CPC Course - Fundamentals Module 1_Lesson 1
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Aviation maintenance officers and technicians at all levels must ensure that all aviation regulations, policies and procedures for the detection and treatment of corrosion for aircraft and associated equipment are followed. A complete Corrosion Prevention & Control (CPC) Program will be achieved by incorporation of the latest state-of-the-art corrosion control technology in the original equipment design, in the manufacturing, in all levels of maintenance, in supply, and in the storage processes. This lesson introduces students to the importance of a CPC program, the costs of corrosion and invites a general discussion of why prevention is a crucial part to any aviation maintenance business.
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CPC Course - Fundamentals Module 1_Lesson 1
- 2. Corrosion Control and Prevention Course Overview • Why • Frequency • No Pressure Washer • Pressure Washer • Cleaning Materials • CPC’s • The Cost of Corrosion • Types of Corrosion • Factors of corrosion • Stopping & Preventing Fundamentals1 Aircraft Wash Procedures2
- 3. Corrosion Control and Prevention Course Overview • Inspection Frequency • Inspection Procedures • Inspection Methods • Corrosion Prone Areas • Preventive Maintenance • Fastener Sealing • Sealing Techniques • Recommended Materials Preventive Maintenance3 Inspection & Repair4
- 5. Corrosion Control and Prevention Course Objectives Understand why is prevention important Identify the different types of corrosion Discuss some mechanical factors Learn how to stop & prevent corrosion
- 6. Corrosion Control and Prevention Corrosion Refresher Why is corrosion prevention important Corrosion Basics Factors influencing corrosion Types of corrosion How to prevent corrosion
- 7. Corrosion Control and Prevention Aviation Corrosion Prevention and Control Policy CORROSION PREVENTION AND CONTROL PROCEDURES are in compliance with TM 1-1500-328-23 (Aeronautical Equipment Maintenance Management Policies and Procedures)
- 8. Corrosion Control and Prevention Aviation Corrosion Prevention and Control Policy IF THERE IS NO CPC PROGRAM ESTABLISHED, AIRCRAFT WILL BE SCHEDULED CPC INSPECTION ON A 90-CALENDAR-DAY INTERVAL
- 9. Corrosion Control and Prevention Aviation Corrosion Prevention and Control Policy
- 10. Corrosion Control and Prevention
- 11. Corrosion Control and Prevention
- 12. Corrosion Control and Prevention
- 13. Corrosion Control and Prevention 0 2 4 6 8 10 12 14 16 1995 1996 1997 1998 1999 2000 2001 Direct cost of corrosion damage – Parts Cost $M 223% -23% 40% -4% 8% -20%
- 14. Corrosion Control and Prevention 0 .5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 1995 1996 1997 1998 1999 2000 2001 $M Indirect cost of corrosion damage – Man-Hours Cost -8% 84% 18% 2% 151% -22%
- 15. Corrosion Control and Prevention 0 2 4 6 8 10 12 14 16 18 20 1995 1996 1997 1998 1999 2000 2001 $M Corrosion Total Cost due to Corrosion
- 16. Corrosion Control and Prevention Total Corrosion Costs
- 17. Corrosion Control and Prevention Total Corrosion Costs
- 18. Corrosion Control and Prevention Aloha Airlines Flight 243 – April 1988
- 19. Corrosion Control and Prevention Aloha Airlines Flight 243 – April 1988
- 20. Corrosion Control and Prevention Aloha Airlines Flight 243 – April 1988
- 21. Corrosion Control and Prevention Aloha Airlines Flight 243 – April 1988 Explosive decompression @ 24,000 feet Airplane operated in coastal environment with exposure to salt and humidity Root cause – Epoxy bond failure which allowed water to enter gap and start corrosion process
- 22. Corrosion Control and Prevention Total Corrosion Costs WITH PROPER MAINTENANCE BY TRAINED CREWS COST AND DAMAGE CAN BE REDUCED PREVENT
- 23. Corrosion Control and Prevention Why study corrosion?
- 24. Corrosion Control and Prevention Why study corrosion?
- 25. Corrosion Control and Prevention
Editor's Notes
- A short introduction to a corrosion control and prevention program. Resources are from online and my personal military documents. This document was created for eLearning and as a reference only for educational purposes. It should not take the place of any approved prevention &/or inspection program. This module was originally developed in Powerpoint and has speaker notes and animations. Email me should you have any questions.
