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A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 DATE : June 2006 SCHEDULED MAINTENANCE DEVELOPMENT A380 PPOOLLIICCYY AANNDD PPRROOCCEEDDUURREESS HHAANNDDBBOOOOKK For further information about this handbook, please contact: AIRBUS S.A.S. Customer Services Directorate Maintenance Engineering Department B.P. No. 33, 31707 Blagnac Cedex, FRANCE REFERENCE: 95A.1689/02 ISSUE number: 12 ISSUE Date : June 2006 A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 Record of Revisions ROR - PAGE: 1 DATE : June 2006 ACCEPTANCE LETTERS A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 Record of Revisions ROR - PAGE: 1 DATE : June 2006 RECORD OF REVISIONS Issue Number Issue Date Reason for Revision 1 Dec. 2002 Initial Issue. Distribution to MRB / ISC. 2 January 2003 Comments received from MRB. 3 April 2003 Comments received from ISC 1 4 June 2003 Comments received from ISC 2 and intermediate ISC 2A meeting in PARIS May 26. 5 January 2004 Comments received from ISC 3 & ISC 4 6 April 2004 Comments received from ISC 5 7 July 2004 Comments received from ISC 6 8 December 2004 Comments received from ISC 7 and ISC 8 9 March 2005 Comments received from ISC 9 10 October 2005 Comments received from ISC 10 11 February 2006 Comments received from ISC 11 12 June 2006 Comments received from ISC 12 A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-1 DATE : June 2006 HISTORY OF CHANGES PPH Ref Issue Date Description of Change Cover sheet February 2006 Picture of the cover sheet changed January 2003 Acceptance Letter, first line, 'approval' added. June 2003 Insertion of MRB and ISC acceptance letters for A380 PPH HOC June 2003 Foot pages revised HOC January 2004 Incorporation of issue 5 revisions HOC April 2004 Incorporation of issue 6 revisions HOC July 2004 Incorporation of issue 7 revisions HOC December 2004 Incorporation of issue 8 revisions HOC March 2005 Incorporation of issue 9 revisions HOC October 2005 Incorporation of issue 10 revisions HOC February 2006 Incorporation of issue 11 revisions HOC June 2006 Incorporation of issue 12 revisions TOC June 2003 Revised TOC January 2004 Pagination changes for sections 3, 4, 5, 6, and appendix C TOC July 2004 Revised 1-4 January 2003 FAR' reference deleted (mistake). 1-4 June 2003 Clarification about airworthiness standards 1-4 March 2005 SFAR88 airworthiness standards included 1-4 June 2006 Additional references for Fuel Tank Safety 2-1 January 2003 Date of JAA AGM added. Any document referenced should have an issue/date. 2-2.1.1 June 2003 Added reference to Appendix F 2-2.1.3 January 2003 Function a). Wording improved. 2-2.1.3 January 2003 Function d) expanded. 2-2.1.4 January 2004 Clarification of the role of the MRB/FAA specialist 2-2.2.2 January 2003 Significant Structure Selection and Significant Structure / Zonal analysis results added to ISC review. 2-2.2.3 January 2003 Function h). 'recommendations' changed to 'proposals'. 2-2.2.3 April 2003 Replacement of ‘transmit proposal’ by ‘provides agreement for proposal’ A380 POLICY AND PROCEDURES HANDBOOK HOC - PAGE: 2 REFERENCE: 95A.1689/02 DATE : June 2006 2-2.2.4 January 2003 Function f) added to the list. 2-2.2.4 January 2004 Addition of paragraph h) for ISC meeting report 2-2.2.6 April 2003 New paragraph. Functions of the ISC advisor to the MWG. 2-2.3.1 January 2003 Paragraph related to MWG composition added to require an adequate knowledge/experience from people involved in the activity. 2-2.3.1 January 2003 Table with the allocation of ATA chapters to MWGs modified to ensure consistency. NOTE added. 2-2.3.1 June 2003 Name of the MWG 9 reworded ‘Interior’ instead of ‘Payload’ 2-2.3.1 January 2004 Structure analysis of ATA 71-80 transferred from MWG3 to MWG 5. 2-2.3.1 April 2004 Pylon drains analysis of ATA 54 transferred from MWG3 to MWG 9. 2-2.3.3 January 2003 Function a). 'ISC' removed (mistake). 2-2.3.3 January 2003 Functions c) and g) revised. New functions n) and o) added. 2-2.3.3 January 2003 Two new types of data to be presented by the MWG Chair to ISC added: i) and j). 2-2.3.3 April 2003 Function q) added to ensure structure specialists representation at MWG3 and MWG8 when dealing with structure MSG-3 analysis. 2-2.3.3 June 2003 Revision of functions g) and m) ’ 2-2.3.3 January 2004 Revise paragraph m) to specify the preparation of two MWG reports 2-3 2-3.1 2-3.2 April 2003 Training paragraph enhanced with ‘personnel requiring training’ and ‘training content’ 2-3.3 June 2003 New paragraph to address training sessions. 2-3.3 January 2004 Addition of zonal analysis training schedule 2-4.4 January 2003 Paragraph added to request the use of 'Transfer Sheets' between MWGs. Reference to the form added. 2-4.4 April 2004 Clarification of data requirements for task transfers to the Zonal Working Group (MWG 6) 2-5.3 April 2004 Clarification of the analysis issue. 2-5.4.1 January 2003 Paragraph reviewed. 2-5.4.1 April 2003 Statement added to improve the management of the ISC action items. 2-5.4.1 June 2003 Added method of identifying ISC action items and editorial change re: required action prior to meeting adjournment and maintaining visibility of closed action items. 2-5.4.1 January 2004 Added Appendix G as reference for meeting report content. 2-5.4.2 January 2003 Paragraph reviewed. 2-5.4.2 April 2003 Statement added to improve the management of the MWG open items. 2-5.4.2 June 2003 Added method of identifying MWG open items and editorial change re: required action prior to meeting adjournment and maintaining visibility of closed action items. 2-5.4.2 January 2004 Addition of MWG Chair Report 2-7.2.3 April 2004 Clarification of the status of the MRBR TR 2-7.2.3 July 2004 MRBR TR process amended A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-3 DATE : June 2006 3-3.2 October 2005 Incorporation of freighter applicabilities 3-3.3 June 2003 LROPS requirements addressed in section 7-5 3-3.3.1 March 2005 Paragraph concerning the purpose of the PPH amended 3-3.4 3-3.4.1 April 2003 Paragraph about modification tracking deeply reviewed 3-3.4 June 2003 Statement regarding traceability of design changes. 3-3.4 January 2004 Section restructured to incorporate a more comprehensive description and to refer to the new Mod review process. 3-3.4.1 June 2003 Revision of the modification review process 3-3.4.2.1 January 2004 MFU process paragraph updated. 3-3.4.2.1 April 2004 MFU process paragraph updated. 3-3.4.2.4 January 2004 Deletion of MFU record table reference Notes. 3-3.4.2.4 April 2004 Paragraph creation concerning Mod prioritisation for MRBR Revision.. 3-3.4.2.6 April 2004 Creation of an additional paragraph called “Modification Review Process for Major Suppliers”. 3-3-4.2.6 July 2004 Reference for Rolls Royce MFU process added 3-3.5 April 2003 ‘Assumptions affecting analysis’ chapter added. 3-3.5 January 2004 Added reference to MSG3 Analysis Status List in Appendix B 3-3.6 June 2006 Incorporate newly approved text for EASA Policy on Fuel Tank System Ignition Source Prevention requirements 3-4 January 2004 Clarification of aircraft utilisation assumptions. 3-5 January 2003 Terms related to 'Maintenance Check / Event' deleted, as intervals do not imply a type/level of maintenance and it could be confusing. 3-5 January 2003 Last paragraph revised and completed. 3-5 April 2003 Introduced greater flexibility in interval selection 3-5 June 2003 Additional usage parameters incorporated. 3-5 January 2004 Clarification of maintenance interval and design objectiveswith respect to fatigue and environmental damage. 3-6 March 2005 SFAR 88 Ignition Prevention paragraph created 4-4 June 2003 The roles and the responsibilities of OAM and OEM were clarified. 4-4.1 January 2003 PPH references for several working steps added/changed 4-4.1 April 2003 Clarification added regarding administrative pages 4-4.1 January 2004 Changed PPH-reference for step 1.5 4-4.2 January 2003 Clarification added regarding History of Changes sheet 4-4.2 April 2003 Clarification added regarding administrative pages and reference to the substantiation of fault-tolerant functions deleted 4-4.2 January 2004 Added reference to modification data in step 2.2 4-4.3 April 2004 Added reference to the need for interval justification in steps 3.4 and 3.7. 4-4.4 January 2003 PPH reference for one working step added A380 POLICY AND PROCEDURES HANDBOOK HOC - PAGE: 4 REFERENCE: 95A.1689/02 DATE : June 2006 4-4.4 April 2003 Statement regarding dispatch of analyses changed from “4 weeks prior to meeting” to “sufficiently in advance of meeting” 4-4.4 June 2003 Reference to Paragraph 2-5.3 made in order to clarify when the analysis data for a meeting need to be dispatched. 4-4.5 January 2003 PPH reference for one working step added 4-4.5 January 2003 Clarification added that History of Changes needs to be established when reworking an analysis. 4-4.5 April 2003 Clarification added regarding administrative pages (Step 5-6) 4-4.5 January 2004 Changed PPH-reference for steps 5.1 to 5.5 4-4.6 January 2003 PPH references for two working steps added/changed. 4-4.6 January 2003 Statement added that MRBR Interface sheet is to be used for ISC review of MWG results. 4-4.6 Junel 2003 Correction of MRBR acronym (Step 6.2) 4-5.1 April 2003 Clarification added that MSI selection does not have to be revised after completion of MSI analysis and that this is an optional step only. 4-5.1 June 2003 Need for keeping the MSI selection up-to-date was stressed. Distinction made to case where selection data are revised solely for the purpose of bring selection and analysis results in agreement with each other. 