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High-Quality Aircraft Fuel Cells Repairs

May 14, 2012 in Aircraft Fuel Cells, Fuel Tank Inspection by admin | No comments

Overview

In the previous post, we shared with you the importance of scheduled inspection and maintenance to maintain flightworthiness. We also shared few tips on understanding the structure of aircraft fuel cells. Once your aircraft has gone through inspection, and has been identified for repairs, you can make use of these tips to perform the next step, repairs. It is critical for you to be aware of FAA approved methods for Repairs and to comply with manufacturer’s guidelines.

Aircraft Fuel Cells Repair

After a thorough inspection, aircraft fuel cells repairs can be initiated. The Federal Aviation Association (FAA) has approved some methods for aircraft fuel cells repair. These are:

  • Heat Cured Factory Repairs
  • Air Cured Field Repairs
  • Coatings – only some are approved.

Repairs must be made in accordance with the manufacturer’s instructions, and ideally by a seasoned repair technician. Repairs can be made in a variety of methods, but in particular, after a welding repair there are important steps that must be taken.

Removal of Flux after Welding

If flux is not completely removed, corrosion can occur. Following these steps will ensure that all flux is removed after the aircraft fuel cell repair is complete:

  1. Wash the inside and outside of the tank with plenty of hot water. Drain thoroughly.
  2. Immerse the tank in either 5 percent nitric or 5 percent sulfuric acid solution. NOTE: If the tank cannot be immersed, then fill it with either solution and wash the outside with the same.
  3. Leave the acid solution to remain in contact with the weld for approximately one hour. Rinse thoroughly with clean water.
  4. Apply acidified 5 percent silver nitrate solution to a small amount of the rinse water used in the prior step. If a heavy white precipitate forms, the cleaning must be repeated.

Regardless of the type of repair performed, a complete aircraft fuel cells inspection is the first step to ensuring thoroughness and completeness of repairs and maintenance procedures. Each repair should be executed using steps outlined by the manufacturer. To keep the aircraft flight ready and in good shape, perform regular inspections and maintenance. Aircraft fuel cells are no exception and a critical component of safety procedures.

For more information on Aircraft Fuel Cells Inspection & Repairs visit our Website.

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High-Quality Aircraft Fuel Cells Repair Starts With a Solid Inspection

April 16, 2012 in Aircraft Fuel Cells, Jet Fuel Systems by admin | No comments

Overview

Aircraft fuel cells require continual maintenance and often repair to maintain flightworthiness. Aircraft fuel is typically stored in three ways:

  • Metal tanks
  • Wet wing or integral tanks
  • Bladders or Fuel Cells

Aircraft fuel cells are very common and should be inspected regularly to keep them in good working condition. To understand more about appropriate maintenance and repair, it is prudent to first understand how fuel cells are made.

Aircraft fuel cells are manufactured by combining two or more layers of material that bonds two liners – inner and outer. It is important that the inner layers are non-porous and resistant to fuel vapors. Outer layers protect the cell from the elements, including heat, ozone and humidity. If manufactured and maintained correctly, aircraft fuel cells can last as long as 20 years.

Start With an Aircraft Fuel Cells Inspection

Performing a thorough inspection is always the first step of any good maintenance process. By inspecting the aircraft fuel cells for general condition, security of attachment and evidence of leaks, the technician knows where to begin. In addition, a thorough examination of fuel tanks or fuel cell vent lines, fuel lines and sump drain attachment fittings is required.

After the baseline review, a more detailed inspection is required in order to determine the correct aircraft fuel cells repair or maintenance.