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- Understanding how to Improve Employee Performance and Development can be broken down into four major areas. In lesson 1, we will discuss measures (events, actions, procedures and methods) of performance, developing accurate ways of measuring performance. Click - Lesson 2 covers encouraging employee development. Mentoring and sharing experiences and knowledge, evaluating strengths and weaknesses, and matching those to work responsibilities. Click
- Discuss goals and purpose of course. Read objectives
- Aviation maintenance commanders and maintenance officers/technicians at all levels must ensure that all Army policies and procedures for the detection and treatment of corrosion for aircraft and associated equipment are followed. CPC will be achieved by incorporation of the latest state-of-the-art corrosion control technology in the original equipment design, in the manufacturing, in all levels of maintenance, in supply, and in the storage processes. A CPC program with aggressive effort will minimize aircraft and equipment damage and increase operational efficiency and readiness. In addition, a well established CPC program will provide for a safer operating environment and reduce maintenance down time. All personnel who operate, maintain, or service aircraft or aviation ground support equipment are responsible for adhering to the commander’s published CPC program. Everyone in the unit must be constantly alert to identify problem areas that can lead to corrosion-induced damage and create potentially dangerous safety and operational hazards to personnel and equipment. All aircraft maintenance personnel must be aware of the catastrophic consequences created by corrosion left unchecked. Aircraft or equipment damage as a result of corrosion is an unacceptable impediment to Army missions and tactical operations.
- During this class, we will discuss: Why corrosion prevention is important to us Understanding what corrosion is and the factors that influences how fast it occurs The common types of corrosion you can expect to see on our aircraft What we can do to prevent corrosion from occurring
- Q-1. All aviation units responsible for aircraft maintenance shall establish corrosion control programs as required by their higher headquarters. The type of program depends on the environment to which the aircraft may be exposed. At sea, conditions are considered to be the most severe. In this environment, aircraft are exposed to salt spray, ship stack gases, and aircraft engine exhausts. In other environments, land-based aircraft may be exposed to industrial gases, salts, rain, mud, and mists containing sea salts. Q-2. A comprehensive CPC program shall include trained maintenance personnel who will be responsible for the prevention, early detection, reporting, and repair of corrosion damage. Such a program requires a dedicated effort by all maintenance personnel to prevent corrosion before it starts. Q-3. The maintenance manager, with the assistance of QC personnel, will establish and implement inspections, procedures, and corrosion preventive measures to augment corrosion control procedures deemed necessary by the aviation maintenance commander and maintenance officer/technician. The maintenance manager delineates both individual and collective responsibilities for the conduct, management, and enforcement of the corrosion preventive and control program. Q-4. The commander ensures that all maintenance supervisors, technical inspectors, aircraft crew members, and selected component repair section personnel receive training in aircraft CPC program according to AR 750-59, TM 1-1500-344-23-1, TM 1-1500-344-23-2, TM 1-1500-344-23-3, TM 1-1500-344-23-4, and TM 1-1500-328-23. Required entries for aircraft forms and records must be outlined and understood by all unit personnel for the unit’s CPC program to be effective. Q-5. These efforts will improve the operational readiness of equipment and minimize costly repairs. In addition, they will prolong the service life of TBO and condition change components installed on assigned aircraft through prompt identification and treatment of corrosion-damaged aircraft repair parts and components.
- TM1-1500-328-23 Section VIII Individuals, Supervisors, Managers will ensure compliance with TM 1-1500-328-23 (Aeronautical Equipment Maintenance Management Policies and Procedures) and will establish additional Corrosion Prevention and Control (CPC) procedures, as necessary, for aviation resources under their control The will appoint a unit CPC monitor. The unit CPC monitor will observe inspections and maintenance operations to evaluate the extent of the program If an aircraft MDS does not have an established CPC program, stated in the applicable publication, they will be scheduled CPC inspections on a 90-calendar-day interval
- Q-9. An effective CPC program shall include thorough cleaning, inspection, preservation, and lubrication, at specified intervals, according to applicable aircraft maintenance TMs and TM 1-1500-344-23-1, TM 1-1500-344-23-2, TM 1-1500-344-23-3, and TM 1-1500-344-23-4, Chapters 3 and 4 and Appendixes C, D, and E. Check for corrosion damage and integrity of protective finishes during all scheduled and unscheduled maintenance. Q-10. Early detection and repair of corrosion will limit further damage. Maintenance personnel treat corrosion as prescribed in applicable references and publications as soon as possible, and use only approved materials, equipment, and techniques. Q-11. The unit CPC monitor will observe inspections and other maintenance actions to determine the extent of corrosion on supported aircraft, ensuring that prompt action is taken to treat any corrosion detected. All problems involving corrosion shall be entered on the aircraft’s DA Form 2408-13-1 according to DA Pamphlet 738-751. The status symbol will depend on the degree of corrosion, location, and allowable limits for the area as directed by the applicable aircraft maintenance technical manual, including ETM/IETM. Q-12. To prevent further deterioration, corrective action must be taken as soon as possible. When a corrosion defect/fault is assigned a “Diagonal (/)” status symbol and corrective action is not initiated within 30 days from date of discovery, the aircraft status symbol will be changed to an “X, grounding condition.” The aircraft will remain grounded and reported as NMC on readiness reports until corrective action has been taken. Q-13. Aviation unit’s NCOICs, maintenance personnel, and crew members will ensure accomplishment of scheduled CPC inspections and actions no later than the specified due date or hours as entered on the DA Form 2408-18. When operational requirements preclude timely accomplishment of scheduled inspections and maintenance actions, the following guidelines are established: Corrosion inspections or actions prompted by a special occurrence or as required by airframe operating time according to the special inspections sections of the airframe and engine technical manuals, including ETMs/IETMs, will be accomplished not later than (NLT) the time specified in the manual. When the aircraft is away from home station and facilities are unavailable, scheduled corrosion inspections and maintenance actions will be deferred with the higher headquarter commander’s approval. Once the aircraft has returned to home station or to a maintenance facility, it will not be flown until required corrosion inspections and corrective maintenance actions are completed according to applicable aircraft maintenance technical manuals, including ETMs/IETMs.
