Attachment_5_-_P-8A_Depot_Spec-AEPD_Rev_A_-_30_Oct_2016_-_Final.pdf

NAVAIR P-8A AEPD Rev A

P-8A

INTEGRATED MAINTENANCE PROGRAM

DEPOT SPECIFICATION

Revision A – 30 October 2016

AGE EXPLORATION PLAN – DEPOT

NAVY MODEL

P-8A

This specification replaces and supersedes P-8A AEPD dated 30 July 2016

DISTRIBUTION STATEMENT C. Distribution is authorized to U.S. Government agencies and their contractors to protect publications required for official use or for administrative or operational purposes.

DESTRUCTION NOTICE. For unclassified, unlimited documents, destroy by any means that will prevent disclosure of contents or reconstruction of the document.

Published by the direction of the Commander, Naval Air Systems Command

Prepared by: __________________ William Adams P-8A FST IMC/ RCM Lead

Approved by: _________________ Rebecca Thacker P-8A Fleet Support Team Leader

Approved by: __________________ David J. Tuemler P-8A In-Service APML william.l.adams1 Signature Stamp rebecca.thacker Becky i

CHANGE HIGHLIGHTS

For P-8A AEPD dated 30 October 2016

Changes from

P-8A AEPD dated 30 July 2016

Location of Change Description of Change Page 1-4 Revised paragraph 1-2 to specify that task intervals contained in PMIC/SMP and this specification take precedence over task intervals contained in Task Cards.

Page D-1

Added Task Cards 20-020-00-01, 20‐050‐00‐01, 20-060-00-01 and 20-070-00-01 as part of Appendix D Systems Inspections.

Page D-4 to D-5

Added Task Cards 27-228-00-02, 27‐228‐00‐03, 27‐228‐00‐04, 27‐228‐00‐05, 27‐228‐00‐06, 27‐ 228‐00‐07 and 27‐228‐00‐08 as part of Appendix D Systems Inspections.

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Table of Contents SECTION I. GENERAL REQUIREMENTS .................................................................. 1-1

1-1.1 GENERAL .............................................................................................. 1-1 1-1.2 CONTENTS ........................................................................................... 1-3 1-1.3 CHANGE RECOMMENDATIONS .......................................................... 1-4

1-2 INTERVALS/STRUCTURAL SERVICE LIFE LIMITS ...................................... 1-4 1-3 DEFINITIONS AND ACRONYMS ................................................................... 1-5

1-3.1 DEFINITIONS......................................................................................... 1-5 1-3.2 ACRONYMS ........................................................................................ 1-18

1-4 MAINTENANCE REFERENCES ................................................................... 1-22 1-4.1 FEDERAL SPECIFICATIONS .............................................................. 1-23 1-4.2 GENERAL MAINTENANCE PUBLICATIONS ....................................... 1-23

1-4.3 P-8A SPECIFIC MAINTENANCE PUBLICATIONS .............................. 1-23

1-4.4 INSTRUCTIONS .................................................................................. 1-24 1-4.5 BULLETINS .......................................................................................... 1-24 1-4.6 MANUALS ............................................................................................ 1-24 1-4.7 DIRECTIVES ........................................................................................ 1-25

1-4.8 P-8A FST DEVELOPED LOCAL PROCESS SPECIFICATIONS .......... 1-25

1.5 AIRCRAFT APPLICATION CODES .............................................................. 1-25

SECTION II DEPOT MAINTENANCE REQUIREMENTS ............................................. 2-1

2-1 GENERAL MAINTENANCE STANDARDS AND PROCESS CONTROL

REQUIREMENTS ........................................................................................... 2-1 2-1.1 MAINTENANCE PROCEDURES ............................................................ 2-1

2-1.3 TECHNICAL DIRECTIVE (TD) / SERVICE ACTION (SA)

COMPLIANCE ........................................................................................ 2-2 2-1.4 DEFECT CORRECTION CRITERIA ........................................................ 2-2

2-1.5 SCHEDULED COMPONENT / REPLACEMENT CRITERIA ................... 2-3

2-1.6 UNSCHEDULED ACCESSORY AND COMPONENT REPAIR

CRITERIA .............................................................................................. 2-3 2-1.7 CONCURRENT COMPONENT REPAIR ................................................. 2-4 2-1.8 ECONOMICAL REPAIR DETERMINATION ............................................ 2-4

2-1.9 AIRCRAFT / ENGINE ORGNIZATIONAL LEVEL SCHEDULED

MAINTENANCE REQUIREMENTS ........................................................ 2-4 2-1.10 CORROSION CORRECTION CRITERIA ............................................... 2-5

2-1.11 GROUND HANDLING, OPERATION, OPERATION AND SAFETY

PRECAUTIONS ..................................................................................... 2-5 2-1.12 STRUCTURAL REPAIRS ....................................................................... 2-6 2-1.13 REPLACEMENT PARTS AND SUBSTITUTIONS .................................. 2-6 2-1.14 UNAUTHORIZED INSTALLATIONS ...................................................... 2-6 2-1.15 DISTURBED SYSTEMS ......................................................................... 2-6 2-1.16 ANTI-FRICTION BEARINGS .................................................................. 2-6 2-1.17 HYDRAULIC CONTAMINATION ............................................................ 2-7 2-1.18 REPAIR OF SYSTEMS CONTROLS ..................................................... 2-7 iii