First, de-fueled tanks should be purged of any explosive fuel/air mixtures. Use the manufacturer’s service instructions to ensure appropriate procedures.  Once complete, the following can be used as a guide to complete the aircraft fuel cells inspection:

  1. Integral Tanks – inspect the interior and seams for any sealant deterioration or corrosion, paying particular attention to the sump area. Check for leaks around skin joints, rivets, screws and bolts. Leaks are categorized as follows:
    1. Slow Seep – very slow fuel seepage in a small area that does not reappear in a short time frame.
    2. Seep – leak that appears in less than an hour after it was wiped dry.
    3. Heavy Seep – fuel leak that reappears immediately after it was wiped dry.
    4. Internal Metal Tanks – check the exterior and interior for corrosion and chafing. Also look for any dents or other anomalies. Sump areas are often an issue, so pay particular attention to these areas, particularly in cases where the sumps are made of cast material.
    5. Flexible Aircraft Fuel Cells – often referred to as bladders, these fuel cells should be inspected for cracking and other signs of deterioration. Bladders should not be allowed to dry out. Additionally, an inspection of the fuel tank caps for appropriate size and type should be performed, as well as determining if the “O” rings are in good condition.

For more information on Aircraft Fuel Cells Inspection visit our Website.

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Aircraft Pre-Purchase Inspection

March 13, 2012 in Pre Purchase Inspection by admin | No comments

Aircraft Pre-Purchase Inspection Process

Once you start to perform the physical inspection, look for signs of accidents or incidents that may not be reflected accurately in the records. Also, make sure the maintenance facility aircraft pre purchase inspection encompasses all areas, starting with critical inspection points first. These include checking:

  • Engine mounts and major structural attachment areas for damage and corrosion
  • Wing attachments, vertical pylon and horizontal stabilizer areas with a 10-power glass for crack indications
  • Floor panels and lavatory areas for corrosion
  • Engines and APU for leaks and drips with a borescope

Next up is a visual inspection. During this phase, look for patches and panel repairs, examine exterior paint for shortcuts, and extend all control surfaces to look at the condition of brackets and drain holes. Check windows for scratches and distortion. Finally ensure all the 337s from your paperwork review match up and review the associated workmanship.

A robust aircraft pre purchase inspection checklist will include a thorough evaluation of the following areas:

  • Airframe
  • Propeller & Engine
  • Engine Start
  • Engine Runup
  • Taxi Test
  • Flight Test

Having a detailed aircraft pre purchase inspection will uncover any corrosion, poor maintenance, and structural issues that you want to know before completing the purchase. Once you have determined that the aircraft maintenance logs are in order and are satisfied that the aircraft passes the inspection, you will have the peace of mind to continue the purchase process.

You can find more information on Pre Purchase Inspection of your aircraft on our Website.

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Buying A New Aircraft? Pre Purchase Inspection is a Must

February 14, 2012 in Pre Purchase Inspection by admin | No comments

Overview

The idea of getting a new plane is exciting. Once you have an idea of the aircraft you want to purchase, then the real work begins. Many people will skip performing a full aircraft pre purchase inspection, particularly if a scheduled inspection and maintenance was recently performed. However, experience has taught us that having a thorough pre purchase inspection will ensure that you have an airworthy aircraft, rather than one that ends up costing you more money.

Pre Purchase Inspection

The cost of an aircraft pre purchase inspection is covered by the buyer. Therefore, selecting an experienced company to perform the inspection is very important, not only to ensure airworthiness and safety of the aircraft, but to also ensure you receive the greatest value. Interview maintenance providers with the following in mind:

  • Do they have an outstanding reputation?
  • Do they have extensive knowledge on the make and model aircraft you are considering?
  • Is the mechanic performing the actual inspection an expert on the aircraft?

 

Once you have chosen the maintenance facility, there are additional steps you want to take to ensure you are appropriately covered in this process. First, make sure there is no bias either toward or against the aircraft you want to purchase. Second, get the entire scope of the inspection in writing so you know up front exactly what services are being delivered.

Before you start the aircraft inspection, make sure you perform a thorough evaluation of the records, including aircraft maintenance logs. Additionally, ensure accurate records showing compliance with manufacturer’s Service Bulletins are available and up-to-date. Many are tied to the aircraft’s scheduled inspection program and may affect how you maintain the aircraft going forward.

All STCs, 337s and major repairs require review for completeness and to ensure incorporation of Instructions for Continued Airworthiness. While many business jets are on a manufacturer-approved maintenance program, it is still worth the time to verify that the aircraft is on the correct program for the serial number and modification status.

