Aircraft No. 6 N925AU, T-25; P3-A; Serial Number

Transcription

1 Aircraft No. 6 N925AU, T-25; P3-A; Serial Number Aircraft Data: Manufacture Date: 1964 Entered airtanker operations: 6/12/1990 FAA Registration Card - See Attachment 6-1. Issued to: Aero Union Corporation Date of Issue: October 12, 1989 Expiration Date: December 31, 2012 FAA Registration Marks: N925AU Aircraft Serial Number: FAA Airworthiness Certificate: Special Airworthiness Certificate ; RESTRICTED Category See Attachment 6-2. Purpose: Forestry and Wildlife Conservation FAA No.: N925AU Serial No.: Builder: Aero Union Corporation Model: P-3A Operating Limitations Dated: 4/20/11 Date of Issue: 4/20/11 Expiry Date: Unlimited Refers to: Type Certificate A32NM USFS Aircraft Approval Card- See Attachment 6-3. Issued to: Aero Union Corporation Date of Issue: 2/14/11 Expiration date: 12/31/11 FAA Registration Marks: N925AU Aircraft Serial Number: Approval for: Airtanker Contract No.: AG-024B-C Note- Supporting USFS Card Inspection records were not found Last Flight Operations Logbook Page No.: Date: 6/3/2011 Aircraft TT: 18, hours Note- No flight entry, rather entry stated Special Inspection completed.

2 Records Review: Logbooks- Airframe 6/12/1990, Aircraft times brought forward from military records. Aircraft TT 13,007.6, TSO /90/1990 and 6/12/1990, Experimental Airworthiness Certificates issued. 6/12/1990, ACTT 13,021.69, First civil annual inspection completed. 6/12/1990, Restricted Category Airworthiness Certificate issued for Forestry and Wildlife Conservation. 1/18/1995, ACTT 14,201.0, performed No. 1 Aircraft Service Period Authorization (ASPA) inspection and annual inspection. 2/15/1998, RADS II retardant tank installed in accordance with Aero Union STC No. SA4861NM, see FAA Form 337 dated 2/11/ /16/2004, Aircraft had touch and go gear up landing (aircrew caught their error and aircraft flew around and landed with the gear down). Various visual and NDI ultra sound inspection on forward main ring fittings, other inspections performed. Changed retardant tank doors. 7/29/2005, ACTT 16,805.9, Completed annual inspection, complied with AFB 356, Rev. A, removed and replaced left and right lower forward wing spar caps, completed Aero Union Phased Depot Level Maintenance General and Phase III inspections and maintenance. 2/24/2010 Logbook audit of Navy and Aero Union records. Completed total landings calculator worksheet, as of 9/30/2009, ACTT 18,361.25, total landings 14,772. 4/2/2010, ACTT 18,361.3, aircraft inspected in accordance with an approved inspection program, reference FAR (f)(4) and was found to be in an airworthy condition, ref. Aero Union Work Order No and /2/2010, 18,361.3, Total cycles 14,772, completed Aero Union Phased Depot Level Maintenance General and Phase I inspections and maintenance, ref. Aero Union Work Order No /26/2011, ACTT 18,559.2, Total cycles 15,033, aircraft inspected in accordance with an approved inspection program, reference FAR (f)(4) and was found to be in an airworthy condition, reference Work Order No. 4009, this includes the following inspection and maintenance segments: 10/19/2010 Phase I- Induction 11/8/2010 Phase II- Inspection 11/11/2010 Phase III- ALS Inspection 11/11/2010 Phase IV- Routine Maintenance 11/11/2010 Phase V- Time/Cycle Maintenance 11/11/2010 Phase VI- Non-routine Maintenance