2-1.19 TEST AND SUPPORT EQUIPMENT ..................................................... 2-7 2-1.20 STRUCTURAL HARDWARE .................................................................. 2-7 2-1.21 PROTECTIVE COVERINGS .................................................................. 2-7 2-1.22 PIPE, TUBING, AND HOSE ................................................................... 2-7 2-1.23 NON-DESTRUCTIVE INSPECTION ...................................................... 2-7 2-1.24 TRANSPARENT PLASTICS ................................................................... 2-8 2-1.25 REINFORCED PLASTICS / COMPOSITES ........................................... 2-8 2-1.26 RADOMES AND ANTENNA COVERINGS ............................................. 2-8 2-1.27 ELECTRICAL SYSTEM ......................................................................... 2-8 2-1.28 PACKINGS, GASKETS AND SEALS .................................................... 2-8 2-1.29 WEIGHT AND BALANCE ...................................................................... 2-8 2-1.30 USAGE / HANDLING OF GASES ......................................................... 2-8 2-1.31 CEMENTS, SEALANTS AND COATINGS ............................................. 2-8 2-1.32 ABRASIVE MATERIALS ....................................................................... 2-8 2-1.33 REPORT REQUIREMENTS .................................................................. 2-9 2-1.34 ENGINEERING SUPPORT REQUIREMENTS ...................................... 2-9

2-2 INDUCTION INTO DEPOT MAINTENANCE ................................................... 2-9

2-2.1 REPORTING CUSTODIAN RESPONSIBILITIES PRIOR TO

DEPOT INDUCTION .............................................................................. 2-9 2-2.2 AIRCRAFT EQUIPMENT INVENTORY ................................................... 2-9 2-2.3 AIRCRAFT RECORDS ANALYSIS........................................................ 2-10 2-2.4 REPORTED DEFECT ANALYSIS ......................................................... 2-10 2-2.5 HYDRAULIC AND FUEL SYSTEMS ..................................................... 2-10 2-2.6 CLEANING ............................................................................................ 2-11 2-2.7 PRESERVATION .................................................................................. 2-11 2-3 SURFACE CONDITIONING ..................................................................... 2-11

2-4 DISASSEMBLY / ASSEMBLY ........................................................................ 2-13 2-4.1 GENERAL ............................................................................................. 2-13

2-4.2 INSTALLATION OF SAFETY DEVICES AND PROCEDURES .............. 2-13

2-4.3 DEFECTS DISCOVERED DURING DISASSEMBLY ............................ 2-13

2-5 INSPECTION PROCEDURES AND ZONE DESCRIPTION ........................... 2-14

2-5.1 GENERAL ............................................................................................. 2-14

2.5.2 ZONE DESCRIPTIONS ......................................................................... 2-14

2-6 STRUCTURAL AND CORROSION REQUIREMENTS .................................. 2-14 2-6.1 EXPLANATION OF HEADINGS ............................................................ 2-14 2-6.2 STRUCTURAL REQUIREMENTS ......................................................... 2-15

2-7 SYSTEMS AND COMPONENTS REQUIREMENTS ..................................... 2-15 2-8 AGE EXPLORATION / ZONAL REQUIREMENTS ........................................ 2-15

SECTION III AEPD FUNCTIONAL CHK FLT AND GOV’T ACCEPT ............................ 3-1 3-1 FINAL PROCESSING ...................................................................................... 3-1

3-1.1 WEIGHT AND BALANCE ........................................................................ 3-1 3-1.2 LOGS AND RECORDS ........................................................................... 3-1 3-1.3 INVENTORY EQUIPMENT ..................................................................... 3-2 iv

3-1.4 HYDRAULIC SYSTEM ............................................................................ 3-2 3-1.5 DEPRESERVATION AND SERVICING ................................................... 3-2

3-2 FUNCTIONAL CHECK FLIGHT ...................................................................... 3-4 3-2.1 DAILY/TURNAROUND/SPECIAL INSPECTIONS ................................... 3-4 3-2.2 CHECK FLIGHT ...................................................................................... 3-4 3-2.3 POST FLIGHT INSPECTION .................................................................. 3-4

3-3 GOVERNMENT ACCEPTANCE ..................................................................... 3-4 3-3.1 ACCEPTANCE CHECKFLIGHT .............................................................. 3-4 3-3.2 CORRECTION OF DISCREPANCIES ..................................................... 3-4 3-3.3 CUSTOMER ACCEPTANCE ................................................................... 3-4

SECTION IV COMPONENT REMOVAL AND REPLACEMENT SCHEDULE .............. 4-1

4-1 GENERAL ........................................................................................................ 4-1 4-2 EXPLANATION OF HEADINGS ....................................................................... 4-1 4-3 COMPONENT REMOVAL REPLACEMENT LIST ............................................ 4-1