Conclusion

Remember that any errors made by previous owners will become your problem after the purchase, including the assessment of fines or even loss of your license. Therefore, ensuring a thorough and professional aircraft pre purchase inspection is performed is critical.

You can find more information on Pre Purchase Inspection of your aircraft on our Website.

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When to Comply With Manufacturer SBs?

December 21, 2011 in ADs & SBs by admin | No comments

In our last post, we shared with you how to determine if the SBs you received are mandatory or not and also how to evaluate and prioritize them when they are mandatory. Next step is to take action to comply with these SBs.

In the United States, the only organization with jurisdiction over aviation matters is the Federal Aviation Administration (FAA). The FAA has gathered all policies regarding legalities in aviation within Title 14 of the Code of Federal Regulations, Parts 1 through 183. This makes up the Federal Aviation Regulations (FARs) which outline the owner’s responsibility concerning aircraft maintenance, safety and inspection among other things.

The FAA mandates rules on operators and determines if a manufacturers’ service bulletin is required to correct airworthiness issues. These mandates are adopted in either an Airworthiness Directive (AD) or an amendment to the operating rules.

Depending upon which Part you operate under determines whether or not manufacturers’ service bulletins are actually mandatory. For example, Part 135 Commuter Air Carrier and On-demand (commercial operator) requires compliance with everything in that Part, including additional aircraft maintenance requirements and approved Operation Specifications. Under these Op Specs, SBs can become mandatory.

Whether you are a commercial or private operator, the reality is that manufacturers’ service bulletins are sent to you to address potential safety issues. Deciding whether or not to actually comply is a matter of common sense, but best practices should apply. Speak with a knowledgeable aircraft maintenance provider to understand the requirements as well as the costs and benefits associated with the compliance. Making an informed decision will ensure your aircraft is safe, you are protected, and have effectively complied with all appropriate manufacturers’ service bulletins.

For more information on SBs and how to be in compliance with these SBs with Scheduled Inspection and Maintenance, visit Global Aircraft Service web site.

 

Not all Manufacturer SBs are Mandatory

December 14, 2011 in ADs & SBs by admin | No comments

Evaluate SB with Aircraft Maintenance Provider

If not all are mandatory, then why should you comply? Obviously the issue of safety is the primary reason. Determining whether or not a service bulletin does, in fact, address the issue of safety is a different concern. Many manufacturers will mark a service bulletin as mandatory whether it truly is or not. Most likely this is to provide legal coverage for the manufacturer.  The only way to know for certain if a service bulletin is critical is to thoroughly discuss the issue with a qualified aircraft maintenance provider. You can then determine the critical nature of the manufacturer service bulletin as it applies to your aircraft safety concerns.

Prioritize the Issue

If the aircraft maintenance provider determines that the SB is not mandatory, then you as the owner must make a decision as to the priority of the issue. There are several factors to consider, including cost. One suggestion is to outline the benefit obtained by compliance with the service bulletin versus the cost of labor and parts to make the necessary adjustment. Another consideration is liability. If complying with the manufacturers’ service bulletin will limit your liability exposure to third-parties, then it may be worth the cost associated with compliance.

For more information on SBs and how to keep your aircraft in great condition with Scheduled Inspection and Maintenance, visit Global Aircraft Service web site.

 

 

Aircraft Manufacturer Service Bulletin

December 5, 2011 in ADs & SBs by admin | No comments

Overview

Aircraft maintenance is critical to the safety of your passengers and crew. Part of that maintenance is complying with manufacturers’ service bulletins. The challenge is that many service bulletins are marked mandatory when they may not be. Furthermore, there are some key factors to consider before making the final decision to actually comply with the service bulletin.

What is a Manufacturer Service Bulletin?

A service bulletin (SB) contains recommendations from manufacturers that can result from various factors, including an improvement developed by the manufacturer, a product defect or an error in published documentation. These service bulletins are issued because the manufacturer believes that as the aircraft owner, you should comply with the recommendations in the SB as they often reflect a safety issue. It is important to recognize that these bulletins are not always sent to aircraft maintenance providers, so it is up to the owner to ensure compliance.