4-5.1 March 2005 Step 2 of the MSI Selection process amended 4-5.1 October 2005 Reference the MSI Validation List for new A380 models, at the end of this paragraph. 4-5.2 January 2003 Example of MSI Selection sheet added. 4-5.2 April 2003 Paragraph split into 4-5.2.1, 4-5.2.2, 4-5.2.3 and 4-5.2.4. 4-5.2.1 April 2003 Statement added to clarify that ATA-chapters not containing any hardware do not have to be listed. 4-5.2.1 April 2003 Statement about justification of items not selected as MSI transferred to the new paragraph 4-5.2.4. 4-5.2.1 June 2003 1st paragraph reworded in order to bring it in line with wording in paragraph 4-5.1. 4-5.2.1.1 October 2005 (Items on Selection List) transferred from 4-5.2.2 (old) 4-5.2.1.2 October 2005 (Determination of Analysis Level) transferred from 4-5.2.3 4-5.2.1.3 October 2005 (Justification of Items not Selected) transferred from 4-5.2.4 4-5.2.2 April 2003 Clarification added that components only have to be listed if no MSI analysis has been selected at the level of the sub-sub-system and at higher levels. 4-5.2.2 April 2003 Statement added that items not installed or not applicable but covered in the ATA- breakdown do not need to be covered in the MSI selection. 4-5.2.2 (old) October 2005 (Items on Selection List) renumbered as 4-5.2.1.1 4-5.2.2 (new) October 2005 New subject (MSI Validation List) added to 4-5.2.2 4-5.2.2.1 October 2005 New subject (General) added to 4-5.2.2.1 4-5.2.2.2 October 2005 New subject (Data to be Entered) added to 4-5.2.2.2 4-5.2.2.3 October 2005 New subject (Additional Guidance) added to 4-5.2.2.3 4-5.2.3 April 2003 Clarified that for every item on the selection list, a statement is given in either the column “MSI” or in the column “Highest Manageable Level”. Example page modified accordingly. 4-5.2.3 April 2003 Statement added to clarify the handling of items used for maintenance purposes only and therefore do not need to be analyzed. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-5 DATE : June 2006 4-5.2.3 October 2005 (Determination of Analysis Level) renumbered as 4-5.2.1.2 and paragraph number 4-5.2.3 deleted 4-5.2.4 April 2003 Modified statement about justification of items not selected as MSI transferred from paragraph 4-5.2.1. 4-5.2.4 October 2005 (Justification of Items not Selected) renumbered as 4-5.2.1.3 and paragraph number 4-5.2.4 deleted 4-5.3 January 2003 Paragraphs about revision and applicability control added 4-5.3 April 2003 Clarification added that any suitable identification letter can be used to differentiate between the different selection lists for the same ATA-chapter (as in the case of the engines). 4-5.3 June 2003 Statement on MSI selection cover sheet changed to clarify that the sheet should state the aircraft models covered by the selection document, not the model definitions. 4-5.3 October 2005 Incorporation of freighter applicabilities. 4-6 April 2003 Statement about a “modified analysis process for fault-tolerant functions” changed to “guidance on how to handle fault-tolerant functions” 4-6 January 2004 Statement for content of paragraph 4-6 was corrected (taking into account that paragraphs 4-6.1.2 and 4-6.1.3 were transferred to paragraph 4-7). 4-6.1 January 2004 Title of paragraph 4-6.1.1 was deleted (paragraph 4-6.1.1 becomes 4-6.1). 4-6.1.2 (old) January 2004 Complete paragraph (including sub-paragraphs) was transferred to paragraph 4-7.2. 4-6.1.2.2 April 2003 Second paragraph deleted referring to the need for a specific analysis methodology for fault-tolerant functions. 4-6.1.2.3 January 2003 Clarification added that fault-tolerance method may only be used if sufficient substantiation is provided in Data Sheet A. 4-6.1.2.3 January 2003 Reference to task effectiveness criteria in paragraph 4-6.6.1.2 added. 4-6.1.2.3 April 2003 Paragraph significantly changed and all statements referring to a separate analysis methodology for fault-tolerant functions deleted. 4-6.1.2.3 June 2003 Last paragraph reformatted. 4-6.1.3 January 2004 Complete paragraph (including sub-paragraphs) was transferred to paragraph 4-7.3. 4-6.1.3.2 June 2003 Reference to a certain number of AFDX switches deleted and spelling mistake (analogue) corrected. 4-6.1.3.3 April 2003 Requirement for an additional work sharing and consequences-of-failure matrix in MSI analysis for ATA 42 added. 4-6.2.1 January 2003 Paragraph added on how to state the applicability of the analysis on the Cover sheet. 4-6.2.1 June 2003 Clarification provided that aircraft models quoted are passenger aircraft models only. 4-6.2.1 October 2005 Incorporation of freighter applicabilities 4-6.2.4 April 2004 Clarified the use of the “History of Changes” sheet 4-6.3.3 January 2003 Statement added that modifications covered by analysis must be listed in Data Sheet A 4-6.3.3 January 2003 Statement added that fault-tolerance substantiation must include data on indications when redundancy has degraded. 4-6.3.3 April 2003 Statement regarding assumption transferred section 3 paragraph 3.5. 4-6.3.3 June 2003 Clarification provided that paragraph 3.5 referred to in previous change is in Section 3 of PPH. 4-6.3.3 January 2004 Information added about modification details to be provided in Data Sheet A. Clarification provided that more detailed data for fault-tolerant functions in Data Sheet A is optional (as the same method is used for all functions, including those that are fault- tolerant). 4-6.3.3 April 2004 Changed wording regarding modification data by referring to chapter 3-3.5 of the PPH. Added clarification that all failure causes need to be adequately covered in the Data Sheet A. A380 POLICY AND PROCEDURESHANDBOOK HOC - PAGE: 6 REFERENCE: 95A.1689/02 DATE : June 2006 4-6.3.3 June 2006 Clarification of how a new Model is reflected in Data Sheet A 4-6.4.1 June 2006 Clarification of how a new Model is reflected in Data Sheet B 4-6.4.2 April 2003 Statement added that functions used for maintenance purposes only do not need to be covered in the analysis. 4-6.4.2 April 2003 Statement referring to the need of separately identifying fault-tolerant functions by means of “FTF” deleted. 4-6.4.2 June 2003 Handling of maintenance functions clarified (to be stated on Data Sheet B but without Level 1 or 2 analysis). 4-6.4.2 March 2005 Selection of function concerning Ignition prevention included 4-6.4.3 April 2003 Sentence requiring at least one functional failure for fault-tolerant functions deleted. 4-6.4.4 April 2003 Clarification added on how to state failure effects for functional failures that the later analysis proves to be hidden. 4-6.4.5 April 2003 Sentence requiring at least one failure cause for functional failures associated with fault- tolerant functions deleted. 4-6.4.5 April 2004 Clarification provided for failure causes in other MSIs/ATA-chapters. 4-6.5.2 January 2003 New heading for paragraph 4-6.5.2 introduced; all subparagraphs of paragraph 6.5.2 renumbered. 4-6.5.2 January 2003 References mentioned in paragraph 4-6.5.2 corrected 4-6.5.2.1 January 2004 Reference to paragraph dealing with BITE changed from 4-6.5.3 to 4-7.1. 4-6.5.2.2 January 2004 Reference to paragraph 4-6.5.5.1 changed to 4-6.5.4.1. 4-6.5.2.3 January 2004 Reference to paragraphs 4-6.5.5.4 and 4-6.5.5.5 changed to 4-6.5.4.4and 4-6.5.4.5. 4-6.5.2.3 April 2004 Clarification provided regarding the need to state the “additional failure” when answering Level 1 question 3. 4-6.5.2.4 January 2004 Reference to paragraphs 4-6.5.5.2 and 4-6.5.5.3 changed to 4-6.5.4.2and 4-6.5.4.3. 4-6.5.3 January 2003 Paragraph 4-6.5.2 and all subparagraphs renumbered 4-6.5.3 (old) January 2004 Complete paragraph (including sub-paragraphs) transferred to paragraph 4-7.1. 4-6.5.3.2 January 2003 Minor correction of text 4-6.5.3.4 April 2003 Clarification added to definition of failure class 4: Indication to the flight crew is not given at the exact time determined by the SSA but at an earlier period fixed by operational considerations. Minor correction added to definition of failure class 6. 4-6.5.3 (new) January 2004 Paragraph 4-6.5.4 (old) renumbered 4-6.5.3. 4-6.5.4 January 2003 Paragraph 4-6.5.3 renumbered 4-6.5.4 (new) January 2004 Paragraph 4-6.5.5 (old) renumbered 4-6.5.4 (including all sub-paragraphs and figure references). 4-6.5.4 (old) January 2004 Paragraph renumbered (now 4-6.5.3). 4-6.5.5 January 2003 Paragraph 4-6.5.4 and all subparagraphs renumbered 4-6.5.5(old) January 2004 Paragraph renumbered (now 4-6.5.4). 4-6.6.1.2 January 2003 Effectiveness criteria for failure-finding tasks in fault-tolerant applications added 4-6.6.1.2 April 2003 Effectiveness criteria for failure-finding tasks in fault-tolerant applications deleted 4-6.6.1.2 April 2003 Minor reformatting of several statements under “Additional Guidance”. 4-6.6.1.3 June 2003 Explanations about the ‘touching’ distance restriction of the GVI A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-7 DATE : June 2006 4-6.6.1.3 January 2004 Minor change of text regarding explanations about the ‘touching’ distance restriction for GVIs. 4-6.6.1.6 April 2003 Statement added on how to justify non-selection of a task in FEC 8. 4-6.6.2 April 2003 Clarification added that level 2 analyses for different failure causes can only be made on the same page if they belong to the same functional failure. 4-6.6.2 April 2003 Reference to specific effectiveness criteria for failure finding tasks associated with fault- tolerant functions deleted. 4-6.6.2 April 2003 Clarification added for data required for tasks that are to be transferred to Zonal Program. 