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Biman Bangladesh Airlines Limited
Report on
Biman Instrument & Hydrostatic Workshop
Prepared as Tasked in Senior Management Course (M3)
Submitted By:
Submitted To:
Shahnoor Ahamad
GM, Training Management Development
Date of Submission
30 August 2022
Md. Monirul Islam
Staff No: P-36621, Engineer Officer
Engineering & Material Management
Acknowledgements
First of all, we would like to express our gratitude to the Almighty Allah for blessing us
with the ability to successfully complete the report in due time.
We would like to extend my heartfelt gratitude to our instructors for their continuous
support and valuable time to complete this report “Instrument & Hydrostatic Shop”.
Without support and guidelines it would not possible to complete this report in due time.
Finally, I would also like to thanks my course mates who also helped us in many ways to
complete the report.
Page 2 of 20
Contents
Title Page..............................................................................................................................1
Acknowledgements ..............................................................................................................2
Content……………………………….…………………………………………………….3
Chapter 1 .............................................................................................................................4
Introduction..........................................................................................................................4
1.1 Overview of Biman Bangladesh Airlines Limited……………………………………...4
1.2 Biman Instrument & Hydrostatic Workshop overview ..................................................5
1.3 Facilitates of Instrument Workshop ................................................................................6
1.4 Facilities of Hydrostatic Workshop……………………………………………………..7
1.5 Facility Layout of Instrument & Hydrostatic Shop.........................................................8
1.6 Organization & Manpower Chart..................................................................................11
1.7 Existing Manpower…………………………………………………………………….11
Chapter 2 ................................................................................................................................12
2.1 Working Procedure ………………………………..……………………..……………12
2.2 Components Incoming and outgoing …………………………………………………..12
2.3 Component and Its maintenance………………………………………………………..13
2.4 Level of Maintenance…………………………………………………………………..14
2.5 Maintenance support for others airlines…………………………………………………15
2.6 Beyond Economic Repair (BER)………………………………………………………..15
2.7 Certification of components…………………...…………………………………………15
2.8 Procedure for On the Job Training (OJT)………………………………………………..17
Chapter 3 ................................................................................................................................17
3.1 Shop Capability................................................................................................................17
3.2 Shop Performance……………………………………………………………………….18
3.3 Foreign Currency Save.....................................................................................................18
3.4 Future Development Plan .................................................................................................19
3.5 Challenges………………………………………………………………………………..19
3.6 Conclusion………………………………………………………………………………..20
Page 3 of 20
Chapter 1
Introduction
1.1 Overview of Biman Bangladesh Airlines Limited
In the wake of the victory against the insurgent Pakistani military, Biman Bangladesh
Airlines was established on 4 January 1972 under the Bangladesh Biman Ordinance
(Presidential order No. 126). Starting with a Douglas DC-3 aircraft, it started its
domestic services on 4 February 1972. After the crash of the DC-3 during a test flight,
two Fokker F27s were added to the fleet. To increase thecapacityeven more, a Douglas
DC-6 was added. Shortly after that, on 4 March 1972,Biman started its first international
flight using a Boeing 707 chartered from BritishCaledonian. By the end of seventies,
Biman had expanded its fleet to include 8 F27sand 5 Boeing 707 to serve domestic and
international destinations. In the first year of operation, Biman carried just over 380,000
passengers in 1,079 flights. Currently,Biman has the youngest fleet in Asia consisting of
21 modern aircrafts – 17 of whichis owned by Biman and 4 are in lease. The latest
aircraft is a Dash 8-400, manufactured by De Havilland Canada. All of the aircrafts
have been endowed withbeautiful names in Bangla by none other than our Honorable
Prime Minister SheikhHasina. A summary of the fleet is provided in table 1.
Table 1: Fleet Summary of Biman
Type of Aircraft Number of Aircraft in
Fleet
Dash-8 5
B737-800 6
B777-300ER 4
B787-8(D) 4
B787-9(D) 2
Biman was transformed into a corporation through Ordinance No. XIX if 1977.
Later in 23rd
July 2007, Biman was converted into a Public Limited Company and
received the corporate logo of white stork flying across the red sun. Biman is now
marching towards with a fleet of average age of just over 6 years to fulfill its vision
of ranking among the first ten airlines in Asia. For that purpose, Biman has air
service agreement with 43 countries and currently hold 18 outstations and 7
domestic destinations excluding Dhaka Hazrat Shahjalal International Airport.
Biman is planning and continuously expanding its network to utilize its capacity to
the fullest and provide services to people home and abroad. At its peak, Biman has
Page 4 of 20
operated flights to 29 international destinations, as far away as New York City to the west
and Tokyo to the East.
The headquarter of the national flag carrier is “Balaka Bhaban”, located at Kurmitola,
Dhaka. Apart from that, Biman has a number of subsidiaries like BimanPoultry, Biman Flight
Catering Center (BFCC), Biman Ground Handling (BGH), Biman Engineering, and
Bangladesh Airlines Training Center (BATC). BATC is the only training center in Southeast
Asia that can issue EASA 147 certification. BFCC is the only catering center that holds the
accreditation of ISO 9001-2015 and ISO 22000-2005 due to its international standard and
strict hygiene maintenance.
Biman Bangladesh Airlines is certified as safe to fly in Europe by the European Aviation
Safety Agency. It has successfully passed the IATA Operational safety Audit (IOSA) and
since then it has been successfully flying to some of its previous destinations in Asia and
Europe. Biman has achieved five start safety rating from an airline safety rating agency. The
rating was awarded by “airlineratings.com” [2]. Biman launched its mobile app named
“Biman Bangladesh Airlines” on December 2019.This has made booking flights, ticketing
and finalizing itinerary whole lot easier.
Apart from commercial purposes, Biman has been fulfilling its Corporate Social
Responsibilities very well. Biman carries the expatriates and helps export manpowerto middle
eastern countries and other destinations. It carries dead bodies of expatriates to the country
for free. During Hajj season, Biman takes the responsibility of the huge lot of the pilgrims
and safely carries them to and from Saudi Arabia. Just like this, by moving forward with
both corporate strategy and social responsibilities, Biman plans to fly the nation’s bi-colored
flag to greater heights, with great pride around the globe.
