Tues 1400 Ogma

Hercules Technical
Issues
David Pinheiro Frederico Lemos

Technical Support Engineer Business Development
www.ogma.pt
OGMA Overview
C-130/L-100 “Hercules”
Authorized Service Center
Authorized Stretch Center
- 20 km North of Lisbon
- Runway - 3Km / 10.600fts
- Covered Area - 139.000 Sq. mt.
(Total of 1.497.000 Sq. ft. )
- 10 Maintenance Hangars
(2 of them sized 400ft. x 200ft. x 50ft)
C-130 Capabilities
Center Wing
• Support to C-130 Versions A to H Upper rainbow
fittings
• Extensive Experience: more than 30 years and 400 checks
Lower rainbow
• B, C & D Checks, Heavy Checks (SMP) fittings
OUTBD Outer
• HSC, PDM, Isochronal Inspections (USAF)
Wing
• Complete WorkPackage Buildup and engineering
Support Specific Programs

 SFAR 88 Compliance (GFI /Tank Inspection)
• Field Teams
 Fatigue Evaluation (EBH) - SB 82-788 / 790
• Major Structural Repairs  Rainbow Fitting Replacement
Structural Repairs
Sloping Longeron
Analisys of the damage Replacement of the Repair & replacement of

sloping longeron the aircraft skin
Cargo Door Repair

Hercules C-130 damage
on service
Damage of the cargo door Cargo door repair

Accessories, Components
PowerPlant
Components Propeller Engine and QEC

Modifications & Upgrades
〉 Self-Protection Systems
〉 Glass Cockpits
〉 Avionics Upgrades
〉 GATM Requirements
〉 Fatigue and Damage Tolerance Analysis

〉 EMI/EMC analysis and test
〉 Aerodynamic Impact of external modifications
Enterprise Excellence
Program
OGMA Excelence Criteria – emphasys in Quality and flow:

- Simplify Procedures;
- Continuous Improvement;
- Client Focus;
 Develop well oriented minds and a tottaly commited

organization;
 Use visual communication and a simple approach to

improve processes;
 Measure and get feedback from to detect problems, present and validate solutions;
 Listen to the customer, provide feedback, present improvement actions plans;
| F-16 UPGRADE PROGRAM | PRODUCTION AND EFFICIENCY | CAPABILITIES | CONTACTS

C-130 INTEGRATED SUPPORT
Customer Satisfaction
Logistical
AIRCRAFT Support
AVAILABILITY
Reliability
Management
QUICK FINAL
ACCEPTANCE CUSTOMER /
Engineering
Support OGMA
COMMUNICATION Communication PARTNERSHIP
TRAINING
Fatigue Life
Management
INTEGRATED Tech Pubs

SUPPORT Support
Configuration
Management
C-130 Technical Issues
1. HERCULES TECHNICAL
- Bleed Air System

- “Melted” Fittings on Static Pressure System
- Chine Angle Repair
- Cargo compartment chine cap repair
- Wing to Fuselage Drag Angle Repair
- GFI’s Installation/Technical Issues
2. OGMA TECHNICAL SURVEYS
3. OGMA FIELD TEAM

BLEED AIR SYSTEM CHECK - Bleed Valve Leakage
• After placing the switch to

“OFF” position the pressure
decays to "0“
• A few seconds after, the

pressure starts to increase
slowly and it stabilizes at 10
PSI (Manifold).
• OGMA removed the bleed valves

P/N 3213722-5-1 and tested them
outside the aircraft
• Even on OFF (closed) position

some air passes through the valve.
•This leak was verified in all

new/overhauled valves.
- There is a residual Pressure Check for new aircraft but LM Aero has not
presented this "Residual Pressure Check" for in-service aircraft.
A "Residual Pressure Check“ table could be developed and

included on TM 382C-2-3 manual for in-service aircraft.
- Bleed Air System

3. OGMA FIELD TEAM

“MELTED” FITTINGS ON STATIC PRESSURE SYSTEM
During test flight, flight crew

reported a +6 knots difference
between Pilot and Co-Pilot Air
Speed Indicator
Troubleshooting result:
- Two “melted” fittings of the

static pressure system
• Two plausible causes for this damage:
-Aircraft Electrical Surge
-Lightning Strike
• Fittings were replaced and the

reported problem solved. However, the
real cause of the damage wasn’t fully
determined!
In similar discrepancies, this may be a common damage

