Maintenance Program Development

Structure MSG3 analyses

Definitions

Environmental Deterioration
result of chemical interaction with its climate or environment

Page 41

Maintenance Program Development

Structure MSG3 analyses

Definitions

Fatigue Damage
cracks due to cyclic loading and subsequent propagation.

Page 42

Maintenance Program Development

Structure MSG3 analyses

Definitions

Wear Damage
Physical deterioration of the surface of an item due to relative motion
between two parts in contact.

Page 43

Maintenance Program Development

IN-SERVICE
EXPERIENCE

DESIGN
INFORMATION

Structure MSG3 analyses

TEST RESULTS
Page 44

FATIGUE
& DAMAGE
TOLERANCE
EVALUATIONS

Maintenance Program Development

Structure MSG3 analyses
SELECTION

AIRCRAFT
STRUCTURE
Significant
Structure

YES

Significant?

NO

Other
Structure

Document the Significant

DOCUMENTATION

IDENTIFICATION

ANALYSIS

Structure (SSD)
Identify Strutural
Significant Items (SSI)
Perform SSI
MSG-3 Analysis
Resulting

RESULTS

Requirements

Structure
MPP

Page 45

To be considered
by Zonal WG

Maintenance Program Development

Structure MSG3 analyses
DAMAGE

EVALUATION

ACCIDENTAL
DAMAGE

Page 46

SUSCEPTIBILITY

DAMAGE
DETECTABILITY
EFFECT ON
CONTINUING
AIRWORTHINESS

SOURCES

ENVIRONMENTAL
DETERIORATION

FATIGUE
DAMAGE

Maintenance Program Development

Structure MSG3 analyses
individual SSI Analysis
Each type of deterioration/damage is analysed separately:
METALLIC

Page 47

NON-METALLIC

ACCIDENTAL DAMAGE
ANALYSIS

ACCIDENTAL DAMAGE
ANALYSIS

ED/CPCP
ANALYSIS

ED (Aging)
ANALYSIS

METALLIC & NON-METALLIC

ACCIDENTAL DAMAGE
ANALYSIS

ED/CPCP
ANALYSIS

FATIGUE DAMAGE

FATIGUE DAMAGE

ANALYSIS

ANALYSIS

ACCIDENTAL DAMAGE
ANALYSIS

ED (Aging)
ANALYSIS

Maintenance Program Development

Structure MSG3 analyses
Corrosion Prevention Control Programme (CPCP)

ATA MSG-3
Operator/Manufacturer
Scheduled
Maintenance
Development

Revision 2

April 1988

November 1993

Objective of CPCP: control corrosion to Level 1 or better

Level 1 Corrosion
Corrosion damage that does not require structural reinforcement or replacement,
Or
Corrosion occurring between successive inspections that exceeds allowable limits but is local
and can be attributed to an event not typical of operator's usage of other aircraft in the same
fleet (e.g. mercury spillage).
Page 48

Maintenance Program Development

Structure MSG3 analyses
Consolidated ED / CPCP Requirement
ED INSPECTION
REQUIREMENT

CPCP
REQUIREMENT

INSPECTION LEVEL

INSPECTION LEVEL

THRESHOLD

CPCP THRESHOLD

INTERVAL

INTERVAL

Sampling (Y/N)

TPS Application (Y/N).

ED/CPCP CONSOLIDATED
MAINTENANCE REQUIREMENT

INSPECTION LEVEL
THRESHOLD

SAMPLING
(Y/N)

INTERVAL
TPS Application (Y/N)
CPCP THRESHOLD (100% Threshold)
Page 49

Maintenance Program Development

Structure MSG3 analyses
SIGNIFICANT
STRUCTRURE
SELECTION
FORMS

Page 50

SIGNIFICANT
STRUCTURE
DOSSIER
FORMS

SSI
ANALYSIS
FORMS

Maintenance Program Development

Structure MSG3 analyses
SSD

SSI

SSI

SSI

AD
ANALYSIS

AD
ANALYSIS

AD
ANALYSIS

ED/CPCP ANALYSIS

ED/CPCP ANALYSIS

ED/CPCP ANALYSIS

ED (Aging)
ANALYSIS

ED (Aging)
ANALYSIS

ED (Aging)
ANALYSIS

FATIGUE DAMAGE
ANALYSIS

FATIGUE DAMAGE
ANALYSIS

FATIGUE DAMAGE
ANALYSIS

REQUIREMENTS

REQUIREMENTS

REQUIREMENTS

CONSOLIDATION
Page 51

TASKS

Maintenance Program Development

Zonal MSG3 analyses

Page 52

Maintenance Program Development

Zonal MSG3 analyses

General Principles
The

Zonal Inspection Requirements = General Visual Inspection

(GVI) requirements for each aircraft zone to check system and

power plant installations , wiring (EWIS- Electrical Wiring
Interconnection Systems) for security and general condition and
structure for general condition

