Maintenance & Condition Inspections for Experimental Aircraft€¦ · About Me • B.S. and Ph.D....

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GoodPracticesforConductingMaintenance&ConditionInspectionsofExperimental

AircraftMichaelFlagella,Ph.D.,A&P,IRMT

Mike’sAeroClassics, Inc.LivermoreAirport(KLVK)

www.MikesAeroClassics.com

AboutMe• B.S.andPh.D.degreesinMolecularBiology(1995,2001)

• Pharma/biotechscientist2001-2012

• Privatepilot(2000)• Own/maintainexperimentalSteenSkybolt

• Airframe&Powerplantmechanic(2014)• FoundedMike’sAeroClassics,Inc.(2014)

• “Tube-and-fabric”aircraft• Experimentalaircraft

• IndependentRotaxMaintenanceTechnician(2015)• MemberofAOPA,EAA,IAC,VAA,WarbirdsofAmerica

Objective

• Tounderstandchallengesassociatedwithmaintaining ourselves.

• Providemethodstoensuremaintenanceoraninspectionisdonewell.

• Provideguidancearoundensuringasafeanduneventfulpost-maintenanceflight.

ChallengesofMaintainingExperimental-AmateurBuiltAircraft• CertificationandmaintenanceofE-ABaircraftaremanagedaccordingtoadifferentregulatoryandpolicyframeworkthannon-E-ABaircraft.

• Unliketype-certificatedaircraft,thereisnorestrictiononwhomayperformmaintenanceonanE-ABaircraft.

• Theexperimentalnatureofamateur-builtaircraftisevidentinthewiderangeofpowerplants,equipment,anddesignfeaturesfoundintheseaircraft.

BiggestChallenge:HumanFactors• Aviationsafetyreliesonmaintenanceperformedbypeople.

• Tools&equipment• TechnicalData• Knowledge&technicalskills

• Accidents/incidents canresultfrommaintenanceerrors

• Partsinstalledincorrectly• Partsmissing(e.g.safetywire/cotterkeys,spacers)

• Toolsleftinenginecompartment• Necessarycheckswerenotperformed

• Manyfactorscandegradeaperson’sabilitytoperformeffectivelyandsafely.

AC43.13-1b,Chapter13.HumanFactorsandhttp://www.faa.gov/about/initiatives/maintenance_hf/ www.MikesAeroClassics.com

“TheDirtyDozen”

• Lackofcommunication• Complacency• Lackofknowledge• Distraction• Lackofteamwork• Fatigue

• Lackofresources• Pressure• Lackofassertiveness• Stress• Lackofawareness• Norms

It is important to know the dirty dozen, how to recognize theirsymptoms, and most importantly, know how to avoid or contain errors.

HumanFactors:PersonalMinimumsChecklist– Beforethemaintenancetask• BEFOREdoingthework,askyourself:

• DoIhavetheknowledgetoperformthetask?• DoIhavethetechnicaldata?• HaveIperformedthetaskpreviously?• DoIhavethepropertoolsandequipment?• HaveIhadthepropertraining?• AmImentallyprepared?• AmIphysicallyprepared?• HaveItakenthepropersafetyprecautions?• DoIhavetheresources(time,parts,money)availabletoperformthetask?

• HaveIresearchedtheFARstoensurecompliance?

HumanFactors:PersonalMinimumsChecklist– Afterthemaintenancetask• AFTERdoingthework,askyourself:

• DidIperformthetasktothebestofmyabilities?• Wasthetaskperformedtobeequaltotheoriginal?• Wasthetaskperformedinaccordancewithappropriatedata?• DidIuseall themethods,techniquesandpracticesacceptabletoindustry?• DidIperformthetaskwithoutpressures,stressanddistractions?• DidIreinspect mywork,orhavesomeoneelse inspectmywork,beforereturningtoservice?

