Airworthiness Administration Federal Aviation - EAA … · Federal Aviation Airworthiness...

Federal AviationAdministrationAirworthiness

Presented to: Upper Cumberland EAA Chapterpp p

By: Pam Charles

Date: 6/17/2017

Who am I ?

Pam CharlesF d l A i ti Ad i i t tiFederal Aviation AdministrationSafety Program Manager, AirworthinessNashville FSDO

615-324-1314Pamela.k.charles@faa.gov

A little about me……

Federal AviationAdministration

Why am I here ?

• The FAAST Program

• Training • Outreach• Education

• Reducing Accidents

Maintenance related Accidents

Improper Maintenance. p p

Inadequate Maintenance.

Failure to Follow Procedures

Virtually all maintenance errors are a result of the failure to follow procedures because of a human factors issue.

Human Factors is the most important safety issue in the performance of maintenance.

The Dirty DozenThe Dirty Dozen

C i i L k f R• Communication

• Complacency

• Lack of Resources

• Pressure

• Lack of Knowledge

Di t ti

• Assertiveness

St• Distraction

• Teamwork

• Stress

• Lack of Awareness

• Fatigue • Norms

A Little About the RegulationsA Little About the Regulations

• Part 43 – does it apply ?

• Part 91 –– Operating Limitations

Mi i E i t– Minimum EquipmentRequirements

Performance Rules (general)(43.13)(43.13)

• 43.13 a) “use the methods, techniques, and ) qpractices prescribed in the current manufacturer’s maintenance manual or I t ti f C ti d Ai thiInstructions for Continued Airworthiness prepared by its manufacturer or other methods techniques and practicesmethods, techniques, and practices acceptable to the Administrator.”

Performance Rules (general)(43.13 a) Cont’d(43.13 a) Cont d

• “use the tools, equipment, and test q pequipment so the work is done in accordance with accepted industry

ti M t i l t l t tpractices. Must use special tools or test equipment recommended by the manufacturer involved or its equivalentmanufacturer involved, or its equivalent acceptable to the Administrator.”

Performance Rules (general)43 13 (cont’d)43.13 (cont d)

• 43.13 b) ……”shall do that work and use )materials that the condition will be at least equal to its original or properly altered condition (with regard to aerodynamic function, structural strength, resistance to vibration and deterioration and othervibration and deterioration, and other qualities affecting airworthiness).”

Maintenance Record Entries(43 9)(43.9)

• 1) A description of work performed.2) Th d t f l ti f th k• 2) The date of completion of the work performed.3) The name of the person performing the• 3) The name of the person performing the work if other than the person approving return to servicereturn to service.

• 4) Upon satisfactory performance of the work, the signature, certificate number, andwork, the signature, certificate number, and kind of certificate held by the person approving the work.

Maintenance Record Entries(43 11)(43.11)

R di f I ti d i ft t t l• Recording of Inspections and aircraft total time.

Bonus QuestionBonus Question

• Incorrectly substituted with hobbs or tach time when making a maintenance recordmaking a maintenance record entry required by FAR Part 43 1143.11 –

AnswerAnswer

• What is AIRCRAFT TOTAL TIME IN SERVICE.

• AC 43-9

Bonus QuestionBonus Question

• An Alteration other than a j lt timajor alteration –

Answer 3 onDefining Moments

• What is a MINOR ALTERATION.

What about a major alteration ?What about a major alteration ?

• Recording.eco d g• Flight Testing.• Operating Limitations.

What about a maintaining my aircraft ?

• Resources other than the esou ces ot e t a t emanufacturer.Contacting the FAA• Contacting the FAA.

• Contacting industry groups.g y g

What about a maintaining my aircraft ?

• Be careful of the internet. e ca e u o t e te et

• Just because you read it there doesn’t make it true.

