CHAPTER 01

INTRODUCTION

1.1 IDENTIFICATION

Oil analysis is similar to visiting your doctor for an annual blood test. The doctor
can determine your overall health and well-being from a very small sample of your
blood. The same can be done with oil lubricated equipment such as engines, gearboxes,
hydraulics, air compressors, and turbines. Description of the Problems Encountered
with the oil contaminations in Turboprop Aircraft powered by turboprop engines have
been in service with the RMAF for over 25 years. One of the oldest of these is the
Hercules C-130 transport, which is equipped with four Allison T-56 turboprop
engines.Filters oil captured a lot of tribological information on the operation of an
aircraft. Retrieval and analysis of filters waste has been shown as useful tool for
managing the health of those units’ engines. It´s necessary to emphasize that the
analysis is tedious as it requires a careful technique, great experience, the evaluator and
homogeneous cleaning filters, involving a comprehensive operating procedure and a
railway mechanics. This has given rise to concern for the long term health of flight-
crews and, in the short term, operational safety problems which may result from
incapacitation of pilots and crew. Extensive technical investigations by N0: 20
Squadron had problems on No: 1 engine unable to start up with all parameters ignition
in normal condition. To identify and rectification carried out in according with
TM382C-2-3 and Servicing Maintenance Progressive 515C card. These fluids are: - 1.
Synthetic lubricating oil, to MIL-L-23699C, NATO 0-156

1
 Figure 1.1 C130H

For this particular project, the C130H aircraft on T56-A-15 power plant lubrication
systems will analyzed after metal chunk found in magnetic chip detector. The goal
must be solve these problems in the maintenance stage where it can be guaranteed with
far more assurance that the comfort and maintenance requirements will be met. The
advantages reported using information from system lubrication and more waste
management specifically on the aircraft engines oil filters are related to the prediction of
useful life of the equipment to maximize availability of the planning and running
maintenance operations, not on the basis of fixed hours but when necessary
internationally known as "condition-based maintenance" (Condition Monitoring), which
combines the prediction with proactive.
Great progress has been made in research to develop technology which allows a better
understanding of the mechanism of the aircraft and methods of controlling it. However,
these research efforts must be accompanied by a design philosophy that recognizes
inadequacies in our technology and allows the incorporation of Earlier Failure
Detection (EFD) program and preventative design features. Such feature as large
number of power plant and reduction gear box that allows the researcher a new
developmental technology used in maintenance of the aircraft which could be used.

2
 1.2 PROBLEM STATEMENT

This paper describes a very successful SOAP Lab preventatives concept which
PUSPEKA RMAF has developed that allows the metal particle counter. The T56-A-15
power plant lubrications systems mainly by trending and analyzed procedure.

Diagram 1.1 Oil System

The power section incorporates, a dry sump lubrication system supplied with oil from
the aircraft tank-furnished tank. After the necessary power section components have
been lubricated and cooled, the oil is scavenged and returned to the aircraft supply
system. Oil from oil tank enters the pressure of the main oil pump, which is mounted on
the front side of the accessories drive housing assembly. Pressure regulating valve
regulate system oil pressure to 50-60 psi. A magnetic drain plugs at the bottom of the
accessory drive housing picks up any magnetic particles which had their origin within
the accessory drive housing, or air inlet housing . The magnetic drain plug near the
outlet of the main scavenge pumps picks up magnetic particles which had their origin
from the diffuser, combustion section or turbine section and reduction gear box.

3
 Diagram 1.2 C130H Power Plant

Elemental analysis tests for various elements found in the oil that may be from wear
Debris contamination or the additives found in the oil. When an oil lubricated
component begins to wear, small amounts of metal become suspended in the oil. These
trace amounts of metal are the first indicators of component wear. If left unattended, the
wear will increase and potential part failure will occur. In extreme cases, metal shavings
from worn gear teeth can be found in the oil. If the wear is severe, metal shavings can
be seen during the oil change. The shavings will contribute to more wear. This situation
can occur in gearboxes, hydraulics, engines, and air compressors. Many components
and parts are made-up of several different metals. This problem can be rectified by build
out a new procedure in according to C130H Technical Manual.

4
 Figure 1.2 Multi element Oil Analysis

1.3 PROJECT OBJECTIVE

To ensure the serviceability of the aircraft and its reliability during flight as follows:
1. Identifying problems during maintenance and trouble shoot.
2. Identifying parts of major components T56-A-15 power plants and requirement
to carry out the particles test contaminations
3. Design a new program of Earlier Failure Detection the maintenance.

5
1.4 LIMITATION

The C130H aircraft is maintained periodically to ensure it airworthiness states

continue and the aircraft serviceability is at its optimum. As such every 50.00 airframe
hours of flying the aircraft will go for Servicing Maintenance Progress (SMP 515C)
The estimation time to complete this task is approximately 05 hours with 02
manpower’s and on completion of this functional testing the result must be certified any
discrepancies, rectification of the system is a requisite before the aircraft allowed to
flying.

