AIRCRAFT STRUCTURAL INTEGRITY MANAGEMENT

ALOHA…….

MEJ HANABLE SUNDAY AK EDWARD TUDMSO 2 FWSS

DIRECTORATE GENERAL TECHNICAL AIRWORTHINESS

MSTA SIRI 07/2011 DI HOTEL MERDEKA PALACE KUCHING PADA 04-06 OKT 11

Accident – Aloha Airlines Flight 283, Boeing 737-200 N73711, 28 April 1988

Fatigue failure of fuselage lap splice due to widespread cracking & bond failure

Causes: Corrosion/fatigue interaction

Outcomes: Ageing aircraft mgmt: WFD, Corrosion,

Repairs

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SCOPE

Introduction Design Development and In Service

Management (ASIP Level 1 - Level 5) ASIMP Information Flow (Implementing) An ASI Program The importance of ASIMP ASI in regards to PU2103 TAMM Reg

3.5.4 ASIMP Management

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AIRCRAFT STRUCTURAL INTEGRITY

Introduction

Structural integrity is the ability of all constituent parts of an aircraft’s

structure to withstand normal operating loads within approved flight limitations

without collapse or unacceptable deformation.

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DESIGN DEVELOPMENT AND IN-SERVICE MANAGEMENT AGAINST FATIGUE

Fail-Safe design principles (Fighters) Damage Tolerance design principles (Transport) Durability considerations (Analysis and Testing) Full Scale Fatigue Testing Ageing aircraft considerations Widespread Fatigue Damage considerations Corrosion control Dedicated ASI Programs…

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ASI PROGRAM INFORMATION FLOW

The heart of ASIP

Implementing the ASIP involves establishing systems that:

Collect the data

Assess the data

Report on the outcomes

Report types include Routine Usage Status

Usage Assessment

Fatigue Assessment

Structural Condition Assessment

These systems will be described and approved in the Management Plan. Specific instructions will be required by the implementing authority .

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ASI Requirement:

Full ASIP requirements /Minimum requires some method to ensure System of Maintenance remains valid while operating

All programs are to be Authorised by DGTA

All programs are to have a manager assigned whose responsibility is to ensure all elements of the ASIP are implemented.

AN ASI PROGRAM

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IMPORTANCE OF THE ASIMP

Structured, comprehensive, proactive statement of current status of ASIP for specific aircraft, shortcomings or gaps in ASIP, prioritised activities required to manage aircraft ASI over

service life, assigned responsibilities for tasks amongst stakeholders, and identification of structural certification basis.

ASIMP is an authorised, controlled document mandating continuing airworthiness requirements

CoA certifcation basis.

The ASIMP is the governing document for the ASIP

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AIRCRAFT STRUCTURE INTEGRITY

References:A. PU2103 TAMM REG 3.5.4 ASIMP MANAGEMENTB. PU2103 TAMM SEC 3 LFT 11 (DRAFT)

Reg 3.5.4.a. Requires CI management to establish and

maintain an ASI management system.- Documented in individual ASIMPs- So far F18, Mig 29, Hawk and C130 (PUSPEKA/CAIDMARK)- The rest ?

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NEW AIRCRAFT

Reg 3.5.4.c (1) and Reg 2.2.3: Requires ASIMP prior to issue of Design Acceptance Certificate by TAR for new aircraft type, major design changes or significant changes of operations consistent with FAR25.1529 Instructions for Continuing Airworthiness (ICA) A400M?? – Already informed project officer via email. EC725??? - Already informed project officer via email. Others if any

CI Manager must ensure Sec 3 Lft 11 para 16 (ASIMP Generation).

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ASI MANAGEMENT

Statement of Operating Intent (SOI) is required to Inform PS 1 ASDR DGTA and AEOs and contractors in supporting ASI management. See Reg 2.2.6 and Sec 3 Lft 11 para 19 to 25.

Reg 3.5.4 .c. (2) and (4) : ASIMP to be updated and reviewed at least an annual basis. See also Sec 3 Lft 11 para 17.

Reg 3.5.4 .c. (3): Any deficiencies identified in ASIMP – TAR to be notified.

Reg 3.5.4 .c. (5): ASIMP specifies the authoritative source or sources for structural inspection programs, structural life limits and component retirement times.

Reg 3.5.4 .c. (6): ASI Projects directed by TAR. Details in Sec 3 Lft 11 para 25. Example of Tear Down Inspection details in Sec 3 Lft 11 para 27.

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PROCEDURES TO MAINTAIN ASI

Reg 3.5.4 .d. (1) : Structure repair and Modification conform CSDSTD ASDR/STI/SB

Reg 3.5.4 .d. (2) : Implement Fatigue Management – ASIMP, Structural Inspection programs (SIP) and structural life limits (SLL). DFM, MUMDIF AND ETC

Reg 3.5.4 .d. (3) :SIP interval, SLL and component retirement times are not exceeded without TAR approval.

Reg 3.5.4 .d. (4) : any amendment to Reg 3.5.4 .d. (3) are to be notified to the TAR.

