Depot Level Maintenance Tech Req Doc 5-22-08.pdf

HSBP 1008R1145

Section J Attachment 4

US Customs and Border Protection

P-3 DEPOT LEVEL MAINTENANCE

TECHNICAL REQUIREMENTS DOCUMENT

24 September 2007

TECHNICAL REQUIREMENTS DOCUMENT

GENERAL

1-1.1 SCOPE

1-1.5 DLM INTERVAL

1-1.6 DEFINITIONS

1-1.7 MAINTENANCE REFERENCES

1-1.8 ACRONYMS

1-1.9 CDRL REQUIREMENTS

1-1.10 PROGRAM REVIEWS

1-1.12 PRODUCT ORIENTED SURVEYS

1-1.13 SPECIFIC EQUIPMENT

1-1.14 DLM OPERATIONAL DOCUMENT APPROVAL

1-1.15 ECONOMICAL REPAIR

1-1.16 MAJOR STRUCTURAL REPAIRS

1-1.17 INVALID NDI REQUIREMENT

1-1.18 INTERIOR AND EXTERIOR FINISHES

1-1.18.1 DISTURBED SYSTEMS

1-1.19 AEW MAINTENANCE REFERENCES

1-1.20 AIRCRAFT FLIGHT SUMMARY REPORT

1-1.20.1 CONTRACT LINE ITEMS NUMBER (CLIN)

1-1.21 PRODUCTION PLAN

1- 1.22 AIRCRAFT CUSTODY/STATUS CHANGE REPORT

1-1.22.1 AIRCRAFT FLIGHT SUMMARY REPORT

1-1.22.2 AIRCRAFT STATUS REPORT

1-1.22.3 CANNIBALIZATION

1-1.23 FIRM FIXED PRICE

1-1.23.1 OVER AND ABOVE

1-1.24 FLIGHT OPERATIONS PLAN

1-1.26 LIAISON ENGINEERING

1-1.26.1 ENGINEERING SUPPORT

1-1.26.2 STANDARD REPAIRS

1-1.26.3 NONSTANDARD REPAIRS

1-1.26.4 MAJOR STRUCTURAL REPAIRS OF THE ROTODOME PYLON/FUSELAGE PYLON SUPPORT STRUCTURE

1-1.27 TECHNICAL PROCESS CHANGES

1-1.28 TECHNICAL DATA

1-1.29 NON-DESTRUCTIVE INSPECTION (NDI)

1-1.29.1WELDING

1-1.30 COMPONENT PLATING FACILITIES

1-1.31 AIRCRAFT EXPLOSIVES

1-1.32 ELECTROSTATIC DISCHARGE CONTROL PROGRAM

1-1.33 SYSTEM SAFETY PROGRAM PLAN

1-1.34 AVIATION MISHAP REPORTING AND INVESTIGATION

1-1.35 QUALITY ASSURANCE PROGRAM

1-1.36 OZONE DEPLETING SUBSTANCES

1-1.37 SUPPLIER QUALITY ASSURANCE SYSTEM PROGRAM

1-1.37.1 PRODUCT INTEGRITY PROGRAMS

1-1.38 AIRCRAFT STATUS REPORT

1-1.41 AIRCRAFT INSPECTIONS (SCHEDULED AND CONDITIONAL)

1-1.42 OPERATIONS SECURITY

1-1.44 P-3B AIRBORNE EARLY WARNING (AEW) AIRCRAFT GENERAL DESCRIPTION

1-1.45 P-3B LONG RANGE TRACKER AIRCRAFT GENERAL DESCRIPTION

LRT BALLAST LOCATION

IN-COMING REQUIREMENTS

2-1 IN-COMING REQUIREMENTS

2-1.1 IN-INCOMING POST FLIGHT BRIEFING

2-1.2 AIRCRAFT LOGBOOKS AND RECORDS

2-1.3 AIRCRAFT EQUIPMENT INVENTORY

2-1,4 SURVIVAL AND LOOSE EQUIPMENT

2-1.5 HYDRAULIC SYSTEM CONTAMINATION

2-1.6 FUEL SYSTEM CONTAMINATION

2-1, 7 TURBO SHAFT ENGINES

2-1.7.1 APU

2-1.8 TOWING, JACKING, HOISTING AND MOORING

2-1.9 AIRCRAFT FUEL LEAK PROCESSING

2-1.10 AIRCRAFT PRESERVATION

2-1.11 MAKE AIRCRAFT HANGAR SAFE

3-1 DEPAINT/APPLICATION AND CORROSION INHIBITING APPLICATION PROCESSES

3-1 DEPAINT/SEALANT CLEAN AND REMOVAL/CORROSION INSPECTION/CORROSION

INHIBITING APPLICATION/RESEAL/ PAINT

3-1.1 EXTERIOR AIRCRAFT PAINT REMOVAL

3-1.2 PAINT REMOVAL, EXTERIOR DETAIL

3-1.3 CLEAN AIRCRAFT

3-1.4 CHEMICAL CONVERSION COATING

3-1.5 EXTERIOR CORROSION INSPECTION

3-1.7 EXTERIOR AIRCRAFT PRIMING

3-1.8 EXTERIOR AIRCRAFT SEALING/PAINTING

3-1.8.1 EXTERIOR PAINT SCHEME MARKING

3-1.9 INTERIOR AIRCRAFT REFINISHING

DISASSEMBLY ACCESS OPEN/CLOSE

4-1 ACCESS OPEN/ DISASSEMBLY/REASSEMBLE/CLOSE

4-1.1 ENTRANCE LADDER

4-1.3 ALL INTERIOR SEATS

4-1.6 DF-301E UHF/DF ANTENNA

4-1.7 NOSE RADOME

4-1.13 AFT RADOME

4-1.16 ECCOSORB BLANKETS (NOSE AND AFT RADOMES)

