Slide 1 - Reducing Maintenance Related Engine Failures
Slide 2 – Introduction
Nearly all maintenance and inspections address situations with the potential for significant damage or harm if not performed properly. The objective of inspections is to reduce the likelihood of mishaps. By performing conformity inspections and post maintenance checks along with checklist use we can reduce the possibility of maintenance related engine failures.
Slide 3 – Introduction
The FAASTeam took a look at 1381 fatal accident from 2008 through 2015.
6.9% of the 1381 accidents were attributed to engine maintenance related failures.
Slide 4 – Objective
Responsibilities in reducing Maintenance Related Engine Failures.
Conformity Inspection can reduce the possibility of a Maintenance Related Engine Failure.
Stress the importance of Post Maintenance Checks.
Development and use of Self-Required Inspection Item (RII) Checklists.
Slide 5 - Conformity Inspections
Definition of Conformity Inspection:
An inspection that may be necessary to determine that completed production products and related parts conform to the approved type design and are in a condition for safe operation.
Slide 6 - Conformity Inspections
Conformity Objective
The importance of a conformity inspection will contribute to the prevention of engine power loss by insuring the aircraft meets it type design and is in a condition for safe operation.
Slide 7 - Conformity Inspections
Conditions
Before a Conformity Inspection is started it is good to determine what type of inspection program the aircraft is on and what type of inspection is to be performed.
This will help determine what areas of the aircraft are to be inspected for conformity
Slide 8 - Conformity Inspections
Conditions
Remember when we are talking about Airworthy as part of a conformity inspection the following apply.
Slide 9 - Conformity Inspections
Conditions
The aircraft must conform to its type certificate (TC).
Slide 10 - Conformity Inspections
Conditions
The aircraft must be in a condition for safe operation.
Slide 11 - Conformity Inspections
Conditions
NOTE: If either of the two conditions below cannot be met, the aircraft is considered to be un-airworthy.
Slide 12 - Conformity Inspections
This applies to an aircraft that has a standard airworthiness certificate. This certificate remains valid as long as the aircraft:
a) Meets its approved type design.
b) Is in a condition for safe operation.
c) Has up-to-date maintenance and preventive maintenance.
d) Alterations are performed in accordance with 14 CFR parts 21, 43, and 91.
e) The aircraft must conform to the “Limitations” and “Supplement” sections within the approved Airplane Flight Manual and any installed STC
Slide 13 - Post Maintenance Flight
Why are post maintenance checks important
Video of what happens if post maintenance engine performance is not verified per the manufactures instruction.
Slide 14 - Conformity Inspections
Responsibility for Inspections: 43.3 Persons Authorized
(a) The holder of a mechanic certificate may perform maintenance
(b) The holder of a repairman certificate may perform maintenance
(c) The holder of a repair station certificate may perform maintenance
(d) The holder of an inspection authorization (65.95) may perform an annual, or perform or supervise a progressive inspection according to 43.13 and 43.15.
Slide 15 - Conformity Inspections
Responsibility for Inspections: Performance Rule 43.15 Persons Authorized
(a) General. Each person performing an inspection required by part 91, 125, or 135 of this chapter, shall—
(1) Perform the inspection so as to determine whether the aircraft, or portion(s) thereof under inspection, meets all applicable airworthiness requirements;
Slide 16 - Conformity Inspections
Regulatory Requirements: 43.15 Additional performance rules for inspections.
(a) General. Each person performing an inspection required by part 91, 125, or 135 of this chapter, shall—
(1) Perform the inspection so as to determine whether the aircraft, or portion(s) thereof under inspection, meets all applicable airworthiness requirements
Slide 17 - Conformity Inspections
Regulatory Requirements: Addition performance rules for inspections. 43.15
- (c) Annual and 100-hour inspections.
(1) Each person performing an annual or 100-hour inspection shall use a checklist while performing the inspection.
Slide 18 - Conformity Inspections
Regulatory Requirements: Addition performance rules for inspections. 43.15
(2) Each person approving a reciprocating-engine-powered aircraft for return to service after an annual or 100-hour inspection shall, before that approval, run the aircraft engine or engines to determine satisfactory performance in accordance with the manufacturer's recommendations of—
(i) Power output (static and idle r.p.m.);
(ii) Magnetos;
(iii) Fuel and oil pressure; and
(iv) Cylinder and oil temperature.
Slide 19 - Conformity Inspections
Regulatory Requirements: Addition performance rules for inspections. 43.15
This is the area that is sometimes overlooked. There is a regulatory requirement to run the aircraft after an inspection. This can prevent power loss accidents after inspections if done properly.
Adhere to manufactures instructions when determining satisfactory performance.
Slide 20 - Conformity Inspections
Resources
Aeronautical publications are the sources of information for guiding aviation mechanics in the operation and maintenance of aircraft and related equipment.
