King Air Inspection Programs - Hawker Beechcraft

Dan Weaver Director, Propeller Aircraft Product Support

2013 Maintenance & Operation Beechcraft Corporation Most Private. Title Page Rights Apply.

Agenda

• Current Maintenance Issues • Accomplishments • Wing Inspection Evaluation • High Utilization Inspection Program • Torque/RPM Limits • Fleet Statistics

Beechcraft Corporation Most Private. Title Page Rights Apply.

Current Maintenance Issues


Inspection / Replacement of Rivets Installed by Kit P/N 101-4045

Background: During a review of kit drawing 101-4045, Beechcraft Engineering discovered that the kit incorrectly called for solid aluminum rivets instead of Hi-Lok fasteners at the forward edge of the upper wing skin panels on some airplanes. Resolution: Mandatory Bulletin SB57-4126 • Issued May 2013 • Provides information to determine type of rivets installed and instructions to install HiLok rivets if needed. Note: This bulletin only applies the B300/C and A200CT model airplanes with kit 101-4045 installed. All other models with kit 101-4045 installed are not affected. Model A200CT (RC-12K), Super King Air, Serials FE-1 through FE-36 Model B300, Super King Air, Serials FL-1 through FL-839 Model B300C, Super King Air, Serials FM-1 through FM-54 and FN-1 Beechcraft Corporation Most Private. Title Page Rights Apply.

Aft Vertical Spar Inspection Background: Possible short Edge Distance may exist on the aft vertical spar angle at the left and right rivets attaching the fillet to the vertical stabilizer aft spar cap. HBC discovered this condition on some airplanes during an inspection of the manufacturing line. Resolution: Mandatory Bulletin SB 55-4106 REV 1 • Re-Issued March 2013 to add additional serial numbers. • Provides information needed to inspect for the short ED condition and the information needed to correct the condition if found.

B200GT: BY-116 through BY-119; BY-123 through BY-133 B200C: BL-166 through BL-169 B300: FL-741 through FL-756; FL-759; FL-763 through FL-780; FL-782, FL-783 and FL-785. B300C: FM-47 through FM-49; FM-51 and FM-52. Beechcraft Corporation Most Private. Title Page Rights Apply.

Cabin Venue Software Upgrade Background: Rockwell Collins has updated the Cabin Venue system software from version 2.1.2 to version 3.0. Version 3.0 software is required in the event that the MCD Blu-ray drive assembly requires replacement. Resolution: Optional Bulletin SB44-4115 • Issued Aug. 2012 • Announces Rockwell Collins Service Bulletin HBC-Venue-44-03

All King Air 350i model airplanes Beechcraft Corporation Most Private. Title Page Rights Apply.

100 Amp Landing Gear Remote Circuit Breaker Background: Some operators have reported nuisance landing gear circuit breaker trips when operating in high ambient temperatures (above 100 degrees F) Resolution: The system has been redesigned to install a 100 amp remote controlled circuit breaker (RCCB) in place of the 60 amp circuit breaker for the landing gear motor circuit. Prevents nuisance circuit breaker trips when operating in high ambient temperatures. This takes affect at FL-792 and FM-53.

B300: FL-792 and after B300C: FM-53 and after Beechcraft Corporation Most Private. Title Page Rights Apply.

100 Amp Landing Gear Remote Circuit Breaker Optional Service Bulletin SB32-4010 announces kit 130-3100 KIT 130-3100-0001 This kit provides parts and information to install a circuit modification to the landing gear system of King Air models B300 serials FL-208 through FL-791 and B300C serials FM-10 through FM-52 KIT 130-3100-0003 This kit provides parts and information to install a circuit modification to the landing gear system of King Air models B300 serials FL-1 Through FL-207 and B300C serials FM-1 through FM-9

B300: FL-1 through FL-791 B300C: FM-1 through FM-52. Beechcraft Corporation Most Private. Title Page Rights Apply.