Page 53

Maintenance Program Development

Zonal MSG3 analyses
The Aircraft is sub-divided into major zones:
e.g A380: 8 Major Zones (External)
100
200
300
400
500
600
700
800

Lower half of fuselage to rear pressure bulkhead

Upper half of fuselage to rear pressure bulkhead
500
Fuselage tail section and stabilizers
Power Plant, Nacelles and Pylons
Left Wing
300
Right Wing
800
Landing Gear & Landing Gear Doors
800
Doors

200
800

400
100
800
400
800
800

Major Sub-Zones (Internal)

Sub-divisions of the Major Zones, e.g. 100 is divided into 110, 120, 130,..
Zones
Sub-divisions of Major Sub-Zones, e.g.
120 is divided into 121, 122, 123,..
Page 54

600

Maintenance Program Development

Enhanced Zonal (EZAP)

wiring and wiring installations within
the Zone

Zonal Analysis Procedure

Page 55

Maintenance Program Development

Zonal Maintenance Requirements
GVI: General Visual Inspection
Visual examination to detect obvious unsatisfactory
conditions and discrepancies in the zone
DET: DETailed Inspection
Full examination of a specific component,
installation or assembly to find damage, failure or
defect.
RST: ReSToration tasks (e.g. cleaning, discard)
Bring the Wiring and Wiring Installation conditions
back to their original Standard
FNC: FuNCtional check
Quantitative test (continuity check-Impedance
loop) to determine if one or more functions of an
item performs within specified limits.
Page 56

Maintenance Program Development

Standard Zonal
To detect degradation of
the whole zone (Structure,
equipment, wiring, L/HIRF
protection, bonding leads,
grounding points, ...)

4 major parameters to be considered

Accidental Damage exposure
Environmental Deterioration Exposure
Zone Density
Importance of the components installed in the zone

Page 57

GVI

Maintenance Program Development

Enhanced Zonal
G Route to
Engine
Generator

P Route
Crossover
M&S
Routes to
Engine etc.

4 major parameters to be considered

Detect wiring
degradation
electrical ignition
source
Avoid combustible
material accumulation
with increased wiring
related risk of fire
Note: appropriate attention
is given to safety related
deterioration of wiring and
wirings installation (Electrical
Wiring Interconnection
Systems, EWIS)

Accidental Damage exposure

Environmental Deterioration Exposure
Zone Density (EWIS Inspect ability)
Potential fire effect on adjacent Wiring and Systems

Page 58

GVI

DET

RST

Maintenance Program Development

HIRF
(High Intensity Radiated Fields)

L
(Lightning)
MRB
and

Aircraft certification
offices

manufacturer to identify an appropriate method capable to confirm that inservice operation will not reduce the HIRF and Lightning protection to a level
that is inadequate to maintain Type Certification objectives
1.Identification of dedicated maintenance tasks if needed MRBR
2.Identification of a Lightning/HIRF protection Assurance Plan specific
tests on a representative sample of the world fleet at specified intervals
Page 59

Maintenance Program Development

L/HIRF maintenance tasks
To detect L/HIRF protection degradation
Aircraft Structure continuity, metal to metal contact
, bonding leads and Metallic networks for Composite
Structures.
Electrical wiring protection Raceways and Braided
conduits -Individual shielding for engine cables in
exposed areas.
Equipment protection clamping and filtering devices
at inputs/outputs prevent damage from
voltage/current resulting from Lightning and HIRF in
addition to the inherent equipment protection.
Systems architecture increasing the nonsusceptibility of Systems to HIRF and Lightning
effects by Segregation of electrical wiring routes

2 major parameters to be considered

Accidental Damage exposure

FNC

Environmental Deterioration Exposure

Page 60

GVI

DET

Maintenance Program Development

L/HIRF assurance plan
Objectives
1. Scheduled maintenance program is adequate to keep the
electromagnetic protection at a satisfactory level.
2. Design of the electromagnetic protection is robust and not susceptible
to any systematic degradation.

