Hercules Technical Issues

David Pinheiro

Frederico Lemos

Technical Support Engineer

Business Development

www.ogma.pt

OGMA Overview C-130/L-100 “Hercules” Authorized Service Center Authorized Stretch Center

- 20 km North of Lisbon - Runway - 3Km / 10.600fts - Covered Area - 139.000 Sq. mt. (Total of 1.497.000 Sq. ft. ) - 10 Maintenance Hangars (2 of them sized 400ft. x 200ft. x 50ft)

C-130 Capabilities Center Wing

• Support to C-130 Versions A to H

Upper rainbow fittings

• Extensive Experience: more than 30 years and 400 checks Lower rainbow fittings

• B, C & D Checks, Heavy Checks (SMP)

OUTBD

• HSC, PDM, Isochronal Inspections (USAF)

Outer Wing

• Complete WorkPackage Buildup and engineering Support • Field Teams • Major Structural Repairs

Specific Programs 

SFAR 88 Compliance (GFI /Tank Inspection)



Fatigue Evaluation (EBH) - SB 82-788 / 790

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Rainbow Fitting Replacement

Structural Repairs Sloping Longeron

Analisys of the damage

Replacement of the sloping longeron

Repair & replacement of the aircraft skin

Cargo Door Repair Hercules C-130 damage on service

Damage of the cargo door

Cargo door repair

Accessories, Components PowerPlant Components

Propeller

Engine and QEC

Modifications & Upgrades 〉 〉 〉 〉

Self-Protection Systems Glass Cockpits Avionics Upgrades GATM Requirements

〉 Fatigue and Damage Tolerance Analysis 〉 EMI/EMC analysis and test 〉 Aerodynamic Impact of external modifications

Enterprise Excellence Program OGMA Excelence Criteria – emphasys in Quality and flow: - Simplify Procedures; - Continuous Improvement; - Client Focus;  Develop well oriented minds and a tottaly commited organization;  Use visual communication and a simple approach to improve processes;  Measure and get feedback from to detect problems, present and validate solutions;  Listen to the customer, provide feedback, present improvement actions plans; | F-16 UPGRADE PROGRAM | PRODUCTION AND EFFICIENCY | CAPABILITIES | CONTACTS

C-130 INTEGRATED SUPPORT

Customer Satisfaction

AIRCRAFT AVAILABILITY QUICK FINAL ACCEPTANCE COMMUNICATION

Communication TRAINING

INTEGRATED SUPPORT

Logistical Support Reliability Management Engineering Support Fatigue Life Management Tech Pubs Support Configuration Management

CUSTOMER / OGMA PARTNERSHIP

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

BLEED AIR SYSTEM CHECK - Bleed Valve Leakage • After placing the switch to “OFF” position the pressure decays to "0“ • A few seconds after, the pressure starts to increase slowly and it stabilizes at 10 PSI (Manifold).

BLEED AIR SYSTEM CHECK - Bleed Valve Leakage

• OGMA removed the bleed valves P/N 3213722-5-1 and tested them outside the aircraft • Even on OFF (closed) position some air passes through the valve. •This leak was verified in all new/overhauled valves.

BLEED AIR SYSTEM CHECK - Bleed Valve Leakage

- There is a residual Pressure Check for new aircraft but LM Aero has not presented this "Residual Pressure Check" for in-service aircraft.

A "Residual Pressure Check“ table could be developed and included on TM 382C-2-3 manual for in-service aircraft.

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

“MELTED” FITTINGS ON STATIC PRESSURE SYSTEM

During test flight, flight crew reported a +6 knots difference between Pilot and Co-Pilot Air Speed Indicator

“MELTED” FITTINGS ON STATIC PRESSURE SYSTEM

Troubleshooting result: - Two “melted” fittings of the static pressure system

“MELTED” FITTINGS ON STATIC PRESSURE SYSTEM • Two plausible causes for this damage: -Aircraft Electrical Surge -Lightning Strike

• Fittings were replaced and the reported problem solved. However, the real cause of the damage wasn’t fully determined! In similar discrepancies, this may be a common damage

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

FS 737 CHINE ANGLE REPAIR • During C check severe corrosion is usually found on FS 737 LH/RH Chine Angle, under paratroop door. • IAW Hercules SRM replace the chine angle or request engineering support; • OGMA is using an alternate solution (repair) upon approval of the customer (or airworthiness authority).