The proper use of these publications will greatly aid in the correct and efficient operation and maintenance of all aircraft.
Slide 21 - Conformity Inspections
Resources
Resources for conformity inspections and satisfactory engine performance can be found:
A. Type Certificate Data Sheets and/or Specifications
B. Manufacturers Maintenance, Parts and Overhaul Manuals and Bulletins
C. Manufacturers Inspection and Testing guidance
D. Airworthiness Directives
E. STC’s, 337’s and any Instructions for continued airworthiness.
F. Structural Repair Manuals
Slide 22 - Conformity Inspections
Paperwork, records and manual review.
Slide 23 - Best Practices for Inspections
Research
Planning
Conformity
Performance of Inspection
Return to Service
Slide 24 - Conformity Inspections
Process for Conforming: Research
Identify/verify current Inspection Program in records
Obtain current aircraft discrepancies
Obtain aircraft records
Review records for aircraft/engine/prop/accessories
Review records for installed STC’s/Major Repairs/Major Alterations
Obtain applicable TCDS-Specifications, 337’s and STC paperwork to include ICA’s
Review Time Limitations and/or overhaul requirements
Generate AD listing
Review SDR database and manufacturer’s service info
Slide 25 - Conformity Inspections
Process for Conforming: Planning
Obtain applicable regulatory Inspection Checklist to include ICA requirements
Develop/Obtain Pre/Post inspection Run-up checklist
Inspection tools/special inspection tools
Appropriate and current technical data
Adequate facilities
Review FAASTeam Risk/Hazard Personal Minimums Checklist Before the task items.
Slide 26 - What You Should Expect To See
A clean, neat and organized shop area
Proper storage of materials and parts
Adequate lighting
Adequate tooling and equipment
Slide 27 - What You Should Expect To See
Slide 28 - What You Should NOT Expect To See
Slide 29 - Post Maintenance Checks
Tools/Equipment/Facilities
Special tools and calibrated test gauges may be needed to verify proper engine operation at the completion of maintenance. Consult manufactures recommendations for specific requirements.
Pictures of calibrated gauges, test cells and tools that may be needed.
Slide 30 - Pre Inspection Run-up
Slide 31 Conformity Inspections
Process for Conforming: Conformity
1. Installed components match records
2. Installed components eligible by TCDS/Specifications/STC/Field Approval
3. Installed STC’s, Major Repairs/Alterations - Field Approvals conform to approved data
4. Verify status of all applicable Airworthiness
5. Directives Correct POH/AFM, weight & balance records
6. Verify placards, instrument markings
7. Check for undocumented repairs and alterations
Slide 32 - Conformity Inspections
Process for Conforming: Inspection
1. Complete and document Pre-inspection Performance Run parameters
2. Identify, segregate, and protect removed parts
3. Comply with new and recurring AD’s
4. Document all discrepancies
5. Follow and annotate inspection checklist as task is completed
6. Practice proper tool control during and after inspection
7. Maintain proper environmental controls and safety
8. Conduct a detailed and complete work flow/shift change turnover briefing as required
9. Review FAASTeam Personal Minimums Checklist - After the Task
Slide 33 - Conformity Inspections
Deficiencies:
1. If found need correction
2. Deficiencies related to power loss are of great importance.
Slide 34 - Conformity Inspections
Process for Conforming: Return to Service
1. Required maintenance performed and discrepancies properly addressed
2. Complete and document Post-inspection Performance Run parameters
3. Proper leak checks as required
4. Proper, legible, complete record entries w/times and/or cycles as required
5. Submit Malfunction and Defect Reports as required
6. Notify operator of flight check requirements if applicable
Slide 35 - Post Maintenance Checks
Objective
Post maintenance checks are required and important to prevent engine power loss. These post maintenance checks are a requirement under 14 CFR Part 43.15 (c) (2) & (3).
Slide 36 - Post Maintenance Checks
Definition
Post Maintenance Checks are checks that are performed after any type of maintenance and before the use of the aircraft.
14 CFR Part 43.15 Addition performance rules for inspections defines the specific checks that are required at the completions of an inspection.
Slide 37 - Regulatory Review
Regulatory Requirements: Addition performance rules for inspections. 43.15 (2) Each person approving a reciprocating-engine-powered aircraft for return to service after an annual or 100-hour inspection shall, before that approval, run the aircraft engine or engines to determine satisfactory performance in accordance with the manufacturer's recommendations of—
(i) Power output (static and idle r.p.m.);
(ii) Magnetos;
(iii) Fuel and oil pressure; and
(iv) Cylinder and oil temperature.
Slide 38 - Post Maintenance Checks
Cautions:
Technicians running and/or taxiing aircraft, especially modern aircraft require considerably more skills and practice than in the past.
Technicians running aircraft have to monitor aircraft systems and maintain control of the aircraft while performing power checks after maintenance.
Additional requirement for radio communication may be required.