4-1.17 INSULATION BLANKETS

4-1.18 APU/APU EXHAUST DUCT/APU DOOR

4-1.20 FLUSH TOILETS

4-1.21 WING TIPS

4-1.22 ELEVATORS

4-1.23 ELEVATOR FRONT SPAR

4-1.24 AILERONS

4-1.25 AILERON FRONT SPAR

4-1.26 RUDDER

4-1.27 RUDDER SPAR ACCESS PANELS

4-1.28 RUDDER BOOST PACKAGE

4-1.30 AIRCRAFT BATTERY

4-1.31 LTN 92 BATTERY

4-1.32 VERTICAL STABILIZER CAP

4-1.33 EMPENNAGE ACCESS PANELS

4-1.33.1 EMPENNAGE INTERNAL COTHEN CHASSIS

4-1.35 #1 & #4 FIRE SHIELD PANELS

4-1.35.1 NACELLE ACCESS PANELS

4-1.36 ENGINE #2 & #3 HRD ACCESS PANELS AND UPPER AND LOWER FIRE SHIELDS

4-1.37 WING ACCESS PANELS

4-1.39 WING AIR CONTROL PANEL INSPECTION PLATES

4-1.40 WING CENTER SECTION ACCESS PANEL

4-1.41 WING CENTER SECTION GROUND PLANE ASSEMBLY

4-1.42 WING CENTROID RISER

4-1.43 FUSELAGE PANELS

4-1.46 BOMB BAY INTERNAL STRESS PANELS

4-1.47 FLIGHT STATION UPPER AND LOWER ACCESS PANELS

4-1.49 EMPENNAGE FILLET PANELS

4-1.51 NACELLE TO WING FILLET PANELS

4-1.52 ENGINE #1 AND #4 TAILPIPES

4-1.53 ENGINE #2 AND #3 TAILPIPES

4-1.54 ENGINE #1 AND #4 EXHAUST STRAIGHTENER

4-1.55 ENGINE #2 AND #3 EXHAUST STRAIGHTENER

4-1.58 ENGINE #1 AND #4 TAILPIPE SHROUDS

4-1.59 ENGINE #2 AND #3 TAILPIPE SHROUDS

4-1.60 NACELLE, WING FILLET PANELS FRONT SPAR

4-1.61 FUSELAGE TO WING AND CENTER SECTION FILLET PANELS

4-1.62 AIRCRAFT FLOOR PANELS

4-1.63 ROTODOME AND PYLON ACCESS PANELS/FAIRINGS (P-3B AEW)

4-1.64 RTA-852L WEATHER RADAR RECEIVER/TRANSMITTER/ANTENNA

ZONAL INSPECTION REQUIREMENTS

5-1 ZONAL INSPECTION PROCEDURES/REQUIREMENTS

5-1.2 NACELLES 1, 2, 3, AND 4 EXTERNAL

5-1.3 NACELLE 1 AND 4 INTERNAL

5-1.4 NACELLES 2 AND 3 INTERNAL

5-1.5 RADOME EXTERNAL

5-1,5.1 RADOME INTERNAL (LRT AIRCRAFT ONLY)

5-1.5.2 RADOME INTERNAL

5-1.6 NOSE LANDING GEAR WHEEL WELL AND DOORS INTERNAL

5-1.7 APU/AIR-CONDITIONING SERVICE BAY INTERNAL

5-1.8 BOMB BAY AND DOORS INTERNAL

5-1. 9 FUEL COMPARTMENT INTERNAL

5-1.11 WATER ALCOHOL / SERVICE BAY

5-1.12 LEFT WING INTERNAL

5-1.13 RIGHT WING INTERNAL

5-1.14 LEFT WING EXTERNAL

5-1.15 RIGHT WING EXTERNAL

5-1.16 LEFT WING LEADING EDGE INTERNAL

5-1.17 RIGHT WING LEADING EDGE INTERNAL

5-1.18 LEFT WING TIP INTERNAL

5-1.19 RIGHT WING TIP INTERNAL

5-1.20 LEFT WING TRAILING EDGE INTERNAL

5-1.21 RIGHT WING TRAILING EDGE INTERNAL

5-1.23 LEFT HORIZONTAL STABILIZER - INTERNAL

5-1.24 RIGHT HORIZONTAL STABILIZER - INTERNAL

5-1.25 LEFT HORIZONTAL STABILIZER, TRAILING EDGE AND ELEVATOR INTERNAL

5-1.26 RIGHT HORIZONTAL STABILIZER, TRAILING EDGE AND ELEVATOR, INTERNAL

5-1.27 VERTICAL STABILIZER, INTERNAL

5-1.28 VERTICAL STABILIZER, TRAILING EDGE AND RUDDER

5-1.30 WING CENTER SECTION-EXTERNAL

5-1.31 WING CENTER SECTION-INTERNAL

5-1.32 WING FAIRING LEFT - INTERNAL

5-1.33 WING FAIRING RIGHT - INTERNAL

5-1.34 FLIGHT STATION FUSELAGE - INTERNAL

5-1.35 FLIGHT STATION FUSELAGE UNDER FLOOR - INTERNAL

5-1.36 OBIS FUSELAGE INTERNAL

5-1.37 TACTICAL/SENSOR DETECTION SYSTEM STATION - INTERNAL

5-1.38 CLUB SEATING, AFT OBS. FUSELAGE - INTERNAL

5-1.38.1 CLUB SEATING, AFT OBS. FUSELAGE - EXTERNAL

5-1.43 STAFF AREA INTERNAL

5-1.44 DORSAL FIN INTERNAL

5-1.45 UNDER FLOOR AREA - INTERNAL

5-1.46 EMPENNAGE EXTERNAL

5-1.47 HF ANTENNA BOOM

5-1.48 RADOME - INTERNAL

STRUCTURAL INSPECTION REQUIREMENTS

6-1 STRUCTURAL INSPECTION REQUIREMENTS

6-1.1 HORIZONTAL STABILIZER, UPPER SURFACE PLANKS - SSI-E2

6-1.2 HORIZONTAL STABILIZER UPPER SURFACE PLANKS - SSI-E5

6-1.3 HORIZONTAL STABILIZER LOWER SURFACE PLANKS - SSI-E3

6-1.4 HORIZONTAL STABILIZER LOWER SURFACE PLANKS - SSI-E6

6-1.5 WING PLANK JOINTS - SSI-F26

6-1.6 WING PLANK JOINTS - SSI-F27

6-1.7 FORWARD MAIN RING FITTING - SSI-F31

6-1.8 FORWARD MAIN RING FITTING - SSI-F32

6-1.9 CENTER SECTION WING PLANKS - SSI-F25

6-1.10 AFT SPAR CAP - SSI-W9

6-1.11 AFT SPAR CAP - SSI-W47

6-1.12 MAIN LANDING GEAR (MLG) DRAG STRUT FITTINGS - SSI-W21

6-1.13 MAIN LANDING GEAR (MLG) DRAG STRUT FITTINGS - SSI-W59

6-1.14 LEFT MAIN LANDING GEAR RIBS - SSI-W18

6-1.16 RIGHT MAIN LANDING GEAR RIBS - SSI-W56

6-1.18 WING PLANKS - SSI-W26

6-1.19 WING PLANKS - SSI-W64

6-1.20 WING SPAN WISE SPLICES AND RUNOUTS - SSI-W28

6-1.21 WING SPANWISE SPLICES AND RUNOUTS - SSI-W66

6-1. 22 LEFT WING ACCESS PANELS - SSI-W29

6-1.23 RIGHT WING ACCESS PANELS - SSI-W67

6-1.24 WING PLANKS - SSI-W30

6-1.25 WING PLANKS - SSI-W68

6-1.26 WING ACCESS PANELS - SSI-W33

6-1 27 WING ACCESS PANELS - SSI-W71

6-1.28 FORWARD SPAR WEB – SSI–S22 (ALL AIRCRAFT WITH GREATER THAN 15,000 FLIGHT HOURS AND ..8 6-1.29 FORWARD SPAR WEB – SSI–S23 (ALL AIRCRAFT WITH GREATER THAN 15,000 FLIGHT HOURS AND ..8

