CH124 Sea King Fleet Update

1. CH124 Sea King Fleet Update “Keepin’ ‘em Flying!!” Major Richard Loewen Senior Design Engineer

3. US Army Air Corps – 1941 – Recruiting Slogan

4. Universal Pictures – 28 November 1941

5. CH124 Highlights • General Fleet Information • Fleet Service Life Status • Attributes of Success • Maintenance Program • Aircraft Structural Integrity • Sunset Years • Challenges & Capabilities • Wrap-Up

6. General Fleet Information 24 of 41 “Available for Operations” (4 x non-active) High Time Aircraft – 16 658 Hrs Low Time Aircraft – 13 081 Hrs Fleet Average – 14 848 Hrs

7. CH124A – ASW - Dipping Sonar, Self Defense, ISR CH124B – Utility & Troop Config (14 Pax)

8. Main Operating Bases & HQ 406 OTS 423 Sqn 12 AMS Shearwater, NS 443 Sqn Victoria, BC NDHQ Ottawa, ON

9. CH124 Highlights • General Fleet Information • Fleet Service Life Status • Attributes of Success • Maintenance Program • Aircraft Structural Integrity • Sunset Years • Challenges & Capabilities • Wrap-Up

10. Fleet Service Life Status • Entered service – May 1963

11. Fleet Service Life Status • Entered service – May 1963 • Oct 1992: ELE extended to Dec 2000 • Oct 1998: ELE extended to Dec 2005 • xxx 2005: ELE extended to Dec 2012 • Jul 2011: ELE extended to Dec 2015

12. Fleet Service Life Status • Summer 2013: 50th Anniversary Celebrations

13. Fleet Service Life Status • Sept 2014: … ELE Extension Request … • Align with CH148 Cyclone (S-92) Introduction • CH124 operations out to August 2018 • Proposed Flying Rates

14. CH124 Highlights • General Fleet Information • Fleet Service Life Status • Attributes of Success • Maintenance Program • Aircraft Structural Integrity • Sunset Years • Challenges & Capabilities • Wrap-Up

15. Attributes of Success

16. Attributes of Success • Maintenance Program • Preventive • Corrective • Upgrades / Modifications • Mechanical System • Avionics/Electrical/Mission System

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

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

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

20. Attributes of Success • Maintenance Program • Aircraft Structural Integrity

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

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

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

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

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

26. Baseline Usage Spectrum

27. Baseline Usage Spectrum CH124 “Composite Worst Case” Spectrum (cont)

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

29. Aircraft Structural Integrity Mgmt Plan • CH124 SUM Dataset • Mission Type; • # of main rotor starts and stops; • # of landings; • # of auto-rotations; • Slung Loads; • Fuel weight at take-off and at landing; • Flight duration; • Approx time spent above 103% Nr; • Approx % of time spent: • Below 90 knots; • Between 90 and 120 knots; • Above 120 knots; • Approx time spent in In-ground Effect (IGE) and Out-of-Ground Effect (OGE) hover; and • Approx time running on ground in flight drive.

30. Aircraft Structural Integrity Mgmt Plan • CH124 Usage Spectrum Mission Weighting

31. Aircraft Structural Integrity Mgmt Plan • Comparison of Mission Usage to Baseline

32. Aircraft Structural Integrity Mgmt Plan • CH124 SUM - Exceedences from Baseline • Limit or adjust usage patterns or mission profile • AC 412 continue to limit usage of Mission A (Recce/Surv) • AC 441 limit usage of Mission H (X-Country / PPIF) • Autorotations / One Engine Inoperative / Waterbird • Add or increase inspection requirements • Reduce Interval for SSI#12- Left/Fwd Sponson Mount to 600hrs

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

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

35. Aircraft Structural Integrity Mgmt Plan • CH124 SCM Policy • SCM Function in CH124 ASIP • SCM Data Sources & Tools • Definition of Structurally Significant Items (SSIs) • Damage Mapping • Corrosion • Fatigue • Mechanical • SCM Reporting • Annually

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

37. Aircraft Structural Integrity Mgmt Plan • SCM Data Sources & Tools • Primary Data Sources • Historical TLIR & PER#4 Reports reviewed in FY11/12 • Up to four reports/aircraft were reviewed • SCM Dataset • Primary Structure not defined in Sikorsky documents • CH124 SCM Policy classifies Primary Structural Elements

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

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

40. Aircraft Structural Integrity Mgmt Plan • CH124 SCM Damage Mapping • Corrosion • Fatigue • Mechanical

41. CH124 Highlights • General Fleet Information • Fleet Service Life Status • Attributes of Success • Maintenance Program • Aircraft Structural Integrity • Sunset Years • Challenges & Capabilities • Wrap-Up

42. Sunset Years

43. Sunset Years • Challenges • 51 Year old Aircraft • Obsolescence • Limited Parts Availability • Long Lead Times • Increased Costs

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

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

46. CH124 Highlights • General Fleet Information • Fleet Service Life Status • Attributes of Success • Maintenance Program • Aircraft Structural Integrity • Sunset Years • Challenges & Capabilities • Wrap-Up

47. 51 Yrs … Keepin’ ‘em Flying!!