Empennage Inspection Program Background: Installation of empennage inspection access panels Resolution: Recommended SB 55-3835 • • • • •

Issued June, 2008 Inspection of interior structure Inspection added to the SIRM 2008 Airworthiness Limitations Manual revised Production effectivity : BB-1972, BL-152 BN10, BT-47, BY-1, FL-522, FM-14 • Revision to the inspection requirements in Chapter 4 approved by the FAA This requirement is being added to the F90 ALM.

F90 - LA-1 Thru LA-236; 200/B200 – BB-2, BB-6 Thru BB-1384, BB-1389 Thru BB-1971; 200C/B200C – BL-1 Thru BL-151, 200T/B200T – BT-1 Thru BT-38; 200CT/B200CT – BN-1 Thru BN-4; 300 – FA-1 Thru FA-230 and FF-1 Thru FF-19; B300 – FL1 Thru FL-521; B300C – FM-1Thru FM-13 & FN-1 Only Beechcraft Corporation Most Private. Title Page Rights Apply.

Wing Attach Bolt Hole Bushing Kits Kit 101-4050 Model B200, serials BB-1193 through BB-1334 some BL and BT serials as well • Wing spar life limited to 9,500 Hours unless Kit 101-4050 is installed Model 300, serials FA-2 through FA-190 • Wing spar life limited to 9,000 hours unless Kit 101-4050 is installed Refer to Chapter 4 for current information • • • •

101- 4050 Kit Requires Special Tooling And Training To Install. There is only one set of the special equipment required to install the kit More aircraft are nearing the limit Aircraft may be modified at any time, no loss of life limit Please plan for this event well in advance Contact Stan Benjamin at HBS ICT. [email protected] 316-676-4503 Beechcraft Corporation Most Private. Title Page Rights Apply.

Aileron Installation Safety Communiqué No. 324

(May 2012)

Issue: Potential for incorrect installation of ailerons HBC has received four reports of partial or complete aileron separation on Beechcraft airplanes due to improper installation techniques. This resulted from the aileron hinge bracket not being fully engaged in the aileron before the attach screws are inserted. This allowed the screws to pass through the aileron skin and the nutplate, but not through the holes in the hinge bracket. HBC reminds owners/operators/maintenance personnel of the importance of adhering to applicable existing inspection and maintenance procedures in the appropriate airplane Maintenance Manual or Shop Manual.

All Models. All Serial Numbers Beechcraft Corporation Most Private. Title Page Rights Apply.

Fuel Leaks Safety Communiqué No. 332

(May 2013)

Issue: Beechcraft has received reports of fuel leaking from wings (Baron and Bonanza models) and nacelles (King Air models). Beechcraft is investigating the fuel leaks that have been reported and will publish additional information as appropriate. Beechcraft reminds all owners/operators to pay particular attention during preflight for potential fuel leaks. Ensure that there are no visible fuel leaks, seeps, or staining. Pilots are reminded to monitor fuel levels during all phases of flight. Beechcraft reminds owners/operators/maintenance personnel of the importance of adhering to fuel-related procedures in the applicable model Airplane Flight Manual, Airplane Maintenance Manual, and Airplane Flight Manual Supplement.


Model Communiqué 2013-02 Issue: Aging Aircraft Inspection Program It is Beechcraft Corporation’s position that the standard inspection program (AMM, SIRM and ALM) meets the minimum requirements to keep the King Air fleet safely flying. The program provides enough detail to alert owner/operators of potential issues for their airplane. Other topics: 20: Ground Stud Installation Tool 21: 350i Cabin Management/Environmental System 23: Elliott Aviation Sound Management System Technical Support 26: Bleed Air Warning System Description and Troubleshooting 28: Fuel Quantity Indication System History and Test Equipment 44: 350i Venue Cabin Management System Software Version 3.0 Service Bulletin 52: Cabin Door Roller Assembly 53: Entry Door Floorboard Assembly 56: Windshield Hump Seal Kit Available Again


Model Communiqué 2013-01 Issue: CLASS (Classic Legacy Aircraft Service & Support) Program Update • Added additional serial numbers of airplanes older than 15 years • Updated list of services • • • • • • • • • •

Original Configuration Research (Drawing Research for Modifications/Parts) Material Specification Requests (Drawing Request) Avionics Component Part and Serial Number Request Publications Information Unavailable from Pay-Per-View Assist with Troubleshooting Assistance Letter of Authorization or Approval from HBC Single Wiring Diagram All Aircraft On-Site Technical Support Access to Manual Set on the Web 24 to 48 hrs (Pay-Per-View) AOG Call Out Fee (Applicable for services required outside of standard business hours)

The CLASS program was introduced several years ago to better address the technical support needs of older airplanes.


