CH124 Sea King Fleet Update “Keepin’ ‘em Flying!!” Major Richard Loewen Senior Design...

CH124 Sea King Fleet Update

“Keepin’ ‘em Flying!!”

Major Richard LoewenSenior Design Engineer

US Army Air Corps – 1941 – Recruiting Slogan

Universal Pictures – 28 November 1941

CH124 Highlights

• General Fleet Information• Fleet Service Life Status• Attributes of Success

– Maintenance Program– Aircraft Structural Integrity

• Sunset Years– Challenges & Capabilities

• Wrap-Up

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)

CH124A – ASW - Dipping Sonar, Self Defense, ISR

CH124B – Utility & Troop Config

(14 Pax)

443 SqnVictoria, BC

NDHQOttawa, ON

406 OTS

423 Sqn

12 AMSShearwater,

NS

Main Operating Bases & HQ

CH124 Highlights




• Wrap-Up

Fleet Service Life Status

• Entered service – May 1963


• 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


• Summer 2013: 50th Anniversary Celebrations


• 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

CH124 Highlights




• Wrap-Up

Attributes of Success


• Maintenance Program– Preventive– Corrective– Upgrades / Modifications

• Mechanical System• Avionics/Electrical/Mission System

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

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

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


• Maintenance Program• Aircraft Structural Integrity


• 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)

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

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


• 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)

COREX Mission Profile

Baseline Usage SpectrumCH124 “Composite Worst Case” Spectrum (cont)

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


• CH124 SUM Dataset


• CH124 Usage Spectrum Mission Weighting


• Comparison of Mission Usage to Baseline


• 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

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)


• 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)


• 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


• 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…


• 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


• 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.


• 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


• CH124 SCM Damage Mapping

• Corrosion• Fatigue• Mechanical

CH124 Highlights




• Wrap-Up

Sunset Years

Sunset Years• Challenges

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

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

CH124 Highlights




• Wrap-Up

CH124 Sea King Fleet Update “Keepin’ ‘em Flying!!” Major Richard Loewen Senior Design...

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