Service bulletins may be called various names, including:

  • Mandatory service bulletin
  • Technical service bulletin
  • Service letter
  • Service instructions

The manufacturer issues the service bulletins to recommend specific action, depending upon the nature of the bulletin subject. For example, SBs can recommend a type of aircraft inspection, replacing parts, performing specific maintenance or limiting operations under certain conditions.

For more information on SBs and how to keep your aircraft in great condition with Scheduled Inspection and Maintenance, visit Global Aircraft Service web site.

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Aircraft Mobile Inspections – Curb Side Service Provides Convenience

October 17, 2011 in Aircraft Mobile Inspection by admin | No comments

Overview

Aircraft requires all types of maintenance, repair and inspections. What if your aircraft requires these services during the leg of a trip? Or you simply prefer to not incur the expense of moving your aircraft to a location for inspection? Now it is possible to have curb side service for your aircraft.

Mobile inspections, repairs, and maintenance are a popular service presently provided by many organizations. Choosing to have a mobile team come to you can save you time and money. These highly-trained professionals are equipped with tools and equipment to perform almost any task. Plus, they typically have years of experience and are well-versed in customer service.

The mobile teams often have access to fleets of trucks or inexpensive air travel and can be at your location within a matter of hours. They provide a multitude of services including:

  • Inspections
  • Painting
  • Detailing
  • Repairs

Mobile Aircraft Service Benefits

In addition to the convenience of having a professional aircraft repair team come to you, there are many benefits to choosing mobile services. For example, the downtime can be minimized significantly. Often the mobile team can resolve an issue more quickly than you or your team. They have access to appropriate parts and can get the tools and highly-trained labor to you in a short amount of time. The repairs will be handled correctly and you will be back in the air quickly.

Cost is another benefit to using mobile service teams. You do not incur the cost of moving your aircraft to a full-service facility nor do you have to pay someone to travel with the plan and watch over it during the maintenance. However, you will pay more for the convenience of a concierge-style repair and maintenance performed by a mobile services team.

How to Choose?

When deciding the best route for your maintenance, you might want to consider several factors. First, consider the type of job you have. Is it one that lends itself to the strengths of the mobile services team? How much potential downtime will you have? Do you feel confident that a mobile team can complete the job on site?

Second, research the company that will provide the mobile team. Check aircraft ratings and thoroughly investigate the list of services. It is also a good idea to research the level of investment the company has made in tools and trucks. Finally, ask questions about how they choose the mobile team. The team should be comprised of the most experienced professionals who also have excellent customer service skills.

Finally, be prepared to handle unforeseen complications. If the mobile services team uncovers a more complicated issue, then you are most likely in for more downtime. Remember that these teams come prepared for the issues at hand, and may not have everything required to immediately fix an additional issue, such as a cracked window.

Aircraft mobile inspections and repair are certainly a trend that will continue to grow. The ability to provide curb side service ensures big benefits for both the mobile providers and the aircraft owners. The good news is now aircraft owners have a choice.

If you have any questions regarding Mobile Services for your aircraft, out technicians at Global Aircraft Services, Inc. are standing by to assist you.

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Aircraft Corrosion Repair and Treatment

October 3, 2011 in Aircraft Corrosion Control by admin | No comments

Overview

In my previous post, I shared with you few important tips on how early detection of Aircraft Corrosion can help. Also, how being proactive in Aircraft’s scheduled maintenance and inspection is critical to the health of your aircraft. Now, once we have through the inspection & detected corrosion, next step is repair and treatment of this problem.

Complete corrosion treatment involves cleaning and stripping the area, removing as much of the corrosion as practical, neutralizing any residual materials in pits and crevices, restoring protective surface films and applying temporary or permanent coatings or paint finishes. There are various blasting techniques that remove corrosion while leaving as much metal intact as possible, including:

  • Vapor
  • Soft-grit
  • Dry vacuum
  • Dry honing (the only approved method of removing corrosion on assembled aircraft)

If the corrosion is severe, then an abrasive wheel can be used. This device is meant to be used on thick metal and requires eye protection to be used at all times. All aircraft corrosion repairs must be made in accordance with the appropriate manuals while using proper measures to ensure the safety of the person making the repairs.