- Discuss: safety, cost, dispatch rates
- OVERVIEW Investigations during the past ten years have identified corrosion as a major factor in electronics failure in the field. As much as 30% to 40% of military avionic failures are due to the corrosion process. This is despite steady improvements in reliability of avionic systems fielded to date and outlines the need for an effective preventive maintenance program. Remember, corrosion prevention is a state of mind. At any time, when someone is inspecting an aircraft, they should have a can or two of CPC to prevent corrosion before is happens!
- Direct cost of corrosion damage The cost parts that have been replaced on the CH47 due to corrosion is shown on this chart. This is in millions of dollars. The numbers on the bars shows the increase or decrease percentage from the previous year. A couple of things to keep in mind about this data: These are parts replaced solely due to corrosion. It does not include parts that were replaced for another reason and also happened to be corroded. There is no turn in credit applied to these numbers. Not all AVIM units turn in their 2407s for inclusion into the database that this was extracted from.
- Indirect cost of corrosion damage This data shows that cost of the man-hours expended due to corrosion on the CH47. Again – this is only due to corrosion. The scale is in millions of dollars again. A conservative rate of $35.00 per hour was used to convert the actual man-hours to dollars.
- Add both parts and man-hours together shows the total cost due to corrosion on the aircraft. Again the scale is in millions of dollars.
- CORROSION COSTS In 1998, a report was prepared for Department of Defense (DoD) under contract by the “North American Technology and Industrial Base Organization” (NATIBO). Corrosion costs for the DoD were estimated to be $10 billion per year. These costs have been broken down to the U. S. Army and estimated at $2.5 billion per year. Many studies have shown it costs less in parts and man-hours to prevent corrosion than it does to repair it.
- Left untreated, corrosion is a serious threat to the structural integrity of the aircraft. The slide shows aftermath of Aloha Airlines Major Structural Failure.
- Aloha Airlines Flight 243, Boeing 737-200, 28 April 1988. Suffered extensive damage after an explosive decompression in flight. 90 pax onboard at takeoff, 1 fatality – flight attendant blown out at initial decompression. Around 13:48, as the aircraft reached its normal flight altitude of 24,000 feet (7,300 meters) about 23 nautical miles (43 km) south-southeast of Kahului, a small section on the left side of the roof ruptured.
- The resulting explosive decompression tore off a large section of the roof, consisting of the entire top half of the aircraft skin extending from just behind the cockpit to the fore-wing area.
- The age of the airplane and the condition of the fuselage (that had corroded and was stressing the rivets beyond their designed capacity) The NTSB investigation concluded that the accident was caused by metal fatigue exacerbated by crevice corrosion (the plane operated in a coastal environment, with exposure to salt and humidity) the root cause of the problem was failure of an epoxy adhesive used to bond the aluminum sheets of the fuselage together when the B737 was MANUFACTURED. Water was able to enter the gap where the epoxy failed to bond the two surfaces together properly, and started the corrosion process.
- Contributing factor was that the extensive and longer “D Check” was performed in several early morning installments (phase), instead of a full uninterrupted maintenance procedure.
- However, perhaps the most important fact that the NATIBO report found was that 40% to 50% of the costs of corrosion could be eliminated with proper maintenance by trained crews using the latest corrosion prevention materials. The Global Aerospace Logistics Maintenance Department is committed to improving the readiness of the fleet and reducing the cost of ownership by reducing the costs of corrosion. This course is just one of the many efforts that the GAL Maintenance office is using to help you, the maintainer, to battle this enemy or ours called corrosion.
- Your example does not have to be sophisticated. The importance here is to able to distinguish between direct and indirect cost. Direct cost: an expense that can be traced directly to a department, process or product such as labor, materials, fuel, power Direct cost of corrosion damage: Repair materials, labor to perform repairs, fuel and power usage in operating tools, hangar and equipment
- Indirect cost: an expense incurred in joint usage Indirect cost of corrosion damage: loss of life, loss of aircraft, loss of missions, unscheduled shutdowns, productivity loss, accidental interruptions.
- Sources: Corrosion Doctors