E Zonal&L HIRF Principles

Maintainability & Maintenance Engineering + Maintenance Planning & Services

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5. Zonal & L/HIRF logic Principles based on Airbus’ experience

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Zonal & L/HIRF logic - Principles

© AIRBU S DEUT SCHLAND GM BH. Al l rights reserved. Confidential and proprietary document.

Table of Contents

1. Introduction

4

2. Zonal & L/HIRF Analysis

9

3. MWG Review Process

61

4. Summary

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© AIRBU S DEUT SCHLAND GM BH. Al l rights reserved. Confidential and proprietary document.

Objectives 1.1.Introduction

Systems and Powerplant Section

Zonal Section Structures Section

MSI--Analyses MSI

SSI--Analyses SSI

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The respective content of the « Systems & PP », « Structures» and « Zonal » sections (or programs) of the MRB Report is based on the results from the works performed by the different MWGs and the ISC in order to define the « initial minimum scheduled maintenance requirements », thanks to the MSG-3 method, through the MRB Process settled for a dedicated a/c program.

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© AIR BUS DEUTSCHL AND GM BH. A ll rights reserved. Confidential and proprietary document.

1. Introduction – MSG-3 Background

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1. Introduction – MSG-3 Background

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Zonal Analysis Procedure ¾

Zonal inspections may be developed from application of the Zonal Analysis Procedure. This requires a summary review of each zone on the aircraft and normally occurs as the MSG-3 analyses of structures, systems,and powerplants are being concluded. These inspections may subsequently be included in the Zonal Inspections.

¾

In top down analyses conducted under MSG-3, many support items such as plumbing, ducting, Other Structure,wiring, etc., may be evaluated for possible contribution to functional failure. In cases where a general visual inspection is required to assess degradation, the zonal inspection is an appropriate method.

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1. Introduction – MSG-3 Background Changes of MSG-3 methodology since revision 2

AT A MS G-3

ATA MSG-3

ATA MSG-3 Oper ator/M anuf actu rer

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Sched uled Maint en an ce Develop ment

ATA MSG-3

Oper ator/M anuf actu rer

ATA MSG-3

Oper ator/M anuf actu rer

Oper ator/M anuf actu rer

Sched uled Maint en an ce Develop ment

Sched uled Maint en an ce Develop ment

Sched uled Maint en an ce Develop ment

Oper ator/M anuf actu rer Sched uled Maint en an ce Develop ment

Revision 2005.1

Rev ision 2003.1

Rev ision 2002.1

Rev ision 2001.1

Rev ision 2

Revised sections on: • Enhanced zonal analysis

New sections on: • Enhanced zonal analysis • L/HIRF analysis

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Changes of MSG-3 methodology since revision 2 Enhanced Zonal Analysis : Allows appropriate attention to be given to safety related deterioration of wiring, particularly in zones with potential for combustible material accumulation The main intent is to reduce existence of electrical ignition sources and combustible material through maintenance tasks Changes in maintenance regulations have been addressed through an Aging Transport Systems Rulemaking Advisory Committee (ATSRAC) The Enhanced Zonal Analysis Procedure (EZAP) was developed by the ATSRAC Task 3 SubCommittee L/HIRF Analysis : The intend of the L/HIRF protection tasks is to reduce the possibility that a single failure cause (e.g. lightning strike) and the occurrence of a common failure cause such as Environmental or Accidental Damage (ED/AD) across (functional) redundant channels could impact aircraft airworthiness

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Zonal & L/HIRF logic - Principles Table of Contents

1. Introduction

4

2. Zonal & L/HIRF Analysis

9

2.1 Generic Process

© AIRBU S DEUT SCHLAND GM BH. Al l rights reserved. Confidential and proprietary document.

2.2 Standard zonal Analysis 2.3 Enhanced zonal analysis 2.4 L/HIRF zonal analysis 2.5 Consolidation/transfer/interface 1. MWG Review Process

61

2. Summary

64

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2.1 Zonal & L/HIRF Analysis - Generic Process Zonal & L/HIRF general principles • MSG-3 document treats Zonal & L/HIRF in two independent sections • Zonal and L/HIRF analyses are performed as one unique procedure taking advantage of the similarity between both processes • Zones are sensitive or not sensitive to L/HIRF threats. As per MSG-3, most of the L/HIRF protection and in particular the aircraft structure continuity are covered by the Standard Zonal Analysis The Zonal & L/HIRF analysis consists of the following sub-processes: © AIR BUS DEUTSCHL AND GM BH. A ll rights reserved. Confidential and proprietary document.

