Hercules Technical Issues Eduardo Nunes www.ogma.pt C130 Program Manager

Hercules Technical Issues
Eduardo Nunes
C130 Program Manager
[email protected]
T: (+351) 21 9581000 Ext. 3221
F: (+351) 21 042 22 78
www.ogma.pt
1.
OGMA OVERVIEW
2.
HERCULES TECHNICAL
- Elevator Trim Tab Hinge Fitting
- Rudder Booster Lever Failure
- Center Wing FWD Upper Spar Cap
3.
OGMA FIELD TEAM
José Salvada
Aircraft MRO Marketing and Sales Director
Ph: (+351) 21 957 90 56
Cell: (+351) 91 289 99 14
Fax: (+351) 21 957 30 56
[email protected]
Together We Fly Higher
www.ogma.pt
OGMA Overview
OGMA Overview
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20 km North of Lisbon
Close to A1 highway
Near Railway Station
Runway
Harbour
OGMA Overview
Runway - 3Km / 10.600fts
Area - 400.000 Sq. mt.
11 Maintenance Hangars
Defence Portfolio
 C-130/ L-100 Hercules
 P-3 Orion
 F-16
 C-212
 C-295
 SA330 Puma
 Alouette II & III
 EH101
 ERJ-145 AEW&C
Manufacturing - Programs
C-130 Maintenance
• 12 Slots for C-130
• C-130 – All Models A-H
• +40 years of experience on C-130
• More than 700 Inspections and Major Repairs
• B, C & D Checks, Heavy Checks (SMP)
• HSC, PDM, Isochronal Inspections (USAF)
• Technical Instructions (SBs, TCTOs, AD, …)
• Electronic Work Card Decks
• Painting Hangar
• Specific Programs:
Wing Replacement / SFAR 88 Compliance
(GFI /Tank Inspection) / Fatigue Evaluation (EBH)
- SB 82-788 / 790 / Rainbow Fitting Replacement /
T56 & AE2100D3 AMC
Complete in-house capability:
AE2100D3
- Only AMC in Europe
T56 / 501D (-7/-14/-15/501)
• More than 1.800 shop visits performed
Complete in-house capability:
- Engine removal from QEC
- Inspection
- Repair and Overhaul
- Accessories repair and Overhaul
- Engine refit into QEC
QEC
Components Repair & Overhaul
OGMA IS A MRO SPECIALIST IN HYDRAULIC, PNEUMATIC &
MECHANICAL MAIN COMPONENTS FOR C130 AND P3 AIRCRAFT
» Engines’ Components, and,
» BRAKES (C130, P3)
» LANDING GEARS (C130, P3)
» WHEELS
OGMA HAS A REPAIR CAPABILITY
LIST OF MORE THAN 1500 P/N
» FIXED PRICE PROPOSALS VS FORECAST
Design Organization
(DOA / POA Certification)
Engineering Support
• Repairs Design – Database
• Mechanical Load & Stress Analysis
• Fatigue and Damage Tolerance Analysis
• Weight and Balance Analysis
• Electrical Power Distribution Analysis
• EMI/EMC analysis and test
• System Safety Assessment
• Human Machine Interface Analysis
• Manual Supplements
• Maintenance Program Update and Operational Training
• Configuration Management (A/C Modifications)
• Manufacturing and Installation Drawings (mechanical, electrical, routing)
Self Protection System
“State of the Art”
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Electronic Warfare
Management System (EWMS)
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Radar Warning Receiver
(RWR)

Missile Warning System
(MWS)

