CH124 Sea King Fleet Update

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CH124 Sea King Fleet Update

• Keepin em Flying!!
• Major Richard Loewen
• Senior Design Engineer

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US Army Air Corps 1941 Recruiting Slogan
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Universal Pictures 28 November 1941
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CH124 Highlights

• General Fleet Information
• Fleet Service Life Status
• Attributes of Success
• Maintenance Program
• Aircraft Structural Integrity
• Sunset Years
• Challenges Capabilities
• Wrap-Up

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General Fleet Information
24 of 41 Available for Operations (4 x
non-active)
High Time Aircraft 16 658 Hrs Low Time Aircraft
13 081 Hrs Fleet Average 14 848 Hrs
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CH124A ASW - Dipping Sonar, Self Defense, ISR
CH124B Utility Troop Config (14 Pax)
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Main Operating Bases HQ
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CH124 Highlights

• General Fleet Information
• Fleet Service Life Status
• Attributes of Success
• Maintenance Program
• Aircraft Structural Integrity
• Sunset Years
• Challenges Capabilities
• Wrap-Up

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Fleet Service Life Status

• Entered service May 1963

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Fleet Service Life Status

• Entered service May 1963
• Oct 1992 ELE extended to Dec 2000
• Oct 1998 ELE extended to Dec 2005
• xxx 2005 ELE extended to Dec 2012
• Jul 2011 ELE extended to Dec 2015

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Fleet Service Life Status

• Summer 2013 50th Anniversary Celebrations

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Fleet Service Life Status

• Sept 2014 ELE Extension Request
• Align with CH148 Cyclone (S-92) Introduction
• CH124 operations out to August 2018
• Proposed Flying Rates

FY14/15 FY15/16 FY16/17 FY17/18 FY18/19
Flying Hours 7200 7200 5500 3700 500
Fleet Size 28 24 20 16 12 to 0
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CH124 Highlights

• General Fleet Information
• Fleet Service Life Status
• Attributes of Success
• Maintenance Program
• Aircraft Structural Integrity
• Sunset Years
• Challenges Capabilities
• Wrap-Up

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Attributes of Success
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Attributes of Success

• Maintenance Program
• Preventive
• Corrective
• Upgrades / Modifications
• Mechanical System
• Avionics/Electrical/Mission System

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Maintenance Program

• Preventive
• Depot Level Maint (Third Level Insp Repair -
  TLIR)
• Base Level Maint (Periodic Inspections PER)
• 600 hrs /- 50 hrs
• PER 1 3 Minor
• PER 2 4 Major
• Squadron Level Maint (Supplementary Insp SUPP)
• 25 hrs /- 2.5 hrs
• After Before Flight Checks
• Corrosion - 1 2 Alternate Every 7 Days
• Conditional Inspections Hard Ldg, Lightening
  Strike, etc

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Maintenance Program

• Corrective
• Structural Repair Manual (Standard Repairs)
• System Maint Manuals (Fault Diagnosis Repair)
• OEM or Contractor Developed Repairs
• Temp or Non-Standard Repairs
• Aircraft Battle Damage Repair

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Maintenance Program

• Upgrades / Modifications
• Mechanical System
• Avionics/Electrical/Mission System
• CD (Depot Level)
• Approx 225 CD mods to date
• CF (Field Level)
• Approx 600 CF mods to date

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Attributes of Success

• Maintenance Program
• Aircraft Structural Integrity

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Attributes of Success

• Aircraft Structural Integrity
• Technical Airworthiness Manual
• Since 2003 provides ASI related Rules Standards
• Replaced Tech Order based on MIL-STD-1530C ASI
• ASI Program Elements
• Statement of Operating Intent
• Baseline Usage Spectrum with Mission Profiles
• Structural Usage Monitoring (SUM)
• Structural Condition Monitoring (SCM)
• Aircraft Structural Integrity Mgmt Plan (ASIMP)