3 11/11/2010 Phase VII- Final checks and Tests 11/18/2010 Phase VIII- Deferred Items Note- Four items were deferred, three items were inspected and complied with and one item was carried over to next winter maintenance. See Attachment 6-4. (Last annual inspection) 2/23/2011, ACTT 18,559.2 Late Entry- Complied with Aero Union S. D. 2037, ring fitting examinations, forward P/N and rear P/N , ref. Work Order /4/2011 ACTT 18, Late Entry- Aircraft sustained hail damage in Abilene, TX, and was ferried to MCC, CA, damage evaluation. Reference FAA Form , dated 5/3/2011. Damage repaired in accordance with Aero Union Engineering Order No. AUC-EO Aircraft returned to service this date, ref. Work Order No <last airframe logbook entry> Engine Logbooks- See Attachment 6-5 for engine, prop and component serial numbers, hours, cycles. Engine No. 1 Serial Number AE105184, 4/1995, Purchase from DRMO sales, Alameda, CA, engine times brought forward from military records, engine TT 15,367, TSO 5,738. 1/2001, Engine TT 15,367, TSO 5,738,compressor repaired by Rolls Royce, Oakland, CA, and built up as a spare engine. 11/20/2007 Engine TT 17,499.3, TSO 7,870.3, changed RGB and test cell run. 4/1/2010, ACTT 18,361.3, Engine TT 18,009.2, TSO 8,380.2, annual inspection performed. 1/24/2011, ACTT 18,559.2, Engine TT 18,207.1, TSO 8,578.1, engine inspected in accordance with an approved inspection program, reference FAR (f)(4) and was found to be in an airworthy condition. Engine No. 2 Serial Number AE103674, Received on aircraft serial number , No. 2 position, from military records, engine TT 15,275.1, TSO /14/2005, ACTT 16,805.1, Engine TT 15,275.1, TSO 8,712.1, installed on T-25, No. 2 position. 3/9/2010 Engine TT 17,126.26, TSO 10,168.26, logbook audit of Navy and Aero Union records, correct, No 14 th compressor wheel. (highest time component) 4/1/2010, ACTT 18,361.3, Engine TT 17,126.2, TSO 10,168.2, annual inspection performed. 1/24/2011, ACTT 18,559.2, Engine TT 17,324.1, TSO 10,366.1, engine inspected in accordance with an approved inspection program, reference FAR (f)(4) and was found to be in an airworthy condition.

4 Engine No. 3 Serial Number AE105296, 2/1/1990, times brought forward from military records, engine TT 8,452.4 TSO 2, /4/2008, Engine 13,270, TSO 7,189.1, Removed due to low power. 8/25/2010, Engine TT 13, 270.0, TSO 10,633.6, engine sent to Rolls Royce, Oakland, CA, for major repairs to compressor, turbine assembly and RGB. Many compressor wheels removed and replaced, turbine assembly replaced, RGB replaced. 12/25/2010, ACTT 18,559.2, Engine TT 13,270.0, TSO 10,633.6, installed on T-25, No. 3 position. 1/24/2011, ACTT 18,559.2, Engine TT 13,270.0, TSO 10,633.6, engine inspected in accordance with an approved inspection program, reference FAR (f)(4) and was found to be in an airworthy condition. Engine No. 4 Serial Number AE103686, 8/18/2009, Engine TT Unknown, TSO 00.0, purchased from US Navy in non-airworthy condition. Compressor assembly sent to Segers Aero Corporation and overhauled on 5/5/2009 and returned to Aero Union in airworthy condition. 8/18/2009, Engine TT Unknown, TSO00.0, overhauled compressor S/N AE mated with overhauled RGB assembly S/N AG02458 and repaired turbine assembly S/N A5510. Engine test cell run. 8/24/2009, Engine TT 8,370 (found in military records), TSO /24/2011, ACTT 18,559.2, Engine TT 8,549.3, TSO 179.3, engine installed on T-25, No. 4 position and inspected in accordance with an approved inspection program, reference FAR (f)(4) and was found to be in an airworthy condition. Selected FAA Form 337, Major Repair and/or Alteration- 1/ Installed Operational Loads Monitoring System, Appareo installed in accordance with LLC, installation instructions document No , Rv. IR, dated 11/27/2007 and Appareo Systems LLC Dwg No , Rev. X04. 2/24/2007, Remove, de-mod removal of major components for the Structural Health Management System installed on 1/21/ /24/2003, Install acoustic crack detection system. 2/1/1998 Install updated RADS II retardant tank system in accordance with Aero Union Corporation STC No. SA4861NM and MDL No /1/1994, Right upper wing plank No. 3 splice cut at W.S /1/1994, Right upper wing plank No. 2 splice cut at W.S /12/1994, Three FAA Form 337 s for upper left wing plank repairs to plank Numbers 3, 5 & 6. 2/1/1993, Two FAA Form 337 s for upper right wing plank repairs to plank Number 5, two locations.