U.S. Departm entof Transportation

ADVISORYCIRCULAR

AC 43.13-1B

ACCEPTABLE M ETHODS,TECHNIQUES, ANDTECHNIQUES, AND

PRACTICES ⎯ AIRCRAFTINSPECTION AND REPAIR

September 8, 1998

CONSOLIDATED REPRINTIncorporates change 1

DEPARTM ENT O F TRANSPO RTATIO NFEDERAL AVIATION ADMINISTRATION

Flight Standard ServiceRegulatory Support Division, AFS-600

For sale by the Superintendent of Docum ents; U S G overnm ent Printing Office; W ashington DC 20402

For sale by the Superintendent of Docum ents; U.S. G overnm ent Printing Office; W ashington, DC 20402

Mechanics Handbooks

Advisory Circular 65-15A

- Tire Care- Tire Maintenance

Ti I ti- Tire Inspection

Bonus Question

The most necessaryThe most necessary maintenance function for safe, long-lasting service f i ft tifrom aircraft tires –

Answer

Proper inflationProper inflation

Bonus Question

The tire pressure check interval recommended byinterval recommended by the FAA in Advisorythe FAA in Advisory Circular 65-15 –

Answer

At least once a week or before each flightbefore each flight.

Bonus Question

Are much more likely toAre much more likely to creep or slip on landing or when brakes are applied–

Answer 3 on Tires

Under-Inflated TiresUnder Inflated Tires.

Bonus Question

Maximum allowable loss of pressure over a twentyof pressure over a twenty four hour period for a non-four hour period for a nonnewly mounted tire–

Answer

What is 5 percent.

Bonus Question

How much of a pressure drop may be expecteddrop may be expected over an initial 24-hourover an initial 24 hour period of a newly mounted tire –

Answer

What is 5 to 10 percent.

.Wheel Bearings -Wheel Bearings -

Wheel Bearings -

• When cleaning be sure to use proper cleaning agent. – Do not use gasoline or jet fuel.

• Dry the bearing by directing a blast of dry air between• Dry the bearing by directing a blast of dry air between the rollers. Do not direct the air so that it spins the bearing as without lubrication, this could cause the bearing to fly apart resulting in injurybearing to fly apart resulting in injury.

• Be sure the grease you use is the type recommended by g y yp ythe manufacturer as well as the manufacturer’s instructions on properly examining the bearings for serviceability? Lacking that, refer to the Technician Handbook.

Wheel Bearings -

• What about re-packing the bearing? Do you know how to l d th t? B tt li i f ll th d dproperly do that? Bottom line is follow the procedures and

heed to all manufacturer instructions, notes, cautions and warnings. Lacking that, refer to the Technician Handbook.

Wheel Bearings -

• When inspecting the bearing, check for defects that would render it unserviceable, such as cracks, flaking, broken bearing surfaces, roughness due to impact pressure or surface wear, corrosion orimpact pressure or surface wear, corrosion or pitting, discoloration from excessive heat, cracked or broken bearing cages, and scored or loose bearing cups or cones that would affect properbearing cups or cones that would affect proper seating on the axle or wheel. If any discrepancies are found, replace the bearing with a serviceable unit. Bearings should be lubricated immediately after cleaning and inspection to prevent corrosion.

Are you Properly Lubricating your i ft ? D ’t thi i thaircraft ? Don’t assume this is the right tool for every application !

Lets Talk about Engine Oil• It creates a slippery gap between moving metal parts in the engine and

reduces friction, heat and wear.• It coats all of the surfaces within the engine, so even when the motor is not

running, it is protected from corrosion.• It disperses the heat that is naturally created by the combustion process

within an engine.• It absorbs and suspends particulate matter like carbon and transports it toIt absorbs and suspends particulate matter like carbon and transports it to

the oil filter so it can be trapped and removed before it causes any major damage.