1.5 IMPORTANCE

Spectrometric oil analysis. It is a diagnostic maintenance tool used to determine

the type and amount of wear particle on lubricant fluid samples. Engines and reducing
boxes a systems are the most frequently monitored computers types. The presence of
unusual concentrations of an item in the sample fluid may indicate an abnormal wear on
your computer. Once the abnormal wear has been verified, the computer may be
repaired or put out of service before a serious failure in one of the lubricated
components. Analysis spectrometric oils streamlines the safety of staff and the
availability of materials at minimal cost, and serves as a vital tool of preventive
maintenance.
Analysis of physical properties. The physical properties of lubricants analyses provide
data in standard conditions of measurement to determine the quality of the lubricant.
These analyses have highly beneficial for the aviation if they are used in conjunction
with spectrometric analysis equipment Applications.

6
1.6 CONCLUSION

The data obtained spectrometric analyses and/or physical properties of lubricants

can be used as guidelines to assist in identifying emerging mechanical failures or to
determine the quality and oil life. Therefore, wear and potential gaps in equipment
components and lubricants, premature failures can be detected before severe failures of
teams and have to make repairs or costly reconstructions. Oil analysis can also be used
to identify inadequate maintenance procedures and parts, components or unsatisfactory
assemblage’s equipment. Wear metal particles or powders loosened the surfaces of
metallic alloys always have the same chemical composition as metal alloys where come
from. The level and the normal rate of each type of metal particle production can be set
for each type of computer through analysis of oil in a certain period of time. Metal
elements specify a witty problem permanently while others will provide only general
information that is happening abnormal wear. When a level and/or an abnormal wear
debris of particle production rate is detected, the chemical identity of abnormally
particulate will provide concerning tracks to the identity of the parties that are eroding
abnormally.
For this chapter, the basic information about oil contaminations had been describes
briefly together with the purpose of the Earlier Failure Detection Program which is from
C130H Technical Manual and PUSPEKA RMAF.

7
 CHAPTER 02

METHODOLOGY

2.1 IDENTIFICATION

The key of project methodology is to strictly following the aircraft maintenance

manual procedure (analysis and measurement). Any deviation from the procedure are
likely to violate the airworthiness of the aircraft, may lead to accident, damage to the
aircraft, injuries and loss of life. It is a must for all technical personnel related to this
operational check to ensure that the validity of the reference that is being used.

(NAVY) NAVAIR 17-15-50.1 (ARMY) TM 38-301-1 (AIR FORCE) T.O. 33-1-37-1

(COAST GUARD) TO 33-1-37-1
30 August 2013

Figure 2.1 Reference

8
2.2 PLANNING PROCESS
The analysis and monitoring common oils allowed users to keep track of
processes of wear and changes in the fundamental properties of its lubricating whose
changes have been warning signs to perform functional checks and perform preventive
operations to avoid failures which, by the nature of the service they provide, would have
disastrous consequences. The "Joint Oil Analysis Technical Support Centre"
(JOAPTSC)- programme has been very successful because it has standardized the
instrumentation and procedures and techniques of diagnosis for all laboratories that give
service to the armed forces, establishing trends wear limits to almost one hundred (100
%) teams operating in their sea and air, land units both combat logistics for establishing
and maintaining a standard program in order to use the analysis of oil as a tool support
of diagnosis for the maintenance of drives, increase .Its goal is flight safety, especially
the safety of flights, improving the provision of equipment to reduce maintenance costs
and extend its useful life

9
 SOAP FLOW CHART

Requirement from
Sqn/Unit/Department

Acknowledge by Head of Aerodynamic Div. or Head Department

Receive of Sample
Sample Registration

Within PUSPEKA NO
YES
Capability

STRIDE

Analyze Sample
Laboratory Work
Data Storage
Result Analysis
Preparing of Engineering
Report

Review by Head
of EFD

Filing & Distributing of

Engineering Report to
Respective Div. and Sqn.

END

Table 2.1: Planning Process Flow Chart

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2.3 OIL SAMPLING PROCESS

The lubrication is essential to the work of a engine, your control has limited the oil level
supervision and their possible visual oil changes and your filters in the programs of
preventive maintenance.

Figure 2.2: Oil Sampling Process

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2.4 MATERIAL PREPARATION

Initial setup is required in preparing for analyzed oil sampling in the

laboratory. The following are the initial setup requirement:

No. Description Picture

1. Rags

2. Tissues

3. Electrode Sharpener

4. Base oil 0ppm

Base oil 100ppm

Table 2.2: MOA and Accessories

12
 Figure 2.2: Key in data and report

2.5 PREPARATION OF OIL ANALSISS

The Spectrometric Oil Analysis Program (SOAP) is a method designed

to provide a better engine/gear box follow-up and it gives early warning of
engine/gear box deterioration.

