Aircraft Maintenance

K08 - Maintenance & Systems

Aeronautical Engineering

4 juni 2013

Program
What is Reliability? Reliability Engineering (philosophies); Design Concepts (redundancy); Failure/Reliability classification; Safety objective; MSG; MSG-2 / failure modes; MSG-3
Aeronautical Engineering Sheet 2, 4 juni 2013

Wat is Reliability?
Broad term on parts/systems: On T0 the part/system is performing a certain function; Continue intended function without failure from T0 to T1; Under stated conditions.

Aeronautical Engineering

Sheet 3, 4 juni 2013

What is Reliability?

Aeronautical Engineering

Sheet 4, 4 juni 2013

What is Reliability?

Aeronautical Engineering

Sheet 5, 4 juni 2013

Definition: Reliability
Reliability is the probability that a part, or system will perform its intended function in a stated condition or environment for a specified period of time without failure.

Aeronautical Engineering

Sheet 6, 4 juni 2013

Definition: Reliability
Four Key Elements: Probability: failure is always possible; Intended Function: Operation without failure; Specified Period Of Time: flight hours or cycles; Stated Conditions: Reliability is restricted to operation under certain conditions.

Aeronautical Engineering

Sheet 7, 4 juni 2013

Reliability Engineering
Traditional philosophy: Essentially no redundancy in design; Mechanical parts wear out; Wear causes failure; Failure effects safety; Maintenance required to ensure safety.

Aeronautical Engineering

Sheet 8, 4 juni 2013

Reliability Engineering
Modern philosophy: Redundancy in design; Total inspection between flights impossible due to complex design; Safety assured by redundancy in design; Maintenance required to assure redundancy.

Aeronautical Engineering

Sheet 9, 4 juni 2013

Design Concepts
Non-Redundant Single Path System:
Input

Output

Reliability of the system: Rs=R1*R2*R3 If one element fails, the system fails.
Aeronautical Engineering Sheet 10, 4 juni 2013

Design Concepts
Redundant Parallel System:

1
Input

2 3

Output

Reliability of the system: Rs=(1-Qs) Where Qs is the un-reliability of the system and Qs=Q1*Q2*Q3.
Aeronautical Engineering Sheet 11, 4 juni 2013

Design Concepts
Redundant Multiple Path System:

Input

1 1

2 2

3 3

Output

Number of paths = 8.
Aeronautical Engineering Sheet 12, 4 juni 2013

Design Concepts
Reliability as a function of system architecture:

Aeronautical Engineering

Sheet 13, 4 juni 2013

Failure Classification
Failure Conditions are classified, according to severity of their effects on the aircraft: 1. No Safety Effect: Failure Conditions that would have no effect on safety; 2. Minor: Failure conditions which would not significantly reduce aircraft safety, and which would involve crew actions that are well within their capabilities;

Aeronautical Engineering

Sheet 14, 4 juni 2013

Failure Classification
3. Major: Failure conditions which would reduce the capability of the aircraft or the ability of the crew to cope with adverse operating conditions to the extent that there would be, a significant reduction in safety margins or functional capabilities, a significant increase in crew workload or in conditions impairing crew efficiency, physical distress to occupants, possibly including injuries, or physical discomfort to the flight crew.

Aeronautical Engineering

Sheet 15, 4 juni 2013

Failure Classification
4. Hazardous/Severe-Major: Failure conditions which would reduce the capability of the rotorcraft or the ability of the crew to cope with adverse operating conditions to the extent that there would be:
a. A large reduction in safety margins or functional capabilities; b. Physical distress or excessive workload that would impair the flight crew's ability to the extent that they could not be relied on to perform their tasks accurately or completely; c. Possible serious or fatal injury to a passenger or a cabin crewmember, excluding the flight crew.

Aeronautical Engineering

Sheet 16, 4 juni 2013

Failure Classification
5. Catastrophic: Failure Conditions which would result in multiple fatalities to occupants, fatalities or incapacitation to the flight crew, or result in loss of the rotorcraft.

Aeronautical Engineering

Sheet 17, 4 juni 2013

Probability Classification
Average Probability Per Flight Hour (P): 1. Probable: P > 1*10-5 2. Remote: 1*10-7 < P 1*10-5 3. Extremely Remote: 1*10-9 < P 1*10-7 4. Extremely Improbable: P 1*10-9

Aeronautical Engineering

Sheet 18, 4 juni 2013

Safety Objective
Failure Condition: 1. No Safety Effect: 2. Minor: 3. Major: 4. Hazardous: 5. Catastrophic: Probability: No requirement. Probable. Remote. Extremely Remote. Extremely Improbable.