1.2 Biman Instrument & Hydrostatic workshop Overview.
Aircraft maintenance is the backbone of an airlines. Successful aircraft maintenance history
makes company goodwill and customer satisfaction. For successful maintenance of aircraft
Biman engineering department started its journey at the beginning of Biman Bangladesh
Airlines.
Biman instrument & hydrostatic shop is the sub-section of Biman engineering and material
management department which is responsible to carry out the maintenance of the aircraft
components as per CAAB approved capability List. Instrument & hydrostatic shop is consist
of following subsystem group:
 Mechanical & Electro-mechanical Group
 Electrical & Electronic Group
 Pressure vessel & Hydrostatic Group.
Page 5 of 20
1.3 Facilities of instrument workshop
Instrument workshop is located at 1st
floor of Engineering Component
Maintenance/S&MM (Annex) Building. It is air-conditioned and the main entrance of the
shop is arranged with double door to control the dust. Major portion of the shop is for
aircraft Instruments/ components like flight instrument, power-plant,
pneumatic/hydraulic, Mechanical, Electrical and miscellaneous Instruments /components,
the other small part is for Gyroscopic Instruments which is separated by another door just
to further protection of dust.
Instrument Maintenance Shop shares a common cleaning room with Radio and Electric Shop.
Besides the main shop, the shop extends its facility into two other separate establishments
namely- a Hydrostatic test plant and Oxygen refilling plant. These two establishments are
located at the northern side of Biman Engineering Hanger. All three premises of
Instrument Shop is equipped with adequate lighting, fire protection equipment and
evacuation passages.
Following are the fixed installations for the Instrument Shop:
Fire Fighting System: The fire alarm system is controlled by a Fire Indicator panel,
which provides automatic warning during fire. There are two dry chemical fire
extinguishers and two fire extinguishers foamed fixed with the wall of the shop. They are
located at the easily accessible places.
Electrostatic Discharge Sensitive (ESD) Device: This shop is equipped with ESDS repair
station with a weekly basis serviceability check list.
Pneumatic Source: The shop is equipped with a low pressure pneumatic line for testing
and cleaning of aircraft Instruments/components.
Air conditioner and De-humidifier: 03 (three) spilt type air-conditioner and 02 (two)
dehumidifier are used inside the main shop to maintain the required environment of the
shop.
Doors: The main shop has two Glass door at the entrance, one for the Gyro Room and
other for common cleaning room and also as alternate exit. Other two establishments are
also provided with necessary entry/exit
Page 6 of 20
1.4 Facilities of hydrostatic workshop
Definition:
Hydrostatic Test: Cylinder qualification procedure consisting of application of internal
pressure with measurement of cylinder expansion, generally performed with water, but
other liquid or gas pressure may be used.
Cylinder: Any type of pressure vessel designed for a minimum internal pressure of 276
kPa, abs (2.8 bar, abs, 40 psia) and used for transportation of compressed gases that is
required by the regulatory to be hydrostatically tested.
Expansion: Increase in cylinder volume due to application of pressure.
Elastic expansion: Increase in cylinder volume due to application of pressure that is
recovered when pressure is released.
Permanent expansion: Increase in cylinder volume due to application of pressure that is
not recovered when pressure is released.
Test pressure: Pressure to which a cylinder is subjected in accordance with the
applicable regulations to verify its fitness for service.
Visual inspection: Internal examination and/or external examination performed as part
of the cylinder requalification process.
Re-qualifier’s identification number (RIN): Four character code assigned by Department Of
Transportation (DOT), USA, to uniquely identify a cylinder requalification/repair/rebuild
facility.
Independent Inspection Agency (IIA): Inspection firm approved by DOT as outlined in 49
CFR 107.805 [1].
Calibrated cylinder: A calibrated cylinder is a cylinder that has been specially
prepared so that it no longer experiences permanent expansion at the pressures for which
it has been calibrated.
Registration: Registration is applicable to water jacket, direct expansion, and proof
pressure methods. The test facility and test apparatus used shall be approved as to type
and operation. Each facility shall have a Re-qualifier Identification Number (RIN) issued
by DOT Pipeline and Hazardous Materials Safety Administration (PHMSA) (49 CFR
107.805) upon the favorable recommendation of the independent inspection agency. RIN
shall be renewed every after five years.
Page 7 of 20
Cylinder Hydrostatic Test (HST) Facility: Instrument Overhaul Shop contains the facility of all
type of Cylinder Hydrostatic Test in water jacket method. The Re-qualifier Identification Number
(RIN) of the facility is H649 (Issued by DOT, USA). All oxygen cylinders, Nitrogen cylinders and
some of fire extinguisher cylinder of Biman fleet as well as other airlines are now being tested in
this facility. It is a sophisticate, modern and automated computer control test system.
Regulation and Inspection: The entire test system, related publication, manpower with training and
record keeping are directly regulated and controlled by the regulations of Department Of
Transportation (DOT), USA i.e. U. S. Code of Federal Regulations (CFR) Title 49 Parts 172.704 as
applicable and 107, 173, 180 related sections. DOT authorized Independent Inspection Agency (IIA)
delegates inspect the facility once in every five years. IIA inspect/conduct the following:
a. Test system serviceability.
b. Man power qualifications & refresh/recurrent training as per CFR 49 Parts 172.704.
c. Documentations and record keeping.
d. Practical assessment examination on hydrostatic test for hazmat employee(s) as per CGA
pamphlets.
e. Theatrical examination for hazmat employee(s) involves in hydrostatic test as per CFR 49
related sections and CGA pamphlets.
f. Oral examination for hazmat employee(s).
After satisfactory inspections on the above mentioned subject the Independent Inspection
Agency (IIA) inspector repot to the Department Of Transportation (DOT), USA for
renewing Hydrostatic Test (HST) approval for next five years. If DOT is satisfied, may
renew the Hydrostatic Test (HST) approval for five years.
Training: Each hazmat employee performing hydrostatic test must be fulfilled the
training/continuation requirements (as applicable) of 49 CFR part 172.704.
1.5 Facility Layout of Instrument & Hydrostatic workshop
Page 8 of 20
Page 9 of 20
Page 10 of 20
CHIEF ENGINEER (EP)
DIRECTOR ENGINEERING & MM
MANAGING DIRECTOR & CEO
ACCOUNTABLE MANAGER
PRINCIPAL ENGINEER
(AVIONICS COMPONENT MAINT.)