2.6 Purpose of S.O.A.P method

To enable an analysis of the oil spectrum, in order to reveal the possible

presence of Microscopic particles produced by an operational anomaly in the
engine lubrication system.

Remark:

A lubrication system can also contain larger particles, visible to the naked eye,

Which are trapped in the filter or on magnetic plugs. These particles usually
imply a serious anomaly, and are not always accompanied by microscopic
Particles detected by S.O.A.P.

13
 2.7 Oil Sampling Procedure

30 Sampling

Wait approximately 30 minutes (After engine shut down) following a flight or

ground run, before siphoning off samples a samples (30 cm³ approx.) from the filler
orifice, or the sample can be collected from the magnetic plug on the main system.

B. Method

Equipment required

• Oil sampling device.

• Standard sampling flask.

• Ultra sonic (for cleaning purpose).

Always sample oil from a machine

30 minu2.2tes. w

Figure 2.3 Top Sampling Tool

14
Figure 2.4 Sample Tube Straightener

Figures 2.5 Bottom Sampling Tools

15
Procedure

• Rinse the sampling material with lead free petrol. Dry under moisture proof air
and rinse twice, using clean engine oil.

• Check the flask is glass and can be thoroughly internally cleaned.

• That its capacity is ≥ 30 cu.cm.

• That it closes tight with respect to liquids and vapor.

• Label the flask with following information:

- Registering number of the sample.

- Official part number and specification of the oil.
- Sampling date.
- Engine/gear box type.
- Time since New (TSN).
- Time since Overhaul (TSO).
- Time since Oil Change (TSOC).
- Reason for sampling.

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2.8 OPERATIONAL CHECK EXECUTION

In all mechanical system there is contact metal-metal between metal surfaces in

motion, especially in times of start and end of movement (boot and stop) generating
powders of different sizes from very small metallic contact product in the above stages
(soft adhesive wear), corrosion processes / rust by prolonged exposure to ambient (wear
corrosion), and even large, action in such particles into circulation (abrasive wear,
fatigue, among others) string result.
Therefore all the necessary information will be in circulation lube oil and may
determine through analyses of oils to help diagnose and predict failures that can
decrease the useful life of the motor itself to be a new tool in any program maintenance
to be deploy especially when reliability and safety of operation is more important than
in aviation.

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2.9 EVALUATEAND ANALISYS

According to, predictive maintenance is to study the temporal evolution of

certain parameters and associate them with the evolution of failures, so determine
period of time, this failure will take an important relevance and allow plan all
interventions with long enough, so that failure don't have serious consequences. Used
oil analysis is a general term to describe scientific evidence and assessments on oils in
order to determine whether they can be kept in operation must be removed, as well as
provide wear generated by the friction of metal surfaces in relative motion evaluated
teams status information. It attempts to determine whether the oil may be retained or
must be changed. A wealth of evidence used to evaluate lubricants. As the specified
evidence, should cover three areas:
Status of the equipment. (Elements)
Status of the lubricant. (Physical properties)
Generally, is necessary to carry out the tests in all three occasionally some test work in
two or more areas, this is used to make us the evidence of any abnormal condition.
Additionally, the manual procedures JOAP (Oil Analysis Program Joint) of the air of
United States force, 2007

18
 Unit Date Date TSN TSO TSOC A/C A/Frame Elements Remarks
Taken Tested Hours Fe Ag Al Cr Cu Mg B Mn Mo Na Ni Pb Si Sn Ti V Zn W

20 SKN 19.12.08 22.12.08 - - - M30-12 15200 4 0 0 0 1 4 1 0 3 0 0 0 2 20 1 1 1 - Normal Range

5.01.09 08.01.09 M30-12 15250 16 0 0 0 2 23 0 0 3 2 1 0 4 18 1 1 46 - Normal Range

13.04.09 16.04.09 M30-12 15300 12 0 0 0 1 13 0 0 2 0 1 0 3 12 1 1 20 - Normal Range

19.06.09 22.06.09 M30-12 15350 10 0 0 0 1 11 0 0 1 0 0 0 2 10 1 1 14 - Normal Range

10.08.09 13.08.09 M30-12 15400 8 0 0 0 2 9 0 0 3 0 0 0 3 8 1 1 11 - Normal Range

Table 2.3 ANALYSIS RESULT

19
 2.9.1 GANTT CHART ON INSPECTION PLANNING

50 HOURS  Routine

100 HOURS  Routine

150 HOURS  Routine

 SOR
ADDITIONAL
 BOI
DIAGNOSTICS  Accident

TABLE 2.4: Normal Monitoring

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 Resample
Trending every 10 hours
Recommendation :
1. Flushing 2. Close monitoring