6-1.30 WING CENTER SECTION UPPER SURFACE WING PLANKS - SSI-F39

6-1.31 WING PLANK DOME NUTS - SSI-F48

6-1.32 WING PLANK DOME NUTS - SSI-F49

6-1 33 UPPER FORWARD ATTACH FITTING - SSI-S1

6-1.34 UPPER FORWARD ATTACH FITTING - SSI-S2

6-1.35 LOWER FITTING - SSI-S3

6-1. 36 LOWER FITTING - SSI-S4

6-1.37 NACELLE ATTACH PLATES AND SPARS - SSI-S5

6-1.38 NACELLE ATTACH PLATES AND SPARS - SSI-S6

6-1.39 RISER RUNOUTS - SSI-S13

6-1.40 RISER RUNOUTS - SSI-S14

6-1.41 LOWER BEAM CAP - SSI-S19

6-1.42 CANTED BULKHEAD AT HORIZONTAL STABILIZER - SSI-S20

6-1.43 VERTICAL STABILIZER ATTACH ANGLE - SSI-S21

6-1.44 SKATE ANGLES - SSI-S7 (“LEAD-THE-FLEET”) (ZONE 11.2)

6-1.45 SKIN DOUBLER - SSI-S9 AND CBP-SSI 003 & 004 (“LEAD-THE-FLEET”) (ZONE 11.2)

• DISCREPANCIES APPROVED BY THE GOVERNMENT HAVE BEEN CORRECTED

6-1.46SKATE ANGLES - SSI-S11 (“LEAD-THE-FLEET”) (ZONE 11.2)

6-1.47 SKATE ANGLES - SSI-S15 (“LEAD-THE-FLEET”) (ZONE 11.2)

6-1.48 SKATE ANGLES - SSI-S17 (“LEAD-THE-FLEET”) (ZONE 11.2)

6-1.49 SKATE ANGLES - SSI-S8 (“LEAD-THE-FLEET”) (ZONE 14.2)

6-1.50 SKIN DOUBLER - SSI-S10 (“LEAD-THE-FLEET”) (ZONE 14.2)

6-1.51 SKATE ANGLES - SSI-S12 (“LEAD-THE-FLEET”) (ZONE 14.2)

6-1.52 SKATE ANGLES - SSI-S16 (“LEAD-THE-FLEET”) (ZONE 14.2)

6-1.53 SKATE ANGLES - SSI-S18 (“LEAD-THE-FLEET”) (ZONE 14.2)

6-1.54 STRINGER 2 & 71 INSPECTION FORWARD OF FS 1117 RING SSI-CBP-001

6-1.55 OUTER WINGS LOWER PANEL 3 AT SCAVENGE PUMP SSI-CBP 002

STRUCTURAL INSPECTION REQUIREMENTS FOR AEW AIRCRAFT ONLY

6-2.1 PYLON FWD LH STRUT TO FUSELAGE MOUNTING, FS 754.6, WL 214.8, BL 27.6L - SSI-AEW1 6-2.2 PYLON FWD RH STRUT TO FUSELAGE MOUNTING, FS 754.6, WL 214.8, BL 27.6R - SSI-AEW2 6-2.3 PYLON AFT LH STRUT TO FUSELAGE MOUNTING, FS 865.3, WL 214.8, BL 27.6L - SSI-AEW3 6-2.4 PYLON AFT RH STRUT TO FUSELAGE MOUNTING, FS 865.3, WL 214.8, BL 27.6R - SSI-AEW4 6-1.2.5 FUSELAGE ROTODOME SUPPORT FWD STRAP EXTERNAL, FS 754.6 TO 763.9 ABOVE WL 123.5 -

SSI-AEW5

6-2.6 FUSELAGE ROTODOME SUPPORT AFT STRAP EXTERNAL, FS 865.3 TO 874.6 ABOVE WL 123.5 - SSI-

AEW6

6-2.6 FUSELAGE ROTODOME SUPPORT LH AFT FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 865.3 AND FS 874.6 - SSI-AEW7

6-2.9 FUSELAGE ROTODOME SUPPORT RH AFT FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 865.3 AND FS 874.6 - SSI-AEW8

6-2.10 FUSELAGE ROTODOME SUPPORT LH FWD FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 754.6 AND FS 763.9 - SSI-AEW9

6-2.11 FUSELAGE ROTODOME SUPPORT RH FWD FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 754.6 AND FS 763.9 - SSI-AEW10

6-2.12 PYLON FWD LH UPPER STRUT TO HOUSING ATTACHMENT, FS 797.5, WL 286.3 - SSI-AEW11 6-2.13 PYLON FWD RH UPPER STRUT TO HOUSING ATTACHMENT, FS 797.5, WL 286.3 - SSI-AEW12 6-2.14 PYLON AFT LH UPPER STRUT TO HOUSING ATTACHMENT, FS 826.5, WL 286.3 - SSI-AEW13 6-2.15 PYLON AFT RH UPPER STRUT TO HOUSING ATTACHMENT, FS 826.5, WL 286.3 - SSI-AEW14