Accomplishments


ELT Antenna Kit Kit 101-4094 Now available for B200 and B300 King Airs to replace the rod type antenna with a blade type antenna. HBC has received reports of the rod type ELT antenna 110-320/323 installed on B200s and B300s breaking in flight. As a result, a blade type antenna has been certified and is currently being installed on new airplanes at the factory.

Effectivity B300 series: FL-337 and After. B200 series: BB-1795 and after; BL-152 and after; BY-1 and after; BZ-1 and after. Beechcraft Corporation Most Private. Title Page Rights Apply.

Exhaust Fairings Improved exhaust stack fairings The fairings are now made from material that will better withstand the high temperatures from the exhaust. • The production cut-in for the new fairings is FL-856, FM-56 and BY-179. • The new fairing is now available through HBP&D. •

LH 101-910209-19

•

RH 101-910209-20


Condenser Blower Inlet Kit 130-5508-0003 Provides parts and information to remove the curved louver and replace with a removable slot style air inlet to improve airflow through the air conditioning condenser during flight.

Effectivity B300: FL-493, FL-500 & after, B300C: FM-14 & after, B200: BB-1978 & after, B200C: Bl-15 & after, B200GT: BY-1 and after Beechcraft Corporation Most Private. Title Page Rights Apply.

Condenser Blower Inlet Redesign for New Production Aircraft The NACA scoop will be removed. The curved louvers will be replaced with flat louvers similar to the louvers on the left-hand side of the airplane.

New Design

Current Design Effectivity B200 and B300: est. late 4th Quarter Beechcraft Corporation Most Private. Title Page Rights Apply.

Wing Bolt Cover Kit Kit 130-1220 Now available for all King Airs models to replace the upper aft wing bolt cover with a cover assembly that provides for greater security.

Effectivity: All King Air Models and All Serials Beechcraft Corporation Most Private. Title Page Rights Apply.

Wing Inspection Program Evaluation Background: The wing inspection requirements in the maintenance manuals are intended for airplanes operated in the “category of service for which they were designed”. That is, “Pressurized Corporate Transportation”. • Majority of cruise is above 10,000 feet • Flight duration of more than an hour.

King Air SIRM 57-XX-00 The inspection schedules (Charts 201) in section one and two of this chapter identifies the inspection areas, initial inspection periods, recurring inspection intervals and component replacement times. These schedules are based on airplane utilization, operation and maintenance in the category of service for which these airplanes were originally designed; specifically, a pressurized executive or corporate transportation vehicles wherein the majority of cruise is above 10,000 feet altitude and flight duration is more than one hour.


Wing Inspection Program Evaluation Resolution: If your airplane is operated in other types of service, the wing inspection requirements in the SIRM may not be appropriate for continued airworthiness. Example of “other” types of service: • • • • • •

Air Taxi/Commuter Air Service Search and rescue Nav aid/airway inspection Maritime Patrol Aerial survey Fire Service

An evaluation should be done to determine if a special inspection program is needed. King Air SIRM 57-XX-00 Should the aircraft be used for missions other than that intended by design, such as an air taxi, commuter air service, pipeline surveillance, livestock/predator animal control, search and rescue, navigation aids inspection, extraordinary service at low altitude or unusually short duration flights (less than 30 minutes), the inspections specified in the Standard Flight Profile Inspection Schedule (Chart 201) are not appropriate for continued airworthiness of the airplane structure. Beechcraft Corporation Most Private. Title Page Rights Apply.

