How to Manage your Condition-Based

Maintenance Program

D.B. “Danny” Green

Helitech International US JHSIT HFDM, HUMS IWG Member, HUMS
September 24, 2013 Reporting Member of the HAI Technical
Committee, IHST HeliShare OGP Lead

Helitech International
September 24, 2013
What to Expect Today What not to Expect Today
• Who/What is IHST • Sales Pitch (I’m only selling proven
concepts not endorsing products)
• Define CBM
• Extensive Vibration Training
• CBM Terminology
• Engineering, Theory and or Scientific
• Why Use CBM?
Debates
– Benefits
• We will not discuss recent events
– Potential Disadvantages
• How do we do it?
• Equipment Offerings
– References
• Interactive Case Studies
• A basic understanding of the
principles of CBM, its “interaction”
with a proactive SMS

Helitech International
September 24, 2013
Helitech International
September 24, 2013
 IHST’s attitude towards safety:

• IHST takes a proactive attitude that anyone’s helicopter

accident belongs to all of us.

• Accidents affect our collective reputation as providers of

air transportation and suppliers of air services…

• We don’t need to accept accidents or a high industry

accident rate, and it affects our profitability if we do so.
– Jack Drake, IHST JHSAT Accident Analysis Group
– Presented at ISASI 2008

Helitech International
September 24, 2013
 WSJ, 9/5/2013
North Sea Crash Underscores Poor
Progress in Helicopter Safety
Civilian Chopper Crashes Have Remained Flat Over Decade

The fatal crash of a Eurocopter oil-rig helicopter in the North Sea last month
underscores stalled progress in reducing commercial helicopter accidents world-
wide.
In spite of advances in cockpit technology and enhanced pilot training, helicopters'
global safety record has failed to improve dramatically over the past few years—
.
and still lags far behind standards for airliners

WSJ 9/5/2013 By: Andy Pasztor and Daniel Michaels

Helitech International
September 24, 2013
Helitech International
September 24, 2013
 WHAT is CBM?

From Wikipedia, the free encyclopedia

Helitech International
September 24, 2013
 Condition-Based Maintenance
From Wikipedia, the free encyclopedia

Condition-based maintenance (CBM), simply described, as

maintenance when need arises. This maintenance is
performed after one or more indicators show that equipment is
going to fail or that equipment performance is deteriorating.
This concept is applicable to mission critical systems that
incorporate active redundancy and fault reporting. It is also
applicable to non-mission critical systems that lack redundancy
and fault reporting.

Always keeping in mind the required FAA/CAA inspection

programs with an emphasis on value added tasks.

Helitech International
September 24, 2013
 in other words…

If it aint broke, don’t

fix it!

Helitech International
September 24, 2013
 CBM Benefits
CBM has some Benefits over planned maintenance:
•Improved system reliability
•Enhanced Safety
•Decreased maintenance costs
•Increased Readiness
•Operation and Support cost benefits
• Reduction of human error influences.
•Other Intrinsic Benefits:
•Increased pilot confidence
•The ability to monitor health of an entire fleet, regardless of physical location
• As the program matures, the potential to predict when certain faults will
occur, based on historical data and specific aircraft data
•The ability to more effectively plan maintenance actions over the long-term

Reference the IHST HUMS Toolkit (IHST.ORG) for complete details

Helitech International
September 24, 2013
 Disadvantages
Some potential disadvantages are:
•High equipment costs (initially and to maintain)
•Possible Increased Manpower
•Increased Training
•Increased IT/Support
•Increased number of components (the VHM/HUMS
system itself) that must be maintained
•Increased weight/Decreased carry capacity

Helitech International
September 24, 2013
 Aviation Maintenance
Options
(A Travel Through Time)

Helitech International
September 24, 2013
 Run to Failure or
FIX it When it BROKE!

Post WWII (PMI)

The Somewhat Present (PdM)

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September 24, 2013
 What Does CBM Look Like?

REF. Bubba’s Aviation Maintenance consultants

Helitech International
September 24, 2013
 What Does CBM Look Like?
CBM
Present Present/Future
(FAA/CAA Required)•HUMS
•FOQA
•VHM
•Advanced Sensing
•Scheduled Inspections
Past •Scheduled Maintenance
Technologies
•MSG3
•Scheduled Overhauls
•HFDM
•Time Lifed Parts
•PdM
Fix it When Its Broke •ADs, SBs, ACs ,CEBs
•CBM
•RCM

Helitech International
September 24, 2013
 Where do we want to be?
Predictive Maintenance Potential Failure P-F Curve
Point where failure
P can first be detected

Point of failure
Point where
failure starts

Time
John Moubray, Reliability Centered Maintenance II

Helitech International
September 24, 2013
 How Do we Do CBM?

Helitech International
September 24, 2013
 Then why do we do it?

SAFTEY, SAFETY ,SAFETY, SAFETY, Maintenance

Benefits, SAFETY, SAFETY, SAFETY…!

Helitech International
September 24, 2013
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 Our CBM Program Philosophy:

One of the key rules by which or organization operates is to

involve the right people in decisions that affect procedures and
equipment. Our entire CBM philosophy is based on that principle.

Safety is above and beyond without question or hesitation our first
and foremost objective!

Our next objective is to minimize unplanned maintenance or at a
minimum, identify and address it on our terms.