4-6.6.2 April 2004 Statement added that interval justification needs to be provided on the Level 2 sheets 4-6.7.1 April 2004 Statement added about the need for interval justification 4-6.7.2 January 2003 Clarification added that specification requirements cannot be the only justification for interval selection 4-6.7.2 April 2003 Wording regarding the use of specification requirements changed: Requirements are not to be considered as compulsory but as “validated”. 4-6.7.3 April 2003 Statement added that a secondary usage parameter should always be stated in the analysis. 4-6.7.3 June 2003 Clarification that usage parameters different from the ones quoted may be used. 4-6.7.3 January 2004 Explanations about the second usage parameter 4-6.7.3 April 2004 Minor clerical corrections made. 4-6.7.6 April 2004 Paragraph regarding interval justification deleted. 4-6.7.6 July 2004 Paragraph regarding policy to be used to take into account corrosion on systems added 4-6.7.6 December 2004 Paragraph added to address other factors influencing task interval. 4-6.8 January 2003 New paragraphs added to highlight the need for acceptance/approval of any sampling procedure 4-6.9.2 April 2003 Clarification added that zonal task reference needs to be added to MRBR Interface sheet when available. 4-6.9.2 April 2004 Statement added regarding the need for ISC approval of combined tasks. 4-6.9.2 March 2005 Policy of the system MRBR task numbering included 4-6.9.2 February 2006 Policy to consolidate tasks from different MSIs 4-6.9.2 June 2006 • Policy to accomplish tasks in conjunction with other ones. • Policy to utilise Months (MO) as the unique usage parameter • Policy on reflecting task transfers to the Zonal Program in the MRBR Interface Sheet • Clarification on identifying the A380-800F in the MRBR Interface Sheet 4-6.9.3 April 2003 Statement added: Reason why the predominant usage parameter was chosen and what the secondary usage parameter was is to be added to the field “Interval Justification”. 4-6.9.3 June 2003 Clarification provided regarding the purpose of the planning data on the Task Data sheet and about the fact that the figures quoted do not include access and preparation times. 4-6.9.3 April 2004 Statements added about the need for interval justification if tasks are combined. 4-7 (old) January 2004 Paragraph 4-7 (old) renumbered 4-8 (including all sub-paragraphs). 4-7.1 January 2003 New paragraph for Change Control added 4-7.2 January 2003 Paragraph renumbered 4-7.2 January 2003 Clarification that applicability "All" only refers to passenger (not freighter) aircraft 4-7.3/4/5/6 January 2003 Paragraphs renumbered A380 POLICY AND PROCEDURES HANDBOOK HOC - PAGE: 8 REFERENCE: 95A.1689/02 DATE : June 2006 4-7.6 June 2003 Reference to A380-800F deleted. 4-7 (new) January 2004 New paragraph created as repository for procedures on BITE/failure classes (4-7.1), fault-tolerance analysis (4-7.2) and IMA (4-7.3). 4-7.1 January 2004 New paragraph for procedures on “BITE, Monitoring, Tests and Failure Classes” (formerly in paragraph 4-6.5.3). 4-7.1.1 January 2004 Clarification added that the maintenance of the avionics systems on A380 is primarily based on the failure detection capabilities of Built-In Test Equipment and that faults or failures detected by BITE result in failure messages that will be used to provide the necessary indications to the operating crew (and that will also be sent to the Centralized Maintenance System (CMS)). 4-7.1.4 January 2004 Clarification added that any failure detected by BITE is covered by a failure message that can be used to trigger an indication to the operating crew (if required) and that will also be transmitted to the Centralized Maintenance System. Definition of all failure classes was amended by replacing “indication” with “effect”. Definition of failure class 2 was changed bydeletion of the reference to “safety repercussions as per SSA”. 4-7.1.5 January 2004 Statement added that for Failure Classes 1, 2 and 3, it must be ascertained that the indication provided to the crew is indeed such that it is definitely noted by the crew. Otherwise, the functional failure needs to be treated as a hidden failure. 4-7.1.6 January 2004 New paragraph added dealing with selection of tasks that make use of the Centralized Maintenance System. 4-7.2 January 2004 New paragraph for procedures regarding systems with fault-tolerant functions (formerly in paragraph 4-6.1.2). 4-7.2.2 January 2004 Replacement of the term OMS by the term CMS. 4-7.2.3 January 2004 Additional clarification provided to stress that method for analysis of fault-tolerant functions is the same as the one used for all other functions. Deletion of paragraph that can be interpreted to refer to separate method. 4-7.3 January 2004 Paragraph for procedures on Integrated Modular Avionics (formerly in 4-6.1.3) was transferred to 4-7.3.. 4-7.3 January 2004 The entire paragraph was reworked on the basis of experience gained with the establishment of IMA-related analyses and the results of the 3rd ISC-meeting. 4-7.3.2.3 December 2004 Table amended for CPIOM-F and CPIOM-G, and addition of the FQMS for CPIOM-F 4-7.3.3.3 April 2004 Statement added about the handling of failure causes in other MSIs if one of the possible failure causes is a CPIOM. 4-8 January 2003 Paragraph split into 4-8.1 and 4-8.2. Last two paragraphs are now in 4-8.1. Two new paragraphs added at the end of 4-8.2. 4-8 April 2003 Minor change to title of paragraph. 4-8 (old) January 2004 Paragraph 4-8 (old) renumbered 4-9 (including all sub-paragraphs). 4-8.1 January 2003 Statements added stressing the importance of tracking assumptions and concerns raised by ISC and MRB advisers. 4-8-1 March 2005 Change control of MSI analysis amended. 4-8.2 October 2005 Incorporation of freighter activities 4-8.3 January 2003 New paragraph added on administrative aspects of systems working group activity. 4-8.3 March 2005 Page numbering of MSI analysis amended. 4-8.6 October 2005 Removal of A380-800 Model from Part 5 of the table 4-8 (new) January 2004 Paragraph 4-7 (old) renumbered 4-8 (including all sub-paragraphs). 4-9 (old) January 2004 Paragraph 4-9 (old) renumbered 4-10. 4-9 (new) January 2004 Paragraph 4-8 (old) renumbered 4-9 (including all sub-paragraphs). 4-9.3 January 2004 Addition of Appendix B reference for MSG3 Analysis Status List 4-10 (new) January 2004 Paragraph 4-9 (old) renumbered 4-10. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-9 DATE : June 2006 4-10 March 2005 Definition of fuel ALIs included following SFAR 88 requirements 5 April 2003 Acronym ‘DI’ is replaced by ‘DET’ in several paragraphs to put it line with the agreed acronym to be used. 5-2.1 January 2003 Last paragraph deleted. CPCP details included in the relevant paragraphs. 5-2.3 January 2003 Glare' is declared as metallic material in order to avoid misunderstandings and confusion with 'non-metallic' definition. 5-2.4 December 2004 Amendment to the Environmental Deterioration definition 5-3.1 January 2003 Paragraph added for SSIs containing 'metallic' and 'non-metallic' structure. 5-3.3 January 2003 New paragraph added to include documentation process. 5-4.4 January 2003 Step 4.2 amended: Form Sheet STR14a added (LEP). 5-4.6 June 2003 The paragraph has been modified such that the main text under “What” refers directly to paragraph 2-5.3. 5-6.1.1 January 2003 Paragraph added on how to state the applicability of the analysis on the SSD Cover sheet. 5-6.1.1 October 2005 Incorporation of freighter applicabilities 5-6.1.4 January 2003 Description of List of Effective SSI Analyses revised to include the 'Issue Number'. 'SSI Description' changed to 'SSI Title'. 5-6.2.2 January 2003 June 2003 Statement added that modifications relevant and covered by the analysis must be listed in the Supporting Data Sheet. 5-8.1.3 January 2003 Paragraph describing an individual List of Effective Pages for the SSI added. 5-8.2.5 March 2005 Explanation of the meaning of the Note D1. 5-8.2.7 January 2003 Glare' is mentioned as metallic material. 5-8.2.8 January 2004 Paragraph added to list attaching and/or connecting elements under the related SSI, where appropriate. 5-8.2.9 January 2004 Paragraph slightly modified to emphasize that ‘interactive or adjacent parts must be identified. 5-8.2.10 January 2004 Paragraph added to identify areas where specified protection schemes have been replaced during assembly. 5–8.3.3 January 2004 Lightning strike transferred from f) to g) ”weather effects” and ‘rain’ is deleted from “weather effects”, f)g)h)I) re-identified. 5-8.5.4 April 2003 Error in the flow chart. ‘… on SSR?’ is added to the third question. 5-8.6.1 December 2004 Amendment to the Environmental Deterioration definition 5-8.6.3 December 2004 Definition of the galvanic couple to use for the galvanic rating 5-8.6.4.1 January 2004 Definition of Galvanic corrosion revised, crevice corrosion redefined and highlighted, galvanic corrosion rating table updated. 5-8.6.4.1 April 2004 Definition of Galvanic corrosion revised, galvanic corrosion rating table updated. 5-8.6.4.1 December 2004 Definition of Galvanic corrosion revised and incorporation of rules. 5-8.6.4.1 March 2005 Definition of Galvanic corrosion revised in case of AD and incorporation of rules. 5-8.6.4.1 February 2006 Galvanic rating table amended 5-8.6.4.1 June 2006 Galvanic rating table amended 5 - 8.6.4.3. January 2004 ‘Hydraulic fluid spillages’ and ‘rain water at entrance areas’ added as examples of environmental rating ‘2’. 5-8.6.4.3. December 2004 Environmental rating table amended with new criteria 5-8.6.4.3. February 2006 Environmental rating table amended with new criteria A380 POLICY AND PROCEDURES HANDBOOK HOC - PAGE: 10 REFERENCE: 95A.1689/02 DATE : June 2006 5-8.6.4.4 December 2004 Protection Rating table amended 5 - 8.6.4.6 January 2004 Crevice corrosion is added to the combination of ratings chart. 