5 3/4/1992Right upper aft spar cap 3.5-inch crack repaired. Airworthiness Limitations Section- A review from the winter 2010/2011 ALS printout (last annual inspection) indicated that a total of 38 inspection items are now due and several inspection items were not completed during the last winter annual inspection principally due to lack of specialized non-destructive test (NDT) equipment. See Attachment 6-6. Note- The FAA Type Certificate Data Sheet for this aircraft requires an active FAA Approved damage tolerance and fatigue evaluation (and monitoring) program in accordance with FAR The Type Certificate Data Sheet makes this specification in Note 4 of the Document. Records Examination and Results- I examined the aircraft and engine logbooks, file folders pertaining to: aircraft registration and airworthiness certificates, FAA Form 337 s, Major Alteration and Major Repair, ALS, USFS Certification and Work Orders. The aircraft maintenance records are detailed, concise and fully describe the inspections and maintenance performed. Aero Union operated a FAA Part 145 Repair Station maintenance facility under FAA Repair Station No. AUCR270C. Examination of the records indicated that appropriate and complete logbook entries and Work Order data and supporting outside part suppliers and material processing facilities certification documents complied with FAA and aerospace industry accepted practices and standards. The winter 2010/2011 annual inspections were extensive and the Work Order inspection cards, supporting parts and special inspection cards indicated that the inspections and maintenance were thorough and complete, excepting for some of the ALS inspections requiring specialized test equipment. The logbook revealed entries pertaining to logbook audits to insure correct aircraft total times and cycles. The P-3A aircraft was inspected and maintained in accordance with Aero Union s FAA Approved Maintenance and Inspection Program, dated October 28, The Aero Union P-3A Maintenance and Inspection Program provides for repetitive annual inspections, calendar inspections, condition inspections, Airworthiness Limitations Inspections (per FAR Part , damage tolerance and Note 4 of the Type Certificate Data sheet), and Phased Depot Level Inspections. The Phased Depot Level Inspections include a general inspection and one of three Phase inspections every 54 months.

6 T-25 had a No. 1 Aircraft Service Period Authorization (ASPA) inspection in 1995, to postpone phase structural inspection. T-25 had two major Depot Level inspections in 2005 and US Navy Airframe Bulletin No. 356, Revision B. This bulletin is a major disassembly of the wing and includes the replacement of critical spar caps and critical highly stressed parts and fittings. T-25 had AFB 356 incorporated on 7/29/2005. The Airworthiness Limitations Section Inspections are mandatory and part of the airworthiness requirements in the Type Certificate Data Sheet. Further, the FAA Type Certificate Data Sheet ALS Inspections require that several primary structural parts be inspected using both visual methods and more sophisticated electronic test equipment methods. Some parts have a finite service life and must be replaced at various aircraft total times and/or total cycles. There were several ALS inspection items that were not complied with. This is not an intentional maintenance omission; rather, this appears to have been a management decision to not procure/rent the necessary sophisticated electronic NDI equipment to perform the inspections. These inspections will need to be accomplished prior to returning the aircraft to service.