6-2.16 PYLON INTERIOR BOX WEBS AND ACCESS PANEL OPENINGS - SSI-AEW15

SYSTEM AND COMPONENTS REQUIREMENTS

7-1 SYSTEM AND COMPONENT REQUIREMENTS

7-1.1 AILERON CONTROL DIFFERENTIAL BELLCRANK ASSEMBLY TORQUE TUBE

7-1.2 AILERON ASSEMBLY

7-1.2.1 AILERON HINGE BEARINGS

7-1.3 ELEVATOR ASSEMBLY

7-1.4 ELEVATOR TORQUE TUBE AND BEARINGS

7-1.5 RUDDER BELLCRANK/TORQUE TUBE

7-1.6 RUDDER ASSY

7-1.8 FUEL TANK 1, 2, 3, 4 SURGE BOX AND BOOST FUEL PUMP SYSTEM

7-1.10 CONTROL COLUMN FRICTION PLATES

7-1.11 ELEVATOR DOWN-SPRING CARTRIDGE

7-1.12 FORCE LINK TAB MECHANICAL SPRING CARTRIDGE

7-1.13 FORCE LINK TAB MECHANICAL ROLL OFF CARTRIDGE

REQUIREMENT

7-1.14 CABIN HEAT EXCHANGERS

7-1.15 BLEED AIR MANIFOLD

DLM REPORTS

8-1 DLM REPORTS

8-1.1 DLM ENGINEERING REPORTS

8-1.2 NBNC REPORT

8-1.3 STRUCTURAL SAMPLING REPORT

8-1.5 WING STRUCTURAL ALTERATION REPORT

8-1.6 MAINTENANCE HISTORY SUMMARY AND CORROSION INSPECTION (MHS&CI) REPORT

FINAL PROCESSING

9-1 FINAL PROCESSING

9-1.1 DEPRESERVATION

9-1.2 DISTURBED SYSTEMS

9-1.3 AIRCRAFT SPECIAL INSPECTIONS

9-1.4 TURBOSHAFT ENGINES

9-1.5 FUEL LEAK CHECK

9-1.6 WEIGHT AND BALANCE

9-1.7 LOGS AND RECORDS

9-1.8 HYDRAULIC SYSTEM CONTAMINATION

9-1.9 MAKE AIRCRAFT READY FOR FLIGHT

9-1.10 FUNCTIONAL/ACCEPTANCE FLIGHTS

9-1.11 GOVERNMENT AIRCRAFT ACCEPTANCE

9-1.12 AEW PECULIAR SYSTEM GOVERNMENT FURNISHED MAINTENANCE REFERENCES

9-1.13 APU

GOVERNMENT FURNISHED EQUIPMENT

General 1-1.1 Scope

This document provides instructions and responsibilities for P-3B Airborne Early Warning (AEW) and Long Range Tracker (LRT) aircraft Depot Level Maintenance (DLM) work and its associated support to the U.S. Customs and Border Protection (CBP). The goal of this maintenance program is to ensure safe, reliable, and available operation of the aircraft throughout its service period in order to meet US Customs and border protection (CBP) mission requirements. This Technical Requirements Document (TRD) establishes the Depot Level Maintenance (DLM) requirements for the P-3B Airborne Early Warning AEW and Long Range Tracker (LRT) systems/equipment and modifications peculiar to the P-3B AEW and LRT aircraft. The depot activity shall perform DLM on the systems/equipment and modifications as required in this Technical Requirements Document. Upon completion of all such repair and DLM, the aircraft and its accessories/components shall be completely reassembled, applicable systems rigged, aligned and/or tested (in accordance with the specified requirements) and the aircraft prepared for the Functional Check Flight process. The aircraft will be flight checked by the Government. The scheduled DLM requirements prescribed in this TRD are the minimum requirements necessary to ensure the timely discovery and correction for actual and/or anticipated defects based on the aircraft intended use. Compliance with these requirements is mandatory. The depot activity shall provide all services, support equipment, tools, tooling, facilities necessary, and any other items necessary in order to perform the requirements of this document. Preceding requirement excludes the identified Government Furnished Equipment (GFE) identified in this TRD.

Unscheduled maintenance requirements are those requirements, which cannot be directly related to any scheduled requirement. These are only discovered as an incidental result of the following functions, which are accomplished as a part of and during the scheduled inspections:

• Review and upkeep aircraft logbooks and all associated records.

• Inspection of the aircraft and its components during DLM

• The DLM requirements described herein provide for airframe, systems, and component inspection;

and for defect correction, preventive maintenance, modification and Technical Directive (TD) compliance, these requirements correspond with safety and reasonable economic considerations.

Additionally, technical support for evaluation of aircraft condition is provided throughout the aircraft service life. These requirements include, but are not limited to:

• A thorough and comprehensive inspection of selected aircraft structure, flight essential systems, and flight critical components by appropriate inspection methods with repair, as required, to ensure the serviceability until the next DLM induction.

• Replacement of time change components, assigned to Depot level, exceeding specified replacement intervals.

• Adjustments, checks, tests, repairs, inspections, preventive maintenance, and the DLM procedures coincidental thereto, shall be accomplished in accordance with applicable directives and publications as directed by this TRD.

• Defect classification shall be subject to review of the Authorized Government Representative (AGR) who will advise and provide recommendations. The correction criteria for each classified defect is as follows:

• Critical Defects All critical defects discovered as a direct result of or incidental to, compliance with DLM requirements shall be corrected in accordance with applicable documents.

• Major Defects All major defects discovered as a direct result of, or incidental to, compliance with DLM requirements may be corrected in accordance with applicable documents and when directed by the Government’s AGR.

• Minor Defects Minor defects discovered as a direct result of, or incidental to, compliance with DLM requirements shall not be corrected except for the following:

• Discrepancies discovered in areas not normally opened or inspected by organizational maintenance. Approval by the Government’s AGR is required.

• Corrosion discrepancies.

• Defects Caused by Repair Activity All defects caused by the DLM activity shall be corrected at no cost to the Government. This includes the cost of materials and man-hours required to accomplish the repair.

• Noted But Not Corrected Defects Defect’s not required to be corrected by the above criteria shall be identified by type, location, and description on the Noted But Not Corrected (NBNC) report for appropriate action.

Component nomenclatures used in this TRD are in general agreement with nomenclature used in the aircraft technical maintenance instruction manuals. Inspection requirements for items identified by nomenclature are applicable to the entire class of part numbers for that item as listed in the P-3 Illustrated Parts Breakdown(s), P-3 Structural Repair Manuals, The inspection, replacement, or other maintenance actions required by this TRD on specific equipment not installed on a particular T/M/S aircraft shall be disregarded. Recommendations for additions, deletions, or changes to the requirements of this TRD shall be submitted to US Customs and Border Protection. and documented on the Maintenance History Summary and Corrosion inspection Report

1-1.5 DLM Interval

This TRD establishes Depot Level Maintenance (DLM) requirements for systems/equipment and modification peculiar to the US Customs and Border Protection P-3B AEW and LRT aircraft. Each DLM will be scheduled at 54 month intervals or not later than 60 months with approval from the COTR.