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Aircraft Structural Integrity Process
Inspection-generated data
SCM uses data from Scheduled maintenance, Repairs
SIs Service bulletins Full-scale tests Foreign
operators OEM
Baseline Usage (SOI)
Structural Condition Monitoring
Fleet Structural Maintenance Plan
Structural Analysis
Final product of ASI process, used to generate
maintenance program
Analytical Methods
Structural Usage Monitoring
Models, software, data
Includes usage data collection, transfer,
analysis and reporting
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Baseline Usage Spectrum

• CH124 BUS Analysis (Sikorsky 2005)
• BUS Development
• Operations Flight Witnessing
• Pilot Interviews
• Usage Data Analysis from CF335 Forms
• Dynamic Component Fatigue Usage Spectrum
• Adjusted fatigue lives
• 9 Mission Profiles
• Produced Composite Worst Case Usage Spectrum

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Baseline Usage Spectrum

• CH124 Mission Profiles
• A Reconnaissance/Surveillance (Recce)
• B Crew Operational Readiness (COREX)
• C Pilot Proficiency Flight (PPF)
• D Maintenance Test Flight (MTF)
• E Helicopter Delivery Service/Utility
  (HDS/Utility)
• F Anti-Submarine Warfare (ASW)
• G Search and Rescue (SAR)
• H Cross-Country/Pilot Proficiency Instrument
  Flight
• K Waterbird (Ceased Trg Fall 2013)

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COREX Mission Profile

• (a) Flight Initiation, RADAR Tracking /
  Surveillance
• (b) SAR Exercise
• (c) SONAR Dips
• (d) Return to Base
• (e) Yard Work (off-levels)
• (f) Yard Work (slung loads)
• (g) Flight conclusion

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Baseline Usage Spectrum
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Baseline Usage Spectrum
CH124 Composite Worst Case Spectrum (cont)
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Aircraft Structural Integrity Mgmt Plan

• CH124 Structural Usage Monitoring (SUM)
• Fatigue monitoring program
• Includes individual aircraft tracking
• Requires sufficient and relevant data to track
  usage
• Review process to compare actual to baseline
• Process to re-evaluate component lives
• Maintenance program review based on findings

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Aircraft Structural Integrity Mgmt Plan

• CH124 SUM Dataset

• Mission Type
• of main rotor starts and stops
• of landings
• of auto-rotations
• Slung Loads
• Fuel weight at take-off and at landing
• Flight duration
• Approx time spent above 103 Nr
• Approx of time spent
• Below 90 knots
• Between 90 and 120 knots
• Above 120 knots
• Approx time spent in In-ground Effect (IGE) and
  Out-of-Ground Effect (OGE) hover and
• Approx time running on ground in flight drive.

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Aircraft Structural Integrity Mgmt Plan

• CH124 Usage Spectrum Mission Weighting

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Aircraft Structural Integrity Mgmt Plan

• Comparison of Mission Usage to Baseline

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Aircraft Structural Integrity Mgmt Plan

• CH124 SUM - Exceedences from Baseline
• Limit or adjust usage patterns or mission profile
• AC 412 continue to limit usage of Mission A
  (Recce/Surv)
• AC 441 limit usage of Mission H (X-Country /
  PPIF)
• Autorotations / One Engine Inoperative /
  Waterbird
• Add or increase inspection requirements
• Reduce Interval for SSI12- Left/Fwd Sponson
  Mount to 600hrs

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Baseline Usage Spectrum

• CH124 Mission Profile - Damage Severity
• Most Damaging - Dynamic Components SSIs
• A Reconnaissance/Surveillance (Recce)
• C Pilot Proficiency Flight (PPF)
• G Search and Rescue (SAR)
• K Waterbird (Ceased Trg Fall 2013)
• Moderate Damage to Specific Components
• D Maintenance Test Flight (MTF)
• E Helicopter Delivery Service/Utility
  (HDS/Utility)
• F Anti-Submarine Warfare (ASW)
• H Cross-Country/Pilot Proficiency Instrument
  Flight
• Non-Damaging
• B Crew Operational Readiness (COREX)

