ch124 sea king fleet update “keepin’ ‘em flying!!” major richard loewen senior design...
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CH124 Sea King Fleet Update
“Keepin’ ‘em Flying!!”
Major Richard LoewenSenior Design Engineer
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US Army Air Corps – 1941 – Recruiting Slogan
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Universal Pictures – 28 November 1941
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CH124 Highlights
• General Fleet Information• Fleet Service Life Status• Attributes of Success
– Maintenance Program– Aircraft Structural Integrity
• Sunset Years– Challenges & Capabilities
• Wrap-Up
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General Fleet Information
High Time Aircraft – 16 658 HrsLow Time Aircraft – 13 081 HrsFleet Average – 14 848 Hrs
24 of 41
“Available for Operations”(4 x non-active)
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CH124A – ASW - Dipping Sonar, Self Defense, ISR
CH124B – Utility & Troop Config
(14 Pax)
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443 SqnVictoria, BC
NDHQOttawa, ON
406 OTS
423 Sqn
12 AMSShearwater,
NS
Main Operating Bases & HQ
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CH124 Highlights
• General Fleet Information• Fleet Service Life Status• Attributes of Success
– Maintenance Program– Aircraft Structural Integrity
• Sunset Years– Challenges & Capabilities
• Wrap-Up
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Fleet Service Life Status
• Entered service – May 1963
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Fleet Service Life Status
• Entered service – May 1963
• Oct 1992: ELE extended to Dec 2000• Oct 1998: ELE extended to Dec 2005• xxx 2005: ELE extended to Dec 2012• Jul 2011: ELE extended to Dec 2015
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Fleet Service Life Status
• Summer 2013: 50th Anniversary Celebrations
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Fleet Service Life Status
• Sept 2014: … ELE Extension Request …– Align with CH148 Cyclone (S-92) Introduction– CH124 operations out to August 2018
• Proposed Flying Rates
FY14/15 FY15/16 FY16/17 FY17/18 FY18/19
Flying Hours 7200 7200 5500 3700 500
Fleet Size 28 24 20 16 12 to 0
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CH124 Highlights
• General Fleet Information• Fleet Service Life Status• Attributes of Success
– Maintenance Program– Aircraft Structural Integrity
• Sunset Years– Challenges & Capabilities
• Wrap-Up
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Attributes of Success
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Attributes of Success
• Maintenance Program– Preventive– Corrective– Upgrades / Modifications
• Mechanical System• Avionics/Electrical/Mission System
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Maintenance Program
• Preventive– Depot Level Maint (Third Level Insp & Repair - TLIR)– Base Level Maint (Periodic Inspections – PER)
• 600 hrs +/- 50 hrs• PER #1 & #3 – Minor• PER #2 & #4 – Major
– Squadron Level Maint (Supplementary Insp – SUPP)• 25 hrs +/- 2.5 hrs• After & Before Flight Checks• Corrosion - #1 & #2 – Alternate Every 7 Days• Conditional Inspections – Hard Ldg, Lightening Strike, etc
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Maintenance Program
• Corrective– Structural Repair Manual (Standard Repairs)– System Maint Manuals (Fault Diagnosis & Repair)– OEM or Contractor Developed Repairs– Temp or Non-Standard Repairs– Aircraft Battle Damage & Repair
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Maintenance Program
• Upgrades / Modifications– Mechanical System– Avionics/Electrical/Mission System
– CD (Depot Level) • Approx 225 CD mods to date
– CF (Field Level)• Approx 600 CF mods to date
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Attributes of Success
• Maintenance Program• Aircraft Structural Integrity
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Attributes of Success
• Aircraft Structural Integrity– Technical Airworthiness Manual
• Since 2003 provides ASI related Rules & Standards
• Replaced Tech Order based on MIL-STD-1530C ASI
• ASI Program Elements– Statement of Operating Intent
– Baseline Usage Spectrum with Mission Profiles
– Structural Usage Monitoring (SUM)
– Structural Condition Monitoring (SCM)
– Aircraft Structural Integrity Mgmt Plan (ASIMP)
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Aircraft Structural Integrity Process
Structural Condition Monitoring
Structural Analysis Fleet Structural Maintenance Plan
Structural Usage Monitoring
Baseline Usage (SOI)
Analytical Methods
SCM uses data from:Scheduled maintenance,RepairsSIsService bulletinsFull-scale testsForeign operatorsOEM
Models, software, data
Includes usage data collection, transfer, analysis and reporting
Final product of ASI process,used to generate maintenance program
Inspection-generated data
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Baseline Usage Spectrum
• CH124 BUS Analysis (Sikorsky 2005)– BUS Development
• Operations & Flight Witnessing• Pilot Interviews• Usage Data Analysis from CF335 Forms
– Dynamic Component Fatigue Usage Spectrum• Adjusted fatigue lives
– 9 Mission Profiles– Produced Composite Worst Case Usage Spectrum
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Baseline Usage Spectrum
• CH124 Mission ProfilesA – Reconnaissance/Surveillance (Recce)
B – Crew Operational Readiness (COREX)
C – Pilot Proficiency Flight (PPF)
D – Maintenance Test Flight (MTF)
E – Helicopter Delivery Service/Utility (HDS/Utility)
F – Anti-Submarine Warfare (ASW)
G – Search and Rescue (SAR)
H – Cross-Country/Pilot Proficiency Instrument FlightK – Waterbird (Ceased Trg Fall 2013)
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COREX Mission Profile
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Baseline Usage Spectrum
