Helitech International
September 24, 2013
D.B. “Danny” GreenUS JHSIT HFDM, HUMS IWG Member, HUMS Reporting Member of the HAI Technical Committee, IHST HeliShare OGP Lead
Helitech International September 24, 2013
How to Manage your Condition-Based
Maintenance Program
Helitech International
September 24, 2013
What to Expect Today • Who/What is IHST
• Define CBM• CBM Terminology
• Why Use CBM?
– Benefits– Potential Disadvantages
• How do we do it?
• Equipment Offerings– References
• Interactive Case Studies
• A basic understanding of the principles of CBM, its “interaction”with a proactive SMS
What not to Expect Today• Sales Pitch (I’m only selling proven
concepts not endorsing products)
• Extensive Vibration Training • Engineering, Theory and or Scientific
Debates • We will not discuss recent events
Helitech International
September 24, 2013
Helitech International
September 24, 2013
IHST’s attitude towards safety:
• IHST takes a proactive attitude that anyone’s helicopter accident belongs to all of us.
• Accidents affect our collective reputation as providers of air transportation and suppliers of air services…
• We don’t need to accept accidents or a high industry accident rate, and it affects our profitability if we do so.– Jack Drake, IHST JHSAT Accident Analysis Group– Presented at ISASI 2008
Helitech International
September 24, 2013
WSJ, 9/5/2013North Sea Crash Underscores Poor Progress in Helicopter Safety Civilian Chopper Crashes Have Remained Flat Over Decade
The fatal crash of a Eurocopter oil-rig helicopter in the North Sea last month underscores stalled progress in reducing commercial helicopter accidents world-wide.
In spite of advances in cockpit technology and enhanced pilot training, helicopters' global safety record has failed to improve dramatically over the past few years—
and still lags far behind standards for airliners.
WSJ 9/5/2013 By: Andy Pasztor and Daniel Michaels
Helitech International
September 24, 2013
Helitech International
September 24, 2013
WHAT is CBM?
From Wikipedia, the free encyclopedia
Helitech International
September 24, 2013
Condition-Based MaintenanceFrom Wikipedia, the free encyclopedia
Condition-based maintenance (CBM), simply described, as maintenance when need arises. This maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating.This concept is applicable to mission critical systems that incorporate active redundancy and fault reporting. It is also applicable to non-mission critical systems that lack redundancy and fault reporting.
Always keeping in mind the required FAA/CAA inspection programs with an emphasis on value added tasks.
Helitech International
September 24, 2013
in other words …
If it aint broke, don ’t fix it!
Helitech International
September 24, 2013
CBM BenefitsCBM has some Benefits over planned maintenance:•Improved system reliability•Enhanced Safety•Decreased maintenance costs•Increased Readiness•Operation and Support cost benefits• Reduction of human error influences. •Other Intrinsic Benefits:
•Increased pilot confidence•The ability to monitor health of an entire fleet, regardless of physical location • As the program matures, the potential to predict when certain faults will occur, based on historical data and specific aircraft data•The ability to more effectively plan maintenance actions over the long-term
Reference the IHST HUMS Toolkit (IHST.ORG) for complet e details
Helitech International
September 24, 2013
Disadvantages
Some potential disadvantages are:•High equipment costs (initially and to maintain)•Possible Increased Manpower•Increased Training•Increased IT/Support•Increased number of components (the VHM/HUMS system itself) that must be maintained•Increased weight/Decreased carry capacity
Helitech International
September 24, 2013
Aviation Maintenance Options
(A Travel Through Time)
Helitech International
September 24, 2013
Run to Failure or
FIX it When it BROKE!
Post WWII (PMI)
The Somewhat Present (PdM)
Helitech International
September 24, 2013
REF. Bubba’s Aviation Maintenance consultants
What Does CBM Look Like?
Helitech International
September 24, 2013
What Does CBM Look Like?
Fix it When Its Broke
•Scheduled Inspections•Scheduled Maintenance•Scheduled Overhauls•Time Lifed Parts•ADs, SBs, ACs ,CEBs
Past
Present (FAA/CAA Required)
Present/Future
•HUMS•FOQA•VHM•Advanced Sensing Technologies•MSG3•HFDM•PdM•CBM•RCM
CBM
Helitech International
September 24, 2013
Where do we want to be?Predictive Maintenance Potential Failure P-F Curve
Time
P Point where failure can first be detected
Point where failure starts
F
Point of failure
John Moubray, Reliability Centered Maintenance II
Helitech International
September 24, 2013
How Do we Do CBM?
Helitech International
September 24, 2013
Then why do we do it?
SAFTEY, SAFETY ,SAFETY, SAFETY, Maintenance Benefits, SAFETY, SAFETY, SAFETY…!
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Helitech International
September 24, 201319
Our CBM Program Philosophy:
� One of the key rules by which or organization operates is to involve the right people in decisions that affect procedures andequipment. Our entire CBM philosophy is based on that principle.
� Safety is above and beyond without question or hesitation our first and foremost objective!
� Our next objective is to minimize unplanned maintenance or at a minimum, identify and address it on our terms.
