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IHST - Helicopter Condition-Based Maintenance Program
 

IHST - Helicopter Condition-Based Maintenance Program

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Managing Your Helicopter Condition-Based Maintenance Program

Managing Your Helicopter Condition-Based Maintenance Program

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    IHST - Helicopter Condition-Based Maintenance Program IHST - Helicopter Condition-Based Maintenance Program Presentation Transcript

    • How to Manage your Condition-Based Maintenance Program Helitech International September 24, 2013 Helitech International September 24, 2013 D.B. “Danny” Green US JHSIT HFDM, HUMS IWG Member, HUMS Reporting Member of the HAI Technical Committee, IHST HeliShare OGP Lead
    • What to Expect Today • • • • • • • • What not to Expect Today • Sales Pitch (I’m only selling proven Who/What is IHST 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 worldwide. 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) Helitech International 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 Past Fix it When Its Broke Helitech International September 24, 2013 •Scheduled Inspections •Scheduled Maintenance •Scheduled Overhauls •Time Lifed Parts •ADs, SBs, ACs ,CEBs •FOQA •VHM •Advanced Sensing Technologies •MSG3 •HFDM •PdM •CBM •RCM
    • Where do we want to be? Predictive Maintenance Potential Failure P-F Curve P Point where failure starts Point where failure can first be detected Point of failure F 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 18
    • 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 Helitech International 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 • Required Personnel START HERE 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. Helitech International 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? Helitech International 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 33
    • AW139 T/R Paddle Change STOP WORK AUTHORITY Used (A/C Grounded Immediately) Helitech International September 24, 2013
    • 430 Tail Rotor Radial STOP WORK AUTHORITY Used (A/C Grounded Immediately) Helitech International 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 38
    • QUESTIONS? D.B. “Danny” Green Mobile 985.768.1823 Office 601.749.4059 dannygreen@chevron.com Helitech International September 24, 2013