INSTRUMENT & Hydrostatic Shop
01 E.O. I/C-VI Tech.
02 E.O.- VITech.
03 J.I.O.- VTech.
03x Jr. Tech.- IV
Tech. 04x Mech- III
Tech.
PRINCIPAL ENGINEER
(AEROSPACE COMPONENT MAINT.)
1.6 Organization & Manpower Layout.
Fig: Organization & Manpower Chart of Instrument & Hydrostatic Shop
2.1Existing Manpower
As per approved organogram 2019 Existing
Manpower
Shortage
of
manpower
Engineer Officer 3 2 46%
Junior Inspection
Officer
3 1
Technician 3 0
Mechanic 4 1
Aircraft Technical
Helper
0 3
Total 13 7
DEPUTY CHIEF ENGINEER COMPONENT MAINTENANCE
Page 11 of 20
Chapter 2
2.1 Working procedure:
Most of the repairable aircraft components are time limited for shop check, functional
check and Overhaul. As such those are removed from the aircraft and sent to the
respective shops as per AMS or against any defect for necessary maintenance. The
work is being carried out in the Shop - according to the CMM/OHM and by full-filling
the Airworthiness requirements as laid down in ANO(AW), CAAB Part145 and other
regulatory requirements of CAAB. Shops usually perform Dis-assembly, Cleaning,
Repair, Overhaul, Inspection/Checks, Modification and Testing on the Components
and Weight Check of Fire Extinguishers, Re-filling of Oxygen Cylinder & HST of
Pressure vessels of various aircraft as per approved capability List. Components
beyond the shop capabilities are sent to outside repair/servicing agencies for necessary
servicing.
2.2 COMPONENT INCOMING & OUT GOING PROCEDURE:
a. Components are loaded in the component maintenance shop from RSP&S for -
Repair / Overhaul / Modification / Cleaning / Inspection / Testing either as schedule
or unscheduled maintenance.
b. On receipt, Component Maintenance personnel of each Shop must check that the
unserviceable Components /Parts are attached with Work Order (with duplicate
copy) and Unserviceable Label/Tag.
c. In-Charge of the respective shop will arrange to record the Component in the
Incoming Register and check for shop capability and detail the concern authorized
person for necessary maintenance. Unserviceable component are kept in the
UNSERVICEABLE RACK or in a designated area.
d. If any component found out of shop capability, the respective shop In-charge or any
Certifying Staff shall arrange to return the component to the RSP&S section
immediately with a comment “OUT OF SHOP CAPABILITY or NO FACILITY”
and signed by the respective Authorized person in the Work Order.
e. For a component under shop capability list, the concern authorized person will
initiate the necessary maintenance work upon collecting the Inspection Worksheet,
CMM and History Card.
f. Concern authorized person will perform the necessary disassembling, cleaning,
inspection/checks, defective parts replacement, troubleshooting, reassembling and
testing and duplicate inspection (by another authorized person of respective
category) etc. process step by step as per Inspection Worksheet or reference taken
Page 12 of 20
from appropriate manuals.
g. Concern authorized person will assist and supervise the function disassembling,
cleaning, defective parts replacement and reassembling. In this case the Concern authorized
person will also ensure that non certifying staffs are signing for the applicable task in the
applicable column.
h. Concern authorized person shall ensures that the every step of
Overhauling/Repairing/Cleaning/ Inspection/Checks/Testing process are progressing as per
latest worksheet, manual and proper tools/special tools/materials are used to meet
operational safety and regulatory requirements.
i. Rectification, material used for accomplishment of component maintenance is to be
recorded in the History Card, Work Order, relevant Inspection worksheets and signed by
the Certifying Staff. Serviceable components are kept in the SERVICEABLE RACK or in a
designated area until released from the shop and handover to RSP&S section.
j. After completion of the necessary maintenance i.e. fulfilling the airworthiness
requirements, the relevant portion of work order & ARC (CAAB Form1) are filled in with
signed and stamped by the certifying staff for declaring the component is released to
service. Certifying Staff of the Shop must ensure, SB‟s, SIL and Mod’s are incorporated
correctly recorded in the Master S.B Card (if, applicable). Form Tracking no. of ARC
(CAAB Form1) will be recorded in the ARC(CAAB Form1) Control Register(Form No:
EMM/CM/5015) and finally Shop In-Charge shall arrange to handover the component to
RSP&S (Parts Control) section.
k. Authorized Release Certificate (ARC) CAAB Form 1 must have Form Tracking Number
allotted from Engineering Production ARC control Register consist of first two digits for
BG and next four digits for the current year and sequential unique number at the right
l. CAAB Form1 and the number must be recorded in a separate column of the Component
Output Register along with other information.
Example:
B G 2 0 1 7 0 0 0 0 1
2.3 Component & Maintenance:
Component: Sub-assembly of an aircraft, engine or propeller. Such as motor, generator,
Oxygen cylinder etc.
Page 13 of 20
Maintenance: Maintenance: means any one or combination of overhaul, repair, inspection,
replacement, modification or defect rectification of an aircraft or component, with the exception of
pre-flight inspection
2.4 Level of Maintenance:
Level-1 : a) General Visual Inspection (GVI), replacement of desiccants, silica-gel (moisturizer
protective agents) or checking of lubricating fluid level etc. for renewal/
extension of rack life as per CMM and minor repair like replacement of small
indicator light/LED, Fuse blown, protective glass cracked/ hazy, bent or broken
connector pins, missing serial number or identification plate etc.
a) Re-filling of Oxygen
b) Weight check
c) A rectification of minor defects which does not involve any test or special
tools & equipment.
d) A rectification other than Repair or Overhaul.
Level-2: Repair, replacement of parts involving Testing/functional check in shop according to
appropriate Overhaul Manual or Component Maintenance Manual.
Level-3: Complete Overhaul according to appropriate Overhaul Manual/ Component
Maintenance Manual (CMM).
m. Fractional Job: Fractional jobs may be required to perform in different shops. When a
fractional job involve on any component, the original shop will have to send the unit with sub-
work order to other shop. After completion of fractional job, the concern authority holder of
the repairing shop will have to sign the sub-work order with mentioning the authority no.
place, date, work done and maintain related documents in that shop. The unit with sub-work
order then passed to the original shop for accomplishment of final work for issue ARC
(CAAB Form1).
