AIRCRAFT STRUCTURAL INTEGRITY MANAGEMENT

ALOHA.

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

Fatigue failure of fuselage lap splice due to widespread cracking & bond failure Corrosion/fatigue interaction Ageing aircraft mgmt: WFD, Corrosion, Repairs

Causes:

Outcomes:

MEJ HANABLE SUNDAY AK EDWARD TUDM SO 2 FWSS DIRECTORATE GENERAL TECHNICAL AIRWORTHINESS

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

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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 aircrafts 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

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 .

The heart of ASIP

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AN ASI PROGRAM

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.

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IMPORTANCE OF THE ASIMP

The ASIMP is the governing document for the ASIP

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.
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AIRCRAFT STRUCTURE INTEGRITY

References: A. PU2103 TAMM REG 3.5.4 ASIMP MANAGEMENT B. 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 2012

No REGULATION DESCRIPTION STATUS REMARKS 1. Reg 3.5.4.a Requires CI management to establish and maintain an ASI management system ASIMP Partially comply RMAF TEMP PART 5 in progress PUTD draft RMN reply done (not yet submit for approval) APMM not yet received BOMBA not yet received A400M informed project EO Yet to comply EC725 - informed project EO CI manager to keep the SOI CAESE/SAO/CI manager /DGTA CI Manager to monitor. CAESE/SAO

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) SOI required to Inform ASDR (DGTA) and AEOs and contractors ASIMP to be update and reviewed at least an annual basis. Any deficiencies identified in ASIMP TAR to be notified. ASIMP specifies the authoritative source or sources for structural inspection programs, structural life limits and component retirement

3. 4. 5. 6.

Reg 2.2.6 and Sec 3 Lft 11 para 19 to 25. Reg 3.5.4 .c. (2) and (4) Reg 3.5.4 .c. (3) Reg 3.5.4 .c. (5)

Not comply Not comply Not comply

Not comply

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CI manager/SAO

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 Implement Fatigue Management ASIMP, Structural Inspection programs (SIP) and structural life limits (SLL). SIP interval, SLL and component retirement times are not exceeded without TAR approval. CAESE/SAO to be notified.

comply

9.

Reg 3.5.4 .d. (2)

Partially comply

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

10.

Reg 3.5.4 .d. (3)

Not comply

11.
12. 13. 14.

Reg 3.5.4 .d. (4)

Reg 3.5.4 .d. (5) Reg 3.5.4 .e. (1) Reg 3.5.4 .e. (2)

any amendment to Reg 3.5.4 .d. (3) are to notified to the TAR.
Environmental Degradation Management ASIMP i.e CPCP and etc. Usage monitoring Data collection ASIMP

Not comply comply Partially comply

Not being practiced

CAESE/SAO to be notified. F18D, Hawk, Mig 29 & C130 F18D, Hawk, Mig 29 & C130

Partially comply

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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. Maintain the integrity data and Operational loads monitoring systems from aircraft ASIMP Notify CI manager and CAESE/SAO SAO/CAESE F18,C130, HAWK & MiG29 Sec 3 Lft 11 para 53.

Comply

16.

Reg 3.5.4 .e. (4)

Partially Comply

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 Decision

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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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