• It neutralizes acids that would otherwise build up in the engine and cause scarring and pitting on smooth polished surfacesscarring and pitting on smooth, polished surfaces

• It prevents the accumulation of sludge. Cheap oils or oil that is way overdue for changing will not only fail to remove sludge and other contaminants, but will begin to break down and actually become sludge.

• It stays thin enough to keep mobile in cold weather and thick enough to still coat surfaces in hot weather - protecting the inside of your engine, no matter what conditions are like on the outside.

Bonus Question

• Why should you always get• Why should you always get your engine up to operational temperature every time you start itevery time you start it –

Answer

• To eliminate water that can break down your oil and

icause corrosion.

Taking care of fabric and patching.

• UV Damageg• Correct Fabric• Correct adhesives

Bonus Question

• FAA recommendations for• FAA recommendations for when Can You use an Unsewed (Doped-On) Fabric RepairRepair –

Answer

• When the VNE for the aircraft is below 150 mph and the damage does not exceed 16 inches in any direction.

• How could exceeding this affect a condition inspection sign-off ?

The Importance of Aircraft FinishesThe Importance of Aircraft Finishes…..

A good intact paint finish is one of the g pmost effective barriers available for placement between metal surfaces and pcorrosive media. Touching up the existing paint finish and keeping it in g p p ggood condition will eliminate most general corrosion problems.g p

Bonus Question

• All Corrosive Attacks Begin gHere –

Answer

• The SURFACE of the metal.

Bonus Question

• This can mask the initial t f istages of corrosion –

Answer

• What is Paint.

• When you see a working rivet, replace and repaint.When you see a working rivet, replace and repaint.

• Working rivets can lead to inter-granular corrosion that can go undetected.

Bonus Question

• The metal used in Aircraft construction most highlyconstruction most highly susceptible to corrosion –p

Answer

Wh t i M i• What is Magnesium.

Bonus Question

• One of two basic methods of corrosion removal –

Answer 4

• What is chemical or mechanical.

• Know when to use which one.

D b t tt ?Do burn certs matter ?

Drag and proper air flowDrag and proper air flow.

Hardware Selection.Hardware Selection.

• Commercial grade hardware found in hardware or automotive t i l l t i t l i l b t i tstores is legal to use on an experimental airplane but is not

recommended by the FAA.

• Common steel bolts purchased from a hardware store are made of low carbon steel that has a low tensile strength usually in the neighborhood of 50,000 to 60,000 psi. They also b d il d h littl i t tibend easily and have little corrosion protection.

• In contrast, aircraft bolts are made from corrosion resistant steel and are heat treated to a strength in excess of 125,000 psi. The same comparison applies to most hardware items.

• AC43-13 presents a table of torque values p qfor nuts and bolts. It shows fine thread and coarse thread series with a minimum and

i t li it i i h dmaximum torque limit in inch pounds.

• Use a torque wrench whenever possible.

• Critical installations should definitely be torqued to proper values.

Rules for hardware also apply to Fasteners !

• Do not assume the engineer role by using hardware or fastener types or sizes that are contrary to your plans or assembly manual.

• A torque wrench is not that expensive and will be a worthwhile investment for a

t b ildcustom builder.

Torque and Tool CalibrationBe absolutely sure your measuring

tools are accurate.

Bonus Question

• The amount of torque applied upon a bolt is dependent onupon a bolt is dependent on what two things –g

Answer

Wh t i L th f W h• What is Length of Wrench and Amount of Force.and Amount of Force.

• What is that formula ?• What is that formula ?

Bonus Question

T h h ld• Torque wrenches should always be stored this way –always be stored this way

Answer

At it’ LOWEST SETTING• At it’s LOWEST SETTING or with NO TORQUEwith NO TORQUE

Safety beltsSafety belts

• A word about the 4 point harness system.p y• For this reporting period (FY2017Q2) there was one (1) accident reported.• The one (1) Q1 accident occurred during 14 CFR Part 91 operations.

