Maintenance Concepts
Continues Airworthiness Maintenance Program (CAMP)
All maintenance is based on the Continuous Airworthiness Maintenance Program, this
program defines per aircraft the maintenance requirements.
Example of References:
– Part M: Operator responsibilities
– FAA FAR 43 (Maintenance)
– FAA FAR 145: Repair station
– EASA Rulemaking
The maintenance organization is described in the MOE: Maintenance Organization
Exposition
Regulations and Controlling Authorities Aviation Industry is a tightly controlled
environment: FAA, EASA, CAA, CAAC, DGAC etc.
Training and Authorizations
Training of staff is performed in accordance with EASA Part 66 rules for certifying staff
– KLM E&M provides in house training through own training department:
o Type certificate training; ground engineers and mechanics
o Human factors training
o Specific technical training courses
– Engine services has dedicated training facility for training of Engine Services
staff
o Engine type training, dedicated skills etc.
– Where required, training is provided by OEM (Original Equipment
Manufacturer)
Quality Assurance and Quality Control and auditing system
Quality Control
– Quality Assurance and Control organization provides independent supervision
and monitoring of quality control, recognitions and authorizations
– Liaison between aviation authorities and KLM E&M
– Audit system:
o E&M facilities are frequently audited by both KLM quality control
organization as well as customers and national aviation controlling
bodies, audit remarks are required to be solved within a defined
timeframe.
Summary MRO Business 2
,On-Condition Maintenance Concept
– Consists primarily of monitoring the aircraft and engine performance at regular
intervals and determining when and which maintenance is required based on
the condition of certain operating parameters.
– Maintenance Tasks are described in MRI’s: Maintenance Required Inspections
performed at fixed intervals per certain number of flight hours.
– Engine inspections include:
o Borescoping the gaspath, using borescope equipment to inspect the
internal gaspath of the engine
o Oil system checks
o Visual zonal inspections
o Functional checks of certain systems
Hard Time Maintenance Concept
– Hard time maintenance concept is based on predetermined “hard times” to
remove components/engines for scheduled maintenance
– Regardless of actual condition
– Objective of hard time concept is to minimize any operational disruption
– Disadvantage: loss of any useable operational remaining life
– Not in use with many operators as main concept
– With certain reliability issues used in isolated cases for a component
Engine Inspections Techniques
Internal inspection of the gaspath condition.
Engine Boreblend
Internal blend repair of damaged airfoil
Thresholds
Counters to determine a required step in maintenance
– Expressed in:
o Flight hours
o Cycles (Take-Off and Landing cycles)
– Used with:
o Aircraft & Aircraft component maintenance
o Engine maintenance
Workscope Planning Guide
– Engines shop maintenance is described in document:
o Workscope Planning Guide (WPG)
§ Defines maintenance thresholds for individual modules and
components
§ Lists Air Worthiness Directives
§ Service Bulletins
§ Specific maintenance tasks based on operational experiences
§ Defines performance targets after maintenance
Summary MRO Business 3
, Engine Removal Reasons
Engines are removed for a variety of reasons:
– Replacement of life limited rotating parts like shafts and disks
– Performance deterioration:
o Thermodynamic: Loss of EGT margin (High Exhaust Gas Temperature)
o Mechanically: High Vibration levels of the rotor system(s)
– Oil leakage/consumption
– Damage to the gaspath due to:
o Deterioration
o Foreign Object Damage (example bird strikes)
– Findings during the regular inspections
Shopvisit Process & Workscoping
Engine overhaul process flow
Engine Introduction in shop;
preperation of
Incoming Engine Steering
Group meeting: work
removal documentation inspection scope determination
Cleaning/
Engine/Module/ Repair Assembly
Inspection
Assy dissasembly
process Process Process
Engine Final Inspection/ Engine
Performance Documentation released for
Test closure
Service
Stage Concept
Stage 0 Stage 1 Stage 2 Stage 3
Repair internal Assembly of assies
Receiving Disassembly
Completeness check Cleaning Repair external Assembly of
modules
Project start-up Parts disposal Replace
Incoming inspection Assembly of engine
Assembly
Workscope preparation Testrun
determination Final Inspection
Workscope approval
Declare serviceable
Engine dispatch
Summary MRO Business 4
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