5-8.6.5 December 2004 Limit the CPCP parts of the ED/CPCP analysis to the “in service “ experience 5-8.6.7. January 2004 TPS code explanation added. 5-8.6.8. January 2004 Paragraph added to state that no sampling is allowed whenever TPS is required. 5-8.7.1.2 June 2006 Environmental parameter paragraph amended 5-8.9.1 April 2003 Reference to the SCCC is included. 5-8.9.1 June 2003 Text explaining the concept and definition of ‘independent’ fatigue inspection requirements. 5-8.9.3.5 April 2003 Typing error. Rating 4. In the ‘examples’ column, it should read:’… ten (10) centimetres square’, instead of ‘… ten (10) square centimetres’. 5-8.9.3.3 June 2003 Explanations about the ‘touching’ distance restriction of the GVI. 5-8.9.4 April 2003 Typing error. The wording below the chart has been revised in accordance with the nomenclature used inside the chart. 5-8.9.5 April 2003 Weight Variants and modifications are mentioned as a possibility in the ‘applicability’ affecting the fatigue damage requirement. 5-8.9.6 June 2003 On fatigue damage analysis flow chart DI replaced by DET. 5-9.2.4 June 2003 Explanations about the ‘touching’ distance restriction of the GVI. 5-9.5.2 January 2003 Paragraph slightly modified to reflect the place where the MPP reference is to be found. 5-9.5.2 December 2004 Amendment to remove the link to the MPP reference to be in line with the new structure format 5-9.6 December 2004 SSI consolidation chart amended 5-9.7 June 2006 Policy to accomplish tasks in conjunction with other ones. 5-9.7.2 December 2004 MPP Task reference paragraph removed to be in line with the new structure format. 5-9.7.2 March 2005 MRBR Task numbering rule included5-9.7.7 March 2005 Definition of the meaning of YE 5-9.7.7 June 2006 Policy to utilise Months (MO) as the unique usage parameter 5-9.7.8 March 2005 Definition of the meaning of YE 5-9.7.8 June 2006 Policy to utilise Months (MO) as the unique usage parameter 5-9.7.9 March 2005 Definition of the meaning of YE 5-9.7.9 June 2006 Policy to utilise Months (MO) as the unique usage parameter 5-9.8 June 2003 Clarification about the purpose of the planning data on the Task Data sheet. 5-10.1 January 2003 Explanation of applicability control revised to put it in line with Systems. 5-10.1 October 2005 Incorporation of freighter applicabilities 5-10.2 January 2003 Numbering of Analysis Forms revised to include an individual LEP for the SSI Analysis. 5-10.2 April 2003 Numbering of Analysis Form STR09. Note ‘Reserved’ changed to ‘Deleted’ to avoid confusion. 6-2 June 2003 Abbreviations corrected to 3 letters A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-11 DATE : June 2006 6-3.1 June 2003 Abbreviations corrected to 3 letters 6-3.2 January 2004 Reference of the consolidation procedure added to the flow chart. 6-4.1 January 2004 Revision of the column MSG3 form. 6-4.2 January 2004 Assurance plan coordination not applicable to initial L/HIRF analysis. 6-4.3 January 2004 Revision of the column MSG3 form. 6-4.4 June 2003 The paragraph has been modified such that the main text under “What” refers directly to paragraph 2-5.3. 6-4.4 January 2004 Paragraph “Preparation for review” totally revised 6-4.5 January 2003 Step 5.1 - 'On aircraft review during last MWG meeting' added. 6-4.5 January 2004 Revision of the column MSG3 form. 6-4.6 January 2004 Revision of the column “remarks”. 6-5.1 January 2004 Administrative data paragraph totally revised. 6-5.1.1 January 2003 Fifth paragraph is amended. 6-5.1.1 6-5.1.2 6-5.1.3 January 2004 Wording improvements. 6-5.2 6-5.2.1 6-5.2.2 January 2004 Wording improvements. 6-5.3.1 January 2003 Wording added for Installed wiring (Location and Route). 6-5.3.1 January 2003 Reference to paragraph 6-5.5.2 deleted). 6-5.3.1 January 2004 Wiring route ‘M’ added. 6-5.3.1 April 2004 Wiring “listed and evaluated” instead of “inspected”. 6-5.3.1 July 2004 Route identification explained 6-5.3.2 January 2004 • Question 2, 3, 4, and 5. Wording improvement. • Steps 6, 7, 8 and 9. Explanations about the use of the form sheets in case of further items. • Possibility to integrate photos from legacy aircraft. 6-5.4.1 January 2004 Wording improvement. 6-5.4.2 January 2003 Some guidance related to 'Importance' has been added to 'Step 3 and 5'. 6-5.4.2 June 2003 Explanations about the ‘touching’ distance restriction of the GVI 6-5.4.2 January 2004 • New Standard Zonal Analysis flow chart with deletion of questions 2 and 4 • New rating table • Clarification about question 6 6-5.4.2 April 2004 ‘Steps 3 and 5’ – Guidance for assessment of importance for fuel tank zones added/changed. 6-5.4.2 February 2006 Statement for insulation added 6-5.5.1 January 2004 New Enhanced Zonal Analysis flow chart. 6-5.5.1 April 2004 Add of the AC120-XX as a referential for Enhanced Zonal Information. 6-5.5.1 December 2004 Amendment to take into account the L/HIRF protection 6-5.5.2 June 2003 Abbreviations corrected to 3 letters A380 POLICY AND PROCEDURES HANDBOOK HOC - PAGE: 12 REFERENCE: 95A.1689/02 DATE : June 2006 6-5.5.2 January 2004 • Clarification about the identification of zones containing wiring Question 1 - Title revised. 6-5.5.2 January 2004 • Instructions revised to reflect updated flow chart in Figure 4. 6-5.5.2 April 2004 • Question 1 - Manufacturer proposal to re-valuate initial Enhanced tasks after 6-12Y added. Combustibility guidance for hydraulic fluid revised. Data amendment for the question 1 & 4 for accumulation of combustible material. • Question 4 - 5mm accumulation guidance removed. • Step 5 - GVI and stand alone GVI levels clarified. 6-5.5.2 July 2004 Paragraph added for dust accumulation 6-5.5.2 February 2006 Addition of the number of aircraft for the assurance plan 6-5.5.3 January 2003 Some guidance and information added to 'Environment' under 'Step 6'. 6-5.5.3 January 2003 Note added at the end of the paragraph requiring justification when interval selected differs from guidance matrix. 6-5.5.3 January 2003 Paragraphs renumbered. 6-5.5.3 June 2003 Explanations about the ‘touching’ distance restriction of the GVI. 6-5.5.3 January 2004 • Question 5 title revised and methodology to identify possible task combination amended. • Step6 - New rating table for interval determination. • Step 8 - Amendment of the rating table for task level identification. • Step 9 - New rating table for interval determination. 6-5.5.3 April 2004 • Question 6 - Update of the definition of “high”, “medium” and “low” potential effect of fire on adjacent wiring and systems in the zone. • Step 9 – Table updated potential effect of fire on adjacent wiring and systems in the area. 6-5.5.3 July 2004 Amendment for the potential effect of fire on wiring systems 6-5.6 March 2005 Amendment of the possible causes of protection elements degradation 6-5.6.1 January 2003 Last paragraph of 5-6.2 added to this paragraph. 6-5.6.1 January 2003 Assurance plan statement transferred chapter 7-4. 6-5.6.1 April 2004 • Zonal L/HIRF analysis scope clarified. • Airbus Zonal L/HIRF analysis policy adoption of MSG3 clarified. 6-5.6.2 January 2003 Complete paragraph deleted. This information is now in paragraph 7-4. 6-5.6.2 January 2004 • New L/HIRF Zonal analysis flow chart. • New rating table. 6-5.6.2.1 June 2003 Explanations about the ‘touching’ distance restriction of the GVI. 6-5.6.2.1 June 2003 Abbreviations corrected to 3 letters 6-5.6.2.1 January 2004 • Question 1. Inspection level determination revised. • Step 2. New rating table for interval determination. • Step 4. Explanation about FNC • Question 6. Improvements. 6-5.6.2.1 April 2004 • Question 1 changed to read Step 1. • Density of equipment – “raceways” deleted and “congested” changed to “high”. • Amendment of the L/HIRF protection deterioration criteria. • Step 2 – Title changed to “Determine GVI task interval”. • Step 4 – Functional Check selection option included for initial programme and Inspection Level selection rating replaced with pure guidance and link L/HIRF functional check with the Airbus assurance plan added. 6-5.6.2.1 March 2005 • Fire deleted of the potential effect of L/HIRF deterioration. • Definition of the L/HIRF protection deterioration criteria amended 6-5.6.2.1 February 2006 • “L/HIRF protection deterioration criteria” definition amended 6-5.6.3 January 2003 Note added at the end of 'Step 2' paragraph requiring justification when interval selected differs from guidance matrix. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-13 DATE : June 2006 6-5.6.3 January 2003 Last paragraph in 'Step 3' is deleted. 6-5.6.3 January 2003 First paragraph in 'Step 4': 'interval' is changed to 'level' (mistake). 6-5.6.3 January 2003 Paragraph added for Functional Check 'FNC' to highlight that it is to be selected only after Assurance Plan findings evaluation. 6-6.1 April 2004 Reference to section 2 Chapter 4.4 for transfer requirement details added. 6-6.2 June 2003 Abbreviations corrected to 3 letters 6-6.2.1 April 2003 Consolidation. Sheets number removed 6-6.2.1 June 2003 Abbreviations corrected to 3 letters 6-6.2.1 March 2005 Deletion of the ZIP reference in the systems/powerplant transfers. 6-6.2.1 March 2005 Deletion of the ZIP reference in the structure transfers. 6-6.2.2 April 2003 Consolidation. Sheets number removed 6-6.2.3 April 2003 Consolidation. Sheets number removed 6-6.2.4 April 2003 Consolidation. Sheets number removed 6-6.2.4 June 2003 SDETreplaced by FNC 6-6.2.4 January 2004 Added note about FNC. 6-6.2.4 April 2004 Removal of the note concerning the FNC. 6-7.1 January 2003 Explanation of applicability control revised to put it in line with Systems. 6-7 June 2003 Explanations about the Task Data sheet 6-7 March 2005 Renumbered to include the new paragraph “MRBR Interface” 6-7.1. 