2.5 Maintenance support for other airlines/outside parties
Components / Parts receive from other airlines/outside parties for repair, overhaul,
modification, shop check, hydrostatic test, recharge; refill of oxygen is routed through the Dy.
Chief Engineer, Engineering Planning, Records &Docs.
Jobs are carried out on the components as specified in work order card in accordance with
instruction in the manufacturer’s manual and as per shop capability and facilities.
On completion of works, respective Principal Engineer or Deputy Chief Engineer of
Component Maintenance raise a request letter to Deputy Chief Engineer, Planning, Records &
Docs mentioning the man-hours, materials and spare parts those are utilized against the
maintenance for processing necessary bills.
Concern shop In-Charge shall deliver the components/parts to the respective Airlines/Operators with
Authorized Released Certificate (CAAB Form1).
1.6 Beyond Economical Repair (BER) Declaring Procedure:
When it is evaluated that the repair/overhaul cost of any Component has become 60% or
more of its purchase value then the repair/overhaul may be declared as Beyond Economical
Repair (BER).
Component found beyond economical repair in any shop, In charge will propose for scrap and
declaration will be made by DCE (CM). Respective Shop In-Charge will liaison with RSP&S
for raising the appropriate Scrap Rejection Certificate (SRC) Form. [a form of RSP&S].
On the basis of certification of shop personnel & RSP&S section the final decision will be
given by Chief of Quality Assurance.
2.7Component Certification procedure:
In-Charge respective Shop/concern authority holder will ensure that an entry of the incoming
component in to Input Register has been done and appropriate personnel have been detailed
for undertaking the job. Details of works : (a) Dismantling (b) Cleaning (c) Inspection /
Checks (d) Repairing (e) Re-assembling, (f)Testing, (g) Re-filling, (h) Weight Check, (i) HST
and (j) Duplicate inspection (as applicable) etc. as applicable are to be carried out in the shop
as per work sheet or appropriate manuals and with compliance of applicable AD, SB„s etc.
Page 14 of 20
Page 15 of 20
After completion of job, the component is tested for its serviceability. On satisfactory
completion of Test, the relevant portion of work order card and a Authorized Release
Certificate i.e. CAAB Form 1 (printed in A4 Size) shall be filled, signed and stamped
authority No. by the Certifying Staff for declaring the Component/Part is Serviceable. Man-
hours, materials etc. utilized are to be recorded in the work order card and in other documents
like Component History Card and Inspection Worksheet etc.
Finally, the Components/Parts released along with Authorized Release Certificate i.e. CAAB
Form 1 and the work order will be handed over to the RSP&S (parts control) section. Work
sheets, History Card and other relevant documents, filled, signed and stamped authority No. by
approved person and kept in the custody of the shop. Certifying Staff in concerned category of
respective Shop shall ensure the incorporation of the applicable AD, SB, SIL and Mods and are
correctly recorded in the Work Sheet and signed and also recorded in the Master SB record
sheet.
Page 16 of 20
2.8 Procedure for providing On Job Training (OJT)
Introduction: Each shop of Component Maintenance Department may require
providing “On Job Training” (OJT) as per requirements and capabilities of the shop
for In-house (BATC) as well as trainees coming from outside Biman. As per OJT
requirements each shop prepares a training program according to the requirements and
allotted hours. The shop In- Charge/concern Principal Engineer detail related authority
holder(s)/Engineer(s) for training and assessment of the trainees. Each shop of
component maintenance department provides the OJT for the following trainees.
a. To its Own Personnel
b. To the Trainee coming from BATC
c. To the Trainee coming from outside Biman
Training procedure: The detailed authority holder/Engineer discuss the subject
(system/component) being trained firstly and show them the practical jobs like
function, testing, disassemble, assemble and troubleshooting etc. The trainer assign job
for the trainees to do practically and answer the question of the trainees. The trainer
also provides necessary training for good housekeeping, standard practice, use of hand
tools and equipment and shop procedure etc.
Assessment of the trainee: The trainer conducts the assessment on every trainee
separately for every assigned job and note down the result on trainees assessment
form. At the end of the training the trainer makes a final assessment on each trainee
and report to In-charge or concern Principal Engineer if required.
Note: All OJT programs are commenced in the shop are controlled by Quality Assurance.
Chapter 3
3.1 Shop Capability: Component shop capability mean authorized to perform work on
those components. At present total 45 components has the capability to do work.
Aircraft Type Number of Components
Dash8-Q400 10
B737 12
B777-300 16
B787-8 & B787-9 07
Total 45
Page 17 of 20
3.2 Performance: shop performance for the year 2021
3.3 Foreign Currency Save: Component maintenance department play a vital role to save
foreign currency. At present component maintenance cost is very high. Instrument & Hydrostatic
shop performed maintenance most of the component locally. As a result this shop save huge
foreign currency.
Foreign currency save chart:
742
652
78 12
Component Input
Compnent
Serviciable
No Shop Capabiliy
Scrap & BER
$1,152,000
$918,000
$640,500
$1,030,500
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
2018 2019 2020 2021
Page 18 of 20
3.4 Future Development Plan: Instrument & hydrostatic shop has following future
development plan:
 Fire extinguisher and Nitrogen cylinder refilling facility
 Fuel tank unit of B777 aircraft test facility
 Elevator Trim indicator of Dash-8 aircraft test facility.
 Develop qualified skill manpower.
3.6Challenges: For future development and better customer service instrument and hydrostatic
shop have to face following challenges:
 Component supply provision (CSP) management
 Finance to establish new facility locally.
 Enough qualified skill manpower buildup.
 24 hours aircraft maintenance support.
 Global unrest and economic crisis.
.
Page 19 of 20
CONCLUSION
Instrument & Hydrostatic shop provide maintenance support Biman and other domestic
& regional airlines and can save and earn a lot of foreign currency. About 22% of total
engineering cost are involve in component maintenance purpose. So that this shop has to
develop facilities to take over maintenance of new components in the shop capability. By
increasing our shop capability and develop skill manpower in this shop we can save and
earn more foreign currency for Biman.
To achieve this target and to reach Biman vision 2030 we must have to maintenance
Biman aircraft component in our local facility by management of Component Support
Programmed (CSP) contact. Otherwise by CSP contact huge foreign currency will be
drained in this sector.
Finally, component maintenance costs are a significant contributor to direct maintenance
costs, therefore itis sensible to establish policies, procedures and oversight for efficient
component management on the off- wing repair cycle.