SECTION V INSPECTIONS NOT ACCOMPLISHED AT AEPD ................................... 5-1

SECTION VI DEPOT LEVEL MAINTENANCE REPORTS ........................................... 6-1 6-1 GENERAL ........................................................................................................ 6-1 6-2 SITUATION SUMMARY ................................................................................... 6-1

6-3 EXAMINER & EVALUATION (E&E) DISCREPANCY REPORTS ..................... 6-1

6-4 MAINTENANCE HISTORY SUMMARY REPORT ............................................ 6-1 6-5 PARTS REQUIRED REPORT (PRR) ............................................................... 6-2 6-6 COSTS PER BUNO REPORT ......................................................................... 6-2 6-7 NOTED BUT NOT CORRECTED (NBNC) REPORT ........................................ 6-2

6-8 MAJOR REPAIR AND ALTERATION REPORT 6-2

Appendix A P-8A Major Airplane Zones ............................................................ A-1

Appendix B Baseline Structural Inspections ....................................................... B-1

Appendix C Structural Fatigue Inspections ......................................................... C-1

Appendix D Systems Inspections ....................................................................... D-1

Appendix E AE / Zonal Inspections .................................................................... E-1 v

List of Figures Figure 1-1.1 P-8A Integrated Program Cycle ............................................................................. 1-2 Figure 1-3.2 Example of MSI Breakdown .................................................................. 1-18 Figure A-1 P-8A Major Airplane Zones ....................................................................... A-1

List of Tables Table 1-1 Summary of AEPD Sections......................................................................... 1-3 Table 1-3.1 (Definitions) ............................................................................................... 1-5 Table 1-3.2 (Acronyms) .............................................................................................. 1-18 Table 1-4 General Maintenance Publications ............................................................. 1-23 Table 1.4-3 P-8A Specific Maintenance Publications ................................................. 1-23 Table 1-4 Instructions ................................................................................................. 1-24 Table 1.4-6 Manuals .................................................................................................. 1-24 Table 1.4-7 Directives ................................................................................................ 1-25 Table 1.4-8 Forms ...................................................................................................... 1-25 Table 6-4.1 Discrepancy Report Data Elements ........................................................... 6-1 Table A-1 P-8A Major Airplane Zone Titles ................................................................. A-1

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SECTION I. GENERAL REQUIREMENTS

1-1 SCOPE

a. This specification establishes the Depot Level (D-Level) requirements of the Integrated Maintenance Concept and Program using Depot Age Exploration requirements for the United States Navy P-8A Poseidon aircraft. Throughout this specification, the depot level inspection will be referred to as Age Exploration Plan Depot (AEPD).

b. For the purpose of this document, all work performed during a scheduled depot visit that is not called out on the P-8A Depot Task Cards or packaged into this specification will be considered as unscheduled work.

c. The P-8 Poseidon is a long-range anti-submarine warfare, anti-surface warfare, intelligence, surveillance and reconnaissance aircraft capable of broad-area maritime and littoral operations. This military derivative has the fuselage of the 737-800 and the wings of the 737-900ER allowing it to leverage off of the Next-Generation 737 lines.

1-1.1 GENERAL

a. Depot Level Maintenance requirements provide for airframe, and systems inspection, defect correction, preventive maintenance. The Depot Level requirements for aircraft subject to this process are the minimum requirements formulated and established to the depth required to ensure the reliability and operational availability of the aircraft at minimum cost for the duration of the established service period and provides support of total service life.

b. The USN P-8A has a three level maintenance concept: Organizational (O-Level), Intermediate (I-Level), and Depot (D-Level). For a brief description of these maintenance types, see Glossary (Acronyms and Definitions) Section.

c. The initial intervals are generated by the P-8A Maintenance Steering Group (MSG-3) analysis and provide a solid foundation for the P-8A maintenance program, and they utilize a calendar based maintenance program. The P-8A maintenance program is further optimized in the Scheduled Maintenance Program (SMP) incorporating MSG-3 driven requirements as well as USN’s unique requirements. The Organizational level maintenance check (“A” Check) occurs every 90 calendar days or 3 months. The Planned Operating Interval (POI) is initially scheduled at 6 years and is repeated every 4 years. Data collected from the AEPD program and other maintenance history will be analyzed using Reliability Centered Maintenance (RCM) to validate or adjust initial POIs.

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Figure 1-1.1 P-8A Integrated Program Cycle

The AEPD requirement includes, but is not limited to:

(1) A thorough and comprehensive inspection of selected aircraft structure and flight critical components by visual and appropriate Non-Destructive Inspection (NDI) methods with repair as required to ensure the serviceability of the affected structure until the next sequential Depot induction.

(2) Replacement of depot level replaceable life/time/event limits components or parts, which will exceed the specified replacement interval prior to the next scheduled Depot induction.

(3) Adjustments, checks, tests, repairs, preventive maintenance, and the airframe repair procedures coincidental thereto shall be accomplished under the applicable directives and publications as directed by this specification.