– * A Maule MX7 suffered a loss of control while attempting to land with a tailwind gusting to 23 kts. Pilot received non-fatal injuries.

• For this reporting period (FY2017Q2) there were two (2) incidents reported.• One Q2 incident occurred during 14 CFR Part 91 operations, and one during

CFR Part 135.

– *A Cirrus with a frosted over windscreen taxied into an Experimental airplane on the ramp. The airplane was being operated under CFR 135.

– *An 8KCAB (Decathlon) suffered blown tire on touchdown.

Wiring selection -

• When troubleshoot and repairing wiring circuits use caution when choosing the proper wire type and size for a repair.

• It is important to use proper tools, quality materials.

• The chart on the previous slide is a chart found in AC 43.13.

Spark plugs and setting of spark plug gap clearanceclearance.

• Anytime you replace or reinstall a spark plug you must be certain it has the proper gap clearance. Improper gap may affect fuel burn efficiency or cause misfire.

• Use the correct tool to clean and gap the spark plug. Plugs g p p p g galso require specific torque.

Bonus Question 1 on Spark Plugs

• Do you or do you not apply anti seize compound on the spark l th d ?plug threads?

• When was the last time your torque wrench was calibrated?

• What would you do if you drop a spark plug on the floor? It is wise to discard it for new.

• Are you sure the right plugs were previously installed? DO NOT assume anything and always check manufactureNOT assume anything and always check manufacture recommendations and parts requirements!!

Bonus Question

• The distance from the plug p ggasket to the end of the threaded portion of the plug –threaded portion of the plug –

Answer

• REACH.

• It is essential to install a spark plug with the correctly required reach. y

Bonus Question

• Prevents Radio Frequency• Prevents Radio Frequency (RF) produce by the ignition system of a piston engine from interfering with Avionicsfrom interfering with Avionics Equipment –

Answer

• Shielding.g

Bonus Question

• Carbon deposits on a plug are an indication of engineare an indication of engine operation with what type p ypmixture –

Answer

T RICH• Too RICH.

Bonus Question 4 on Spark Plugs

• Who determines the choice of Spark Plug to be used in

Ai ft E ian Aircraft Engine –

Answer 4 on Spark Plugs

• The ENGINE MANUFACTURER.

Bonus Question

• An Under-torqued spark plug can cause poor heatplug can cause poor heat conduction which may lead yto –

Answer

Wh t i HOT SPOT d/• What is a HOT SPOT and/or PRE-IGNITIONPRE IGNITION

Bonus Question

• Black Oily deposits on a plug and missing at lowerplug and missing at lower power settings indicates –p g

Answer

What is OIL FOULINGWhat is OIL FOULING.• Oil on spark plugs can be caused by failing valve stem guides p p g y g g

and bad stem seals. As pressure builds up in the crankcase, excessive oil enters the combustion chamber through worn-out piston rings or cylinder walls and forces its way to spark plugs.

• The most common sign of spark plug fouling is engine misfires. Oil blocks the electrical current needed to create sparks that combust fuel, leading to poor performance, higher fuel consumption and bad emissions. Misfiring engines can shake badly during idling and can cause engine mounts e ent all to fail

eventually to fail.

Bonus Question

• Can you remove a data plate y pfrom a type certificated engine ??

Answer

• What is Yes, with ,permission from the FAA.

Bonus Question

D Ai thi Di ti• Do Airworthiness Directives Apply to ExperimentalApply to Experimental Aircraft ?

Answer

Y if li t d i th• Yes, if listed in the applicability section.applicability section.

A Word About Condition InspectionsInspections

• Applicability to Part 43 performance rules

• Operating limitations.

• Knowing the requirements to protect your• Knowing the requirements to protect your investment !

A Word About Condition InspectionsInspections

• Appendix D vs. Recommended Condition inspection in AC 90 89A and the Mechanicsinspection in AC 90-89A and the Mechanics Handbook.

Questions ?

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