• DidImaketheproperrecordentriesfortheworkperformed?• DidIperformtheoperationalchecksaftertheworkwascompleted?• AmIwillingtosignonthebottomlinefortheworkperformed?• AmIwillingtoflyintheaircraftonceitisapprovedforthereturntoservice?

ConditionInspectionsforE-ABWhatisaConditionInspection?• Acondition inspection istheequivalent ofan"annualinspection" ofatype certificatedaircraft.

• Theoperatinglimitationsonyour homebuilt willinclude thefollowing (orsomething similar):“Noperson shall operatethis aircraftunless within thepreceding12calendar (usually) months ithas hada conditioninspectionperformedinaccordancewiththescopeanddetailofAppendixDtopart43,orotherFAA-approved programs, andfound tobeinacondition forsafeoperation.”

• Condition inspections shallberecorded intheaircraftmaintenance recordsshowing thefollowing (orasimilarlyworded) statement:"Icertifythatthisaircrafthasbeeninspectedon(insertdate)inaccordancewiththescopeanddetailofappendixDtopart43andfoundtobeinaconditionforsafeoperation."Theentrywillinclude theaircrafttotaltimeinservice, and thename, signature, certificatenumber, andtypeofcertificateheld bythepersonperforming theinspection.

WhocanperformaConditionInspection?• Theinspection canbeperformedbyanylicensed A&Pmechanic, anFAAApprovedRepairStation, orbythebuilder of theairplaneprovided thebuilder obtains a"Repairman'sCertificate"fromtheFAA.

• Unlike anannual foratypecertificatedaircraft,theA&Pmechanic doesNOThavetohavehis/her"InspectionAuthorization."

UseanInspectionChecklist• Eachpersonperformingaconditioninspectionshalluseachecklistwhileperformingtheinspection

• Maybetheperson’sowndesign• Oneprovidedbythemanufacturer• Oneobtainedfromanothersource• Mustincludethescopeanddetailoftheitems inAppendixDofPart43

• Ensuresnothingismissedduringinspection• Keepsyouorganized

InspectionChecklistExample

DiscrepancyLog(”SquawkList”)

• Listofitemsthatwerefoundduringtheinspection,orbyowner/operator,thatneedattention

• RoughrunningwithinacertainrangeofRPM• StaticinterferenceofradioduringTx/Rx• Reportedaltitude isdifferentfromaltimetersetting• Smallcrackstartingtoformatcowlfastener• Desiretoaddormodifyequipment(e.g.replaceexhaustsystem)

• DiscrepancyLogcanbeappendedtoInspectionChecklist• Includedetailabouttheissueandhowitwasresolved:

• Datefound,howrepaired,andbywhom(owner,AMT,repairstation)

AC20-106,AircraftInspectionfortheGeneralAviationAircraftOwner• TheHabitofInspection

• BeginbyperformingPreflightInspections• WorkuptoDetailed Inspections• UseManufacturer’sRecommendations asaguide• Developasystemanduseaninspectionchecklist• Onceadopted,donotdeviatefromtheprocedure

• Ifdefectsarenotedorsuspected,haveadetailedassessmentdonebysomeonewithknowledgeofyourparticularexperimentalaircraft,oracertificatedmechanic.

Maintenance&InspectionDo’sandDon’ts

DO…• havepropertools.*• usechecklist/procedure&sticktoit.• removeallinspectionplates&cowlings• cleanallitemstobeinspected.• checkallmovingpartsforproperlubrication&lockingdevicesforsecurity.

• inspectforpropersafetying techniques,andresafety apartyouhaveunsafetiedBEFOREinspectingthenextitem.

• seekassistancewhenindoubt.• thejobrightthefirsttime.

DON’T…• behurried– taketimetoproperlyinspecteachitem.

• movethepropunlessmags are“OFF”orignitionsystemisotherwiserenderedinoperative.

• presumeanitemissafeuntilithasbeenchecked.

• performanycomplexinspectionormaintenanceoperationunlessyouareproperlytrainedand/orsupervised.