(4) The scheduled maintenance requirements executed during the Depot Maintenance comprise the minimum requirements necessary to ensure the timely discovery and correction of actual and/or anticipated defects. Compliance with these requirements is mandatory. For scheduled maintenance requirements, only those that are defined as “DEPOT” will be performed. Non-depot level tasks may be performed if they are authorized by Commander, Naval Air Forces (CNAF) and PMA-290 on individual work package for each P-8A being inducted into Depot Maintenance.

(5) Unscheduled maintenance requirements which are discovered as an incidental result of the following items.

(1) Review of aircraft logbooks and records

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(2) Operational and functional testing of systems

(3) Examination of the aircraft and its associated components during Depot Maintenance.

(6) This specification applies equally to government and commercial Depot Repair Points

(DRP) except as specifically noted herein. Waiver of any requirements shall be coordinated with and approved by the P-8A Fleet Support Team (FST).

1-1.2 CONTENTS

This summarizes the contents of each section.

Table 1-1 Summary of AEPD Sections

SECTIONS SUMMARY

SECTION 1

(General

Instructions)

General instructions for scope/purpose of AEPD, revision info, maintenance intervals, definitions of the terms and list of maintenance publications/documents/directives to perform Depot Maintenance.

SECTION 2

(Depot

Maintenance Requirements)

General and specific maintenance standards accomplished by DRP.

Reporting custodian aircraft preparation responsibilities;

DRP induction procedures (including preliminary inspections); Surface conditioning; Disassembly;

Structural, Age Exploration Tasks/Zonal Inspections, Fatigue Inspections; System/Components Inspection Requirements.

SECTION 3

(Functional Checks and Functional

Check Flight)

Functional Check Flight (FCF) requirements to be supported by the DRP prior to government acceptance of the reworked aircraft.

SECTION 4

(Component Removal and Replacement)

List of aircraft systems or components requiring replacement and/or removals as function of aircraft flight hours, unit operating time cycles, or Depot intervals.

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SECTIONS SUMMARY

SECTION 5

(Inspections Not Accomplished At AEPD)

Inspections that were accomplished as part of the depot event that will exclude the requirement for inspection tasks at the organizational level. This is for reporting activity after aircraft is returned from the DRP to avoid duplication of effort when completion of special/phase inspections is required upon return to the reporting activity.

SECTION 6

(Depot

Maintenance Reports)

Description of the engineering report, which will be submitted to the FST by the DRPs for each aircraft undergoing Depot Maintenance.

1-1.3 CHANGE RECOMMENDATIONS

a. Recommendations to add, delete, or change the Depot Maintenance requirements detailed herein are encouraged and should be addressed to Integrated Maintenance Concept (IMC)/Program (P) Lead.

Commanding Officer Fleet Readiness Center Southeast ATTN: P-8A FST IMC/P Lead Naval Air Station Jacksonville, FL 32212-0016

All changes will be approved by the P-8A FST and documented via Specification Interim Change Notice (SICN). All changes will be provided to the DRP from the PCO via contract modification as required.

b. During the accomplishment of the tasks of this document, technical manual deficiencies shall be identified by the DRP by submitting Technical Publication Deficiency Report (TPDR) per the COMNAVAIRFORINST 4790.2 series, with supporting documentation to the P-8A FST for review.

1-2 INTERVALS/STRUCTURAL SERVICE LIFE LIMITS

In general, the NAVAIR P-8A Scheduled Maintenance Plan (SMP) / Periodic Maintenance Information Card (PMIC), and this specification provide the intervals and operational service life for all scheduled tasks and take precedence over intervals contained in P-8A unique Task Cards. Furthermore, the structural life limits discussed in this specification have or will be incorporated in the NAVAIR P-8A SMP / PMIC. The NAVAIR P-8A SMP / PMIC has incorporated all tasks approved by the NAVAIR PMA-290 Assistant Program Manager Logistics (APML) that are determined necessary to maximize operational readiness and safety. Service periods, planned operational service life, and authorized extensions are established by, and contained in OPNAVINST 3110.11 series.

OPNAVINST 3110.11 series is supplemented by OPNAVINST 13120.1 series, which provides structural life limits for all US Navy fixed wing aircraft.

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1-3 DEFINITIONS AND ACRONYMS

This section lists definition of terminology applied to the maintenance and rework of P-8A aircraft. Those not listed but used in this spec. shall be defined per COMNAVAIRFORINST 4790.2 series and interpreted in the context of the requirements of this specification. Generally accepted interpretations shall not be acceptable for deviation from the definitions of this specification.

1-3.1 DEFINITIONS

The definitions and acronyms are not all inclusive but pertain to maintenance and rework requirements in this specification.

Table 1-3.1 (Definitions)

TERMS DEFINITION

A Check Primary O-Level inspections are packaged for completion as part of a 90 Day calendar inspection cycle designated as an "A" Check. "A" Check Inspections are completed using commercial formatted P-8A Task Cards and are performed at fixed intervals throughout the Service Life of the aircraft.