Aeronautical Engineering

Sheet 19, 4 juni 2013

Safety Objective

Aeronautical Engineering

Sheet 20, 4 juni 2013

MSG logic:
Maintenance Steering Group (MSG); Founded by the Air Transport Association (ATA); MSG-1 (1968), intended for 747-100; MSG-2 (1970), generally applicable; MSG-3 (1980), improved philosophy.

Aeronautical Engineering

Sheet 21, 4 juni 2013

MSG-2 logic:
3 Maintenance Processes: Hard Time (HT): Maximal interval for maintenance task. Overhaul and Life limit; On Condition (OC): Repetitive inspections, determine condition of parts, system, or structure; Condition Monitoring (CM): Parts with no HT of OC. Condition monitoring requires appropriate means for finding/resolving problem areas.
Aeronautical Engineering Sheet 22, 4 juni 2013

MSG-2 Decision Logic:

Is there a failure mode which has a direct adverse effect on flight safety?

No
Is there an indication to the flight crew when a function ceases to perform upon demand?

No

Yes Yes
Is reduction in failure resistance detectable by maintenance?

Yes
Is there an adverse relationship between age and reliability?

No

No
CM

No

Is reduction in failure resistance detectable by maintenance?

Yes
OC HT HT

Yes
OC

Aeronautical Engineering

Sheet 23, 4 juni 2013

Component failures.

Traditional view:
Failure age-related; Only for limited types of equipment; Fatigue, corrosion, abrasion, evaporation.
Aeronautical Engineering Sheet 24, 4 juni 2013

Component failures.

11%

89%

Aeronautical Engineering

Sheet 25, 4 juni 2013

Component failures.
For most equipment failures: No relation to time in service; Failure is unpredictable; Cost effective handling by early detection of future failure.

Aeronautical Engineering

Sheet 26, 4 juni 2013

Aeronautical Engineering

Sheet 27, 4 juni 2013

MSG-3 logica:
MSG-3 recognizes: Damage tolerance; Multiple failures; Failure effect on adjacent structure; Crack growth; Threshold exploration. Scheduled Maintenance Program: Tasks and intervals.
Aeronautical Engineering Sheet 28, 4 juni 2013

MSG-3 logica:
Prevent deterioration of safety/reliability levels: 1. Lubrication and Servicing: application of lubricants, replenishing fluids; 2. Operational Check: task to ensure intended purpose (no quantitative tolerances); 3. Visual Check: observation to ensure intended purpose (no quantitative tolerances);

Aeronautical Engineering

Sheet 29, 4 juni 2013

MSG-3 logica:
Prevent deterioration of safety/reliability levels: 4. Inspection: examination against specified standard; 5. Functional Check: quantitative check for function within limits; 6. Restoration: return item to specific standard; 7. Discard: removal from service.

Aeronautical Engineering

Sheet 30, 4 juni 2013

1 2 3 MSG-3 Decision Logic:

Is occurrence of a functional failure evident to the operating crew during performance of their normal duties?

Yes
Does the functional failure or secondary damage resulting from the failure have a direct adverse effect on operating safety?

No No
Does combination of hidden failure and one additional failure of a system related or backup function have adverse effect on operating safety?

Immediate Impact

Yes
Evident Safety

Yes
Evident Operational Economics

No
Evident Nonoperational Economics

Yes
Hidden Safety

No
Hidden Nonsafety Economic

2
Aeronautical Engineering

5
Sheet 31, 4 juni 2013

Delayed Impact

Does the functional failure have a direct adverse effect on operating capability?

1
Evident Safety

2
Evident Operational Economics

3
Evident Nonoperational Economics

4
Hidden Safety

5
Hidden Nonsafety Economic

OPERATIONAL / VISUAL CHECK

Yes

Is a check to verify operation applicable and effective?

No
INSPECTION / FUNCTIONAL CHECK

Yes

Is an inspection or functional check to detect degradation of function applicable and effective?

RESTORATION

Yes Yes

No
Is restoration task to reduce failure rate applicable and effective?

No
Is a discard task to avoid failures or to reduce failure rate applicable and effective?

DISCARD

TASK / COMBINATION

Yes

No
Is a task or combination of tasks applicable and effective?

1 No

REDESIGN MANRATORY

No

Redesign Desirable or No Scheduled Maintenance Required

LUBRICATION AND SERVICING

Yes

Is lubrication or servicing task applicable and effective?

Aeronautical Engineering

Sheet 32, 4 juni 2013

Reliability Maintenance Program:

Reliability programs developed for maintenance programs; Based upon MSG logic; To ensure effectiveness of tasks; To ensure adequate intervals; Reliability programs may result in escalation, deescalation or addition of tasks; Monitoring effectiveness of Maintenance Program.

Aeronautical Engineering

Sheet 33, 4 juni 2013