Wing Inspection Program Evaluation Additional considerations: • Modifications


Wing Inspection Program Evaluation Criteria: • Less than 10,000 ft • Duration of less than 1 hour

Contact Beechcraft Technical Support to request the evaluation. There is no charge for the evaluation 316-676-3140 or 800-429-5372 [email protected]


High Utilization Inspection Program


King Air Inspection Programs - History In 1957, P&WC began the development of a “small” turboprop engine. That engine became known as the PT6.


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King Air Inspection Programs - History • PW&C shipped the first production engine (PT6-6) to Beechcraft in 1963 to use on the first King Air prototype, know as the Model 87. • The first flight was on January 20th 1964 • Certified in June 1964 • First delivery was on October 8th 1964.


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King Air Inspection Programs - History The history of the inspection programs reflects the fact that the King Air evolved from piston airplanes, (Queen Air and Twin Bonanza). Original King Air Inspection Program (1964) The original King Air inspection program was patterned after the standard 100 hour/annual inspection program that is typically used for piston airplanes. This was our “OEM approved” inspection program required by Part 91 for multi-engine turbine airplanes. • Complete inspection required every 12 months and/or 100 hours • Additional Items: • Landing Gear Inspection Interval 1,000 Hours. • Power Plant Overhaul Interval 600 hours. The complete airplane was inspected every 12 months and/or 100 hours of operation Beechcraft Corporation Most Private. Title Page Rights Apply.

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King Air Inspection Programs - History

Late 60’s The inspection program was revised in the late 60’s to provide more flexibility, reduced down time and reduced inspection man hours. This program was patterned after the FAR Part 91 Progressive Inspection program: • The airplane is inspection in 4 “phases” • Each inspection was to be completed at 150 hour intervals • All 4 inspection to be completed within 18 months. • Additional Inspection Items: – Landing Gear Inspection Interval 7,500 Hours or 5 Years. – Engine Overhaul Interval 3,000 Hours.

The complete airplane was inspected every 18 months and/or 600 hours of operation Beechcraft Corporation Most Private. Title Page Rights Apply.

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King Air Inspection Programs - History

Current Inspection Programs In the late 90’s, the current “Phase Inspection” program was introduced to further reduce inspection costs and provide more flexibility Phase Inspection Program: • The airplane is inspected in 4 “Phases” • Each Phase must be completed at 200 hour intervals • One inspection is required every 12 months • All 4 Phases to be completed within 24 months. • Additional Inspection items: • Landing Gear Inspection Interval 8,000 Cycles or 6 Years. • Engine Overhauls 3,600 hours. The calendar time for a complete inspection cycle is increased from 18 to 24 months. Time between inspection is increased from 150 to 200 hours. Beechcraft Corporation Most Private. Title Page Rights Apply.

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Special Mission operators have requested increased times between inspections for high utilization airplanes Goal – develop an inspection program that: • Reduces down-time • Increase time between inspections • Reduce inspection costs


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High Utilization Inspection Program This inspection program is designed for those airplanes operated more than 400 hours per year. Similar to the current Phase Inspection Program • 4 major inspections (now called Detail Inspections) • The interval between Detail Inspections is increased from 200 hours to 400 hours. • Same basic scope and detail as the current Phase inspections. Some items that could not be increased to 400 hours • Routine inspections are added at the 200 hour point between the 400 hour Detail inspections. • The Routine Inspection covers lubrication items and “Walk Around” with certain operational checks. • It is designed for minimal man hours and down time.


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King Air Inspection Programs Inspection Program Comparison 400hrs per year

Phase Inspection Program

800hrs per year

1600hrs per year

Number of Completed Insp.