Access Access (access panel) is a physical part that has additional characteristics in that it provides a means to access other parts or areas. (i.e. lower fwd radome access panel, elevator hinge cover access, fuel tank access door, etc)

Accessible Areas exposed by the removal of non-permanent fasteners, access doors, panels, fairings, etc, or other disassembly required by a maintenance requirement, which does not involve destructive disassembly unless otherwise specified.

Abrasion The wearing of material by rubbing or scraping (i.e.

chafing)

Accessory A part, subassembly, or assembly designed for use in conjunction with or to supplement another assembly, unit, or set.

Air Vehicle Everything that goes airborne with the aircraft except crew. The air vehicle consists of the aircraft with aircraft systems and mission systems. It includes armament and ordnance system components and weapons and dispensable stores.

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

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TERMS DEFINITION

Assembly Any combination or number of parts or subassemblies joined together to perform a specific function.

Accidental Damage Physical deterioration of an item caused by contact or impact with an object or influence which is not a part of the aircraft, or by human error during manufacturing, operation of the aircraft, or maintenance practices.

Age Exploration A process used to collect specific data to replace estimated or assumed values, optimize or validate data used and assumptions made during an RCM analysis.

This may include exploration of characteristics or effects of age or usage on a given failure mode.

Airworthiness Limitations

A section of the Instructions for Continued Airworthiness that contains each mandatory replacement time, structural inspection interval, and related structural inspection task. This section may also be used to define a threshold for the fatigue related inspections and the need to control corrosion to Level 1 or better. The information contained in the Airworthiness Limitations section may be changed to reflect service and/or test experience or new analysis methods.

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

Calibrate To determine and make required corrections in calibration standards or precision measurement equipment used in precise measurement or to repair, adjust and align equipment so that it functions within assigned tolerances;

may consist of the comparison of two instruments, one of which is a certified calibration standard of known accuracy, to detect and adjust any discrepancy.

Chafing The wearing away of material by rubbing or scraping (synonymous with abrasion).

Check An examination to determine functional capability or physical integrity of an item.

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 Any self-contained part, combination of parts, subassemblies or units, which perform a distinctive function necessary to the operation of a system.

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(synonymous with unit)

Component Maintenance Manual

Information required check, repairing, adjusting and testing units or assemblies, normally performed away from the airplane because of the need for special equipment.

Composite Material A material composed of two or more different constituents, the combination of which results in a products superior in some structural and mechanical properties to any of its constituents parts. For P-8A, any non-metallic material used for structures are considered composite.

Condition To inspect for (condition) implies a visual examination to determine the existence of external damage corrosion, and defects that could render the article unacceptable for continued use.

Conditional Inspection An unscheduled inspection required as a result of an over limit or unanticipated situations such as bird strike, hard landing, tire burst, galley spillage, Dry Bay Fire Protection System (DBFBS) bottle discharge, etc.

Configuration The functional and physical characteristics of material as described in technical documents and achieved in a product.

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 referenced therein (DoD directive 5010.19)

Consumable Generally bulk-type materials such as fuel, lubricants, cements, compounds, paints, chemicals, dyes, splices, patches, etc., called out in maintenance and repair procedures for aircraft, engines, equipment, and component end items. These materials are items used only once.

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

Corrosion Level 1 Corrosion damage that does not require structural reinforcement or replacement. Or corrosion occurring between successive inspections that exceeds allowable limits but is local and can be reworked/blended-out within allowable limits (as defined by Structure Repair Manual (SRM)) and can be attributed to an event not typical of operator usage of other aircraft in the same fleet.

Corrosion Level 2 Corrosion occurring between successive inspections that require a single re-work / blend- out which then exceeds allowable limits, requiring a repair / reinforcement, or

1-8 complete or partial replacement of structure or corrosion occurring between successive inspections that is widespread and approaching allowable SRM limits.

Corrosion Level 3 Corrosion found during the first or subsequent inspections, which is determined to be an urgent airworthiness concern, requiring expeditious action.

Corrosion Prevention and Control Program

(CPCP)

A program of maintenance tasks implemented at a threshold designed to control an aircraft structure to Corrosion Level 1 or better. P-8A Structural tasks integrate CPCP as part of the structural inspections.

Crack A break, fracture, crevice, or separation in the structure of a part.

Crazing Fine cracks, which may extend in a network, often found in plastic material (i.e. windshields, canopy glass, windows, etc.).

Damage Impairment of an aircraft/item/part by a physical force.

Damage (Accidental) Physical deterioration of an item caused by contact or impact with an object or influence which is not a part of the aircraft, or by human error during manufacturing, operation of the aircraft, or maintenance practices.

Damage (Environmental)

Physical deterioration of an item's strength or resistance to failure as a result of chemical interaction with its climate or environment.

Damage Tolerance The attribute of an airframe, component or system that permits it to retain its required strength, integrity and/or function for a period of unrepaired usage after it has sustained specific levels of fatigue, wear, corrosion, cracking, accidental and/or discrete source damage.