� Our Analysts interface with Maintenance constantly and seek the counsel of Subject Matter Experts who are subject to change depending on the issue in question and/or the aircraft type. � Seek the wisdom of ten rather the knowledge of one.
� We also keep management and operations abreast of any situations so they can make any necessary changes in equipment, tools or personnel.
“
Helitech International
September 24, 2013
Tools/Tricks of the Trade
Helitech International
September 24, 2013
The latest IHST Toolkit: HUMS
Start Here
Helitech International
September 24, 2013
Before you startIdentify detailed requirements: • Benefits vs. Cost
• Available Equipment– VHM, HUMS
– T.C., STC
– Carry-On
• Required Personnel– Analyst
– Maintenance Support
– I.T. Support
• In-House or Contract Analysis
• Regulatory Requirements
• Contractual Requirements
• I.T. requirements
• Training Requirements
START HERE ISHT.ORG
Helitech International
September 24, 2013
The latest IHST Toolkit: HUMS
Helitech International
September 24, 2013
Content developed by leading industry HUMS experts.
Helitech International
September 24, 2013
Resources include reference materials, a listing of equipment providers and actual case studies.
Helitech International
September 24, 2013
Tools/Tricks of the Trade�Vibration Monitor Data
�Vibration Spectrum Data
�Vibration Signature Data
�Logsheets, Inspection Forms, AOCRs
�Trending
�Limits/Rate of Change
�Aircraft Advisories, Fault logs, Exceedences
�Proper Interviews:Pilots, Mechanics and anyone else who may know anything about the
conditions in question.
Helitech International
September 24, 2013
Lessons Learned
Helitech International
September 24, 2013
Life Lessons Learned from a HUMS Analyst1) If you are going to fly around with the added weight and cost of the
equipment…USE IT!2) Weekly downloads are insufficient for timely and accurate analysis.
– Daily is preferred but between flights is becoming regular practice in some operations due to the length of flights.
3) Communicate, Communicate, Communicate– Pilots, mechanics, dispatchers, written reports, i.e. logsheets,
inspection forms AOCRs follow the clues.4) Be curious, be nosey, be a pain in the butt, ask why 5 times, just
get the answers (we’re talking CSI stuff here)!5) Being wrong is okay, being scared of being wrong is not. Humility
while painful, could cost or save lives!6) When in doubt seek a higher power (someone has probably seen it
before) paralysis through analysis is unacceptable in our trade!D.B. “Danny “ Green
Helitech International
September 24, 2013
Most Common Findings:� Main Rotor: Shear Restraints, Trim Tabs, Isolation Mounts,
Bearings� Tail Rotor: Bearings, Trunnions, Blades, Gearboxes� Tail Rotor Drive: Hanger Bearings, Drive Shafts, Hanger
Bearing Mounts and Airframe Cracks� Main Transmission: Output Shafts, ECU Drive� Engines: FOD, Worn Mounts, Oils Pumps, Shafts� Oil Coolers: Fan/Blower Bearings, Trash� Starters: Bearings, Brushes, Looseness� Hydraulic Pumps: Shafts, Seals, Drives and Stripped Studs
Helitech International
September 24, 2013
SMS
What does that have to do with SMS?
What is SMS? My simple definition is to have programs in place to address problems before they ever exist.
What could possible address this better than CBM and FDM.
Helitech International
September 24, 2013
Interactive Vibration Case Studies…
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Can you Analyze the Problem?
Helitech International
September 24, 2013
AW139 Hydraulic PumpTrending vibration increases noted in the #1 hydraulic pump drive but no limits exceeded. After review of the log sheets, it was noted that a 100 hour hydraulic pump inspection was performed in the previous days. The aircraft had a upcoming scheduled hangar check, the pump was inspected based on our data and two loose studs were found.
Helitech International
September 24, 2013
AW139 Worn Hydraulic Pump Case Study
Noticed increased vibration trending on the #2 input hydraulic pump. No limits were exceeded but when the aircraft was down for other maintenance, the pump was removed to inspect based on this data and the worn pump drive shaft was found as well as damage to the pump.
“
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Helitech International
September 24, 2013
AW139 T/R Paddle Change
STOP WORK AUTHORITY Used(A/C Grounded Immediately)
Helitech International
September 24, 2013
430 Tail Rotor Radial
STOP WORK AUTHORITY Used(A/C Grounded Immediately)
Helitech International
September 24, 2013
430 Tail Rotor Gearbox
Helitech International
September 24, 2013
430 Main Rotor F/A and Vertical Increase
Helitech International
September 24, 2013
Hanger Bearing Case Study#1 hanger bearing showed increased Broad Band
Vibrations (1P and 2P were normal). After visual inspection and rotational check for smoothness, the bearing was greased. Grease solved problem for several days but the problem would return (see below). This process was repeated until the aircraft was available for the next hangar check (very large job, remote a/c) and the bearing could be changed.
Replacement solved the problem and upon teardown and root cause inspection, it was noticed that the balls were riding across the outer race once the fresh grease would break down thus increasing the Broad Band vibes.
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9.26 mm 7.5 mm
Helitech International
September 24, 2013
QUESTIONS?
D.B. “Danny” Green
Mobile 985.768.1823 Office 601.749.4059