Our Analysts interface with Maintenance constantly and seek the
counsel of Subject Matter Experts who are subject to change
depending on the issue in question and/or the aircraft type.

Seek the wisdom of ten rather the knowledge of one.

We also keep management and operations abreast of any
situations so they can make any necessary changes in equipment,
tools or personnel.

Helitech
“ International

September 24, 2013 19

 Tools/Tricks of the
Trade

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September 24, 2013
 Start Here

The latest IHST Toolkit: HUMS

Helitech International
September 24, 2013
 Before you start
Identify detailed requirements:
• Benefits vs. Cost
• Available Equipment
– VHM, HUMS
– T.C., STC
– Carry-On
START HERE
• Required Personnel ISHT.ORG
– Analyst
– Maintenance Support
– I.T. Support
• In-House or Contract Analysis
• Regulatory Requirements
• Contractual Requirements
• I.T. requirements
• Training Requirements

Helitech International
September 24, 2013
 The latest IHST Toolkit: HUMS

Helitech International
September 24, 2013
Content developed
by leading
industry HUMS
experts.

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September 24, 2013
Resources include
reference materials, a
listing of equipment
providers and actual case
studies.

Helitech International
September 24, 2013
 Tools/Tricks of the Trade
 Vibration Monitor Data
 Vibration Spectrum Data
 Vibration Signature Data
 Logsheets, Inspection Forms, AOCRs
 Trending
 Limits/Rate of Change
 Aircraft Advisories, Fault logs, Exceedences
 Proper Interviews:
Pilots, Mechanics and anyone else who may know anything about the
conditions in question.

Helitech International
September 24, 2013
 Lessons Learned

Helitech International
September 24, 2013
 Life Lessons Learned from a HUMS Analyst
1) If you are going to fly around with the added weight and cost of the
equipment…USE IT!
2) Weekly downloads are insufficient for timely and accurate analysis.
– Daily is preferred but between flights is becoming regular
practice in some operations due to the length of flights.
3) Communicate, Communicate, Communicate
– Pilots, mechanics, dispatchers, written reports, i.e. logsheets,
inspection forms AOCRs follow the clues.
4) Be curious, be nosey, be a pain in the butt, ask why 5 times, just
get the answers (we’re talking CSI stuff here)!
5) Being wrong is okay, being scared of being wrong is not. Humility
while painful, could cost or save lives!
6) When in doubt seek a higher power (someone has probably seen it
before) paralysis through analysis is unacceptable in our trade!
D.B. “Danny “ Green

Helitech International
September 24, 2013
 Most Common Findings:

Main Rotor: Shear Restraints, Trim Tabs, Isolation Mounts,
Bearings

Tail Rotor: Bearings, Trunnions, Blades, Gearboxes

Tail Rotor Drive: Hanger Bearings, Drive Shafts, Hanger
Bearing Mounts and Airframe Cracks

Main Transmission: Output Shafts, ECU Drive

Engines: FOD, Worn Mounts, Oils Pumps, Shafts

Oil Coolers: Fan/Blower Bearings, Trash

Starters: Bearings, Brushes, Looseness

Hydraulic Pumps: Shafts, Seals, Drives and Stripped Studs

Helitech International
September 24, 2013
 SMS

What does that have to do with SMS?

What is SMS? My simple definition is to have

programs in place to address problems before they
ever exist.
What could possible address this better than CBM
and FDM.

Helitech International
September 24, 2013
 Interactive Vibration Case Studies…

Can you Analyze the Problem?

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September 24, 2013
31
 AW139 Hydraulic Pump
Trending vibration increases noted in the #1 hydraulic pump drive but no limits
exceeded. After review of the log sheets, it was noted that a 100 hour hydraulic pump
inspection was performed in the previous days. The aircraft had a upcoming scheduled
hangar check, the pump was inspected based on our data and two loose studs were
found.

Helitech International
September 24, 2013
 AW139 Worn Hydraulic Pump Case Study
Noticed increased vibration trending on the
#2 input hydraulic pump. No limits were
exceeded but when the aircraft was down
for other maintenance, the pump was
removed to inspect based on this data and
the worn pump drive shaft was found as
well as damage to the pump.

Helitech
“ International

September 24, 2013

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 AW139 T/R Paddle Change

STOP WORK AUTHORITY Used

(A/C Grounded Immediately)

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September 24, 2013
 430 Tail Rotor Radial

STOP WORK AUTHORITY Used

(A/C Grounded Immediately)

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September 24, 2013
 430 Tail Rotor Gearbox

Helitech International
September 24, 2013
 430 Main Rotor F/A and Vertical Increase

Helitech International
September 24, 2013
 Hanger Bearing Case Study
#1 hanger bearing showed increased Broad Band
Vibrations (1P and 2P were normal). After visual
inspection and rotational check for smoothness, the
bearing was greased. Grease solved problem for
several days but the problem would return (see
below). This process was repeated until the aircraft
was available for the next hangar check (very large
job, remote a/c) and the bearing could be changed.
Replacement solved the problem and upon teardown
and root cause inspection, it was noticed that the
balls were riding across the outer race once the fresh
grease would break down thus increasing the Broad
Band vibes.

9.26 mm 7.5 mm

Helitech International
September 24, 2013
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 QUESTIONS?

D.B. “Danny” Green

Mobile 985.768.1823 Office 601.749.4059
dannygreen@chevron.com

Helitech International
September 24, 2013