Reg 3.5.4 .d. (5): Environmental Degradation Management ASIMP CPCP, CCIP, ST and etc. See also Sec 3 Lft 11 para 51 to 53.

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PROCEDURES TO SUPPORT CONTINUING ASSESSMENT OF ASI

Reg 3.5.4 .e. (1): Usage monitoring DFM, MUMDIF and etc

Reg 3.5.4 .e. (2): Data collection – ASIMP Reg 3.5.4 .e. (3): Maintain records – Primary

structure Defects, inspections, repairs and Modifications

Reg 3.5.4 .e. (4): Maintain the integrity data – ASIMP Usage monitoring & operational Loads monitoring

Reg 3.5.4 .e. (5): Aircraft ageing audit – mid life point or 15 yrs in service . Guidance and Authorized by TAR. See also Sec 3 Lft 11 para 54 to 56.

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CURRENT STATUS ASI 2012No REGULATION DESCRIPTION STATUS REMARKS

1. Reg 3.5.4.a Requires CI management to establish andmaintain an ASI management system

ASIMP

Partially comply

RMAF – TEMP PART 5 in progress PUTD – draftRMN – reply done (not yet submit for approval)APMM – not yet receivedBOMBA – not yet received

2. Reg 3.5.4.c (1) and Reg 2.2.3

Requires ASIMP prior to issue of design Acceptance Certificate by TAR for new aircraft type, major design changes or significant changes of operations consistent with FAR25.1529 Instructions for Continuing Airworthiness (ICA)

Yet to comply

A400M – informed project EO

EC725 - informed project EO

3. Reg 2.2.6 and Sec 3 Lft 11 para 19 to 25.

SOI required to Inform ASDR (DGTA) and AEOs and contractors

Not complyCI manager to keep the SOI

4. Reg 3.5.4 .c. (2) and (4)

ASIMP to be update and reviewed at least an annual basis.

Not complyCAESE/SAO/CI manager /DGTA

5. Reg 3.5.4 .c. (3)

Any deficiencies identified in ASIMP – TAR to be notified.

Not comply

CI Manager to monitor. CAESE/SAO

6. Reg 3.5.4 .c. (5) ASIMP specifies the authoritative source or sources for structural inspection programs, structural life limits and component retirement times.

Not comply CI manager/SAO

7. Reg 3.5.4 .c. (6) ASI Projects directed by TAR. Address major ASI deficiencies.

TAR decision

Refer draft ASI Sec 3 Lft 11 para 25

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CURRENT STATUS ASI 2012

No REGULATION DESCRIPTION STATUS REMARKS

8. Reg 3.5.4 .d. (1) Structure repair and Mod conform CSDSTD i.e. ASDR/STI/SB/Mod comply

CAESE/SAO to be notified.

9. Reg 3.5.4 .d. (2) Implement Fatigue Management – ASIMP, Structural Inspection programs (SIP) and structural life limits (SLL).

Partially comply SAO

10. Reg 3.5.4 .d. (3) SIP interval, SLL and component retirement times are not exceeded without TAR approval.

Not comply

F18 Inspection from 6000 to 8000 flt hrs.CN235-22- SIP from 5000 Ldg cycles to 7000 Ldg cycles.

11. Reg 3.5.4 .d. (4) any amendment to Reg 3.5.4 .d. (3) are to notified to the TAR.

Not complyNot being practiced

12. Reg 3.5.4 .d. (5) Environmental Degradation Management ASIMP i.e CPCP and etc. comply

CAESE/SAO to be notified.

13. Reg 3.5.4 .e. (1) Usage monitoringPartially comply

F18D, Hawk, Mig 29 & C130

14. Reg 3.5.4 .e. (2) Data collection – ASIMP

Partially comply

F18D, Hawk, Mig 29 & C130

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CURRENT STATUS ASI 2012

No REGULATION DESCRIPTION STATUS REMARKS

15. Reg 3.5.4 .e. (3) Maintain records – Primary structure defects, inspections, repairs and modifications. Comply

Notify CI manager and CAESE/SAO

16. Reg 3.5.4 .e. (4) Maintain the integrity data and Operational loads monitoring systems from aircraft– ASIMP Partially

Comply

SAO/CAESEF18,C130, HAWK & MiG29

17. Reg 3.5.4 .e. (5) Aircraft ageing audit – mid life point or 15 yrs in service . Guidance and Authorised by TAR. See also Sec 3 Lft 11 para 54 to 56.

TAR DecisionSec 3 Lft 11 para 53.

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CONCLUSION & RECOMMENDATION

Conclusion:

Most of SAO have not submitted their ASIMP to DGTA for Approval.

Recommendation:

RMAF – to submit ASIMP for approval. RMN - to submit ASIMP for approval. PUTD – In the process of approval by DGTA. APMM - to submit ASIMP for approval. BOMBA – to come out with ASIMP and submit for approval. Target date: SAO to submit ASIMP to DGTA in 3 months time. SAO to have ASIP assigned program manager. ASIMP Review Meeting will be conducted annually. ASI workshop/course will be conducted annually.

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Q & A

THANK YOU

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