• Zone description • Zonal Analysis: - Standard Zonal Analysis part (applies to all zones) - Enhanced Zonal Analysis part (applies to zones with wiring) • Lightning/High Intensity Radiated Field (L/HIRF) Zonal Analysis (applies to L/HIRF protection elements) • Consolidation XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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2.1 Zonal & L/HIRF Analysis - Generic Process

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Any Airbus aircraft is divided into 9 major zones as follows: Major Zones (External) 100 Lower half of fuselage (below cabin floor), including radome to ramp 200 Upper half of fuselage (above cabin floor) to end of main deck cargo compartment 300 Stabilizers and fuselage rear section 400 Power plant (including propeller) 500 LH wing 600 RH wing 700 Landing gear & landing gear doors 800 Doors 900 Special use (e.g. external fuel pods…)

Major Sub-Zones (Internal) Sub-divisions of major zones, e.g. 100 is divided into 110, 120, 130… Zones (Internal) Sub-divisions of major sub-zones, e.g.120 is divided into121,122,123... XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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2.1 Zonal & L/HIRF Analysis - Generic Process

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Aircraft zoning principles (A340 example)

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2.1 Zonal & L/HIRF Analysis - Generic Process

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Aircraft zoning principles (A340 example)

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2.1 Zonal & L/HIRF Analysis - Generic Process

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Aircraft zoning principles (A340 example)

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2.1 Zonal & L/HIRF Analysis - Generic Process

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Aircraft zoning principles (A340 example)

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2.1 Zonal & L/HIRF Analysis - Generic Process

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Aircraft access panel numbering principles (A340 example)

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2.1 Zonal & L/HIRF Analysis - Generic Process Zonal Inspection Program (ZIP) principles

The Zonal Inspection Program has one single level of inspection!

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General Visual Inspection (GVI)

Inspection to be carried out from within touching distance, unless otherwise stated A mirror may be necessary to ensure visual access to all exposed surfaces in the inspection area XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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2.1 Zonal & L/HIRF Analysis - Generic Process Zonal Inspection Program (ZIP) principles • The Zonal Inspection Program provides the General Visual Inspection (GVI) requirements for each aircraft zone to inspect system and powerplant installations for security and general condition and structure for general condition

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• The Zonal Inspection Program is based on dividing the aircraft into zones. Each zone is usually defined by a clearly defined physical boundary, e.g. rib, bulkhead, frames, etc… • Each zone is to be inspected as far as visible with the relevant access open/removed • The extent of the inspection is defined by the access e.g. identification of access doors, positioning of flight control surfaces, removal of lining and insulation, etc… • Inspections are recommended to be accomplished at or before stated intervals XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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2.1 Zonal & L/HIRF Analysis - Generic Process Zonal Inspection Program (ZIP) principles • Each zone is analysed for type of damage/deterioration to structure/systems located in the zone which may occur in-service • Zonal inspection tasks do not provide a summary of all the individual systems and structural items to be inspected in the affected zone

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• Therefore it is considered that a person performing inspections has an adequate knowledge of overall aircraft construction and systems • Zones may need more than one inspection at different intervals due to the depth at which the zone is to be examined requiring different levels of accessibility - e.g. The cargo compartment requires 3 ZIP inspections each requiring a different level of access (1.5 MO - door, 5 YE specific panels and 10YE all access open)

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2.1 Zonal & L/HIRF Analysis - Generic Process Common Analysis Process

Standard

Zonal

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Enhanced Zonal

L/HIRF

L/HIRF and Zonal analysis (Standard, Enhanced) procedures have been combined to make maximum use of similar procedural steps & synergies between the three zonal analysis parts XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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2.1 Zonal & L/HIRF Analysis - Generic Process

© AIR BUS DEUTSCHL AND GM BH. A ll rights reserved. Confidential and proprietary document.