• taketheattitude“Itcan’thappentome.”

MaintenanceCaseStudy“WhenIturnonmyplane’sMasterSwitch,theNav lightscomeon!”

Ownerhad recentlyhadthealtimeterreplaced.Atechnician likelydropped theinstrument nutanddid notretrieveitaftermaintenance, causing ashort circuitacross theNav lightswitchfrommain busbar.

ThisisanexampleofForeignObjectDebris(“FOD”)andapotential firehazard.

©M.Flagella ©M.Flagella ©M.Flagella

ForeignObjectDebris(”FOD”)

“FOD is any object located in an inappropriate location in the airportenvironment that has the capacity to injure airport or air carrierpersonnel and damage aircraft.”

FOD has the potential to damageaircraftduring critical phases of flight:• Cuttingaircrafttires• Becomelodgedintoflightmechanisms• Shortingoutelectricalsystem

FAAAC150/5210-24 “ForeignObjectDebrisManagement”

Air France Flight 4590 (2000)

FODTaxonomy• FODcomposedofanymaterialandbeanycolorandsize

• FODtypicallyfromOTHERaircraft• TypicalFODcomprisedof:

• Aircraftandenginefasteners(e.g.nuts,bolts,washers,safetywire)

• Aircraftparts(e.g.fuelcaps,oilsticks,accesspanels)

• Mechanics’toolsandrags• Flightlineitems(pens,luggagezippers&wheels,sodacans,waterbottles)

• Naturalmaterials(leaves,wildlife)

FODManagement• AircraftMaintenance:

• Accountforanddisposeofnuts,bolts,washers,safetywire,etc.

• Accountforhandtoolsusedinrepairjobs

• AidstocontrolFOD:• Checklists• Cut-outtooltrayliners• Usespill-proofbags,magnetictraysandtoolboxes.

Carelessnessandoverconfidencearemoredangerousthandeliberatelyacceptedrisk.

-WilburWright,1901

AC90-109– AirmentransitiontoExperimentalorUnfamiliarAirplanes• HazardIdentification

• Identifyspecificsafetyhazard(s)• Example:Stall/spinduringbase-finalturn

• RiskAssessment• Determinetheseverityofthehazard(s)

• Example:Potentially fatal• Determinethelikelihoodthatthehazardwilloccur

• Example:Minimal likelihood

• RiskMitigation– actionsthatminimizeorunderstandrisk• Obtainspecifictraining• Usespecificsafetyequipment• Reviewdesigner’soperationalinformation&yourflightplan

• Theseareconsiderationscommontoallairplaneswww.MikesAeroClassics.com

AC90-89B- Amateur-BuiltAircraftandUltralightFlightTestingHandbook• Assistamateurbuildersindevelopingaircraftflightplans.• Guidanceforflighttestingaftermodifyinganexperimentalaircraft

• Levelofmodification(looktoFAR21.93forgeneralguidance)• MajorChangethataffects“weight,balance,structuralstrength,reliability,operationalcharacteristicsorothercharacteristicsaffectingtheairworthinessoftheproduct.”

• Flighttestinginsomeformisadvisable• Revealanymalfunctionsorunintendedconsequencesofmodification• Allowthepilottobecomefamiliarwiththe(new/altered)operationoftheaircraft• Example:ensureanewinstrumentisproperlyworkingandthatyouknowhowtouseit.

Conclusions

Foryourpost-maintenance flighttobesafeanduneventful:• Youarementallyandphysicallyreadytoperformmaintenanceorinspection,

• Youhavetherighttools&information,• Youunderstandthetask(s)tobeperformed,• Youwillfollowgoodmaintenancepractices,and• Youhaveaplanandwillfollowit.

Thanksandsafeflying!MichaelFlagellaLVKHangar357www.MikesAeroClassics.comMike@MikesAeroClassics.com

Maintenance & Condition Inspections for Experimental Aircraft€¦ · About Me • B.S. and Ph.D....

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