Aircraft Corrosion Control

While many improvements have been made to the materials and coatings used to protect aircraft from corrosion, developing a solid aircraft corrosion treatment and control program is an important part of every maintenance plan. Detailed daily inspections are needed, and all preventative maintenance programs should include:

  • Thorough rinsing and cleaning to remove salt and other corrosive agents. Pay special attention to exposed areas such as landing gear.
  • Periodic lubrication to seal the metal against moisture.
  • Immediate treatment of corrosion and touchup of damaged paint areas.
  • Keep drain holes free of blockage.
  • Drain fuel cell sumps daily.
  • Wipe down exposed critical areas every day.
  • Seal aircraft against water for protection during foul weather,
  • Proper ventilation of aircraft to prevent moisture from gathering.
  • Use protective covers on parked aircraft, particularly during inclement weather.

Aircraft corrosion repair can be very costly, particularly if the corrosion goes unnoticed for a period of time. Developing an aircraft corrosion control program that includes appropriate inspections, treatments and timely repairs will save time, money and ensure the safety of your aircraft while in flight.

 

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Aircraft Corrosion Inspection

September 6, 2011 in Aircraft Corrosion Control by admin | No comments

Overview

Most aircraft components are made of metal, making them susceptible to corrosion. From the time an aircraft is exposed to the elements, particularly damp, salty marine environments, corrosion becomes a concern. Even with the advent of better materials, staying on top of aircraft corrosion inspections and performing immediate repair and treatment of corroded areas is extremely important to ensure your aircraft is airworthy.

Corrosion is the deterioration of metal by either chemical or electrochemical attack, and can take place on either internal or external surfaces. Corrosion typically changes the surface of your aircraft, weakening the interior or loosening or damaging adjacent components. There are many factors that affect corrosion, including climate and foreign material, such as soil, oil, great, salt water, spilled battery acids, caustic cleaning solutions, welding and brazing flux residues. That is why continual inspections, prevention treatments and repairs are necessary parts of a good aircraft corrosion control program.

Aircraft Corrosion Inspection

There are two general classifications of corrosion – direct chemical attack and electrochemical attack. In both types, the metal is converted into a metallic compound such as an oxide, hydroxide or sulfate. Forms of corrosion include:

  • Surface
  • Dissimilar Metal
  • Intergranular
  • Stress
  • Fretting

To perform a thorough inspection, it is important to know what areas are most prone to corrosion. These include:

  • Exhaust Trail Areas
  • Battery Compartments and Battery Vent Openings
  • Bilge Areas
  • Wheel Well and Landing Gear
  • Water Entrapment Areas
  • Engine Frontal Areas
  • Cooling Air Vents
  • Wing Flap and Spoiler Recesses
  • External Skin Areas

Inspections should be performed daily, particularly on those aircraft that are on or near water.

A detailed inspection will include the following steps:

  1. Thorough cleaning of the area being inspected.
  2. Perform a visual inspection with a magnifying glass.
  3. Remove paint from areas that are of concern.
  4. Perform a second visual inspection with a magnifying glass.
  5. Refer to the appropriate structural repair manual for damage limits. It is important to consider prior metal loss, including metal on each side of the damage, when assessing corrosion damage.

Upon completion of the aircraft corrosion inspection, any damage found must be evaluated. Typically the severity of corrosion damage is grouped as follows:

  • Light – scarred protective coating or light surface corrosion characterized by discoloration and pitting to a depth of approximately 1-mil maximum.
  • Moderate – similar to light except there are typically blisters of evidence or scaling and flaking. Pit depths may be as deep as 10 mils.
  • Severe – Often includes severe intergranular corrosion, blistering, scaling or flaking. Pit depths are deeper than 10 mils.
  • Repairable damage –Corrosion damage exceeds the limits of the MIM or SRM. The affected part may be used after repair.
  • Nonrepairable damage – damage exceeds established repair limits and must be replaced or require a special depot-level repair.

At Global Aircraft Service, Inc, our skilled technicians are at your service to answer any questions you may have regarding Aircraft Corrosion Causes & Prevention.

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