FAA-DER, RS-DER Repair Process Familiarization

Transcription

1 FAA-DER, RS-DER Repair Process Familiarization Los Angeles * Taipei * Singapore * Charleston Queensland * Dubai * New Delhi * Quito

2 Topics of Discussion: APECS History & Background FAA-DER Description FAA RS-DER Description Repair Specifications & Alterations Aircraft Modifications/Alterations/Repairs Supplemental Type Certification (STC) Parts Manufacturer Approval (PMA) The DER-Client Relationship & Summation

3 APECS Background & History Formed in Late 2007, APECS is an Engineering Consulting Firm that specializes in providing Support to Maintenance Repair Organizations (MRO s) which are involved in the Commercial and/or Military Aviation business. APECS provides Engineering (Including FAA-DER), Regulatory, Business and Sourcing Support as well as providing On-Site Training, Manual Development, Business Development and Sales & Marketing Support.

4 FAA-DER Description A DER, Designated Engineering Representative is an individual appointed by the FAA to act as their Technical Surrogate for the approval of the Technical Data used in Repairs, PMAs, STCs or other FAA-recognized functions. An FAA-DER holds an engineering degree or equivalent, possesses technical knowledge and experience, and meets the qualification requirements of FAA Order

5 FAA-DER Description -- Cont d A DER may approve TECHNICAL DATA in support of: Repair Specifications/Alterations Aircraft Modifications (Internal and External) including One-Time Mods/Alterations/Installations Supplemental Type Certificates (STC) **Parts Manufacturing Approval (PMA) * -- In Support of an FAA Form 337 Release ** -- Test & Computation Only, Otherwise a DER can only Recommend Approval

6 FAA-DER Description -- Cont d FAA-DERs can also: Consult on Client Repair and/or Modification Projects Create and Approve Aircraft Modification Data (STC s) Approve Alternate Replacement Parts (PMA s) Design and Approve Repair/Mod Approval Processes Having an FAA-DER Approval is the SAME THING as if the approval was granted directly by the FAA, and it should be noted that DER Approved Repairs/Modifications are NOT in the CMM and are generally not approved by the OEMs.

7 FAA-DER Description -- Cont d Benefits of DER Support include: The Creation of Direct Cost $avings Allowance for MRO Engineering Flexibility Generation of In-House Capabilities Providing the MRO with New Competitive Advantages

8 FAA RS-DER Description An RS-DER, Repair Specification DER is a new Delegation instituted by the FAA in 2010 by FAA Order E. DERs with this delegation are able to approve both Serial Number Specific as well as non serial number specific Major Repair Data and manage RS approvals. Repair specifications provide an alternative to the methods, techniques and/or practices contained in the current manufacturer s manuals, service bulletins, or instructions for continued airworthiness (ICA).

9 FAA RS-DER Description -- Cont d An RS-DER Approval is for the Repair Specification Process which describes: 1) What the specific repair accomplishes, 2) When the repair is applicable, 3) How the repair will be accomplished, 4) How the repair is substantiated, 5) How the repair will be inspected, 6) How the repair must be maintained, and 7) How the repair specification will be kept up to date.

10 FAA RS-DER Description -- Cont d An acceptable Repair Specification: 1. Results in a consistent, repeatable end state that shows compliance to applicable airworthiness standards. 2. Provides the technical data for use in approving the aircraft or product for return to service. 3. Is a procedure not listed in the current manufacturer s maintenance manual, ICA or FAA-approved portions of service documents. 4. Is intended to be used repeatedly. 5. Is authorized for use by the FAA for a specific, certificated maintenance entity.

11 FAA RS-DER Description -- Cont d Elements of a Repair Specification include: 1. RS-DER Cover/Title Page 2. RS-DER Checklist 3. Quality Control Component 4. Failure Mode Effect Analysis (FMEA) 5. Technical Substantiation Component 6. Instructions for Cont d Airworthiness (ICA)

12 FAA RS-DER Description -- Cont d RS-DER Cover/Title Page: Format in accordance with FAA Order Includes signatures of FAA RS-DER and an Authorized Representative of the Certificate Holder. This can be ANY individual tasked with ensuring the Repair Specification will be processed in accordance with all Regulatory conditions.

13 FAA RS-DER Description -- Cont d RS-DER Checklist: Developed in accordance with FAA Order Includes a comprehensive check of all the relevant metrics involved in the development and processing of an RS-DER approval package.