Defect Any nonconformance of a unit or part with specified requirements (synonymous with Discrepancy)

Defect, Critical A defect that constitutes a hazardous or unsafe condition, or as determined by experience and judgment could conceivably become so, relative to the deleterious effect on the prime intended function, safety of flight, or mission capability of the aircraft or its operating personnel.

Defect, Major A defect, other than critical, that could result in failure, materially reduces, or if not corrected, will degrade the usability of the unit or part for its intended purpose.

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Defect, Minor A defect that does not materially reduce or if not corrected will not degrade the usability of the unit or part for its intended purpose, or is a departure from standards which has no significant bearing on the effective use or operation of the unit or part.

Delaminating/Disbond Structural separation or cracking that occurs at or in the bond plane of a structural element, within a structural assembly, caused by in service accidental damage, environmental effects and/or cyclic loading.

Daily Inspection An inspection conducted to inspect for defects to a greater depth than the turnaround inspection.

D-Level Maintenance This check is not limited to but includes structural inspections, inspection of control cabin, mission cabin, cargo compartments, etc., detailed and operational check of systems, hard time and life-limited part replacements, structural/system/component repairs/replacements discovered during routine inspection, servicing and lubrication, replenishment of fluids/air, engine run-up (if applicable), test flight and fixing flight test faults. The initial and repeat depot check is performed at 6 YR and 4 YR, respectively. Depot Maintenance is similar to heavy maintenance or D check and may include structural samplings. It is not limited to but includes induction, disassembly, inspection, assembly, painting, and preparation for Functional Check Flight (FCF).

Designated Repair Point

(DRP)

The government or commercial industrial establishment designated by the Naval Air Systems Command or the DoD as having DLM responsibility for rework of a particular model aircraft or component.

Discard A task that involves the removal of an item that has reached the end of its service life. Once removed the item is to be discarded (thrown away/destroyed) and replace with a serviceable item.

Economic Effects Failure effects which do not prevent aircraft operation, but are economically undesirable due to added labor and material cost for aircraft or shop repair.

Electrical Wiring Interconnection System

(EWIS)

An electrical connection between two or more points including the associated terminal devices (e.g., connectors, terminal blocks, splices) and the necessary means for its installation and identification.

Enhanced Zonal Analysis Procedure

(EZAP)

EZAP is an analytical procedure, which identifies the physical and environmental conditions contained in each zone of an airplane, analyzes the effects of these conditions on electrical wiring and components, and assesses the possibilities for smoke and fire. The end

1-10 result of the analysis is inspection and restoration tasks in the form of EWIS ICA.

Environmental Deterioration (ED)

Physical deterioration of an item's strength or resistance to failure as a result of chemical interaction with its climate or environment.

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

Examination An element of inspection (generally non-destructive) consisting of investigation, without the use of special laboratory appliances or procedures, or supplies and services to determine conformance to those specified requirements that can be determined by such investigations.

Failure The inability of an item to perform within previously specified limits.

Failure Cause Why the functional failure occurs.

Failure Condition The effect on the aircraft and its occupants, both direct and consequential, caused or contributed to by one or more failures, considering relevant adverse operational or environmental conditions.

Failure Effect What is the result of a functional failure?

Fatigue Damage The initiation of a crack or cracks due to cyclic loading and subsequent propagation.

Fatigue Related Sampling Inspection

Inspections on specific aircraft selected from those which have the highest operating age/usage in order to identify the first evidence of deterioration in their condition caused by fatigue damage.

Fault An identifiable condition in which one element of a redundant system has failed (no longer available) without impact on the required function output of the system Maintenance Significant Item (MSI). At the system level, a fault is not considered a functional failure.

Fault-Tolerant System A system that is designed with redundant elements that can fail without impact on safety or operating capability.

Fleet Support Team A team delegated the authority and assigned the responsibility to perform specific in-service maintenance engineering and logistical management functions in support of a particular aircraft program. This function for the P-8A is currently performed by the P-8A FST, Fleet Readiness Center Southeast (FRCSE) by direction of Naval Air Systems Command.

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Foreign Object Damage

(FOD)

Damage to any portion of the aircraft caused by impact or ingestion of birds, stones, hail or other debris or tools.

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

Function The normal characteristic actions of an item.

Functional Check A quantitative check to determine if one or more functions of an item perform within specified limits.

Functional Check Flight Airborne operational test performed to determine whether the airframe, power plant, accessories and other items of equipment are functioning in accordance with (IAW) predetermined standards when subjected to the intended operating environment.

Functional Failure Failure of an item to perform its intended function within specified limits.

Gouge A damaged area where the result is a cross-sectional change caused by a sharp object and gives a continuous, sharp or smooth groove in the material.

HIRF/L High Intensity Radiated Field / Lightning. HIRF/L Protection Systems are comprised of components that avoid, eliminate, or reduce the consequence of an HIRF/L event.

IMC/P Site Coordinator Individual designated by the PMA to coordinate all communications and negotiations between the Controlling Custodian and the DRP. Local cognizant authority for Specification requirements, work/no work criteria, NBNC, defect classification, basic, and over and above work. All P-8A depot sites will have an IMC/P Coordinator.