6 June 2006 Policy to accomplish tasks in conjunction with other ones. 6-7.1.8 June 2006 Policy to utilise Months (MO) as the unique usage parameter 6-8 April 2003 Headline. Word ‘meeting’ written after MWG, removed 6-8 June 2003 Renumbered 6-8 March 2005 Renumbered 6-8.1 June 2003 Renumbered 6-8.1 March 2005 Renumbered 6-8.2 June 2003 Renumbered and reference to freighter removed 6-8.2 March 2005 Renumbered 6-9 June 2003 Renumbered 6-9 March 2005 Renumbered 6-9.1 October 2005 Incorporation of freighter applicabilities 6-9.2 October 2005 Removal of the A380-800 Model. 6-10 March 2005 Renumbered A380 POLICY AND PROCEDURES HANDBOOK HOC - PAGE: 14 REFERENCE: 95A.1689/02 DATE : June 2006 7-2.1.2 January 2003 Last paragraph revised to include wording related to 'SSA/MSG-3 compatibility check'. 7-3.3 January 2003 Specific document for this process is mentioned for reference. 7.4 April 2003 L/HIRF sampling every Six years instead of Five years 7-4 January 2003 Paragraph revised entirely. App. A-3 January 2003 The JAA AGM Sec.2, Part 2, Chapter 16 included is now a 'clean' version without identification of changes. App. B January 2003 New form added 'MWG Transfer Sheet' (TRS01). App. B January 2003 Structure Analysis Form STR08. 'Issue' column added.'SSI Description' changed to 'SSI Title'. App. B January 2003 New Form Sheet (STR14a). Individual LEP for SSI Analysis. App. B January 2003 Structure Analysis Forms for SSIs (STR22 and STR24) have been re-arranged. No thechnical content changed. App. B January 2003 Structure Analysis Forms for SSIs (STR13 to STR25). The footer has been slightly changed. App. B January 2003 Structure Analysis Form STR27. Order of 'MPP' column and 'SSI Requirement' column has been changed'. App. B April 2003 The Structure Analysis Forms have been amended to state ‘DET’ instead of ‘DI’, according to the acronym used in the PPH. App. B January 2003 Zonal/LHIRF Protection Analysis - Evaluation Sheet 2. Step 3 reworded to read:'3. Item Description'. According to modification of paragraph 6-5.6.3. App. B April 2003 MSG3 analysis form sheets added. Appendix B April 2003 Standard Zonal analysis evaluation sheet 1. Numbering of question revised Appendix B April 2003 L/HIRF protection analysis. Evaluation sheet 1 and 2. Interval determination rating table revised to be in accordance with the PPH Appendix B June 2003 SSI STR numbers added and MWG Transfer sheet added Appendix B June 2003 SSI STR numbers added and MWG Transfer sheet added Appendix B January 2004 Zonal analysis work sheets revised Appendix B January 2004 A380 MFU Record table added (Details TBD) Appendix B January 2004 MSG3 Analysis Status List added Appendix B January 2004 Enhanced Zonal Analysis evaluation sheet 1 revised Appnedix B April 2004 Enhanced and L/HIRF form sheets revised according to PPH changes. Appendix B April 2004 A380 MFU Record table added. Appendix B July 2004 Evaluation sheet 2 & 3 of the enhanced zonal amended Appendix B December 2004 Page 4.3.1 and 5.2.1 of the zonal form sheets amended Appendix B December 2004 New structure form sheets included Appendix B March 2005 Page 5.3.1, 5.4.1, 5.5.1 of the zonal form sheets amended. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 History of Changes- PAGE: HOC-15 DATE : June 2006 Appendix B March 2005 New system form sheets included Appendix B October 2005 MSI validation list layout included as item 7 App. C April 2003 Corrosion Rating Tables added. App. C January 2004 Corrosion sensitivity ratings updated on pages C5, C10, C15, C20 and C34. App. C December 2004 Corrosion Rating Tables updated. App. C February 2006 Corrosion Rating Tables updated. App. D April 2003 The ‘Significant Structure Definition’ is amended to put it in line with the one included in the text of the PPH (paragraph 5-2.3). App D October 2005 Environmental deterioration definition amended App. D1 April 2003 GVI Stand-alone definition added App. D1 June 2006 Term added (Modification Follow-up) App. D2 June 2003 Acronyms added App. D2 January 2004 Acronyms added (ECAM, ADCN, V&V) App. D2 June 2006 Acronym added (MFU) App. E January 2003 Schedule added. App. F January 2003 New. Appendix created to include composition of MRB / ISC / WG. App. F April 2003 Organization revision (MRB composition, ISC composition) App. F June 2003 Name of the MWG 9 reworded ‘Interior’ instead of ‘Payload’. Revision of MRB and ISC composition. Appendix F January 2004 Revision of ISC. Operators and manufacturer Lists. Appendix F April 2004 Revision of ISC. Operators and manufacturer Lists. Appendix F December 2004 Revision of authorities (observers) Lists and MWG5 & MWG9 Chairperson name. Appendix F March 2005 Revision of authorities (observers) Lists. Appendix F June 2006 Update of Airworthiness Authorities/Airlines/ Airbus participants Lists. App. G June 2003 New appendix: Required data for MWG report to ISC App. G January 2004 Appendix expanded to include MWG meeting reports, MWG Chair reports and ISC meeting reports. App. G April 2004 MWG Chair reports contents to ISC updated. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 Table of Contents - PAGE: TOC-1 DATE : June 2006 TABLE OF CONTENTS SCHEDULED MAINTENANCE DEVELOPMENT .................................1 ACCEPTANCE LETTERS..................................................................................................................2 RECORD OF REVISIONS ...........................................................................................................................4 HISTORY OF CHANGES ....................................................................................................................1 TABLE OF CONTENTS ........................................................................................................................1 SECTION 1: INTRODUCTION............................................................................................................................. 1-1 1 BACKGROUND.............................................................................................................................................. 1-1 2 PURPOSE ....................................................................................................................................................... 1-1 3 STANDARD OF MSG-3 REVISION................................................................................................................ 1-1 4 AIRWORTHINESS REQUIREMENTS............................................................................................................ 1-1 SECTION 2: ORGANIZATION AND ADMINISTRATION.............................................................................. 2-1 1 GENERAL ....................................................................................................................................................... 2-1 2 ORGANIZATION ............................................................................................................................................ 2-3 3 TRAINING....................................................................................................................................................... 2-9 4 COMMUNICATION ..................................................................................................................................... 2-11 5 MEETING ORGANIZATION AND MEETINGS REPORTS .........................................................................2-11 6 MRB REPORT APPROVAL.......................................................................................................................... 2-13 7 REVISION PROCESS ................................................................................................................................... 2-14 SECTION 3: ANALYSIS PROCEDURE. GENERAL......................................................................................... 3-1 1 INTRODUCTION............................................................................................................................................ 3-1 2 OBJECTIVES .................................................................................................................................................. 3-1 3 SCOPE ............................................................................................................................................................ 3-2 4 AIRCRAFT UTILIZATION ASSUMPTIONS................................................................................................. 3-11 5 INTERVAL FRAMEWORK ........................................................................................................................... 3-12 SECTION 4: SYSTEMS AND POWERPLANT ANALYSIS PROCEDURE.................................................... 4-1 1 INTRODUCTION............................................................................................................................................ 4-1 2 PRINCIPLES................................................................................................................................................... 4-1 3 BASIC ANALYSIS PROCEDURE ................................................................................................................... 4-2 4 DETAILED PROCEDURAL STEPS ............................................................................................................... 4-3 5 MSI SELECTION ............................................................................................................................................ 4-7 6 MSI ANALYSIS PROCEDURES ................................................................................................................... 