NDT Application in Aircraft Industry / Human Faktor Effect

Report
NDT Application in Aircraft Industry / Human Faktor Effect
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Short personal introduction
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Name :
Jiří brus
Date of Birth :
1962
NDT carier start : 1985
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Actual NDT qualification :
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LII EN 473
VT, PT, MT, UT, RT, ET
LII EN 4179/NAS 410
VT, PT, MT, UT, RT, ET
LIII EN 4179/NAS 410
VT, PT, MT, UT, RT, ET
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Actual positions
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Director and owner accredited NDT
laboratory No. 1400
Head of Job Air NDT Center
Outsite NDT L III servis for :
- Technical laboratory
TLO OPAVA
- UNEX Uničov a.s.
- Aircraft Industry
LET Kunovice
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NDT Application in Aircraft Industry / Human Faktor Effect
As a comitted member of CNDT regional group No. 6 North
Moravia I got delegation from chairman of that group Mr. Solnař
to hand over many regards to all attendants of this meeting.
October 6-10, 2014 Prague
NDT Application in Aircraft Industry / Human Faktor Effect
General Content
Why this subject ?
Human error has been documented as a primary
contributor to more than 70 percent of commercial
airplane accidents.
Boeing human factors professionals work with
engineers, pilots, and mechanics to apply the latest
knowledge about the interface between human
performance and commercial airplanes to help
operators improve safety and efficiency in their daily
operations.
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Subject introduction
Aircraft mechanic / NDT mechanic
Applicable NDT methodes
VT methode application
Direct visual inspection VS boroscopy
PT methode application
Different qualification request
UT-T thickness measurement
Nominal thickness knowlege necessity
MT methode
Residual magnetizm check
ET methode
Indirect influence to IACS value
Conclusion
Recomendation
NDT Application in Aircraft Industry / Human Faktor Effect
Aircraft mechanics
NDT mechanics
Somebody who is higly trained and educated
- Aircraft structure
- Aircraft parts maintenance and check
Somebody who is higly trained and educated
- Applicable NDT methodes
- Sensitivity and test condition check
Knowlege from NDT area
during the job practice and cooperation
with NDT technician
Knowlege from maitainance area
during the job practice and cooperation
with B1 technician
Human faktor training necessary.
Human faktor training necessary
NDT Application in Aircraft Industry / Human Faktor Effect
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VISUAL INSPECTION METHODE
Human faktor effect – responsibility take-over
(during boroscopy inspection instead direct
visual inspection specified area)
Example 1
Official NDT request
Airbus NTM 57-20-50
Responsibility on NDT in full
because
NTM include – procedure
- inspection area specification
- possible damage specification
NDT Application in Aircraft Industry / Human Faktor Effect
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VISUAL INSPECTION METHODE
Official acces panels
Drain holes
NDT Application in Aircraft Industry / Human Faktor Effect
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VISUAL INSPECTION METHODE
Human faktor effect – responsibility take-over
(during boroscopy inspection instead direct
visual inspection specified area)
Example 2
Official Task Card request :
Perform general visual inspection of the zone IAW TC 5711-622-80I
- All components will be ispected for :
Security of attachements, visible connections, electrical bonding, safety
wiring, leakage, cracks, corrosion, chafing, evidence of overheating,
condition of painting and corrosion treatment and cleanlines.
NDT Application in Aircraft Industry / Human Faktor Effect
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VISUAL INSPECTION METHODE
Example 2 :
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Responsibility on B1 in full
because
- there is not NDT procedure
- there is not request for NDT
qualification
Remark:
EWIS training - Electrical Wiring Interconnection Systém
NDT person probably will be not trainined for connection,
electrical bonding , safety wiring…etc.
NDT Application in Aircraft Industry / Human Faktor Effect
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PENETRANT TESTING METHODE
Human faktor effect – qualification and type application understanding
(many confliction request comparing part 145 / AC manual)
Example
Part 145 EASA is speaking about colour
penetrant testing wchich means in fakt
Type 2 acc. ASTM E1417.
NDT Application in Aircraft Industry / Human Faktor Effect
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PENETRANT TESTING METHODE
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NDT Manual request
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SAAB
NDT 51-08-00
Type 2, Not used for fatigue cracks or tight defects
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BOEING
NDT 20-20-02
Type 2, Inspection of ground handling or support equipment, tools and tooling only.
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AIRBUS
NDM 51-80-00
For general use on aircraft in-service inspections the following penetrants are recommended:
(1) Type I, Method C, Level 2, 3 or 4 (Solvent removable, fluorescent).
NDT Application in Aircraft Industry / Human Faktor Effect
• PENETRANT TESTING METHODE
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Final „Only Option“ = FPI application
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Test condition check – time / temperature / PSM5 / UV-light / day-light
Right type application / sensitivity 2, 3, 4 ? ? ?
