit or a raceway)
and its bonding to the aircraft structure. This impedance is representative of the
protection element integrity and efficiency.
Loop Impedance
Clamp
Loop Resistance
Tester (LRT)
Page 61
Zonal MSG3 analyses Consolidation

• List of aircraft zones
• Analysis type (Standard, Enhanced, L/HIRF)
(Zone selection)
Zone number: XXX, YYY:

• Description / access
• Contains (structure items, systems components,
wiring, L/HIRF protection elements) (Zone description)
L/HIRF ZONAL ENHANCED STANDARD ZONAL STRUCTURE SYSTEM & POWERPLANT

ANALYSIS ZONAL ANALYSIS ANALYSIS ANALYSIS ANALYSIS
Stand-alone GVI’s, GVI’s GVI’s & VCK’s

DET’s & RST
Task consolidation Task consolidation

(Consolidation)
System & Powerplant Zonal Program

Program
Page 62
Zonal MSG3 analyses

Failure modes not identified
through the SSI/MSI
analysis but naturally
inspected by the zonal
• Failure modes identified

through the SSI/MSI
analysis but naturally
inspected by the zonal
(e.g. corrosion)
• MSI/SSI tasks transferred
into the zonal program
Page 63
The MRB Report
Systems & Zonal &

Structure
Powerplant L/HIRF
Page 64
MWG
activities
completed Manufacturer
develops the ISC validates
+ MRB Report MRBR
Proposal proposal
ISC validates
MWG results
Authorities
approve the
MRB Report
Page 65
The MRB Report
Page 66
The MRB Report
Administration pages:
Approval Letters,
Record of Revisions,
Summary of changes from previous revision,
List of Effective Pages
Section A: Introduction
Purpose & Scope
A350 Models covered
Reference to the basis (MSG3 revision, PPH)
Aircraft Utilization Assumptions
Revision Policies
Overall Document Description
Section B: General Rules that Apply to Sections C, D & E
Page 67
Systems &
Powerplant
Page 68
Structure
Page 69
Zonal &
L/HIRF
Page 70
The MRB Report
Section F: Requirements for U.S. Operators

Contains additional requirements which must be embodied
by the US certificated Operators to complement the ones
listed in sections A, B, C, D and E of the MRB Report.
Page 71
A typical Maintenance Programme development planning
Operators’ needs
Flight test
Page 72
9 5 training sessions
9 4 MRB meetings
9 10 ISC meetings
9 53 MWG meetings
More then 800 MSG

analysis dossiers
reviewed
Representing more
than 8000 meeting
man-days
1st complete MPP

available and
submitted prior to 1st
Flight
Page 73
The MRBR process
has demonstrated added value and efficiency
Is adapted to the operators’ needs and constraints
Permanently evolves to remain adapted and efficient
Potential consequences of reduced operator participation

Initial program not validated by global operations
Future program changes won’t be driven by operators
Less sharing of in-service experience
Without Operator’s active participation the MRB process may die!

Risk of a more-conservative Maintenance Program
Page 74
Even before the start of the MRBR process Maintenance Engineers get
involved in Aircraft design development
Page 75
Example: A350 V&V
Information is available on line and/or on physical media (DVD)
On Line access available via AirbusWorld
Page 76
Access to MRBR
“Maintenance & Engineering” Page
Page 77
Access to MRBR
“Prepare Maintenance
Prepare Maintenance Program”
Page 78
Access to MRBR
Review Airbus Maintenance Requirements
Access MRB Report and associated compliance documents
Page 79
Access to MRBR
MRB Reports available in PDF version and MS XLS (tables)
Page 80

Maintenance Program Development: Structure MSG3 Analyses

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Maintenance Program Development

Structure MSG3 analyses Definitions

Structure MSG3 analyses Definitions

Structure MSG3 analyses Definitions

Structure MSG3 analyses

Structure MSG3 analyses AIRCRAFT

Significant YES NO Other

Document the Significant

Structure MSG3 analyses

Structure MSG3 analyses

ACCIDENTAL DAMAGE ACCIDENTAL DAMAGE ACCIDENTAL DAMAGE ACCIDENTAL DAMAGE

ED/CPCP ED (“Aging”) ED/CPCP ED (“Aging”)

FATIGUE DAMAGE FATIGUE DAMAGE

Structure MSG3 analyses

Structure MSG3 analyses

Structure MSG3 analyses

Structure MSG3 analyses

ED/CPCP ANALYSIS ED/CPCP ANALYSIS ED/CPCP ANALYSIS

ED (“Aging”) ED (“Aging”) ED (“Aging”)

FATIGUE DAMAGE FATIGUE DAMAGE FATIGUE DAMAGE

REQUIREMENTS REQUIREMENTS REQUIREMENTS

Zonal MSG3 analyses

Zonal MSG3 analyses

The Zonal Inspection Requirements = General Visual Inspection

400 Power Plant, Nacelles and Pylons 800

500 Left Wing 400

Enhanced Zonal (EZAP)

Zonal Analysis Procedure

Zonal Maintenance Requirements

GVI: General Visual Inspection

DET: DETailed Inspection

FNC: FuNCtional check

4 major parameters to be considered

•Accidental Damage exposure

manufacturer to identify an appropriate method capable to confirm that in-

1.Identification of dedicated maintenance tasks if needed Æ MRBR

L/HIRF maintenance tasks

2 major parameters to be considered

L/HIRF assurance plan

1. Scheduled maintenance program is adequate to keep the

Zonal MSG3 analyses Consolidation

Zone number: XXX, YYY:

L/HIRF ZONAL ENHANCED STANDARD ZONAL STRUCTURE SYSTEM & POWERPLANT

Stand-alone GVI’s, GVI’s GVI’s & VCK’s

Task consolidation Task consolidation

System & Powerplant Zonal Program

Zonal MSG3 analyses

• Failure modes identified

Systems & Zonal &

Section F: Requirements for U.S. Operators

More then 800 MSG

1st complete MPP

Is adapted to the operators’ needs and constraints

Permanently evolves to remain adapted and efficient

Potential consequences of reduced operator participation

Future program changes won’t be driven by operators

Less sharing of in-service experience

Without Operator’s active participation the MRB process may die!

Information is available on line and/or on physical media (DVD)

On Line access available via AirbusWorld

“Maintenance & Engineering” Page

Review Airbus Maintenance Requirements

The Zonal Inspection Requirements = General Visual Inspection

Is adapted to the operators’ needs and constraints

Permanently evolves to remain adapted and efficient

Potential consequences of reduced operator participation

Future program changes won’t be driven by operators

Less sharing of in-service experience

Information is available on line and/or on physical media (DVD)

On Line access available via AirbusWorld