4-15 7 SUPPLEMENTARY METHODOLOGIES .................................................................................................... 4-55 8 ANALYSIS ADMINISTRATION .................................................................................................................... 4-70 9 MWG ANALYSIS REVIEW PROCEDURE .................................................................................................. 4-75 10 INTERFACE WITH TYPE CERTIFICATION PROCESS ......................................................................... 4-77 SECTION 5: STRUCTURE ANALYSIS PROCEDURE..................................................................................... 5-1 1 INTRODUCTION............................................................................................................................................ 5-1 2 PRINCIPLES................................................................................................................................................... 5-1 3 BASIC ANALYIS PROCEDURE ..................................................................................................................... 5-4 A380 POLICY AND PROCEDURES HANDBOOK Table of Contents - PAGE: TOC-2 REFERENCE: 95A.1689/02 DATE : June 2006 4 DETAILED PROCEDURAL STEPS ............................................................................................................... 5-7 5 PROCEDURE FOR IDENTIFICATION OF SIGNIFICANT STRUCTURE................................................. 5-11 6 SIGNIFICANT STRUCTURE DOSSIER DOCUMENTATION..................................................................... 5-15 7 SSI IDENTIFICATION AND MANAGEMENT ............................................................................................. 5-19 8 SSI ANALYSIS ............................................................................................................................................... 5-23 9 SSI REQUIREMENTS CONSOLIDATION ................................................................................................... 5-62 10 ANALYSIS ADMINISTRATION................................................................................................................. 5-69 11 SAMPLING PROGRAM............................................................................................................................ 5-71 12 MWG MEETING ANALYSIS REVIEW PROCEDURE ............................................................................. 5-71 SECTION 6: ZONAL AND L/HIRF ANALYSIS PROCEDURE ....................................................................... 6-1 1 INTRODUCTION............................................................................................................................................ 6-1 2 PRINCIPLES................................................................................................................................................... 6-1 3 BASIC ANALYSIS PROCEDURE ................................................................................................................... 6-2 4 DETAILED PROCEDURAL STEPS ............................................................................................................... 6-4 5 ZONAL AND L/HIRF ANALYSIS PROCEDURE............................................................................................ 6-6 6 CONSOLIDATION OF REQUIREMENTS ................................................................................................... 6-30 7 MRBR INTERFACE ...................................................................................................................................... 6-31 8 TASK DATA................................................................................................................................................... 6-33 9 ANALYSIS ADMINISTRATION..................................................................................................................... 6-33 10 MWG ANALYSIS REVIEW PROCEDURE ............................................................................................... 6-35 SECTION 7: TYPE CERTIFICATION INTERFACE ........................................................................................ 7-1 1 GENERAL ....................................................................................................................................................... 7-1 2 CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs).................................................................... 7-1 3 AIRWORTHINESS LIMITATION ITEMS (ALIs) ............................................................................................ 7-2 4 L/HIRF ............................................................................................................................................................ 7-3 5 LONG RANGE OPERATIONS (LROPS) ........................................................................................................ 7-4 SECTION 8: RESERVED ...................................................................................................................................... A-1 APPENDIX A: REFERENCE DOCUMENTATION............................................................................................ A-2 1 GENERAL .......................................................................................................................................................A-2 2 SCHEDULED MAINTENANCE RELATED JARs / FARs ..............................................................................A-2 3 MAINTENANCE REVIEW BOARD PROCEDURES......................................................................................A-9 4 MSG-3 REVISION 2002.1 .............................................................................................................................A-12APPENDIX B: A380 MSG-3 ANALYSIS FORM SHEETS ................................................................................ B-1 1 MSI ..................................................................................................................................................................B-1 2 SSI ...................................................................................................................................................................B-8 3 Zonal & L/HIRF ............................................................................................................................................B-21 4 Communication .............................................................................................................................................B-34 5 Analysis Status List........................................................................................................................................B-35 6 A380 MFU Record Table ..............................................................................................................................B-36 7 A380 MSI Validation List Layout:.................................................................................................................B-37 APPENDIX C: CORROSION RATING TABLES................................................................................................ C-1 APPENDIX D: GLOSSARY, ACRONYMS AND ABBREVIATIONS .............................................................. D-1 1 GLOSSARY..................................................................................................................................................... D-1 2 ACRONYMS AND ABBREVIATIONS ............................................................................................................ D-6 APPENDIX E: SCHEDULING ..............................................................................................................................E-1 APPENDIX F: ORGANIZATION..........................................................................................................................F-1 1 GENERAL .......................................................................................................................................................F-1 2 MRB COMPOSITION .....................................................................................................................................F-1 3 ISC COMPOSITION .......................................................................................................................................F-2 APPENDIX G: REQUIRED DATA FOR MWG AND ISC MEETING REPORTS .................................................. G-1 A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 SECTION 1 - PAGE: 1-1 DATE :June 2006 SECTION 1: INTRODUCTION 1 BACKGROUND The Joint Aviation Authorities (JAA) requirements and Federal Aviation Administration (FAA) regulations require Airbus -as the A380 type certificate holder- to prepare, revise as necessary, and submit for approval to the relevant Airworthiness Authorities the initial minimum scheduled maintenance/inspection requirements that are applicable to the A380 aircraft. These initial maintenance/inspection requirements are developed by members from a representative number of customer airlines, aircraft manufacturers and regulatory advisors who combine knowledge and experience with the final aim to compile a Maintenance Program Proposal (MPP) that is acceptable to the Maintenance Review Board (MRB). Once approved by the MRB, this proposal becomes the MRB Report (MRBR). 2 PURPOSE The purpose of this Policy and Procedures Handbook (PPH) is to compile all the necessary information required by the relevant working bodies involved in the development of the A380 initial minimum scheduled maintenance/inspection requirements. This PPH sets forth the policies and details those procedures to be followed by the joint Airline/Manufacturer Working Groups (WGs), Industry Steering Committee (ISC) and Maintenance Review Board (MRB). 