FS 737 CHINE ANGLE REPAIR

FS 737 CHINE ANGLE REPAIR Cost comparison (OGMA) between the two solutions No NRE for the repair – engineering approved repair • REPLACE Chine Angle

REPAIR Chine Angle

• Labour: Intensive

• Minimum Technician effort

• Parts costs: High

• Parts cost: 25% of the replace option

• Aircraft Down Time (2 Weeks) • Aircraft Down Time 2 Days

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

CARGO COMPARTMENT CHINE CAP REPAIR • During C check is corrosion usually found in cargo compartment chine caps (ring tie down bays) • IAW Hercules SRM typical repair is provided for damages at FS 517, 557, 617 and 717; • OGMA is using an alternate solution (repair) upon approval of the customer (or airworthiness authority) for all FS.

CARGO COMPARTMENT CHINE CAP REPAIR Cost comparison (OGMA) between the two solutions No NRE for the repair – engineering approved repair REPLACE Chine Cap

REPAIR Chine Angle (USAF)

• Labour: Intensive

• Minimum Technician effort

• Parts cost: High

• Parts cost: less than 20% of the replace option

• Aircraft Down Time (2 Weeks)

• Aircraft Down Time 2 Days

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

WING TO FUSELAGE DRAG ANGLE REPAIR

• During accomplishment of SB 82752, repair was found on the wing to fuselage drag angle assembly, P/N 3305083 • Repair straps were identified with P/N QAD3022407-1

WING TO FUSELAGE DRAG ANGLE REPAIR

• Following Lockheed instructions, OGMA removed and inspected both repair and drag angle

WING TO FUSELAGE DRAG ANGLE REPAIR • No damage found after the inspection was completed; this fact could not be confirmed until after the inspection was complete • Despite an exhaustive search, without knowing the QAR number LM Aero was unable to find this specific repair in their records; After the parts were disassembled and inspected the QAR number was found • OGMA reinstalled the repair per Lockheed instructions • Other A/C were found with similar repairs; not reported because weren’t accomplishing this SB

Be alert for similar situations!

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

GFI’S INSTALLATION/TECHNICAL ISSUES • Several differences between A/C configuration/GFI’s installation DWG’s were found • OGMA reported this discrepancies and worked in straight collaboration with Lockheed

Lockheed issued a helpful SK DWG to correct the discrepancies

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

TECHNICAL SURVEYS Purpose: • Assess the need for a field team •

Better prepare the work package

•

Prepare the bill of materials before A/C arrival for maintenance

•

Trim the commercial proposal to the actual status of the aircraft (avoid surprises to both customer and OGMA)

SMALLER T.A.T.

TECHNICAL SURVEYS Focus Areas: • Main structural items (corrosion and cracks) • Engines / QEC condition • Avionics and wiring condition and configuration • Aircraft logbook • Engines and aircraft historical records and documentation • Assess aircraft operational usage

C-130 Technical Issues 1. HERCULES TECHNICAL - Bleed Air System - “Melted” Fittings on Static Pressure System - Chine Angle Repair - Cargo compartment chine cap repair - Engine heat shield repair - Wing to Fuselage Drag Angle Repair - GFI’s Installation/Technical Issues 2. OGMA TECHNICAL SURVEYS 3. OGMA FIELD TEAM

TECHNICAL FIELD TEAMS Every time an aircraft is: • due to scheduled maintenance • down for a long period of time • down due to a specific incident

OGMA FIELD TEAMS WILL PROVIDE A QUICK RESPONSE TIME AND SUPPORT CUSTOMERS AT ANY LOCATION

FIELD TEAM • Airframe discrepancies correction • Avionics systems discrepancies correction • Engines discrepancies correction • Pre-flight run up’s • Test flight • Ferry flight to repair station

Questions?

David Pinheiro C-130 Technical Support Engineer [email protected] M: +351 21 9581000 Ext. 3225

Frederico Lemos Business Developing Manager [email protected] M: +351 21 9581000 Ext. 3955

Fernando Renda Sales Manager [email protected] M: +351 91 28 999 07

José Salvada Head of Marketing and Sales [email protected] M: +351 91 28 999 14