NDT Application in Aircraft Industry / Human Faktor Effect
• PENETRANT TESTING METHODE
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Personal qualification request – for information only
SAAB 340
BOEING 737
AIRBUS 320
Stated in NDT-M
Stated in SOPM only
PT procedure 20 pages
Stated in NDT-M
PT procedure 15 pages
NDT-M 51-08-00
SOPM 20-20-02
NDT-M 51-80-00
NDT-M 51-81-00
Related documents
AMS 2644
ASTM E 1417
Related documents
AMS 2644
ASTM E1417
Related documents
AMS 2644
ASTM E 1417
PT in NTM and
Immediately in
introduction there is a
request for qualification
I.A.W EN 4179
NTM does not
contain PT
There is no request for
qualification
PT in NTM
But there is no request
for qualification
NDT Application in Aircraft Industry / Human Faktor Effect
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ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
Human faktor effect – technique and equipment adequate to test request
(nominal thickness proficiency)
NDT Application in Aircraft Industry / Human Faktor Effect
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ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
Human faktor effect – technique and equipment adequate to test request
(nominal thickness proficiency)
1. step / to choose right equipment and see right echo
NDT Application in Aircraft Industry / Human Faktor Effect
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ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
Human faktor effect – technique and equipment adequate to test request
(nominal thickness proficiency)
2. step / right probe and right equipment setting
Thickness reading for probe MSEB4 using 1. back wall echo
If reading will be done from 3rd peak
0,37
instead 2nd peak – difference is +0,37mm
0,37
0,37
3,67
3,3
Because : λ = cL / f = 5,92 / 4 = 1,48 mm
3,3
3
2
3
λ / 4peaks = 1,48 / 4 = 0,37 mm
2
1
4
For us – Al mat. and 12 MHz probe =
4
1
(6,32 / 12 / 4 = 0,131mm)
NDT Application in Aircraft Industry / Human Faktor Effect
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ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
(nominal thickness proficiency)
NDT Application in Aircraft Industry / Human Faktor Effect
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ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
(nominal thickness proficiency)
NDT Application in Aircraft Industry / Human Faktor Effect
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ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
(nominal thickness proficiency)
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IAW SRM (Standard Repair Manual) we have to check fuselage thickness for
change of 10% of nominal thickness, wchich can be in many cases about 1,00
mm. So the maximum blending allowed is to 0,10 mm.
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Compare:
REQUEST
0,10 mm
VS
ACCURACY
0,131 mm
NDT Application in Aircraft Industry / Human Faktor Effect
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MAGNETIC PARTRICLE TESTING METHODE
Human faktor effect – unexpected residual magnetism
(unallowable on engine parts and others)
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Request - magnetic particle inspection (using coil and/or central conductor)
NDT Application in Aircraft Industry / Human Faktor Effect
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MAGNETIC PARTRICLE TESTING METHODE
Human faktor effect – unexpected residual magnetism
(unallowable on engine parts and others)
Easy task – engin shaft magnetizing
in coil using alternating current
NDT Application in Aircraft Industry / Human Faktor Effect
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MAGNETIC PARTRICLE TESTING METHODE
Human faktor effect – unexpected residual magnetism
(unallowable on engine parts and others)
NDT Application in Aircraft Industry / Human Faktor Effect
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EDDY CURRENT TESTING METHODE
Human faktor effect – optainable accuracy during measuring
(strong manual request for evaluation)
Example – BOEING NTM Part 6 51-00-00 Procedure 20
Equipment….
• (d) Can clearly identify conductivity changes of 0.5 percent IACS (0.3 MS/m) in the
applicable conductivity range.
• (e) Can measure the conductivity of the applicable reference standards with a
precision of plus or minus 0.5 percent IACS (0.3 MS/m) better.
NDT Application in Aircraft Industry / Human Faktor Effect
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EDDY CURRENT TESTING METHODE
Human faktor effect – optainable accuracy during measuring
(strong manual request for evaluation)
1 temperature – effect, calibration standard (IACS 29,88%) measuring in 5 min
32
31.5
31
30.5
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29.5
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28.5
28
27.5
Series1
Series2
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2
3
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10 11 12 13 14
NDT Application in Aircraft Industry / Human Faktor Effect
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EDDY CURRENT TESTING METHODE
Human faktor effect – optainable accuracy during measuring
(strong manual request for evaluation)
Example – BOEING NTM Part 6 51-00-00 Procedure 20
IACS value for some alloys ….
Alloy
Temper
IACS
MS/m
2024
0
45,5 - 49,0
26,4-28,4
7075
0
44,0 - 47,5
25,5-27,5
NDT Application in Aircraft Industry / Human Faktor Effect
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EDDY CURRENT TESTING METHODE
Human faktor effect – optainable accuracy during measuring
(strong manual request for evaluation)
!! Warning !!
There are six factors which affect the accuracy of eddy current conductivity
measurements. These are :
1 temperature,
2 lift-off,
3 curved surfaces,
Before you officially record change 1% IACS
4 edge effect,
make shure you make all value correction
5 materials thickness,
and you consider all factors.
6 and cladding as well
NDT Application in Aircraft Industry / Human Faktor Effect
„Easy?“ Conclusion
VT methode
Always make sure you know, what are you looking for !
PT method
Remember aircraft producer different stand to personal qualification and think about rigt
penetrant type and sensitivity application !
UT-T method
Recorded thickness compare with drawing and/or documentation before final evaluation
MT method
Even use alternating current always check residual magnetism and use demagnetizing
coil in any case !
ET method
Consider all indirect influence to recorded IACS value before you make final decision !
NDT Application in Aircraft Industry / Human Faktor Effect
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RECOMMENDATION
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Acording to an old practis the certyfied aircraf mechanic must attend to first
fly after aircraft servicing.
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Remember you can use in future an aircraft you personally checked.
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I wish you only safety fly with happy comeback.
Thank you for your attention.

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