50 HOURS

Resample
Trending every 10 hours
Recommendation :
1. Flushing 2. Close monitoring
100 HOURS

Resample
Trending every 10 hours
Recommendation :
1. Flushing 2. Close monitoring
150 HOURS

Strike
ADDITIONAL
Chemical Lab
DIAGNOSTICS

TABLE 2.5: Close Monitoring

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 CHAPTER 3

FINDINGS AND ASSESSMENT

3.1 IDENTIFICATION

The methodology used in the aircraft in particular industry can understand as

sampling in accordance with a protocol based initially on hours flown by the engine
and for them, carry out an analysis laboratory to assess its contents in metals, as well
as viscosity and other microbial factors. This technique and its associated criteria
depend on for their precise interpretation of experience certain conditions of
frequencies and the rest of factors that may involve some kind of distortion in the
normal evolution of the oil control.

3.2 RESULT AND ANALYSIS

This technique and its associated criteria depend on for their precise
interpretation of experience certain conditions of frequencies and the rest of factors
that may involve some kind of distortion in the normal evolution of the oil control.
The purpose of machine condition monitoring is to determine the present health of
machineries. Capturing the abnormal symptoms of machineries from vibration
signaturesinvolves the use of signal processing algorithms on measured vibrations.
The objective of this
Maintenance is decrease of the costs operation, keep inevitable level of the reliability,
safety and discretion on living environment so that standing time of maintenance of
the operation facilities has been reduced or stand on.

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 CHAPTER 4

DISCUSSION, RECOMMENDATIONS AND CONCLUSIONS

4.1 DISCUSSION
The successful and smoothness of this operational check is very much depend
on its planning, group discussion and the teamwork of the subordinates. The safety
aspects are paramount factor to this check as it may inflict damages to the aircraft,
injury or even loss of life to personnel..Operation and/or defective maintenance time.
The American society for testing and materials (ASTM) establishes standards for
assessing such properties in new oils and oils including methods standardized for
laboratories engaged in these analyses. Lubricants manufacturers set the maximum and
minimum that can reach these properties to keep their lubrication properties. Some
contributions have been considered in this project, as regards the monitoring of the
State or degree of internal wear engine, who considers preventive maintenance, based
on the rule of oil analysis is a tool to maximize the life and the availability of
computers, oil-based application that helps both to prevent and reduce or eliminate
costly failures such as reducing unnecessary services unavailability and the
maintenance.
Keywords— Oils contaminants, wearing models, artificial intelligence techniques

4.2 RECOMMENDATIONS

To develop a formulation that allows estimating, in function of time, the mass

production of metals in the engine it will be adopted an incremental formulation,
evaluating the control values in the points of the engine’s oil change. This
approximation has the assumed weakness that it doesn’t tolerate absences in data of
intermediate and not controlled oil changes, and also requires knowing the oil
contribution during each period, to maintain the levels, as an indication of the velocity
of the pass of oil to the engine

23
4.3 CONCLUSIONS
In this work, it is justified the convenience of applying techniques for
monitoring the contaminants in the oil of aircraft’s engines, so to evaluate its potential
contribution to predictive maintenance techniques. It is also identified the difficulty of
the analysis with each sample, because of the variability of each airplane model and
each equipment within a model, as well as the different frequency of the sampling. For
this reason, it has been formulated a constructive incremental model of production of
metals dragged to the lubrication system, that allows to take into account the different
age of the oil. From this formulation, there will be applied data mining techniques to
estimate the coefficients through regressors and to adjust the estimation of the metals
production along the functioning periods, as key elements to construct a law for the
evolution of contaminants
From the results described in this paper, it can be summarized; the vibration
levels throughout the cabin and cockpit have been achieved. It can be concluded that
this operational check is successful; the maintenance personnel have the sufficient
knowledge and resources to perform the task. On completion, documentation to record
the results, software development, references and precision equipment have been
submitted, reviewed by PUSPEKA RMAF.

24
 REFERENCES

1. C130H Technical Manual

2. Servicing Maintenance Progress 515C Card
3. NAVAIR 17-15-50.3 Pg A-35
4. Si and Sti from Manufacturer
5. “Publikasi Udara 2202 Arahan Kejuruteraan Pesawat Terbang” Independent
Checking, Royal Malaysian Air Force, 2006. Sect.1, Leaflet 4
6. “Publikasi Udara 2202 Arahan Kejuruteraan Pesawat Terbang” Cleanliness
of Servicing Areas, Royal Malaysian Air Force, 2006. Sect.5, Leaflet 1
7. “Publikasi Udara 2302 Arahan Kejuruteraan Pesawat Terbang” Loose Article
Inspection, Royal Malaysian Air Force, 2006. Sect.3, Leaflet

25