Number of Man-hours


Number of Man-hours


Number of Man-hours

2 phases

132

4 phases

264

8 phases

528

Notes: Information is based on A King Air B300 Current Phase Inspection Flat Rate - 66 hours average per Phase Inspection Hi-Ut Routine Inspection Flat rate - 12 hours average Hi-Ut Detail Inspection Flat Rate – 60 hours average


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800hrs per year

1600hrs per year


Number of Man-hours


Number of Man-hours


Number of Man-hours


2 phases

132

4 phases

264

8 phases

528

Proposed High Utilization Program

1 Detail 1 Routine

72 total

2 Detail 2 Routine

144

4 Detail 4 Routine

288



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800hrs per year

1600hrs per year


Number of Man-hours


Number of Man-hours


Number of Man-hours


2 phases

132

4 phases

264

8 phases

528

Proposed High Utilization Program

1 Detail 1 Routine

72 total

2 Detail 2 Routine

144

4 Detail 4 Routine

288

Savings

60 man-hours $6000

120 man-hours $12,000

240 man-hours $24,000



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High Utilization Inspection Program Program Applicability and Requirements • High Utilization Inspection Program is available to the following airplanes: • B300 FL-1 and After, FM-1 and After • 300(avail. Early 2014) FA-1 and After • B200 BB-1158, BB-1167, BB-1193 and After (1985 and after) • B200C BL-73 and After (1984 and after) • B200T BT-31 and After (1985 and after) • B200GT BY-1 and After (Only applicable to airplanes with Hydraulic Landing Gear and Triple Element Spar) • Must be operated a minimum of 400 hours per year • It is a paid program, but is provided free with a Support Plus contract (Parts and Labor)


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Subscription through Technical Publication: • Subscribe to the program through Beechcraft Tech Pubs • Maintenance Manual Supplement • Serialized Letter of Authorization

Contact Beechcraft Technical Publications to subscribe to the High Utilization Inspection program


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Phase Inspection Program Update Changes to the Phase Inspection Program (early 2014) • No longer required to remove the interior at Phase 3 – Required to inspect systems and components under floor – Crosstie inspection removed form Phase 3 • Special Inspection Added – Interior removal now required at 2500 cycles or 6 years

Fuselage Inspection • No Change to the currently required at 5000 cycles and reoccurring every 1000 cycles • We are collecting data to support a request to the FAA to increase inspection interval Beechcraft Corporation Most Private. Title Page Rights Apply.

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Fleet Statistics


90 Series King Air Data 90/A90/B90/ C90

C90B/C90GT

E90/F90

Total Built

1434

729

583

Total in Service

1128

717

512

Total Flight Hours (Projected)

12,702,037

1,731,872

4,740,203

Total Landings (Projected)

14,129,780

1,727,837

4,440,772

Avg. Flt Hours Per Month

25

21

23

Avg Landings Per Month

31

21

25

Fleet Leader

LJ-75

LJ-1881

LW-111

Hours (Projected)

21,529

13,969

24,904

Landings (Projected)

11,899

6,140

27,450

Model


100 / 200 Series King Airs Model

100

200

B200

Total Built

383

1207

1137

Total in Service

290

1056

1094

4,370,203

10,486,334

7,058,582

873,528

9,204,663

8,473,035


30

34

31

Avg.Landings Per Month

30

34

35

B-157

BB-68

BB-1309

31,041

34,607

25,441

42,764

11,762

35,592

Total Flight Hours (Projected) Total Landings (Projected)

Fleet Leader Hours (Projected)



B200GT

Model

B200GT

Total Built

163

Total in Service

163

Total Flight Hours (Projected) 77,327 Total Landings (Projected) 83,185 Avg. Flt Hours Per Month

20

Avg. Landings Per Month

18

Fleet Leader

BY-69

Hours (Projected) 2,351 Landings (Projected) 3,166


300 / 350 Series King Airs

Model

300

B300 (350)

Total Built

247

875

Total in Service

232

796

1,819,322

2,381,629

1,644,725

2,279,663


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27


26

26

FA-12

FL-280

14,684

16,101

7,922

16,098

Total Flight Hours (Projected)

Total Landings (Projected)

Fleet Leader Hours (Projected)



King Air Totals

Model

All King Air

Total Built

6638

Total in Service

5950

Total Flight Hours (Projected) 45,367,509 Total Landings (Projected) 42,857,188 Avg. Flt Hours Per Month

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Questions? This presentation and its contents are Beechcraft Corporation Most Private. It may not be reproduced, published, or disclosed in whole or in part outside the company without the written permission of Hawker Beechcraft Corporation Beechcraft Corporation Most Private. Title Page Rights Apply.

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