Electronic Countermeasures
Jammer (ECM)
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Advanced Countermeasures
Dispensing Systems
Avionics Upgrades
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Glass Cockpit
Instruments & Control Panels
Multi – Function Displays
VHF/UHF Radios (8,33 MHz ch
spacing)
Mode Transponders
(E-)TCAS
TACAN
IFF
FMS
Auto-Pilot
Inertial Navigation Systems/GPS
Radio Altimeter
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Flight Data Recorder
Engine Instrument Digital System
…
DESIGN AND TEST TOOLS
 AutoCAD, CATIA V4 & V5
 PATRAN/NASTRAN
 AFGROW, FRANC2D, FRANC3D
 Avionics test equipment;
 DT and NDT test facilities and laboratories;
 Configuration Management software
 Requirements Management software
 Handbooks related with design structural analysis
C-130 Full Fleet Support (FFS)
The concept that allows the operator to
focus their resources on the operational
missions!
Operational Advantages
Focus on the mission
Improved Aircraft Availability
Economical Advantages
Budget Control and cost forecast effectiveness
Concept “Pay by the hour”
Improved Fiability
Cost reduction
A single point of contact
Integrated solution and long term relationship
Increase of Human resources availability
Rationalization of resources
Application of the concept “One Stop Shop
(stock, space and staff)
Improved Supply Chain
E+
Corporate
Excellence Program
Lean Philosophy - Encompasses 100% of OGMA Employees
Kaizen and Continuous Improvement Methodology
Eliminate waste from the Maintenance Process
– Eliminate unnecessary tasks
– Eliminate unnecessary efforts for necessary tasks
– Streamlining Process
LEAN ON C-130
MAINTENANCE
Streamlining Process
• Mapping out the maintenance
process
step-by-step
• Highlight the bottlenecks
• Look for root causes
• Search for the
effective solutions
LEAN ON C-130
MAINTENANCE
Time Observation
(Spaguetti Diagram)
• Watch the operator
performing his work
• Draw the operator’s path on
the hangar, and record the
cycle times for each
maintenance step
Technicians walking
more than 4Km a day!!!
LEAN ON C-130
MAINTENANCE
Point-of-Use Tooling (Mechanic Surgeon)
Specially built cart, containing everything necessary for the task is taken
to the aircraft
C-130 Servo actuator
Pneumatic and Anti-icing Ducts
LEAN ON C-130
MAINTENANCE
Eliminate time preparing Materials and Components
BEFORE
Time spending looking for parts
AFTER
Preassembled fuel system lines
Hercules Technical
1.
OGMA OVERVIEW
2.
HERCULES TECHNICAL
- Elevator Trim Tab Hinge Fitting
- Rudder Booster Lever Failure
- Center Wing FWD Upper Spar Cap
3.
OGMA FIELD TEAM
Elevator Trim Tab Hinge Fitting
• Severe wear of elevator trim tab
attaching
bolts
(P/N
AN177CH16) was found in
some C130 aircraft operators
• Bolts
were
retained
for
investigation and all fleet was
inspected
Elevator Trim Tab Hinge Fitting
• In-flight rupture of LH elevator trim tab hinge fitting
• Bolts found with severe wear
PROBABLE CAUSES:
• Applied torque of horn fitting joint assemblies
• Different tapers on bushings
Elevator Trim Tab Hinge Fitting
PROBABLE CAUSES:
1) Applied torque of horn fitting joint assembly
• Maintenance manuals do not clearly indicate the correct torque value for
the assembly
• LM clarified that Torque on nut P/N73781CM720 should be 205+/-35
in.lbs per LM Aero Process Specification 0581
Elevator Trim Tab Hinge Fitting
PROBABLE CAUSES:
2) Different tapers on bushings
• Correct bushings must have an angle of 68º.
Some were found to be 79º!
• If wrong set is used (different tapers), the
contact area between bushings will be limited
and will cause fast wear. This wear will cause
play in the join and the torque is no longer
effective causing abnormal wear by friction of
bolts.
Replace both new cone bushings at the same time, not
individually, or the entire horn assembly (3326589-1)
79º
68º
Hercules Technical
1.
OGMA OVERVIEW
2.
HERCULES TECHNICAL
- Elevator Trim Tab Hinge Fitting
- Rudder Booster Lever Failure
- Center Wing FWD Upper Spar Cap
3.
OGMA FIELD TEAM
Rudder Booster Lever Failure
• A C130 operator reported an in air
mishap, resulting in the loss of the
Rudder Booster System.
• Inspection of Rudder Booster
Assembly found Lever Assembly
P/N 354648-1 (sub assembly of
rudder booster P/N 372021-7)
ruptured in four places
• Defective part under investigation
• Similar events known by USAF,
European operators and LM.
Rudder Booster Lever Failure
PROBABLE CAUSES:
• This type of failure is found after the aircraft
has been exposed to sustained High Winds
while the booster and utility hydraulic
systems were not adequately pressurized and
the flight controls cycled to use the snubbing
effect
in
the
boost
packs.
• Use Card No SP-283 is recommended to
inspect for damage any time the aircraft has
been subjected to High Winds
Hercules Technical
1.
OGMA OVERVIEW
2.
HERCULES TECHNICAL
- Elevator Trim Tab Hinge Fitting
- Rudder Booster Lever Failure
- Center Wing FWD Upper Spar Cap
3.
OGMA FIELD TEAM
Center Wing
FWD Upper Spar Cap
• During 2013 “C” checks inspection of
two different operators, a layer of stress
corrosion was found on center wing FWD
upper spar cap WS 72 LH.
- C130H, 30 year insp, EBH 20,878
- C130H, 30 year insp, EBH 19,496
• If damage enters large block of material
on LS shape, no repair is possible
• Use of Card No SP-311 is recommended
but initial inspection is set to 30,000
EBH!
WS72 LH
Hercules Technical
1.
OGMA OVERVIEW
2.
HERCULES TECHNICAL
- Elevator Trim Tab Hinge Fitting
- Rudder Booster Lever Failure
- Center Wing FWD Upper Spar Cap
3.
OGMA FIELD TEAM
OGMA Field Team
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While preparing for take-off, a C-130 operator reported a Fairing Foam of
blade de-icing heater detachement from propeller #3.
Extensive damages were reported on RH side of fuselage FWD to cargo air
conditioning compartment.
OGMA Field Team
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OGMA sent a Field Team and material to
local site
Temporary repair for ferry flight made on
site
Replacement of propeller
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Avionics systems discrepancies correction
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Functional and operational tests
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Support You Wherever You Are!
Questions?
Eduardo Nunes
C130 Program Manager
[email protected]
José Salvada
Marketing and Sales Director
[email protected]
Manuel Borges
Sales Manager
[email protected]
Ana Filipe
Service Center Contract Manager
[email protected]
THANK YOU
OGMA - Indústria Aeronáutica de Portugal S.A.
Parque Aeronáutico de Alverca
2615-173 - Alverca - Portugal
T: (+351) 21 958 10 00/ 21 957 90 00
F: (+351) 21 958 04 01/ 21 958 12 88
www.ogma.pt