References:
CAAB ANO Part 145
Civil Aviation Rules 1984 (CAR-84)
Biman Maintenance Organization Exposition (MOE)
Component Maintenance Procedure Manual (CMP
Page 20 of 20
Md. Monirul Islam, P-36621,Report.pdf

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Md. Monirul Islam, P-36621,Report.pdf

  • 1. Biman Bangladesh Airlines Limited Report on Biman Instrument & Hydrostatic Workshop Prepared as Tasked in Senior Management Course (M3) Submitted By: Submitted To: Shahnoor Ahamad GM, Training Management Development Date of Submission 30 August 2022 Md. Monirul Islam Staff No: P-36621, Engineer Officer Engineering & Material Management
  • 2. Acknowledgements First of all, we would like to express our gratitude to the Almighty Allah for blessing us with the ability to successfully complete the report in due time. We would like to extend my heartfelt gratitude to our instructors for their continuous support and valuable time to complete this report “Instrument & Hydrostatic Shop”. Without support and guidelines it would not possible to complete this report in due time. Finally, I would also like to thanks my course mates who also helped us in many ways to complete the report. Page 2 of 20
  • 3. Contents Title Page..............................................................................................................................1 Acknowledgements ..............................................................................................................2 Content……………………………….…………………………………………………….3 Chapter 1 .............................................................................................................................4 Introduction..........................................................................................................................4 1.1 Overview of Biman Bangladesh Airlines Limited……………………………………...4 1.2 Biman Instrument & Hydrostatic Workshop overview ..................................................5 1.3 Facilitates of Instrument Workshop ................................................................................6 1.4 Facilities of Hydrostatic Workshop……………………………………………………..7 1.5 Facility Layout of Instrument & Hydrostatic Shop.........................................................8 1.6 Organization & Manpower Chart..................................................................................11 1.7 Existing Manpower…………………………………………………………………….11 Chapter 2 ................................................................................................................................12 2.1 Working Procedure ………………………………..……………………..……………12 2.2 Components Incoming and outgoing …………………………………………………..12 2.3 Component and Its maintenance………………………………………………………..13 2.4 Level of Maintenance…………………………………………………………………..14 2.5 Maintenance support for others airlines…………………………………………………15 2.6 Beyond Economic Repair (BER)………………………………………………………..15 2.7 Certification of components…………………...…………………………………………15 2.8 Procedure for On the Job Training (OJT)………………………………………………..17 Chapter 3 ................................................................................................................................17 3.1 Shop Capability................................................................................................................17 3.2 Shop Performance……………………………………………………………………….18 3.3 Foreign Currency Save.....................................................................................................18 3.4 Future Development Plan .................................................................................................19 3.5 Challenges………………………………………………………………………………..19 3.6 Conclusion………………………………………………………………………………..20 Page 3 of 20
  • 4. Chapter 1 Introduction 1.1 Overview of Biman Bangladesh Airlines Limited In the wake of the victory against the insurgent Pakistani military, Biman Bangladesh Airlines was established on 4 January 1972 under the Bangladesh Biman Ordinance (Presidential order No. 126). Starting with a Douglas DC-3 aircraft, it started its domestic services on 4 February 1972. After the crash of the DC-3 during a test flight, two Fokker F27s were added to the fleet. To increase thecapacityeven more, a Douglas DC-6 was added. Shortly after that, on 4 March 1972,Biman started its first international flight using a Boeing 707 chartered from BritishCaledonian. By the end of seventies, Biman had expanded its fleet to include 8 F27sand 5 Boeing 707 to serve domestic and international destinations. In the first year of operation, Biman carried just over 380,000 passengers in 1,079 flights. Currently,Biman has the youngest fleet in Asia consisting of 21 modern aircrafts – 17 of whichis owned by Biman and 4 are in lease. The latest aircraft is a Dash 8-400, manufactured by De Havilland Canada. All of the aircrafts have been endowed withbeautiful names in Bangla by none other than our Honorable Prime Minister SheikhHasina. A summary of the fleet is provided in table 1. Table 1: Fleet Summary of Biman Type of Aircraft Number of Aircraft in Fleet Dash-8 5 B737-800 6 B777-300ER 4 B787-8(D) 4 B787-9(D) 2 Biman was transformed into a corporation through Ordinance No. XIX if 1977. Later in 23rd July 2007, Biman was converted into a Public Limited Company and received the corporate logo of white stork flying across the red sun. Biman is now marching towards with a fleet of average age of just over 6 years to fulfill its vision of ranking among the first ten airlines in Asia. For that purpose, Biman has air service agreement with 43 countries and currently hold 18 outstations and 7 domestic destinations excluding Dhaka Hazrat Shahjalal International Airport. Biman is planning and continuously expanding its network to utilize its capacity to the fullest and provide services to people home and abroad. At its peak, Biman has Page 4 of 20
  • 5. operated flights to 29 international destinations, as far away as New York City to the west and Tokyo to the East. The headquarter of the national flag carrier is “Balaka Bhaban”, located at Kurmitola, Dhaka. Apart from that, Biman has a number of subsidiaries like BimanPoultry, Biman Flight Catering Center (BFCC), Biman Ground Handling (BGH), Biman Engineering, and Bangladesh Airlines Training Center (BATC). BATC is the only training center in Southeast Asia that can issue EASA 147 certification. BFCC is the only catering center that holds the accreditation of ISO 9001-2015 and ISO 22000-2005 due to its international standard and strict hygiene maintenance. Biman Bangladesh Airlines is certified as safe to fly in Europe by the European Aviation Safety Agency. It has successfully passed the IATA Operational safety Audit (IOSA) and since then it has been successfully flying to some of its previous destinations in Asia and Europe. Biman has achieved five start safety rating from an airline safety rating agency. The rating was awarded by “airlineratings.com” [2]. Biman launched its mobile app named “Biman Bangladesh Airlines” on December 2019.This has made booking flights, ticketing and finalizing itinerary whole lot easier. Apart from commercial purposes, Biman has been fulfilling its Corporate Social Responsibilities very well. Biman carries the expatriates and helps export manpowerto middle eastern countries and other destinations. It carries dead bodies of expatriates to the country for free. During Hajj season, Biman takes the responsibility of the huge lot of the pilgrims and safely carries them to and from Saudi Arabia. Just like this, by moving forward with both corporate strategy and social responsibilities, Biman plans to fly the nation’s bi-colored flag to greater heights, with great pride around the globe. 