3 STANDARD OF MSG-3 REVISION The document “Operator/Manufacturer Scheduled Maintenance Development”, as developed by the Maintenance Steering Group -3 Task Force (MSG-3), Revision 2002.1, published by the Air Transport Association of America (ATA) and referred to as ‘MSG-3 Rev.2002.1’ is the basis for the analysis procedures described in this PPH. Any reference within this PPH to the MSG-3 document must be understood, unless otherwise stated, as the MSG-3 Rev.2002.1 document. 4 AIRWORTHINESS REQUIREMENTS The initial certification basis for the A380 aircraft regarding airworthiness standards for issue of type certificates are JAR 25 at Change 15 and 14 CFR part 25, (FAR 25) including Amendments 25-1 through 25-98. JAR stands for Joint Aviation Requirements and JAR 25 is the European counterpart to Federal Aviation Regulations (FAR) 25. The JAR/FAR used for Type Certification of the A380 aircraft requires that maintenance information be established prior to delivery of the first aircraft. The particular requirements concerning maintenance programs are: A380 POLICY AND PROCEDURES HANDBOOK SECTION 1 - PAGE: 1-2 REFERENCE: 95A.1689/02 DATE : June 2006 FAR/JAR Title 25.1529 and Appendix H Instructions for Continued Airworthiness 25.571 Damage Tolerant and Fatigue Evaluation of Structure SFAR 88 Amdt 21-78 Fuel Tank Safety Special Federal Aviation Regulation 25.981 Fuel Tank Ignition Prevention INT/POL/25/12 Fuel Tank Safety 25.1309 Equipment, Systems and Installations EASA D 2005/CPRO/RH/50213 EASA policy statement on the Process for developing instructions for maintenance and inspection of fuel tank system ignition source prevention. Includes Guidance Material. EASA D 2006/CPRO/LAP/PME/50761 EASA policy statement on fuel tank safety (supersedes 50213 Part A and B). Guidance Material provided in 50213 remains valid. FAA Memo ANM 112-05-001 6th Oct 04 FAA policy statement to standardise guidance for compliance with Special Federal Aviation Regulation 88 In APPENDIX A, an extract of these regulations is provided. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 SECTION 2 - PAGE: 2-1 DATE : June 2006 SECTION 2: ORGANIZATION AND ADMINISTRATION 1 GENERAL The organization and administration of the Maintenance Review Board (MRB), Industry Steering Committee (ISC) and Maintenance Working Groups (MWG) follows the guidelines as established in the following documents: • JAA Administrative & Guidance Material (AGM), Section 2, Part 2, Chapter 16: 'Procedures for Maintenance Review Boards'. (Dated 01.Dec.98). • FAA Advisory Circular AC No: 121-22A: 'Maintenance Review Board Procedures' NOTE: These documents are included in Appendix A. According to these guidelines, the organization that develops the MRB Report consists of the following working bodies: • Maintenance Review Board (MRB) • Industry Steering Committee (ISC) • Maintenance Working Groups (MWG) This section provides the composition and functions of each working body as well as the main responsibilities of the manufacturer. On the following page, a figure showing the interaction between these working bodies, their basic composition and the main documents produced is shown. Also this section describes the basic procedures to be followed by the working bodies administrative issues, such as those related to communication among them, meeting organization, approval of the MRB Report and revisions of the documents. A380 POLICY AND PROCEDURES HANDBOOK SECTION 2 - PAGE: 2-2 REFERENCE: 95A.1689/02 DATE : June 2006 WORKING BODIES AND DOCUMENTS PARTICIPANTS REPORTS/DOCUMENTS WORKING BODIES MSG-3 ANALYSES INDUSTRY STEERING COMMITTEE POLICY AND PROCEDURES HANDBOOK MAINTENANCE WORKING GROUPS INDUSTRY STEERING COMMITTEE MAINTENANCEPROGRAM PROPOSAL MAINTENANCE REVIEW BOARD MAINTENANCE REVIEW BOARD REPORT Operators Manufacturers Airworth. Authorities Operators Manufacturers Airworth. Authorities Airworth. Authorities Operators Manufacturers Airworth. Authorities A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 SECTION 2 - PAGE: 2-3 DATE : June 2006 2 ORGANIZATION 2.1 MAINTENANCE REVIEW BOARD (MRB) The A380 Maintenance Review Board (MRB) is responsible for approving the initial minimum scheduled maintenance requirements, which are contained in the MRB Report and revisions thereto. 2.1.1 COMPOSITION See Appendix: F 2.1.2 FUNCTIONS OF THE MRB The duties and responsibilities of the MRB Chair and members are described in JAA Administrative & Guidance Material Chapter 16.12 and FAA Advisory Circular AC 121-22A, Chapter 3. The main function and responsibilities of the MRB, under the direction and management of the MRB-Chair, include: a) Provide the ISC with a list of MRB members and MRB advisers to the MWGs b) Review and accept the Policy and Procedures Handbook (PPH) prepared by the manufacturer and approved by the ISC c) Establish the extent of regulatory authority participation and assignment of MRB advisors to the MWGs d) Coordinate all MRB activities and associated matters with the ISC Chair through the MRB Chair e) Offer advice and guidance to the ISC and MWGs f) Ensure that the appropriate regulatory authorities are in attendance at all MWG meetings g) Participation in the CMR process as described in AMJ 25-19 / AC 25-19 h) Participation in the ALI process as described in Section 7-2 of this PPH 2.1.3 FUNCTIONS OF THE MRB ADVISERS TO THE MWG The main functions of the MRB advisers to the MWGs are: a) Attend MWG meetings and provide advice (e.g. on how to ensure compliance with PPH guidelines) to the MWG members b) Attend MRB meetings if required c) Advise the MWG as early as possible of concerns or issues with the MSG-3 analysis results or interval selection Provide progress reports to the MRB Chair prior to the next scheduled ISC meeting. This report will contain an assessment of MWG activities, including notification of controversial or potential problem areas. A copy of the progress report may be sent to MWG Chair. 2.1.4 FUNCTIONS OF THE MRB/FAA SPECIALIST Where the issue under discussion requires specific competencies (such as L/HIRF, GLARE, IMA…) an additional representative from the regulatory authorities may be needed to join the MWG. He will not substitute for the MRB advisor. He will assist the MRB advisor and MWG by providing any technical information when required. A380 POLICY AND PROCEDURES HANDBOOK SECTION 2 - PAGE: 2-4 REFERENCE: 95A.1689/02 DATE : June 2006 2.2 INDUSTRY STEERING COMMITTEE (ISC) The ISC establishes policies, directs the activities of the MWGs and is responsible for the establishment of the Maintenance Program Proposal (MPP). The ISC activities will be coordinated with the MRB Chair through the ISC Chair /Co-Chair. 2.2.1 COMPOSITION The ISC is composed of members from a representative number of operators and representatives of the prime airframe and engine manufacturers. Operators may delegate ISC participation to nominated representatives such as personnel from contracted Maintenance Organisation for the specific type of aircraft. Such delegated person should act on behalf of the operator. The attendance of maintenance organisation personnel in the working groups and other MRB related activities would have to be sanctioned by the ISC Chair. In such case the ISC Chair should preferably ensure a good balance between operators and maintenance organisation representatives. MRB representatives will be invited to ISC meetings. The A380 ISC is chaired by an airline member and co-chaired by an airframe manufacturer member. In addition, an Assistant to the ISC Co-chair is nominated. An ISC advisor is assigned to each MWG to advise on overall policy and report any difficulties to the ISC. 2.2.2 FUNCTIONS OF THE ISC It is the responsibility of this committee to establish policy, set initial goals for scheduled maintenance check intervals, direct the activities of Working Groups or other working activity, carry out liaison with the manufacturer and other operators, prepare the final program recommendation and represent the operators in contacts with the Regulatory Authority. The ISC should see that the MSG-3 process identifies 100 % accountability for all Maintenance Significant Items and Significant Structure, whether or not a task has been derived from the analysis. Prior to the MWGs starting the analysis review, and as early as possible during the ISC activities, the ISC conducts a preliminary review of the MSI and Significant Structure Selection: a) Review of “Candidate” MSI / Significant Structure selection lists b) Provisional approval of items selected by manufacturer (before the analysis of an item is established) c) Allocation of MSIs / Significant Structure to the working groups (to allow estimation of workload and detailed planning for WG activities) The ISC review of the working group results will concentrate on the following issues: - Review of MSI / Significant Structure Selection: Review and agreement of MSI / Significant Structure selection lists presented by the working groups, including approval of items selected for analysis and those not selected for MSG-3 analysis - Review of MSI / Significant Structure / Zonal analyses results: Review, discussion and approval of tasks selected by the MWG, including task description, interval and other data necessary for inclusion in the MRB Report. This review is to be done by means of the respective MRB Report Interface sheets - Review of items raised for ISC consideration: Review, discussion and decision of items raised for ISC consideration and decision in order to allow the MWG to close open procedural items of a general nature and items for which no agreement could be reached in the WG. