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

US Army Air Corps – 1941 – Recruiting Slogan

Universal Pictures – 28 November 1941

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

General Fleet Information 24 of 41 “Available for Operations” (4 x non-active) High 16658.1 = AC 412 Low 12956.5 = AC 435 – Crashed Jul 13 Low 13081.4 = AC 429 Avg 14848.39 = avg AF Hrs High Time Aircraft – 16 658 Hrs Low Time Aircraft – 13 081 Hrs Fleet Average – 14 848 Hrs

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

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

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

Fleet Service Life Status Entered service – May 1963

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

Fleet Service Life Status Summer 2013: 50th Anniversary Celebrations

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

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

Attributes of Success

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

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

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

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

Attributes of Success Maintenance Program Aircraft Structural Integrity

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)

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

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

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)

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

Baseline Usage Spectrum Sikorsky Report SER-611984 “Composite Worst Case” Spectrum, presented in Table 22, be used for the dynamic component and airframe fatigue assessments.

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

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

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;

Aircraft Structural Integrity Mgmt Plan CH124 Usage Spectrum Mission Weighting

Aircraft Structural Integrity Mgmt Plan Comparison of Mission Usage to Baseline

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

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.

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)

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

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…

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

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.

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

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

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

Sunset Years

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

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

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

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

51 Yrs … Keepin’ ‘em Flying!!

Fleet Service Life Status Entered service – May 1963