1.2 Biman Instrument & Hydrostatic workshop Overview. Aircraft maintenance is the backbone of an airlines. Successful aircraft maintenance history makes company goodwill and customer satisfaction. For successful maintenance of aircraft Biman engineering department started its journey at the beginning of Biman Bangladesh Airlines. Biman instrument & hydrostatic shop is the sub-section of Biman engineering and material management department which is responsible to carry out the maintenance of the aircraft components as per CAAB approved capability List. Instrument & hydrostatic shop is consist of following subsystem group:  Mechanical & Electro-mechanical Group  Electrical & Electronic Group  Pressure vessel & Hydrostatic Group. Page 5 of 20
  • 6. 1.3 Facilities of instrument workshop Instrument workshop is located at 1st floor of Engineering Component Maintenance/S&MM (Annex) Building. It is air-conditioned and the main entrance of the shop is arranged with double door to control the dust. Major portion of the shop is for aircraft Instruments/ components like flight instrument, power-plant, pneumatic/hydraulic, Mechanical, Electrical and miscellaneous Instruments /components, the other small part is for Gyroscopic Instruments which is separated by another door just to further protection of dust. Instrument Maintenance Shop shares a common cleaning room with Radio and Electric Shop. Besides the main shop, the shop extends its facility into two other separate establishments namely- a Hydrostatic test plant and Oxygen refilling plant. These two establishments are located at the northern side of Biman Engineering Hanger. All three premises of Instrument Shop is equipped with adequate lighting, fire protection equipment and evacuation passages. Following are the fixed installations for the Instrument Shop: Fire Fighting System: The fire alarm system is controlled by a Fire Indicator panel, which provides automatic warning during fire. There are two dry chemical fire extinguishers and two fire extinguishers foamed fixed with the wall of the shop. They are located at the easily accessible places. Electrostatic Discharge Sensitive (ESD) Device: This shop is equipped with ESDS repair station with a weekly basis serviceability check list. Pneumatic Source: The shop is equipped with a low pressure pneumatic line for testing and cleaning of aircraft Instruments/components. Air conditioner and De-humidifier: 03 (three) spilt type air-conditioner and 02 (two) dehumidifier are used inside the main shop to maintain the required environment of the shop. Doors: The main shop has two Glass door at the entrance, one for the Gyro Room and other for common cleaning room and also as alternate exit. Other two establishments are also provided with necessary entry/exit Page 6 of 20
  • 7. 1.4 Facilities of hydrostatic workshop Definition: Hydrostatic Test: Cylinder qualification procedure consisting of application of internal pressure with measurement of cylinder expansion, generally performed with water, but other liquid or gas pressure may be used. Cylinder: Any type of pressure vessel designed for a minimum internal pressure of 276 kPa, abs (2.8 bar, abs, 40 psia) and used for transportation of compressed gases that is required by the regulatory to be hydrostatically tested. Expansion: Increase in cylinder volume due to application of pressure. Elastic expansion: Increase in cylinder volume due to application of pressure that is recovered when pressure is released. Permanent expansion: Increase in cylinder volume due to application of pressure that is not recovered when pressure is released. Test pressure: Pressure to which a cylinder is subjected in accordance with the applicable regulations to verify its fitness for service. Visual inspection: Internal examination and/or external examination performed as part of the cylinder requalification process. Re-qualifier’s identification number (RIN): Four character code assigned by Department Of Transportation (DOT), USA, to uniquely identify a cylinder requalification/repair/rebuild facility. Independent Inspection Agency (IIA): Inspection firm approved by DOT as outlined in 49 CFR 107.805 [1]. Calibrated cylinder: A calibrated cylinder is a cylinder that has been specially prepared so that it no longer experiences permanent expansion at the pressures for which it has been calibrated. Registration: Registration is applicable to water jacket, direct expansion, and proof pressure methods. The test facility and test apparatus used shall be approved as to type and operation. Each facility shall have a Re-qualifier Identification Number (RIN) issued by DOT Pipeline and Hazardous Materials Safety Administration (PHMSA) (49 CFR 107.805) upon the favorable recommendation of the independent inspection agency. RIN shall be renewed every after five years. Page 7 of 20
  • 8. Cylinder Hydrostatic Test (HST) Facility: Instrument Overhaul Shop contains the facility of all type of Cylinder Hydrostatic Test in water jacket method. The Re-qualifier Identification Number (RIN) of the facility is H649 (Issued by DOT, USA). All oxygen cylinders, Nitrogen cylinders and some of fire extinguisher cylinder of Biman fleet as well as other airlines are now being tested in this facility. It is a sophisticate, modern and automated computer control test system. Regulation and Inspection: The entire test system, related publication, manpower with training and record keeping are directly regulated and controlled by the regulations of Department Of Transportation (DOT), USA i.e. U. S. Code of Federal Regulations (CFR) Title 49 Parts 172.704 as applicable and 107, 173, 180 related sections. DOT authorized Independent Inspection Agency (IIA) delegates inspect the facility once in every five years. IIA inspect/conduct the following: a. Test system serviceability. b. Man power qualifications & refresh/recurrent training as per CFR 49 Parts 172.704. c. Documentations and record keeping. d. Practical assessment examination on hydrostatic test for hazmat employee(s) as per CGA pamphlets. e. Theatrical examination for hazmat employee(s) involves in hydrostatic test as per CFR 49 related sections and CGA pamphlets. f. Oral examination for hazmat employee(s). After satisfactory inspections on the above mentioned subject the Independent Inspection Agency (IIA) inspector repot to the Department Of Transportation (DOT), USA for renewing Hydrostatic Test (HST) approval for next five years. If DOT is satisfied, may renew the Hydrostatic Test (HST) approval for five years. Training: Each hazmat employee performing hydrostatic test must be fulfilled the training/continuation requirements (as applicable) of 49 CFR part 172.704. 1.5 Facility Layout of Instrument & Hydrostatic workshop Page 8 of 20