1-1.6 Definitions

The following definitions are provided to establish the terminology, as applied to the maintenance and DLM requirements of this TRD. Terminology not defined in these paragraphs and used by this TRD shall be understood under the definitions of OPNAVINST 4790.2, and interpreted within the context of the requirements of this TRD. Generally accepted interpretations or colloquial usage of terminology shall be unacceptable rationale for any deviation from the definitions of this TRD.

• Abrasion The wearing away of the applicable material by rubbing or scraping. (Synonymous with

CHAFING.)

• Accessible Areas exposed by the removal of access doors, panels, fairing, etc., and such other disassembly required by the maintenance requirements and not involving destructive disassembly unless specified.

• Accessory A part, subassembly, or assembly designed for use in conjunction with or to supplement another assembly, or a unit or set contributing to the effectiveness thereof without extending or varying the basic function of the assembly or set.

• Aircraft Wiring All electrical wiring considered part of the standard configuration of the aircraft that is permanently installed, and not an integral part of any accessory, component, or “black box”.

• Airframe The structural component, including the framework and skin, of such parts as the fuselage, empennage, wings, control surfaces, landing gear (minus tires) and engine mounts.

• Airframe Accessories The items of equipment that are required for operation of the aircraft and that cannot be considered an integral part of the airframe or engine, such as wheels, brakes, hydraulic equipment, fuel system, deicing equipment, anti-icing equipment and other items not an integral part of the airframe, regardless of whether attached to the engine or airframe.

• Approved Government Representative (AGR) The representative of the Government cognizant for accepting products or services, for approving work or changes to work, or similar duties from contractors or vendors This distinction is necessary to distinguish Government as a contractor from Government as a customer. The AGR represents the customer Government.

• Assembly A number of parts or subassemblies, or any combination thereof, joined together to perform a specific function.

• Attachment A part, subassembly, or assembly designed for use in conjunction with another assembly, unit, or set contributing to the effectiveness thereof by extending or varying the basic function of the assembly, unit, or set.

• Avionics System Aircraft electrical, electronic, instrument flight control, fire control, missile and bombing equipment and their subsystems, either independent equipment, groups of equipment, or integrated systems necessary to accomplish assigned military missions.

• Calibrate To repair, check, or correct the graduations or indices of measuring devices or to repair, adjust, and align equipment so that it functions within assigned tolerances.

• Caution. Indicates danger to the weapon system. The caution precedes the item to which it refers.

• Chafing The wearing away of the applicable material by rubbing or scraping. (Synonymous with

Abrasion)

• Check To perform a thorough examination to ascertain the existence of unacceptable deviations from the intended state or condition as established by applicable document.

• Check Flight Airborne operational tests performed to determine whether the airframe, power plant, accessories, and other items of equipment are functioning in accordance with predetermined standards while subjected to the intended operating environment.

• Checkout A sequence of functional, operational, and calibration tests to determine the condition and status of a system or element thereof.

• Cleanliness The state of being free from impurities, impediments, and foreign matter not specified to be applied to the surface in question.

• Component A number of parts of subassemblies, or any combination thereof, joined to perform a specific function.

• Component Scheduled Removal Components whose overhaul or replacement schedule is established as a function of service use (flight hours, unit operating time or calendar time, cycles, event, Standard Depot Level Maintenance).

• Component Wiring The components required for the installation, connection, and/or continuation of electrical circuit segments, including relays, switches, fuses, connectors (plugs and receptacles), splices, terminals, terminal panels, grounding studs, harnesses, clamps, conduits, anti-chafing material, etc.

• Condition Inspection A visual examination to determine the existence of external damage and defects that could render the article unacceptable for continued use.

• Configuration Identification The current approved or conditionally approved technical document for a configuration item as set forth in specifications, drawings, and associated lists and documents.

• Continental United States (CONUS) The states on the North American mainland bound by borders with Canada on the north, and Mexico on the south. The United States with the exception of the states of Alaska and Hawaii.

• Corrosion An action or process, which destroys metal by chemical or electrochemical action and converts it into an oxide, hydroxide, or sulfate compound.

• Damage The impairment of a part by physical force.

• Defective The state of possessing a deviation from specified requirements.

• Deformation Any disfigurement or change in form or shape from the intended design configuration.

• Delamination A physical break of the bond between the binder material and any two or more plies of laminated panels fabricated of plastic, metal, or other materials or combinations thereof.

• Depot Activity The industrial establishment, either Government or Commercial, designated by the US

Customs and Border Protection as having maintenance responsibility for DLM for a particular model aircraft.

• Deterioration The breakup, eating away, or decomposition of a substance by the action of weather, corrosive material, or other environmental condition.

• Discrepancy Any deviation, disagreement, difference, or inconsistency, physical or otherwise, of an aircraft part or assembly from the design specification, usage or operation (synonymous with Defect).

• Distortion Any disfigurement or change in form or shape from the intended design configuration resulting from a twisting or torsional action.

• Disturbed System A system whose installed integrity has been interrupted, broken, or interfered with to the extent that system installation and operation cannot be assured without certification by a functional/operational test.

• Economical Repair Repair that can be accomplished using the economical repair criteria of

NAVAIRINST 4700.20

• Emergency Maintenance The requirement for service, inspection, repair, replacement, modification, and TD compliance to be accomplished on individual aircraft on an unscheduled basis.

• Erosion The act of wearing away by corrosion, friction, scraping, or rubbing.

• Essential Repair Restricted to those repairs, bench checks, functional checks, adjustments, tests, and work necessary to assure that an end item is restored to a serviceable condition and will efficiently accomplish its intended purpose. Essential Repair prohibits expending man-hours accomplishing unnecessary disassembly and complete overhaul.

• Evidence Factual data which establishes the possibility of an existing or impending unsatisfactory condition.

• Evaluation An investigation to determine condition, i.e., the existence of defects and damage.

• Exterior Surface That part of the airframe exposed to the elements when in a “clean” flight configuration including wing and stabilizer control(s). Does not include landing gear structure, wheel wells, etc., or areas exposed by extension of landing gear.

• Failure The inability of a part, unit set, or system to perform its required function within established limits.

• Fleet Support Team (FST) The NAVAIR designated activity assigned the responsibility and delegated the authority to perform aircraft maintenance engineering and logistic functions.

• Fraying The wearing away by rubbing, usually of woven, braided, or stranded material, which results in a worn or ragged appearance.

• Functionally Significant Item (FSI) Components, subassemblies, systems, or subsystems that are considered the most important for their effect on the safety of the aircraft and personnel, on the operational reliability of the system or aircraft, or on the economic aspects of repairs and replacements.

• Functional Test The quantitative evaluation of a system or component to assure its ability to perform over the full operating range as designed and within specified limits. Test equipment is normally used to provide precise inputs and to make measurements.