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 SECTION 2 - PAGE: 2-5 DATE : June 2006 2.2.3 FUNCTIONS OF THE ISC CHAIR The Chair should be elected from within the operators present at the ISC. He/she is responsible for the general oversight of the ISC activities. The ISC Chair: a) Presides at meetings of the ISC. b) Certifies the accuracy of the ISC Meeting Reports in collaboration with the ISC Co-Chair. c) Invites new customers to become ISC members. d) Encourages ISC members to actively participate. e) Ensures that working groups have a balanced membership. f) Monitors the progress of working groups. g) Conducts in-depth reviews of working group reports. h) Provides agreement for proposals (e.g. PPH, MPP, etc.) to the MRB. i) Provides agreement to manufacturer’s Temporary Revision proposals. 2.2.4 FUNCTIONS OF THE ISC CO-CHAIR The ISC Co-Chair is appointed by Airbus. He/she: a) Assists in maintaining liaison with the ISC members and their organizations to enhance its effectiveness. b) Certifies the accuracy of the ISC Meeting Reports in collaboration with the ISC Chair. c) Establishes appropriate working groups. d) Proposes appropriate chairpersons for working groups. e) Assumes all responsibilities of the ISC Chair in the absence of the ISC Chair. f) Notifies respective MWG Chairs on decisions affecting their activity g) Ensures that the presentation material for the ISC meetings meets the required technical standard. h) Prepares an ISC meeting report (i.e. Minutes) in accordance with section 2-5.4.1 and Appendix G. 2.2.5 FUNCTIONS OF THE ASSISTANT TO THE ISC CO-CHAIR The Assistant to the ISC Co-chair is appointed by Airbus. The Assistant: a) Assists the ISC Co-chair. b) Administers ISC matters. c) Ensures that notes are taken, motions voted and recorded, and all decisions/consensus documented at each meeting.d) Follows-up the action items created by the ISC. e) Monitors the overall planning and advises the ISC Chair and the ISC Co-chair of any difficulties encountered. 2.2.6 FUNCTION S OF THE ISC ADVISOR TO THE MWG The ISC Advisor assigned to the respective MWG has the following primary responsibilities: a) Represents ISC operator participation during MWG meetings. A380 POLICY AND PROCEDURES HANDBOOK SECTION 2 - PAGE: 2-6 REFERENCE: 95A.1689/02 DATE : June 2006 b) Ensures compliance with PPH guidelines and policies during all phases of the MSG-3 analysis process. c) Confirms 100% accountability of all Maintenance Significant Items (MSIs) and Structural Significant Items (SSIs). d) Provides guidance from an overall operator perspective during each step of the analysis. e) Assists in resolving disagreements among MWG members, including MRB Advisors, regarding analysis methodology and results (i.e. failure class, type of task if selected, applicability, interval, justification…etc.). f) Reports the progress of MWG activity to the ISC Chair and Co-Chair. g) Notifies the ISC of unresolved issues and potential problem areas identified at the MWG level. h) Clarifies the ISC position concerning decisions that override MWG proposals. 2.3 MAINTENANCE WORKING GROUPS (MWGs) The MWGs will review, amend and endorse the MSG-3 analysis proposals made by the manufacturer and provide an initial list of minimum scheduled maintenance tasks and intervals to the ISC. 2.3.1 COMPOSITION There are nine (9) Maintenance Working Groups consisting of specialist representatives from the participating operators, the prime airframe manufacturer and engine manufacturers. Regulatory authorities attend in an advisory capacity. In addition, the ISC will nominate a representative to advise MWG on policy issues, as necessary. In order to cope with the complexity involved in some aircraft systems and features, it is required that the MWG members possess an adequate level of knowledge and experience regarding the relevant system/portion of the aircraft whose analysis is to be discussed. Zonal analysis introduces significantly different expertise than before, consequently, operators knowledge and experience will be requested to support the analysis process specially in the following fields: - In-service wiring condition - In-service combustible material accumulation - L/HIRF wiring protection The MWGs are chaired by a manufacturer’s representative, which is appointed by Airbus and accepted by the ISC. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 SECTION 2 - PAGE: 2-7 DATE : June 2006 For the A380 scheduled maintenance initial development, the following Working Groups have been established: MWG # Name Allocated ATA Chapters / Zones Remarks MWG 1 Hydraulics and Flight Controls 27: Flight Controls 29: Hydraulic Power 55: Stabilizers (systems only) Structure analysis of ATA 55 will be discussed in MWG5. MWG 2 Environmental 21: Air Conditioning 26: Fire Extinguishing 30: Anti-Ice (except 30-21) 35: Oxygen 36: Pneumatics MWG 3 Powerplant (RR & EA) and APU 71 to 80 49: Airborne Auxiliary Power 30-21: Engine Anti-Ice Structure analysis of ATA 71-80 will be discussed in MWG5. MWG 4 Avionics 22: Autopilot 23: Communications 24: Electric 31: Instruments 33: Lights 34: Navigation 42: Integrated Modular Avionics and Avionics Data Communication Network 44: Cabin Systems 45: On Board Maintenance System 46: Information System MWG 5 Structure 52: Doors 53: Fuselage 54: Pylon 55: Stabilisers 56: Windows 57: Wings Structure analysis of ATA 32 will be discussed in MWG8 MWG 6 Zonal and L/HIRF All aircraft zones MWG 7 Fuel 28: Fuel MWG 8 Landing Gear 32: Landing Gears Structure analysis of ATA 32 will be discussed in MWG8. MWG 9 Interior 25: Equipment / Furnishing 38: Water / Waste 50: Cargo and Accessory Compartments 52: Doors (systems only) 53: Fuselage (systems only) 54: Pylon (drainage) 56: Windows (systems only) 57: Wings (systems only) Structure analysis of ATA 52, 53, 56 and 57 will be discussed in MWG5. NOTE: Within MWG-5, only structure analysis will be reviewed. Some structure analyses will be discussed in MWG-8. A380 POLICY AND PROCEDURES HANDBOOK SECTION 2 - PAGE: 2-8 REFERENCE: 95A.1689/02 DATE : June 2006 2.3.2 FUNCTIONS OF THE MWG The responsibilities of the MWGs are the following: a) Review the manufacturers selection of significant items, b) Review the MSG-3 analysis proposals performed by the manufacturer and revise as required c) Select the most suitable interval for each task in accordance with the PPH guidelines d) Prepare a list of initial minimum scheduled maintenance tasks and intervals e) Provide the ISC with meeting report including a progress report and a list of open items and inform the MRB as required 2.3.3 FUNCTIONS OF THE MWG CHAIR The MWG Chair is responsible for ensuring an adequate technical representation and diversity within the working group and for ensuring consideration of all technical viewpoints in accomplishing the task. The MWG Chair: a) Works with the ISC Co-Chair and the Assistant to the ISC Co-chair to select MWG members. b) Works with the ISC Co-Chair and Assistant to the ISC Co-chair to secure and maintain a balanced MWG membership that will materially contribute to the final product and team success. The MWG Chair may expand or contract the working group as necessary to attain final product and team success. c) Has the casting vote where MWG members are evenly split on a decision. d) Ensures that all MWG members have a clear understanding of the task assignment and schedule completion date. e) Ensures that the PPH rules are followed by the MWG. f) Considers all background material relevant to the task. g) Ensures that notes are taken, motions voted and recorded, and all decisions/consensus documented at each meeting. This should include any concerns or advice raised by the MRB or ISC advisors. NOTE: Prior to the meeting adjournment, the following items shall be summarised and agreed upon : • Any changes to the MSG-3 analysis • Follow-up action for existing and/or new open items • Other major decisions made during the course of the meeting The availability of an electronic copy of the revised analysis, revised open item list and meeting summary by the end of the meeting, would assist participants in disseminating this information more efficiently. h) Must promote collaboration, consider all elements contributed by participants, ensure each suggestion receives full consideration by the working group, combine all constructive suggestions/ideas to reach a positive, useful outcome or decision, and resolve conflict. i) Calls meetings of the working group, including preparation meetings of appropriate specialists. j) He/she endeavours to balance meeting locations to minimize participant costs and to schedule tentative meeting dates to reduce work conflicts and maximize participation. k) Advises the ISC Co-Chair and the Assistant to the ISC Co-chair of any meetings to be included in the overall planning of the Maintenance Program development. A380 POLICY AND PROCEDURES HANDBOOK REFERENCE: 95A.1689/02 SECTION 2 - PAGE: 2-9 DATE : June 2006 l) Compiles agenda items and documents to be reviewed at MWG meetings, and distributes them to each MWG member well in advance (4 weeks) to working group meetings. m) Prepares a MWG Meeting Report (i.e. minutes) and a MWG Chair Report in accordance with section 2-5.4.2 and Appendix G and presents the MWG Chair Report at the ISC meeting. Any other status report should be submitted to the ISC Co-Chair and Assistant to the ISC Co-chair no later than (two weeks) prior to each ISC meeting. n) Ensures that MWG members are informed of ISC decisions. This may be achieved
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