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Aircraft Structural Integrity Mgmt Plan

• CH124 Structural Condition Monitoring (SCM)
• Program to monitor structural repairs and
  inspection records
• Long-term impact assessment of structural repairs
• Review of inspection records to determine trends
• Review of structural related in-service
  monitoring data
• Process to re-evaluate the maintenance program
• Adjust Preventive Maint Inspections
• (i.e. Corrosion Control)

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Aircraft Structural Integrity Mgmt Plan

• CH124 SCM Policy
• SCM Function in CH124 ASIP
• SCM Data Sources Tools
• Definition of Structurally Significant Items
  (SSIs)
• Damage Mapping
• Corrosion
• Fatigue
• Mechanical
• SCM Reporting
• Annually

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Aircraft Structural Integrity Mgmt Plan

• SCM Function in CH124 ASIP
• Monitor Structural Repairs Inspection Records
• Consider Primary Structure as a minimum
• Determine trends in frequency of damage by
  location
• Review service difficulty reports impacting ASI
  longterm
• Document identified trends provide
  recommendations
• Dynamic Components
• Currently outside SCM scope but coming soon

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Aircraft Structural Integrity Mgmt Plan

• SCM Data Sources Tools
• Primary Data Sources
• Historical TLIR PER4 Reports reviewed in
  FY11/12
• Up to four reports/aircraft were reviewed
• SCM Dataset
• Primary Structure not defined in Sikorsky
  documents
• CH124 SCM Policy classifies Primary Structural
  Elements

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Aircraft Structural Integrity Mgmt Plan

• CH124 SCM Definition of SSIs
• The part is a subset of aircraft primary
  structure
• Failure of the part could cause direct loss of
  the aircraft (Category I)
• Failure of the part could cause substantial
  damage to the aircraft (Category II)
• The part has been shown, by experience or
  analysis, to be prone to damage and
• Part geometry and/or load carrying capability and
  material did not change with a structural
  modification yet show a history of chronic,
  severe damage.

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Aircraft Structural Integrity Mgmt Plan

• 37 x Structurally Significant Items
• SSI List is available to review if interested
• 64 x Structurally Significant Modifications
• modifications or repairs on the aircraft that
  have a significant impact on the life and
  airframe structural integrity

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Aircraft Structural Integrity Mgmt Plan

• CH124 SCM Damage Mapping
• Corrosion
• Fatigue
• Mechanical

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CH124 Highlights

• General Fleet Information
• Fleet Service Life Status
• Attributes of Success
• Maintenance Program
• Aircraft Structural Integrity
• Sunset Years
• Challenges Capabilities
• Wrap-Up

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Sunset Years
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Sunset Years

• Challenges

• 51 Year old Aircraft
• Obsolescence
• Limited Parts Availability
• Long Lead Times
• Increased Costs

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Sunset Years

• ELE Initiatives
• Parts Procurement Project
• FY14/15 FY15/16
• Aircraft Sampling Inspection
• Post TLIR Areas of Interest
• Obsolescence Mod Projects
• Minor system updates

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Sunset Years

• Capabilities through Transition
• Increased focus on Intelligence, Reconnaissance,
  and Surveillance
• Prototype EO/IR, TCDL, SONAR Digitization
• Three letter snake namesFrom ASP to BOA.
• Augmented Surface Plot
• Basic Operational Augmentation
• Tactical Mission System enhancements

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CH124 Highlights

• General Fleet Information
• Fleet Service Life Status
• Attributes of Success
• Maintenance Program
• Aircraft Structural Integrity
• Sunset Years
• Challenges Capabilities
• Wrap-Up

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51 Yrs Keepin em Flying!!
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Fleet Service Life Status

• Entered service May 1963