• Electric/Electronic Wiring Circuits Verification (General) A test of system wiring and wiring components to verify ability of aircraft wiring to perform its intended function when mated to its operational equipment. May be accomplished by either of the following procedures:

• Functional or operational test of the system using existing aircraft equipment, if operable, or “Slave” units if available. Tests shall be limited to the depth required to demonstrate adequacy of system wiring

• Any suitable method of continuity checks.

• Groove Any narrow furrow, depression, or slit on the surface of a part.

• Group A collection of units, assemblies, or subassemblies which is a subdivision of a set or system, but which is not capable of performing a complete operational function (See SYSTEM).

• Inclusion A void or discontinuity in the molecular structure of metal.

• Inspect To perform a critical investigation of an item, unit, component, or airframe through the visual, authority, olfactory, and tactile senses, utilizing simple manipulation, gauging, and measurements, as required, for the specific intent of determining its conformance to the assigned specification within the tolerances permitted. The process may require partial disassembly of such items.

• Conditional Inspection An unscheduled inspection required as a result of an over limit situation which occurs during operation of the aircraft (e.g., hard/overweight landings, engine over speed/over temp., etc.). A logbook entry is required for a conditional inspection of an aircraft and any component/equipment having an Aeronautical Equipment Service Record (AESR) logbook

• Special Inspection A scheduled inspection with a prescribed interval other than daily, calendar/phased, major engine or DLM. The intervals are specified in the applicable Periodic Maintenance Inspection Card manual and are based on elapsed calendar time, flight hours, operating hours, or number of cycles/event (e.g., 28,112 days/300, 600 hours, etc.). Logbook entries are required.

• Inspect and Repair as Necessary (IRAN) The process of inspecting and repair of an item only to the extent to make the item serviceable.

• Interior Surfaces Interior surfaces are all aircraft surfaces excluding areas defined as exterior. (SEE EXTERIOR). Interior aircraft surfaces are considered any area on the aircraft within a specific aircraft zone covered by an exterior skin, plank, access panel, door, antennas, radomes, or leading edge.

They also include but not are limited to under-floor, inside access panels, access panel surfaces, flap wells, wheel wells, hydraulic service center, rudder/elevator booster “hell hole” and APU compartments, inside bomb bay, inside fuel cell cavities etc.

• Lead-The-Fleet The Lead-The-Fleet aircraft designation is given to aircraft (all P-3 TMS) which have accumulated the largest percentage Fatigue Life Expended (FLE).

• Magnetic Control Used to indicate where the applications of special procedures are necessary to minimize excess levels of magnetism.

• Major Structural Damage Damage which requires removal and repair or replacement of airframe structural members.

• Mission Capable That capability built into the aircraft by the manufacturer, and by the incorporation of subsequent necessary modifications and changes, to enable the aircraft to perform its intended mission. Mission capability does not infer a degree of operational readiness, but indicates that the aircraft can be made operationally ready by the operating activity.

• Mission Essential Equipment All equipment, parts, and/or accessories necessary to perform a specified mission.

• Modify To alter in appearance, performance, function, position, or effect.

• NAVAIR The Naval Air Systems Command.

• Nick Any notch, slit, cut, indention, or chip on the surface of a part.

• Note An information item. The note may precede or follow the item to which it refers.

• Noted But Not Corrected A defect determined by the DLM activity to be within Organizational level maintenance capabilities requiring specific documentation by the depot activity.

• Operationally Ready (OR) the material condition statuses of a safe flyable aircraft.

• Operational Service Period (OSP) The period, expressed in months and/or hours between Depot

Level Maintenance actions.

• Operational Test The exercise of a system or component, within its operating modes, to assure operation without interference and in proper direction and sequence of an intended performance.

Normal operation is verified through observation of overall performance without resort to measurement.

• Part One piece, or two or more pieces joined together, which is not normally subject to disassembly without destruction of designed use.

• Depot Level Maintenance (DLM) Depot Level Maintenance is described as requirements to be accomplished upon attainment of a specified number of calendar months.

• Pitting Any small, approximately circular indentation, depression, hollow, or scar in the surface of a part, generally the result of corrosion or erosive action.

• Quality Assurance A planned program of actions necessary to provide confidence that material conforms to established standards.

• Quick Engine Change Assembly (QECA) A Quick Engine Change Kit completely assembled on a quick engine change stand with the engine and all accessories, excluding the propeller.

• Ready For Issue (RFI) A condition of an item in which all requirements of repair, check/test, PDM, or modification, as applicable, have been accomplished, making it capable of performing the function or requirements for which originally designed or later modified as directed by approved TDs.

• Ready for Use A serviceable item which can be installed on an aircraft without requiring inspection or repair.

• Refinish Restoration of an existing surface finish without complete removal of all of the existing finish.

The process of refinishing includes cleaning affected area to remove all loose and scaling paint or other finish material, defective sealant, soil, and contaminants; feather edging the original finish to smooth surface; application of new finish coatings ( including sealant, chemical conversion coating, primer and top coats) to provide protection from corrosion and to provide uniform appearance.

• Refurbishing The repair and renovation of aircraft interior furnishings.

• Reinstall The return of a part or component to its former position to accomplish its former function after its removal to facilitate inspection, repair, or for security purposes.

• Remove The physical separation of an item from its designed position. Removal is normally required to facilitate a maintenance action on the item removed or on the area or items exposed by the removal.

• Repair Whatever is required to restore an item to serviceable status.

• Replace To install a like serviceable item in place of the removed item.

• Service The performance of any act required to keep an item of equipment in operating condition such as lubricating, fueling, oiling, cleaning, etc. “Service” does not include periodic replacement of parts for any corrective maintenance tasks.

• Serviceable A condition of an item in which all requirements of repair, check/test, repair, or modification, as applicable, have been accomplished, making it capable of performing the function or requirements for which it was originally designed or later modified as required by approved TDs.

• Service Life The projected total operational time of an airframe or component. This total is the sum of the service period criteria (time, cycles, months) over the total number of planned service periods.

Extensions beyond the service life require engineering approval on an individual basis.

• Service Period The projected operational interval of an item in terms of operating time, cycles, or calendar age as determined through engineering estimates or actual operational experience. The time or age figure (i.e. 1500 hours, 24 months, etc.) used in relation to service period represents the point at which continued use of the item would create a high probability of failure within a short period of time.

• Specified Used to define a definite amount, operation or limitation which has been established and is contained in applicable directives.

• Structural Sampling Program (SSP) A program designed to monitor changes in the material condition of SSI’s due to fatigue and/or corrosion using representative sampling techniques.