Slide 39 - The Risk to Operational Safety
Slide 40 - Post Maintenance Checks
Let’s look at some standards for 3 types of aircraft engines.
Slide 41 - Post Maintenance Checks
Additional performance rules for inspections 43.15 (2) (i) Power output (static and idle r.p.m.)
Type Certificate Data Sheets are a source for Power Output information. Example: Textron/Cessna TCDS 3A12 for a Model 172P lists
Engine Lycoming O-320-D2J
Engine Limits For all operations, 2700 rpm (160 hp)
Propeller Limits (a) McCauley 1C160/DTM 7557
Static rpm at maximum permissible throttle setting:
Not over 2420, not under 2300
No additional tolerance permitted
Slide 42 - Post Maintenance Checks
Additional performance rules for inspections 43.15 (2) (i) Power output (static and idle r.p.m.)
The TCDS for a Textron/Cessna TCDS 3A21 for a Model T210M indicates:
Engine Limits Takeoff (5 min. at 2700 r.p.m., 36.5 in. Hg. mp. (310 hp.) For all other operations 2600 r.p.m., 35 in. Hg. mp. (285 hp.)
Note: On a turbocharged engine there is a specific RPM and manifold pressure requirement.
Slide 43 - Post Maintenance Checks
Additional performance rules for inspections 43.15 (3) Turbine engine powered
The TCDC for a Textron/Cessna TCDS A7CE for a Model 425 with a PT6A-112
Turbine engines also have specific test limits per the manufactures recommendations to insure proper engine operation after maintenance.
Slide 44 - Post Maintenance
Static Check
Insert Video of Static Check run.
Slide 45 - Problems after Run????
Slide 46 - Post Maintenance Checks
Deficiencies
Should deficiencies be found during a post maintenance engine run these items will need to be corrected prior to return to service.
After the correction of any deficiencies has been completed, an engine run-up will need to be performed to determine that any discrepancies or abnormalities have been corrected. This should be standard practice.
Slide 47- Post Maintenance Checks
Process
You have to run it. This is the bottom line. You need to verify operation per the manufactures instruction to verify after you are done that it is in a condition for safe operation.
Video: Test running engine after maintenance.
Slide 48 - Post Maintenance Checks
Human Factors
Don’t let human factors enter into your decisions when evaluating the post maintenance inspection/test runs.
Slide 49 - What does the NTSB think!
Slide 50 - What can be done to prevent engine failures?
There are things that can be done to prevent engine failures such as:
1. Routine preventive maintenance program.
2. Use the aircraft
3. Engine oil analysis.
4. Hangar Aircraft
5. Have discrepancies repaired prior to flight
6. Comply with the manufactures recommended overhaul and inspection times for all components.
Slide 51 - Self-Required Inspection
Item (RII) Checklist
Suggested RII checklist is not an all-inclusive checklist and should be modified to enhance the Technician’s own inspection/maintenance checklist currently being used.
Although RII are not required by regulation for GA Maintenance, it is considered a best practice and should be utilized to reduce maintenance related accidents.
Slide 52 - After Maintenance Checklist
Ensure the maintenance discrepancy is corrected IAW applicable manufacture’s procedures.
Ensure functional check is accomplished if applicable, i.e. leak and pressure checks, electrical and freedom of movement for all flight controls and engine controls.
Ensure all fasteners are secure, i.e. proper torque, safety wired, cotter pinned, new self-locking nuts, etc.
Ensure all tools are accounted for and not left in the aircraft.
Close all access panels or doors.
Complete log book entry.
Slide 53 - After Inspection Checklist
Ensure all applicable inspection items have been checked off as completed.
Ensure all discrepancies have been cleared.
Ensure all Airworthiness Directives have been complied with.
Ensure the aircraft meets its type design or is modified in an approved manner.
Do a complete sweep of the aircraft looking for loose tools and equipment.
Ensure all panels and doors are secured and any fasteners are secured.
Do a complete visual inspection to ensure all engine and flight controls work correctly and are properly secured.
Do a complete systems check to ensure the avionics are functioning.
Confirm proper braking is available.
Do post inspection engine(s) run up to ensure proper power levels are reached and all hydraulic and pneumatic systems are functioning properly.
Confirm that constant speed propellers cycle when the control is moved.
After post inspection engine runs, confirm no fluid leakage is found.
Complete all logbook entries.
Slide 54 - Checklist Errors
While checklists do provide a means of guidance for a technician through complex procedures, they are not impervious to human error.
Slide 55 - Checklist Errors
Errors related to checklist usage generally fall into one of these five categories:
1. Checklist interrupted
2. Checklist item overlooked
3. Use of the wrong checklist
4. Failure to use a checklist
5. Checklist confusion
Slide 56 - Don’t take your responsibility lightly
We have all heard the statement:
Remember it is the pilot that makes the final airworthiness determination usually at the takeoff end of the runway. If in doubt do not fly.