  • 11. CHIEF ENGINEER (EP) DIRECTOR ENGINEERING & MM MANAGING DIRECTOR & CEO ACCOUNTABLE MANAGER PRINCIPAL ENGINEER (AVIONICS COMPONENT MAINT.) INSTRUMENT & Hydrostatic Shop 01 E.O. I/C-VI Tech. 02 E.O.- VITech. 03 J.I.O.- VTech. 03x Jr. Tech.- IV Tech. 04x Mech- III Tech. PRINCIPAL ENGINEER (AEROSPACE COMPONENT MAINT.) 1.6 Organization & Manpower Layout. Fig: Organization & Manpower Chart of Instrument & Hydrostatic Shop 2.1Existing Manpower As per approved organogram 2019 Existing Manpower Shortage of manpower Engineer Officer 3 2 46% Junior Inspection Officer 3 1 Technician 3 0 Mechanic 4 1 Aircraft Technical Helper 0 3 Total 13 7 DEPUTY CHIEF ENGINEER COMPONENT MAINTENANCE Page 11 of 20
  • 12. Chapter 2 2.1 Working procedure: Most of the repairable aircraft components are time limited for shop check, functional check and Overhaul. As such those are removed from the aircraft and sent to the respective shops as per AMS or against any defect for necessary maintenance. The work is being carried out in the Shop - according to the CMM/OHM and by full-filling the Airworthiness requirements as laid down in ANO(AW), CAAB Part145 and other regulatory requirements of CAAB. Shops usually perform Dis-assembly, Cleaning, Repair, Overhaul, Inspection/Checks, Modification and Testing on the Components and Weight Check of Fire Extinguishers, Re-filling of Oxygen Cylinder & HST of Pressure vessels of various aircraft as per approved capability List. Components beyond the shop capabilities are sent to outside repair/servicing agencies for necessary servicing. 2.2 COMPONENT INCOMING & OUT GOING PROCEDURE: a. Components are loaded in the component maintenance shop from RSP&S for - Repair / Overhaul / Modification / Cleaning / Inspection / Testing either as schedule or unscheduled maintenance. b. On receipt, Component Maintenance personnel of each Shop must check that the unserviceable Components /Parts are attached with Work Order (with duplicate copy) and Unserviceable Label/Tag. c. In-Charge of the respective shop will arrange to record the Component in the Incoming Register and check for shop capability and detail the concern authorized person for necessary maintenance. Unserviceable component are kept in the UNSERVICEABLE RACK or in a designated area. d. If any component found out of shop capability, the respective shop In-charge or any Certifying Staff shall arrange to return the component to the RSP&S section immediately with a comment “OUT OF SHOP CAPABILITY or NO FACILITY” and signed by the respective Authorized person in the Work Order. e. For a component under shop capability list, the concern authorized person will initiate the necessary maintenance work upon collecting the Inspection Worksheet, CMM and History Card. f. Concern authorized person will perform the necessary disassembling, cleaning, inspection/checks, defective parts replacement, troubleshooting, reassembling and testing and duplicate inspection (by another authorized person of respective category) etc. process step by step as per Inspection Worksheet or reference taken Page 12 of 20
  • 13. from appropriate manuals. g. Concern authorized person will assist and supervise the function disassembling, cleaning, defective parts replacement and reassembling. In this case the Concern authorized person will also ensure that non certifying staffs are signing for the applicable task in the applicable column. h. Concern authorized person shall ensures that the every step of Overhauling/Repairing/Cleaning/ Inspection/Checks/Testing process are progressing as per latest worksheet, manual and proper tools/special tools/materials are used to meet operational safety and regulatory requirements. i. Rectification, material used for accomplishment of component maintenance is to be recorded in the History Card, Work Order, relevant Inspection worksheets and signed by the Certifying Staff. Serviceable components are kept in the SERVICEABLE RACK or in a designated area until released from the shop and handover to RSP&S section. j. After completion of the necessary maintenance i.e. fulfilling the airworthiness requirements, the relevant portion of work order & ARC (CAAB Form1) are filled in with signed and stamped by the certifying staff for declaring the component is released to service. Certifying Staff of the Shop must ensure, SB‟s, SIL and Mod’s are incorporated correctly recorded in the Master S.B Card (if, applicable). Form Tracking no. of ARC (CAAB Form1) will be recorded in the ARC(CAAB Form1) Control Register(Form No: EMM/CM/5015) and finally Shop In-Charge shall arrange to handover the component to RSP&S (Parts Control) section. k. Authorized Release Certificate (ARC) CAAB Form 1 must have Form Tracking Number allotted from Engineering Production ARC control Register consist of first two digits for BG and next four digits for the current year and sequential unique number at the right l. CAAB Form1 and the number must be recorded in a separate column of the Component Output Register along with other information. Example: B G 2 0 1 7 0 0 0 0 1 2.3 Component & Maintenance: Component: Sub-assembly of an aircraft, engine or propeller. Such as motor, generator, Oxygen cylinder etc. Page 13 of 20
  • 14. Maintenance: Maintenance: means any one or combination of overhaul, repair, inspection, replacement, modification or defect rectification of an aircraft or component, with the exception of pre-flight inspection 2.4 Level of Maintenance: Level-1 : a) General Visual Inspection (GVI), replacement of desiccants, silica-gel (moisturizer protective agents) or checking of lubricating fluid level etc. for renewal/ extension of rack life as per CMM and minor repair like replacement of small indicator light/LED, Fuse blown, protective glass cracked/ hazy, bent or broken connector pins, missing serial number or identification plate etc. a) Re-filling of Oxygen b) Weight check c) A rectification of minor defects which does not involve any test or special tools & equipment. d) A rectification other than Repair or Overhaul. Level-2: Repair, replacement of parts involving Testing/functional check in shop according to appropriate Overhaul Manual or Component Maintenance Manual. Level-3: Complete Overhaul according to appropriate Overhaul Manual/ Component Maintenance Manual (CMM). m. Fractional Job: Fractional jobs may be required to perform in different shops. When a fractional job involve on any component, the original shop will have to send the unit with sub- work order to other shop. After completion of fractional job, the concern authority holder of the repairing shop will have to sign the sub-work order with mentioning the authority no. place, date, work done and maintain related documents in that shop. The unit with sub-work order then passed to the original shop for accomplishment of final work for issue ARC (CAAB Form1).