Zonal Inspection Program task levels (ZIP) • Standard Zonal analysis: - GVI (General Visual Inspection) • Enhanced Zonal analysis: - Stand-alone GVI, a GVI which is not performed as part of a zonal inspection - RST (Restoration), cleaning being the most probable - DET (Detailed Inspection) • L/HIRF protection analysis: - Stand-alone GVI, a GVI which is not performed as part of a zonal inspection - DET (Detailed Inspection) - FNC (Functional Check), resistance measurement • Structure & System/Powerplant maintenance requirements transferred for consolidation include: - GVI (General Visual Inspection) - VCK (Visual Checks), system/powerplant analysis only XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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These visual inspection requirements are covered under the Zonal Inspection Program (ZIP)

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2.1 Zonal & L/HIRF Analysis - Generic Process

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Enhanced zonal & L/HIRF task levels (ATA20) • Standard Zonal analysis: - GVI (General Visual Inspection) • Enhanced Zonal analysis: - Stand-alone GVI, a GVI which is not performed as part of a zonal inspection - RST (Restoration), cleaning being the most probable - DET (Detailed Inspection) • L/HIRF protection analysis: - Stand-alone GVI, a GVI which is not performed as part of a zonal inspection - DET (Detailed Inspection) - FNC (Functional Check), resistance measurement • Structure & System/Powerplant maintenance requirements transferred for consolidation include: - GVI (General Visual Inspection) - VCK (Visual Checks), system/powerplant analysis only XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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These non ZIP tasks will be listed in the systems & powerplant section (ATA chapter 20)

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Zonal & L/HIRF logic - Principles Table of Contents

1. Introduction

3

2. Zonal & L/HIRF Analysis

8

2.1 Generic Process

© AIRBU S DEUT SCHLAND GM BH. Al l rights reserved. Confidential and proprietary document.

2.2 Standard zonal Analysis 2.3 Enhanced zonal analysis 2.4 L/HIRF zonal analysis 2.5 Consolidation/transfer/interface 1. MWG Review Process

60

2. Summary

63

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© AIR BUS DEUTSCHL AND GM BH. A ll rights reserved. Confidential and proprietary document.

2.1 Zonal & L/HIRF Analysis - Generic Process

Standard Zonal Zonal Inspection Program (ZIP) General Visual Inspections (GVI) to detect visual degradation of the whole zone content (structure, equipment, wiring, L/HIRF protection, bonding leads, grounding points...) XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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2.3 Zonal & L/HIRF Analysis - Standard Part Standard zonal analysis principals • The standard zonal analysis process is based on four parameters: - Accidental damage - Environmental damage - Density - Importance

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• The final rating in the matrix box provides guidance for the inspection intervals (zonal guidance interval) • Intervals are defined according to applicable in-service experience • Access is defined according to zone layout/installation • It is expected that the area to be inspected is clean enough to minimise the possibility that accumulated dirt or grease might hide unsatisfactory conditions • Any cleaning that is considered necessary should be performed before the zonal inspection task XM33 Trai ning - Z onal & L/HIRF Logic - Principl es

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2.3 Zonal & L/HIRF Analysis - Standard Part

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Standard zonal analysis interval guidance rating ACCIDENTAL DAM AGE Ground Handling Cargo Handling Maintenance Weather effects Foreign objects Fluid spillage Passenger traffic Others… N/A=0, Low=1,

ENVIRONMENTAL DAM AGE Temperature Vibration Humidity Contamination Chemical (toilet fluids,..) Others…

DENSITY Low Moderate High Low IMPORTANCE Moderate

Moderate=2, High=3

High

1

2

3

2

3

4

3

4

4

Select the highest rating !

AD FACTOR

1 2 3

ED FACTOR 1 2 3 1 2 3 2 3 4 3 4 4

AD/ED FACTOR

1 2 3 4

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IMPORTANCE/DENSITY FACTOR 1 2 3 4 >144MO 96-144MO 72-96MO 48-72MO 96-144MO 72-96MO 48-72MO 24-48MO 72-96MO 48-72MO 24-48MO 12-24MO 48-72MO 24-48MO 12-24MO 144 MO 96-14 4MO 72-96 MO 48-72 MO

24-48 MO

24-48 MO

12-24 MO

12-24 MO

72MO 72-48MO 48-24MO 72-48MO 48-24MO 24-12MO 48-24MO 24-12MO