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Baseline Usage SpectrumCH124 “Composite Worst Case” Spectrum (cont)
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Aircraft Structural Integrity Mgmt Plan
• CH124 Structural Usage Monitoring (SUM)– Fatigue monitoring program
• Includes individual aircraft tracking• Requires sufficient and relevant data to track usage
– Review process to compare actual to baseline– Process to re-evaluate component lives– Maintenance program review based on findings
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Aircraft Structural Integrity Mgmt Plan
• CH124 SUM Dataset
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Aircraft Structural Integrity Mgmt Plan
• CH124 Usage Spectrum Mission Weighting
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Aircraft Structural Integrity Mgmt Plan
• Comparison of Mission Usage to Baseline
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Aircraft Structural Integrity Mgmt Plan
• CH124 SUM - Exceedences from Baseline– Limit or adjust usage patterns or mission profile
• AC 412 continue to limit usage of Mission A (Recce/Surv)• AC 441 limit usage of Mission H (X-Country / PPIF)• Autorotations / One Engine Inoperative / Waterbird
– Add or increase inspection requirements• Reduce Interval for SSI#12- Left/Fwd Sponson Mount to 600hrs
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Baseline Usage Spectrum• CH124 Mission Profile - Damage Severity
Most Damaging - Dynamic Components & SSIsA – Reconnaissance/Surveillance (Recce)
C – Pilot Proficiency Flight (PPF)
G – Search and Rescue (SAR)
K – Waterbird (Ceased Trg Fall 2013)
Moderate Damage to Specific ComponentsD – Maintenance Test Flight (MTF)
E – Helicopter Delivery Service/Utility (HDS/Utility)
F – Anti-Submarine Warfare (ASW)
H – Cross-Country/Pilot Proficiency Instrument Flight
Non-Damaging
B – Crew Operational Readiness (COREX)
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Aircraft Structural Integrity Mgmt Plan
• CH124 Structural Condition Monitoring (SCM)– Program to monitor structural repairs and
inspection records– Long-term impact assessment of structural repairs– Review of inspection records to determine trends– Review of structural related in-service monitoring
data– Process to re-evaluate the maintenance program
• Adjust Preventive Maint Inspections – (i.e. Corrosion Control)
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Aircraft Structural Integrity Mgmt Plan
• CH124 SCM Policy– SCM Function in CH124 ASIP– SCM Data Sources & Tools– Definition of Structurally Significant Items (SSIs)– Damage Mapping
• Corrosion• Fatigue• Mechanical
– SCM Reporting• Annually
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Aircraft Structural Integrity Mgmt Plan
• SCM Function in CH124 ASIP– Monitor Structural Repairs & Inspection Records;– Consider Primary Structure as a minimum;– Determine trends in frequency of damage by location;– Review service difficulty reports impacting ASI
longterm;– Document identified trends & provide
recommendations;
– Dynamic Components • Currently outside SCM scope but coming soon…
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Aircraft Structural Integrity Mgmt Plan
• SCM Data Sources & Tools– Primary Data Sources
• Historical TLIR & PER#4 Reports reviewed in FY11/12• Up to four reports/aircraft were reviewed
– SCM Dataset• Primary Structure not defined in Sikorsky documents• CH124 SCM Policy classifies Primary Structural
Elements
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Aircraft Structural Integrity Mgmt Plan
• CH124 SCM Definition of SSIs– The part is a subset of aircraft primary structure;
– Failure of the part could cause direct loss of the aircraft (Category I);
– Failure of the part could cause substantial damage to the aircraft (Category II);
– The part has been shown, by experience or analysis, to be prone to damage; and
– Part geometry and/or load carrying capability and material did not change with a structural modification yet show a history of chronic, severe damage.
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Aircraft Structural Integrity Mgmt Plan
• 37 x Structurally Significant Items– SSI List is available to review if interested
• 64 x Structurally Significant Modifications– modifications or repairs on the aircraft that have a
significant impact on the life and airframe structural integrity
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Aircraft Structural Integrity Mgmt Plan
• CH124 SCM Damage Mapping
• Corrosion• Fatigue• Mechanical
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CH124 Highlights
• General Fleet Information• Fleet Service Life Status• Attributes of Success
– Maintenance Program– Aircraft Structural Integrity
• Sunset Years– Challenges & Capabilities
• Wrap-Up
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Sunset Years
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Sunset Years• Challenges
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Sunset Years
• ELE Initiatives– Parts Procurement Project
• FY14/15 & FY15/16
– Aircraft Sampling Inspection• Post TLIR Areas of Interest
– Obsolescence Mod Projects • Minor system updates
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Sunset Years
• Capabilities through Transition– Increased focus on Intelligence, Reconnaissance,
and Surveillance;– Prototype EO/IR, TCDL, SONAR Digitization
– Three letter snake names…From ASP to BOA.• Augmented Surface Plot• Basic Operational Augmentation
– Tactical Mission System enhancements
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CH124 Highlights
• General Fleet Information• Fleet Service Life Status• Attributes of Success
– Maintenance Program– Aircraft Structural Integrity
• Sunset Years– Challenges & Capabilities
• Wrap-Up
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