14 FAA RS-DER Description -- Cont d Quality Control Component: Developed in accordance with FAA Order Includes a statement that provides revision control capability. Includes a statement that provides inspection procedures. Includes a statement for configuration control.

15 FAA RS-DER Description -- Cont d Failure Mode Effects Analysis: Describes the DIRECT consequences of the failure of the Repair/Mod including: Effect of Repair/Mod on Weight and Balance Effect of Repair on Strength of Component Effect of Repair on Part Operation and Performance Effect of Repair on Overhaul Interval and limitations Compatibility with Other Repairs, Mating Parts and Materials Effect of Repair on Functional Failure Rate

16 FAA RS-DER Description -- Cont d Technical Substantiation Component: Provides a DIRECT relationship between the development of the Repair/Modification and the Factor of Safety for the process and end result. Shows CONCLUSIVE Technical proof that the Repair/Mod is viable and will not result in an adverse condition within the flight vehicle.

17 FAA RS-DER Description -- Cont d Instructions for Continued Airworthiness: Developed in accordance with FAA Order Provides a DIRECT link to the Manufacturer and/or Operator approved Technical Manuals and indicates how the Repair/Mod will affect the continued safe operation of the vehicle.

18 Repair Specifications/Alterations These are the Processes to Consider in Repair Specification/Alteration Development: What is behind the damage to the article? What are the Repair Processes available? Is the Repair Technically Viable? It is IMPORTANT to note that EVERY Part CAN BE Repaired, however it is the Responsibility of the Engineer to Determine if that part SHOULD BE Repaired. SAFETY IS NUMBER ONE

19 Repair Specifications/Alterations Things to Consider when looking at a Damaged Article: 1) What is the SYSTEMIC reason for the damage to the part? a) Is the wear/damage/failure mode always the same? b) Is there a Design flaw in the part that can be corrected? c) Does a mod to the NHA need to be considered? 2) What is the REPLACEMENT COST & USAGE of the part? 1) Do we have the internal capability to process the repair? 2) Do we have access to an acceptable Sub-contractor? 3) What is the CRITICALITY of the part?

20 Repair Specifications/Alterations Some Common Repair Processes: 1) Gas Tungsten Arc Welding (GTAW) i.a.w. AWS D17.1:2001 2) Electro-Plating: a) Chrome Plating i.a.w. Specification QQ-C-320 b) Nickel Plating i.a.w. Specification QQ-N-290 c) Cadmium Plating i.a.w. Specification QQ-P-416 d) Silver Plating i.a.w. Specification QQ-S-365 3) Metal Spray Application: a) Plasma Spray i.a.w. Specification AMS 2437 b) High Velocity Oxy-Fuel (HVOF) i.a.w. Specification AMS 2447 c) Cold Spray i.a.w. Specification MIL-STD ) Installation of an Insert

21 Repair Specifications/Alterations Examples of Damage to Common Articles Valve Body Damaged Area 1) Main Bore 2) Bearing Bores 3) Flange 4) Threaded Port Pertains to: Flow Body, Pneumatic Valves, Anti-Icing Valve, and any other similar articles. Repair 1) Plating or Metal Spray a. Chrome b. Nickel + Chrome c. HVOF Metal Spray 2) See Item 1 3) GTAW Weld or Flange Replacement 4) GTAW Weld or Cold Spray

22 Repair Specifications/Alterations Examples of Damage to Common Articles Shaft Damaged Area 1) Outside Diameter 2) Threads 3) Through Holes Pertains to shafts from: CSD/IDG, ACM, Air Turbine Starter, Valve, Actuator, or any other similar article. Repair 1) Plating or Metal Spray a. Chrome b. Nickel + Chrome c. HVOF Metal Spray or GTAW Weld or Cold Spray 2) See Item 1 3) See Item 1

23 Repair Specifications/Alterations Examples of Damage to Common Articles ANY Housing 1) Bores Damaged Area 2) Threaded Ports 3) Miscellaneous Damage Pertains to: CSD/IDG, ACM, Air Turbine Starter, Gear Box, Actuator, or any other similar article. Repair 1) Plating or Metal Spray a. Chrome b. Nickel + Chrome c. HVOF Metal Spray 2) GTAW Weld or Cold Spray 3) GTAW Weld or Cold Spray