The tests carried out in the frame of the Assurance Plan consist in measuring the loop
impedance made by the protection element (e.g. a braided conduit or a raceway)
and its bonding to the aircraft structure. This impedance is representative of the
protection element integrity and efficiency.
Loop Impedance
Clamp

Loop Resistance
Tester (LRT)
Page 61

Maintenance Program Development

Zonal MSG3 analyses Consolidation
List of aircraft zones
Analysis type (Standard, Enhanced, L/HIRF)

Zone number: XXX, YYY:

Description / access
Contains (structure items, systems components,
wiring, L/HIRF protection elements)

L/HIRF ZONAL
ANALYSIS

ENHANCED
ZONAL ANALYSIS

Stand-alone GVIs,
DETs & RST
Task consolidation

(Zone selection)

(Zone description)

STANDARD ZONAL
ANALYSIS

STRUCTURE
ANALYSIS

SYSTEM & POWERPLANT

ANALYSIS

GVIs & VCKs

GVIs
Task consolidation

(Consolidation)
System & Powerplant
Program
Page 62

Zonal Program

Maintenance Program Development

Zonal MSG3 analyses
Failure modes not identified
through the SSI/MSI
analysis but naturally
inspected by the zonal

Failure modes identified

through the SSI/MSI
analysis but naturally
inspected by the zonal
(e.g. corrosion)
MSI/SSI tasks transferred
into the zonal program

Page 63

Maintenance Program Development

The MRB Report
Systems &
Powerplant

Page 64

Zonal &
L/HIRF

Structure

Maintenance Program Development

MWG
activities
completed

+
ISC validates
MWG results

Manufacturer
develops the
MRB Report
Proposal

ISC validates
MRBR
proposal

Authorities
approve the
MRB Report

Page 65

Maintenance Program Development

The MRB Report

Page 66

Maintenance Program Development

The MRB Report
Administration pages:
 Approval Letters,
 Record of Revisions,
 Summary of changes from previous revision,
 List of Effective Pages
Section A: Introduction
 Purpose & Scope
 A350 Models covered
 Reference to the basis (MSG3 revision, PPH)
 Aircraft Utilization Assumptions
 Revision Policies
 Overall Document Description
Section B: General Rules that Apply to Sections C, D & E

Page 67

Maintenance Program Development

Systems &
Powerplant

Page 68

Maintenance Program Development

Structure

Page 69

Maintenance Program Development

Zonal &
L/HIRF

Page 70

Maintenance Program Development

The MRB Report
Section F: Requirements for U.S. Operators
 Contains additional requirements which must be embodied
by the US certificated Operators to complement the ones
listed in sections A, B, C, D and E of the MRB Report.

Page 71

Maintenance Program Development

A typical Maintenance Programme development planning

Operators needs
Flight test

Page 72

Maintenance Program Development

9 5 training sessions
9 4 MRB meetings
9 10 ISC meetings
9 53 MWG meetings
More then 800 MSG
analysis dossiers
reviewed
Representing more
than 8000 meeting
man-days
1st complete MPP
available and
submitted prior to 1st
Flight
Page 73

Maintenance Program Development

The

MRBR process

has demonstrated added value and efficiency

Is adapted to the operators needs and constraints
Permanently evolves to remain adapted and efficient

Potential

consequences of reduced operator participation

Initial program not validated by global operations

Future program changes wont be driven by operators
Less sharing of in-service experience

Without Operators active participation the MRB process may die!

Risk of a more-conservative Maintenance Program
Page 74

Maintenance Program Development

Even before the start of the MRBR process Maintenance Engineers get
involved in Aircraft design development

Page 75

Example: A350 V&V

Maintenance Program Development

Information
On

Page 76

is available on line and/or on physical media (DVD)

Line access available via AirbusWorld

Maintenance Program Development

Access to MRBR

Maintenance & Engineering Page

Page 77

Maintenance Program Development

Access to MRBR

Prepare Maintenance
Prepare Maintenance Program

Page 78

Maintenance Program Development

Access to MRBR

Review Airbus Maintenance Requirements

Access MRB Report and associated compliance documents

Page 79

Maintenance Program Development

Access to MRBR

Page 80

MRB Reports available in PDF version and MS XLS (tables)