  • 15. 2.5 Maintenance support for other airlines/outside parties Components / Parts receive from other airlines/outside parties for repair, overhaul, modification, shop check, hydrostatic test, recharge; refill of oxygen is routed through the Dy. Chief Engineer, Engineering Planning, Records &Docs. Jobs are carried out on the components as specified in work order card in accordance with instruction in the manufacturer’s manual and as per shop capability and facilities. On completion of works, respective Principal Engineer or Deputy Chief Engineer of Component Maintenance raise a request letter to Deputy Chief Engineer, Planning, Records & Docs mentioning the man-hours, materials and spare parts those are utilized against the maintenance for processing necessary bills. Concern shop In-Charge shall deliver the components/parts to the respective Airlines/Operators with Authorized Released Certificate (CAAB Form1). 1.6 Beyond Economical Repair (BER) Declaring Procedure: When it is evaluated that the repair/overhaul cost of any Component has become 60% or more of its purchase value then the repair/overhaul may be declared as Beyond Economical Repair (BER). Component found beyond economical repair in any shop, In charge will propose for scrap and declaration will be made by DCE (CM). Respective Shop In-Charge will liaison with RSP&S for raising the appropriate Scrap Rejection Certificate (SRC) Form. [a form of RSP&S]. On the basis of certification of shop personnel & RSP&S section the final decision will be given by Chief of Quality Assurance. 2.7Component Certification procedure: In-Charge respective Shop/concern authority holder will ensure that an entry of the incoming component in to Input Register has been done and appropriate personnel have been detailed for undertaking the job. Details of works : (a) Dismantling (b) Cleaning (c) Inspection / Checks (d) Repairing (e) Re-assembling, (f)Testing, (g) Re-filling, (h) Weight Check, (i) HST and (j) Duplicate inspection (as applicable) etc. as applicable are to be carried out in the shop as per work sheet or appropriate manuals and with compliance of applicable AD, SB„s etc. Page 14 of 20 Page 15 of 20
  • 16. After completion of job, the component is tested for its serviceability. On satisfactory completion of Test, the relevant portion of work order card and a Authorized Release Certificate i.e. CAAB Form 1 (printed in A4 Size) shall be filled, signed and stamped authority No. by the Certifying Staff for declaring the Component/Part is Serviceable. Man- hours, materials etc. utilized are to be recorded in the work order card and in other documents like Component History Card and Inspection Worksheet etc. Finally, the Components/Parts released along with Authorized Release Certificate i.e. CAAB Form 1 and the work order will be handed over to the RSP&S (parts control) section. Work sheets, History Card and other relevant documents, filled, signed and stamped authority No. by approved person and kept in the custody of the shop. Certifying Staff in concerned category of respective Shop shall ensure the incorporation of the applicable AD, SB, SIL and Mods and are correctly recorded in the Work Sheet and signed and also recorded in the Master SB record sheet. Page 16 of 20
  • 17. 2.8 Procedure for providing On Job Training (OJT) Introduction: Each shop of Component Maintenance Department may require providing “On Job Training” (OJT) as per requirements and capabilities of the shop for In-house (BATC) as well as trainees coming from outside Biman. As per OJT requirements each shop prepares a training program according to the requirements and allotted hours. The shop In- Charge/concern Principal Engineer detail related authority holder(s)/Engineer(s) for training and assessment of the trainees. Each shop of component maintenance department provides the OJT for the following trainees. a. To its Own Personnel b. To the Trainee coming from BATC c. To the Trainee coming from outside Biman Training procedure: The detailed authority holder/Engineer discuss the subject (system/component) being trained firstly and show them the practical jobs like function, testing, disassemble, assemble and troubleshooting etc. The trainer assign job for the trainees to do practically and answer the question of the trainees. The trainer also provides necessary training for good housekeeping, standard practice, use of hand tools and equipment and shop procedure etc. Assessment of the trainee: The trainer conducts the assessment on every trainee separately for every assigned job and note down the result on trainees assessment form. At the end of the training the trainer makes a final assessment on each trainee and report to In-charge or concern Principal Engineer if required. Note: All OJT programs are commenced in the shop are controlled by Quality Assurance. Chapter 3 3.1 Shop Capability: Component shop capability mean authorized to perform work on those components. At present total 45 components has the capability to do work. Aircraft Type Number of Components Dash8-Q400 10 B737 12 B777-300 16 B787-8 & B787-9 07 Total 45 Page 17 of 20
  • 18. 3.2 Performance: shop performance for the year 2021 3.3 Foreign Currency Save: Component maintenance department play a vital role to save foreign currency. At present component maintenance cost is very high. Instrument & Hydrostatic shop performed maintenance most of the component locally. As a result this shop save huge foreign currency. Foreign currency save chart: 742 652 78 12 Component Input Compnent Serviciable No Shop Capabiliy Scrap & BER $1,152,000 $918,000 $640,500 $1,030,500 $0 $200,000 $400,000 $600,000 $800,000 $1,000,000 $1,200,000 $1,400,000 2018 2019 2020 2021 Page 18 of 20
  • 19. 3.4 Future Development Plan: Instrument & hydrostatic shop has following future development plan:  Fire extinguisher and Nitrogen cylinder refilling facility  Fuel tank unit of B777 aircraft test facility  Elevator Trim indicator of Dash-8 aircraft test facility.  Develop qualified skill manpower. 3.6Challenges: For future development and better customer service instrument and hydrostatic shop have to face following challenges:  Component supply provision (CSP) management  Finance to establish new facility locally.  Enough qualified skill manpower buildup.  24 hours aircraft maintenance support.  Global unrest and economic crisis. . Page 19 of 20
  • 20. CONCLUSION Instrument & Hydrostatic shop provide maintenance support Biman and other domestic & regional airlines and can save and earn a lot of foreign currency. About 22% of total engineering cost are involve in component maintenance purpose. So that this shop has to develop facilities to take over maintenance of new components in the shop capability. By increasing our shop capability and develop skill manpower in this shop we can save and earn more foreign currency for Biman. To achieve this target and to reach Biman vision 2030 we must have to maintenance Biman aircraft component in our local facility by management of Component Support Programmed (CSP) contact. Otherwise by CSP contact huge foreign currency will be drained in this sector. Finally, component maintenance costs are a significant contributor to direct maintenance costs, therefore itis sensible to establish policies, procedures and oversight for efficient component management on the off- wing repair cycle. References: CAAB ANO Part 145 Civil Aviation Rules 1984 (CAR-84) Biman Maintenance Organization Exposition (MOE) Component Maintenance Procedure Manual (CMP Page 20 of 20