24 Repair Specifications/Alterations Examples of Damage to Common Articles ANY Wheels 1) Bores 2) Vanes 3) Hub 4) Threads Damaged Area Pertains to: ACM, Cooling Turbine, Air Turbine Starter, or any other similar articles. Repair 1) Plating or Metal Spray a. Chrome b. Nickel + Chrome c. HVOF Metal Spray 2) GTAW Weld or Cold Spray 3) GTAW Weld, Cold Spray, or Insert Installation 4) GTAW Weld, Cold Spray, or Insert Installation

25 Repair Specifications/Alterations Examples of Damage to Structural Components (Incl Engine) Damaged Area 1) Skin 2) Honeycomb 3) Structural Members 4) Other Repairs 1) Addition of Doubler 2) Honeycomb Repair 3) GTAW Weld or Cold Spray 4) Other

26 Repair Specifications/Alterations Examples of Damage to Landing Gear Components Damage 1) Wear 2) Corrosion/Pitting 3) Other Repairs 1) Plating 2) GTAW Weld 3) Cold Spray 4) Other

27 Repair Specifications/Alterations A few words about Cold Spray. Cold Spray is the newest form of Powdered Metal Application. The advantages of Cold Spray versus Plasma Spray is that it adheres to the parent material at the molecular level through hypersonic impingement and the powder itself is primarily comprised of powdered metal instead of plastic adhesion materials. More importantly, the strength of Cold Spray is similar to the Parent Material since it utilizes parent material in the Cold Spray Process. Cold Spray application results in no Heat Affected Zone which makes it superior to welding when used as an alternative.

28 Repair Specifications/Alterations Examples of Excellent Cold Spray Candidate Articles: Damaged Area 1) Pilot Diameter 2) Pump Pads 3) Bore 4) Threaded Ports 5) Eroded/Corroded areas Pertains to: CSD/IDG, ACM, Air Turbine Starter, Gear Box, Landing Gear, Wheels, Actuator, or any other similar article.

29 Repair Specifications/Alterations GTAW Pre-Heat and Heat Treat/Stress Relief : (in Degrees Fahrenheit) Material Preheat Stress Relief (Fahrenheit) Material Preheat Stress Relief (Fahrenheit) 4130 Series Steel N/A hr 6061 Series Aluminum hrs 17-4PH Series Stainless N/A hr AZ31B Series Mag 375+/ hrs CRES 300 Series N/A hr 6AL-4V Series Titanium N/A 1015 for 2 hrs Inconel 718 Series Steel N/A hr

30 Repair Specifications/Alterations Technical Substantiation: Once a Repair Process has been decided, it is important to consider the Technical viability of the repair as you develop the repair process. This is the foundation for proving the repair will result in a SAFE and quality part. Details such as the weld filler rod, appropriate heat treats (pre and post) and post repair article strength characteristics can be determined through basic engineering practices such as the review of current welding standards and the calculation of the Factor of Safety (Fs) for the repaired part.

31 Repair Specifications/Alterations BARLOW S FORMULATION AND CALCULATIONS (Reference Title 14 CFR Part ) S t = Pr/t = Pd/2t, where: S t = Tangential Stress in psi. P = Internal Pressure ultimate Load (Max operating pressure from the CMM) r = Cylinder Bore Radius (inches) d = Cylinder Bore Diameter (inches) t = Min. Cylinder Bore Wall Thickness (in) F s = S y / S t, where: F s = Factor of Safety (>2.0, i.a.w. 14 CFR (d)) S y = Min Tensile Yield Strength of the material (ksi) S t = Maximum Tangential Stress (psi)

32 Repair Specifications/Alterations SAMPLE BARLOW S CALCULATION TABLE Table 1.4: 4340 Alloy For a 4-inch Diameter Vessel (Tensile Yield Strength of 4340 Alloy is 108ksi) in in in in in in in in in 5000 psi psi psi psi psi psi psi psi psi psi psi Factor of Safety (Minimum of 2.0 is Required per FAR (d)

33 Aircraft Modifications A DER may approve TECHNICAL DATA in support of both Internal and External Aircraft Modifications: *One-Time Modifications/Alterations/Installations Interior Modifications including Seating, IFE, etc. Exterior Modifications including Painting, Logos, etc. Modification/Product Improvements for Aircraft, Engines, APUs and Associated Components. Our Team of Dedicated and Experienced Engineers and Draftsmen can perform most all aspects of these mods.