• Structurally Significant Item (SSI) Those local areas of primary structure which are identified, by analysis, to be the most important due to vulnerability to fatigue and/or corrosion and failure effect.

• Subassembly Two or more parts, which form a portion of an assembly or a unit, replaceable as a whole, but having a part or parts which are individually replaceable.

• Substitute Items Two or more items possessing such functional and physical characteristics as to be capable of interchangeability for particular application and without alterations of the items themselves.

• Substitute Material Two or more items possessing such functional and physical characteristics as to be capable of interchangeability for particular applications without alteration of the items themselves.

• System A combination of parts, assemblies, and sets joined together to perform a specific operational function or functions.

• Warning Indicates danger to personnel. The warning precedes the item to which it refers.

• Weapons System The complete integrated aircraft including all airframe and system or components thereof.

• Work Unit Code (WUC) A numeric and or alphabetic character code used to identify an aircraft system, subsystem, assembly, component, etc., on which maintenance is performed.

• Zonal Inspection A general visual inspection of all structure and installations contained within the designated boundaries of a zone.

• Zone A specific area of the aircraft defined by physical boundaries, title, and major installations. Zone descriptions are described in the NAVAIR 01-75PAA-6-3.

1-1.7 Maintenance References

The basic Technical Manuals (NAVAIR Manuals), instructions, drawings, standards and notices referenced in this TRD may be used as job guides, check lists and fault isolation guides. The Technical Manuals specified herein shall be interpreted to include the latest changes, supplements, and revisions.

The use of Government approved best business practices are encouraged when they are economically feasible and to the advantage of the Government. Compliance with maintenance references is mandatory when:

• They are aircraft or equipment specific.

• They prescribe repair policies, use of materials and repair procedures.

• When directed by the Government.

Note

Maintenance references are listed in this TRD. The most current version or edition of the maintenance references used through this TRD shall be used. The depot activity is responsible for obtaining any updated maintenance references with the task(s) intended in this TRD.

1-1.8 Acronyms ACO: Administrative Contracting Officer AEW Airborne Early Warning AGR: Authorized Government Representative APML: Assistant Program Manager for Logistics ATDR: Aircraft Technical Directives Requirements BER: Beyond Economical Repair CBP Customs Border Protection CDRL: Contract Data Requirements List CFM: Contractor Furnished Material DLM Depot Level Maintenance DID: Data Item Description ECN: Engineering Change Notice EHR: Equipment Historical Record EOC: Equipment Operational Capability EPW: Engineering Progress Work FCF: Functional Check Flight FLE: Fatigue Life Expended, expressed as percent FLI: Fatigue Life Index FST: Fleet Support Team GFM: Government Furnished Material IAW: In Accordance With ICN: Interim Change Notification IFR/IMC: Instrument Flight Rules/Instrument Meteorological Conditions IRAN: Inspect and Repair as Necessary ISIS: Isochronal Scheduled Inspection System LED: Local Engineering Directive LPS: Local Process Specification MCR: Manual Change Request MHS: Maintenance History Summary MRC: Maintenance Requirement Card NAVICP: Navy Inventory Control Point NBNC: Noted But Not Corrected NDI: Non-Destructive Inspection O&A: Over and Above

OSP: Operating Service Period PCO: Procuring Contracting Officer PMIC: Periodic Maintenance Information Card PMRM: Periodic Maintenance Requirements Manual PMS: Planned Maintenance System QECA: Quick Engine Change Assembly RAC: Rapid Action Change RAMEC: Rapid Action Minor Engineering Change RCM: Reliability Centered Maintenance RDT&E: Research, Development, Test and Evaluation RFI: Ready For Issue RFU: Ready for Use SRC: Scheduled Removal Component SSI: Structurally Significant Item T/M/S: Type/Model/Series TD: Technical Directive TDSA: Technical Directive Status Accounting TPDR: Technical Publications Deficiency Report TRD: Technical Requirements Document TS: Technical Specification VA: Vibration Analysis VFR/VMC: Visual Flight Rules/Visual Meteorological Conditions WRA: Weapons Replaceable Assembly WUC: Work Unit Code

1-1.9 CDRL Requirements

Commercial depot activity: CDRL requirements will be addressed separately in the contract.

1-1.10 Program Reviews The depot activity shall host Program Reviews to discuss status, and to resolve issues and problems concerning the US Customs and Border Protection P-3 AEW/LRT DLM program IAW requirements specified in the US Customs and Border Protection DLM contract.

1-1.12 Product Oriented Surveys

The Government may conduct Product Oriented Surveys and Evaluations to verify that the technical requirements are consistent with the DLM effort in quality and performance. These Surveys will assist the contract administrative office of the depot activity and the Government on-site representative(s) in resolving problems pertaining to policies, procedures, and specifications.

1-1.13 Specific Equipment

Inspection, replacement or other maintenance actions required by this TRD on specific equipment not installed on a particular aircraft shall be disregarded.

1-1.14 DLM Operational Document Approval

DLM Operational documents for accomplishing all work/inspection requirements of this TRD shall be subject to review by the AGR.

1-1.15 Economical Repair

An item is considered Beyond Economical Repair (BER) if the repair cost is greater than the repair cost established by NAVICP. BER or non-repairable items shall be replaced with serviceable items. The item shall be repaired when directed by the AGR and:

• Economically feasible.

• Work will stop because a replacement item is not available.

1-1.16 Major Structural Repairs

For repairs of a critical or major nature exceeding the depth of coverage of the NA 01-75PAA-3-1, NA 01- 75PAA-3-1.1, or NA 01-75PAA-3-2 the depot activity shall submit a detailed description of damage and repair plan (see Engineering Support,) to the AGR for disposition. When authorized a logbook entry shall be made in the miscellaneous history section describing the location and type of repair performed.

1-1.17 Invalid NDI Requirement

An NDI requirement for an area may be considered invalid by a previous structural repair contained within that same area. When a required NDI requirement can not be accomplished due to a previous repair, the depot activity shall notify the Government for authority to invalidate such NDI requirement. Invalidation of NDI requirements by the Government shall be documented in the Maintenance History Summary and Corrosion Inspection Report.

1-1.18 Interior and Exterior Finishes

All interior and exterior surface areas affected (discrepancies noted during the inspection process) by compliance with this TRD shall be refinished to meet or exceed the finishing requirements of MIL-F-7179 and MIL-F-18264 and are considered basic to this document.

1-1.18.1 Disturbed Systems

When aircraft system integrity has been disturbed as part of, or incidental to the compliance with this TRD, the depot activity shall comply with all checks required by the appropriate P-3 technical manual and the OPNAVINST 4790.2.

