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 = AC 412
Low = AC 435 – Crashed Jul 13
Low = AC 429
Avg = avg AF Hrs
High Time Aircraft – Hrs
Low Time Aircraft – Hrs
Fleet Average – Hrs

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

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

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
FY14/15
FY15/16
FY16/17
FY17/18
FY18/19
Flying Hours
7200
5500
3700
500
Fleet Size 28 24 20 16
12 to 0

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
(d) Return to Base
(e) Yard Work (off-levels)
(b) SAR Exercise
(f) Yard Work (slung loads)
(c) SONAR Dips
(g) Flight conclusion

26. Baseline Usage Spectrum
Sikorsky Report SER
“Composite Worst Case” Spectrum, presented in Table 22, be used for the dynamic component and airframe fatigue assessments.

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

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)
Damage Severity on Dynamic Components and SSIs.

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!!

50. Fleet Service Life Status
Entered service – May 1963