34 Aircraft Modifications -- Cont d Aircraft Modifications (and some Repairs) can be Processed through either: Full Supplemental Type Certificate One-Time Supplemental Type Certificate An FAA Form 337 Release

35 Supplemental Type Certificates (STC) A Supplemental Type Certificate is (STC) is a type certificate (TC) issued when an applicant has received FAA approval to modify an aircraft from its original design. The STC, which incorporates by reference the related TC, approves not only the modification but also how that modification affects the original design. A DER may approve Technical Data associated with an STC Application and act as an agent to support that application through the FAA Approval Process.

36 Supplemental Type Certificates (STC) Our Team has a strong working relationship with the FAA, and can provide Cradle-to-Grave support of the STC Process including providing all necessary paperwork, setting up and performing necessary testing, and many other functions associated with the STC Process. Some projects we have supported include: Interior Modification of Malaysian Air Systems B Conversion of the Evergreen B747 tanker/fire-fighter Modification of the MD80 Fuel Tank Configuration Installation Approval of External Wing Tanks for a T-34A

37 One-Time STC APECS Aerospace Corporation A One-Time Supplemental Type Certificate (STC) may be issued for a particular aircraft, identified by make, model, and serial number. A One-Time STC cannot be amended and the holder is not eligible for production approval. A DER may approve Technical Data associated with an STC Application and act as an agent to support that application through the FAA Approval Process. The One-Time STC application process is an abbreviated version of that used for a Full STC Application.

38 One-Time STC s -- Cont d Our Team has a strong working relationship with the FAA, and can provide support for the One-Time STC Process including providing all necessary paperwork, setting up and performing necessary testing, and many other functions associated with the One-Time STC Process. Some projects we have supported include: Installation of a Light Array Display on a Bell 206 Helicopter Installation of a Modified Seat for a Cessna Caravan Installation of Aux Fuel Tanks on an AH1 Apache Helicopter used by the US Forest Service for Fire Detection.

39 FAA Form 337 Release An FAA Form 337 Release is also known as a Field Approval, and is a method by which FAA approves technical data used to accomplish a major repair or a major alteration on a single aircraft, provided the repair or alteration is not classified as a major change in type design. An FAA Aviation Safety Inspector s (ASI) or their designee will endorse Block 3 of FAA Form 337, Major Repair and Alteration, thus approving the data on that form.

40 FAA Form 337 Release Cont d DERs with the appropriate special authorization may develop data in support of a specific major alteration or repair for a Field Approval if, and only if, the DER Approved data is all that are needed to support the FAA Form 337. However, if the major alteration or repair requires data in addition to the DER-approved data, then an FAA Aviation Safety Inspector s (ASI) endorsement in Block 3 of an FAA Form 337, Major Repair and Alteration, is required on that form.

41 Parts Manufacturing Approval (PMA) Our Team has a strong working relationship with the FAA, and can provide Total Product Development Support through the PMA Process including providing all necessary paperwork, setting up and performing necessary testing, and many other functions associated with the PMA Process. Our DERs can also provide *limited approval for the PMA development. * -- Test & Computation Only, Otherwise a DER can only Recommend Approval

42 The DER/Client Relationship APECS Engineers and our Partners hold FAA-DER and RS-DER delegations in the following Technical Disciplines: Acoustical Engineering Engine Engineering Flammability Flight Test Electrical Systems Power-plant Engineering Propeller Engineering Software Engineering Structural Engineering System & Equipment Engineering

43 The DER/Client Relationship APECS Responsibilities. 1. Determine the Timeline for Project Completion 2. Develop/Analyze the Technical Plan and Data 3. Approve the Technical Data and/or Process 4. Follow-through with the FAA as required. Client Responsibilities. 1. Prioritize internal Projects based on Need and Cost. 2. Develop the Technical Plan and Data Needs 3. Discuss the Project with APECS Engineering 4. Provide APECS with Required Technical Data/Dwgs

44 Other Supported Functions of APECS Asia-Pacific Engineering Consulting Services, LLC also provides the following support activities for Commercial and Military Aircraft: Engineering; from basic to complex including repair development, consulting, CAD, etc. Regulatory; including FAA, EASA, CAAC and others. Business Development; including business plan development, market entry assessment and etc. Quality Assurance; including Global Regulatory, ISO9000 and AS9110 system development. Marketing; including providing market entry and the global support of our strategic partners. For further information please visit our web-site at.

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