1-1.19 AEW Maintenance References Figure 1-1. The organizational manuals for the AEW peculiar system/equipment consists of three separately bound volumes:

• Avionics Systems In-Flight Maintenance Manual (USCS AEW-12),

• Electrical Systems In-Flight Maintenance Manual (USCS AEW-12-9),

• Airframe Maintenance Instructions Manual Supplement (USCS AEW-2).

The purpose of each of these volumes is to present information required for organizational level maintenance of the AEW peculiar systems/ equipment when used in conjunction with EPW (AEW) drawings and other component manuals/ documents listed in the System Support Plan (SSP) for each AEW system.

Organizational level scheduled maintenance requirements for USCS P-3 series aircraft are contained in USCS 01-75AEW-6 Series manuals.

1-1.20 Aircraft Flight Summary Report

The depot activity shall report accrual of flight time during the period the aircraft is at the depot facility.

Flight time shall be reported on OPNAV form 4790/21A. Send copies of all monthly flight summaries compiled on aircraft to AGR

1-1.20.1 Contract Line Items Number (CLIN)

Contract Line Item Numbers (CLINs) will be addressed separately in the commercial contract and will apply only to the commercial depot facility.

1-1.21 Production Plan

The depot activity shall establish and maintain with current information the following in anticipation of complying with the DLM program requirements:

• A production plan which includes, as a minimum, identification of the critical path and critical processes for the modification, fabrication, repair, assembly and integration of components, parts and systems. This plan shall also include anticipated proof-out methods to verify production accuracy and quality.

• A plan for a program and establishment of said program in order to provide management with proactive positive insight and control of the production process. This program shall cover, as a minimum, scheduling and planning, material and parts purchasing, tooling, material product flow, manpower and facilities, identification and management of all the inter-disciplinary relationships affecting product quality, and any other necessary resources.

• A method to identify, assess and reduce any risk associated with implementation of any improvements in the manufacturing, assembly, integration and testing areas.

• The depot activity shall also develop a plan to minimize work-around. The planning and performance approach of the depot activity shall demonstrate top management involvement and commitment to this comprehensive program resulting in minimization of assembly and integration complexity and maximization of production efficiency and cost reduction consciousness.

The production status and any improvement changes shall be routinely presented during technical interchange meetings and program management reviews.

1- 1.22 Aircraft Custody/Status Change Report

The depot activity shall submit custody/status reports IAW requirements specified in the US Customs and Border Protection DLM contract

1-1.22.1 Aircraft Flight Summary Report

The depot activity shall report accrual of flight time IAW requirements specified in the US Customs and Border Protection DLM contract

1-1.22.2 Aircraft Status Report The depot activity shall submit a production status report IAW requirements specified in the US Customs and Border Protection DLM contract

1-1.22.3 Cannibalization

Cannibalization of any aircraft part will require US Customs and Border Protection approval prior to cannibalization. Cannibalization will be documented and included as part of the Maintenance History Summary and Corrosion Inspection Report. The cost of approved cannibalization man-hours and materials, when performed for the convenience of the depot activity will be absorbed by the depot activity.

1-1.23 Firm Fixed Price The depot activity shall provide all services, support equipment, equipment, tools, tooling, and facilities (excluding the identified Government Furnished Material (GFM) and Government Furnished Equipment (GFE)), necessary to perform the requirements of this contract under the Fixed Price requirements. DLM TRD task requirements are Fixed Priced requirements. These Fixed Priced DLM TRD tasks shall include, but are not limited to: General Requirements, In-coming Requirements, Paint Removal Process, Clean, Corrosion Inspection, Corrosion Removal, Corrosion Treatment, Sealant Removal, Prime, Reseal, Paint, Fuel Leak Repair, Disassembly, Access Open/Closes, Zonal Inspection Requirements, Structural Inspection Requirements, System and Component Requirements and DLM Reports.

1-1.23.1 Over and Above

Any tasks that are performed that are not specified in this TRD as part of the basic requirement will be considered Over & Above (O&A) requirements. All Over & Above tasks shall be authorized by the AGR prior to commencing work.

1-1.24 Flight Operations Plan

The depot activity shall develop air and ground procedures that ensure the following requirements are met:

• Ensure that a Flight Operations Program is in effect to prevent injury to personnel and damage to aircraft in accordance with DFAR clause 252.228-7001 “Ground and Flight Risk,” and NAVAIRINST 3710.1.

• Record files for ACO, as required in NAVAIRINST 3710.1.

• Develop procedures for the evacuation and protection of aircraft in the event of severe weather

(hurricane, strong winds, etc.). The depot activity shall include provisions for sheltering, securing, or repositioning the aircraft, as well as for notifying the Government Administrative Office of the actions taken.

• Publish an Air Operations Manual. The manual shall consist of written procedures for flight operations at the depot activity and in the local operating areas. The Air Operations Manual will cover, at least the following primary areas of concern and shall incorporate the requirements of OPNAVINST 3710.7 (Navy personnel) and NAVAIRINST 3710.1 (Personnel from the depot activity):

• Flight Management: The flight management section shall address flight scheduling to include the following:

• Procedures for obtaining approval for flights, including induction and functional check flights. In cases where a type of flight is conducted repeatedly for the same purpose, the approval may be for all flights of that specified type, having the same mission profiles.

• Ground Crew Requirements. This section will include information on the qualifications, certifications, and training programs of personnel involved in engine run-ups, aircraft tow operations, fuel service operations, and aircraft fire fighting and rescue operations. This section will also identify technical manuals and checklists which will be used in performing all functions for which technical data has been published. This includes towing, refueling, and scheduled and unscheduled maintenance. Technical manuals/checklists for the P-3 Depot Maintenance Program, as well as flight operations shall include:

• Procedures that ensure all changes, revisions and supplements are promptly posted in the basic technical data available.

• Provisions for determining weight and balance for each aircraft and flight.

• Procedures for issuance of certificates, licenses and permits.

• Procedures for the care and maintenance of life support equipment.

• Planning and Flight Mission Procedures: The planning and flight mission procedures section shall be developed around the following criteria:

• Mission profile for each regularly conducted flight shall be covered in the flight operations procedures; include the establishment of specific geographic areas or point-to-point routes and flight following procedures for the conduct of flights.

• Mission profiles and specified geographical areas should make maximum use of ground radar and ground radio to monitor position and status of aircraft.

• Operational procedures at the depot activity shall include the following items. If the flight activity is physically located at a fully operational civil or military airfield that has these procedures in operation, the depot activity must…