Inspection – Detailed

(DET)

An intensive examination of a specific item, installation or assembly to detect damage, failure or irregularity including but not limited to the following: crack, pulled apart parts, loose and/or flaked paint, discoloration, bend, twist and/or distortion, wrinkle and/or buckle, loose or missing fasteners, pulled out fasteners, delamination, fiber breakout, misalignment, interference, nick and/or gouge, and corrosion. This inspection is made within touching distance under an external white light source, i.e., 150-watt standard spotlight or 40-watt high-intensity light or equivalent, held within four feet. Any area where a defect is suspected is examined using a 5-10X magnifying lens to verify that there is a defect. Other inspection aids, e.g., a mirror, may be necessary. Surface cleaning and elaborate access procedures may be required

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Inspection - General Visual (GVI)

A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity including but not limited to the following:

crack, pulled apart parts, loose and/or flaked paint, discoloration, bend, twist and/or distortion, wrinkle and/or buckle, loose or missing fasteners, pulled out fasteners, delamination, fiber breakout, misalignment, interference, nick and/or gouge, and corrosion. This level of inspection is made from within touching distance, unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area.

This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or droplight and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.

Inspection - Special Detailed (SDI)

An intensive examination of a specific item, installation, or assembly to detect damage, failure or irregularity. The examination is likely to make extensive use of specialized Inspection Techniques and/or equipment. Intricate cleaning and substantial access or disassembly procedure may be required.

Interval (Initial - Repeat) Initial Interval - Interval between the start of service-life and the first task accomplishment Repeat Interval - The interval (after the initial interval) between successive accomplishments of a specific maintenance task.

Item Any level of hardware assembly (i.e., system, sub-system, module, accessory, component, unit, part, etc.).

Landing (LDG) The controlled return of an aircraft in flight to the surface.

It includes touch and goes providing the landing gear touches the surface.

Lubrication and Servicing

Any act of lubricating or servicing for the purpose of maintaining inherent design capabilities.

Maintenance Concept A collection of ideas and philosophies in maintenance which are used as the basis for the development of a specific maintenance program, procedure or policy.

Maintenance Significant Item - (MSI)

Items identified by the manufacturer whose failure a.

could affect safety (on ground or in flight), and/or b. is undetectable during operations, and/or c. could have significant operational impact, and/or d. could have significant economic impact (See Figure 1-3.1 below)

Maintenance Tasks An action or set of actions required to achieve a desired outcome which restores an item to or maintains an item in serviceable condition, including inspection and determination of condition.

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Non-metallics Any structural material made from fibrous or laminated components bonded together by a medium. Materials such as graphite epoxy, boron epoxy, fiber glass, Kevlar epoxy, acrylics and the like are non-metallics. Non-metallics include adhesives used to join other metallic or non-metallic structural materials.

Modify To alter in appearance, performance, functions, position or effect.

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

Nondestructive Testing and Inspection (NDT/I)

The technologies (methods) for determining characteristics about the physical condition of a part of material, without permanently changing it. NDI is the application of nondestructive testing to the inspection of parts, structure, and material to determine condition/ serviceability. Typical defects and conditions to be detected are those not detectable visually, like fatigue and stress corrosion cracks, inclusions, porosity, delaminations, disbonds, enclosed FOD, etc. The most frequently used nondestructive testing methods are Fluorescent Penetrant, Magnetic Particle, Eddy Current, Ultrasonics and Radiographic. Methods used less frequently in the aircraft industry include thermal imaging, gamma and neutron radiography, and acoustic emission.

Noted But Not Corrected (NBNC) Defects

All discrepancies that have not been corrected shall be noted on an NBNC list and are to be provided to the reporting custodian.

O-Level Maintenance Organizational maintenance or O-Level is performed by an operating unit (squadron) daily to support its own operations.

Operational Check An operational check is a task to determine that an item is fulfilling its intended purpose. Does not require quantitative tolerances. This is a failure finding task.

Operational Effects Failure effects which interfere with the completion of the aircraft mission. These failures cause delays, cancellations, ground or flight interruptions, high drag coefficients, altitude restrictions, etc.

Other Structure Structure which is judged not to be a Principle Structural Element. "Other Structure" is defined both externally and internally within zonal boundaries.

Over and Above For the purpose of this document, any discrepancies discovered while performing inspections within this document and with the concurrence of the IMC/P Site Coordinator, will be considered as over and above. All over-and-above discrepancies are therefore priced

1-14 separately.

Preservation The protection of aviation assets (aircraft, SE and mobile facilities) from material degradation during periods of inactivity, storage, or shipment.

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

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

Potential Failure A defined identifiable condition that indicates that a degradation process is taking place that will lead to a functional failure.

Principle Structural Element

Primary structure which contribute significantly to carrying flight, ground, and pressurization loads, and whose failure could result in the catastrophic failure of the airplane.

Principle Structural Elements are also known as Structural Significant Items.

Redundant Functional Elements

Two or more independent physical elements of a system/item providing the same function.

Refinish To restore an existing surface finish without removal of all the existing finish. The process of refinishing includes cleaning the affected are to remove all loose and scaling paint or other finishing material, soil, and contaminants;

feather-edging the remaining original finish to a smooth surface; and applying new finishing coatings (including chemical conversion coatings).

Reinstall The installation of a part or component in its former position to accomplish its former function.

Repair Whatever is required to restore an item to serviceable status, including preparation, disassembly, and inspection, and fault correction, replacement of parts, adjustment, reassembly, calibration, and test.

Repair as required The unscheduled repair as directed by IMC Site Coordinator of discrepant items when the repair is technically feasible or economically justified and is based on inspections and tests or authorized directives to restore the item to an operable condition.

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

Reporting Custodian

Navy squadrons/units and commercial contractors assigned custody of aircraft. An organizational unit of the

1-15 lowest echelon of command accepting responsibility, involving the accountability to the Chief of Naval Operations, for aircraft and engines.

Restoration That work necessary to return the item to a specific standard. Restoration may vary from cleaning or replacement of single parts up to a complete overhaul.

Rework The preventive process employed to preclude the occurrence of a defect. Rework is normally accomplished before a potential defect occurs. In some cases, rework may be employed as a repair after the defect has occurred. In either case, a specific rework is a one-time process.

Sampling Inspection A depot level inspection for impending failures or specified defects on a designated structurally significant item/component which is performed on less than all of the fleet of a Type/Model/Series (T/M/S) aircraft and requires the completion of a sampling report from to document sampling inspection findings.

Safe for Flight The material condition of an aircraft which, considering mission requirements and environmental conditions, permits it to be launched, flown and landed safely and ensures the aircrew has, as a minimum, the operable equipment for safe flight required by: NAVAIR 01 Series Manual, Aircraft NATOPS; OPNAVINST 3710.7, General

NATOPS.

Safety Freedom from those conditions that can cause death, injury, occupational illness, damage to or loss of equipment or property, or damage to the environment.

Safety/Emergency Systems or Equipment

A device or system that:

1) enhances the evacuation of the aircraft in an emergency or, 2) if it does not function when required, results in a failure condition that might have an adverse effect on safety.

Scheduled Maintenance Plan/ Periodic Maintenance Information Card (PMIC)

The Scheduled Maintenance Plan (SMP) / Periodic Maintenance Information Card (PMIC) incorporates all Boeing recommended scheduled maintenance tasks and additional tasks as approved by PMA 290 P-8A APML that are determined necessary to optimize operational readiness and safety. Volume I contains all of the information required for a Fleet squadron to conduct all scheduled maintenance inspections. Volume II contains all of the information required for the NAVAIR Maintenance Planner to package Organizational level A-checks and Volume III contains all Depot Maintenance Tasks.

Scuff/Sand/Overpaint The complete removal of all paint oxide from the exterior

1-16 paint system by scuff sanding, necessary treatment, primer, and reapplication of the paint top coat.

Servicing The performance of any act (other than corrective maintenance) required to maintain an item of equipment in operating condition, such as lubricating, fueling, oiling, cleaning, etc., but does not include periodic replacement of parts or any corrective maintenance task.

Secondary Structure Structure which carries only air or inertial loads generated on or within the secondary structure. Most secondary structures are important to the aerodynamic performance of the airplane.

Structural Significant Item

Any detail, element or assembly, which contributes significantly to carrying flight, ground, pressure or control loads and whose failure could affect the structural integrity necessary for the safety of the aircraft. Also known as Principle Structural Elements.

Structural Assembly One or more structural elements which together provide a basic structural function.

Structural Detail The lowest functional level in an aircraft structure. A discrete region or area of a structural element, or a boundary intersection of two or more elements.

Structural Element Two or more structural details which together form an identified manufacturer's assembly part.

Structural Function The mode of action of aircraft structure. It includes acceptance and transfer of specified loads in items (details /elements /assemblies) and provides consistently adequate aircraft response and flight characteristics.

Subassembly A number of parts, subassemblies, or any combination thereof joined together to perform a specific function and which can be disassembled without destruction of a designed use.

Subsystem A major functional portion of a system which contributes to operational completeness of the system.

System A combination of inter-related items arranged to perform a specific function.

Task Card All maintenance tasks listed in this P-8A SMP Document will have a corresponding P-8A Maintenance Task Card to be used for completion of the task. The task cards are configured to the same degree that the P-8A Maintenance Manual is configured. They include the text and illustrations pulled from the P-8A configured Maintenance Manual. They cover all requirements of the recommended scheduled maintenance program outlined

1-17 in this SMP and are printed in a standard format. P-8A task cards are numbered sequentially by Air Transport Association (ATA) chapter.

Touch up The action for a localized area of the aircraft’s surface which involves feathering of the adjacent paint, surface treatment, primer, and application of a top coat.

Threshold See “Interval – Initial”

Threshold Period A period during which no occurrences of the failure can reasonably be expected to occur after the item enters into service.

Turnaround Inspection An inspection conducted between flights to ensure the integrity of the aircraft for flight, verify proper servicing, and to detect degradation that…