- Bleed Air System

3. OGMA FIELD TEAM

FS 737 CHINE ANGLE REPAIR
• During C check severe corrosion is
usually found on FS 737 LH/RH
Chine Angle, under paratroop door.
• IAW Hercules SRM replace the chine

angle or request engineering
support;
• OGMA is using an alternate solution

(repair) upon approval of the
customer (or airworthiness
authority).
Cost comparison (OGMA) between the two solutions
No NRE for the repair – engineering approved repair
• REPLACE Chine Angle REPAIR Chine Angle
• Labour: Intensive • Minimum Technician effort
• Parts costs: High • Parts cost: 25% of the replace

option
• Aircraft Down Time (2 Weeks)
• Aircraft Down Time 2 Days
- Bleed Air System

3. OGMA FIELD TEAM

CARGO COMPARTMENT CHINE CAP REPAIR
• During C check is corrosion usually
found in cargo compartment chine
caps (ring tie down bays)
• IAW Hercules SRM typical repair is

provided for damages at FS 517,
557, 617 and 717;
• OGMA is using an alternate solution

(repair) upon approval of the
customer (or airworthiness
authority) for all FS.
CARGO COMPARTMENT CHINE CAP REPAIR
Cost comparison (OGMA) between the two solutions
No NRE for the repair – engineering approved repair
REPLACE Chine Cap REPAIR Chine Angle (USAF)
• Labour: Intensive • Minimum Technician effort
• Parts cost: High • Parts cost: less than 20% of the

replace option
• Aircraft Down Time (2 Weeks)

• Aircraft Down Time 2 Days
- Bleed Air System

3. OGMA FIELD TEAM

WING TO FUSELAGE DRAG ANGLE REPAIR
• During accomplishment of SB 82-

752, repair was found on the
wing to fuselage drag angle
assembly, P/N 3305083
• Repair straps were identified with

P/N QAD3022407-1
• Following Lockheed instructions,

OGMA removed and inspected
both repair and drag angle
• No damage found after the inspection was
completed; this fact could not be confirmed
until after the inspection was complete
• Despite an exhaustive search, without knowing

the QAR number LM Aero was unable to find
this specific repair in their records; After the
parts were disassembled and inspected the
QAR number was found
• OGMA reinstalled the repair per Lockheed

instructions
• Other A/C were found with similar repairs; not

reported because weren’t accomplishing this
SB
Be alert for similar situations!
- Bleed Air System

3. OGMA FIELD TEAM

GFI’S INSTALLATION/TECHNICAL ISSUES
• Several differences between A/C

configuration/GFI’s installation DWG’s
were found
• OGMA reported this discrepancies and

worked in straight collaboration with
Lockheed
Lockheed issued a helpful SK DWG to

correct the discrepancies
- Bleed Air System

3. OGMA FIELD TEAM

TECHNICAL SURVEYS
Purpose:
• Assess the need for a field team
• Better prepare the work package
• Prepare the bill of materials before

A/C arrival for maintenance
• Trim the commercial proposal to

the actual status of the aircraft
(avoid surprises to both customer
and OGMA)
SMALLER T.A.T.
TECHNICAL SURVEYS
Focus Areas:
• Main structural items

(corrosion and cracks)
• Engines / QEC condition
• Avionics and wiring condition
and configuration
• Aircraft logbook
• Engines and aircraft historical
records and documentation
• Assess aircraft operational
usage
- Bleed Air System

- Engine heat shield repair
3. OGMA FIELD TEAM

TECHNICAL FIELD TEAMS
Every time an aircraft is:
• due to scheduled maintenance
• down for a long period of time
• down due to a specific incident
OGMA FIELD TEAMS WILL PROVIDE A QUICK RESPONSE

TIME AND SUPPORT CUSTOMERS AT ANY LOCATION
FIELD TEAM
• Airframe discrepancies correction
• Avionics systems discrepancies
correction
• Engines discrepancies correction
• Pre-flight run up’s
• Test flight
• Ferry flight to repair station
Questions?
David Pinheiro Frederico Lemos Fernando Renda José Salvada

C-130 Technical Support Engineer Business Developing Manager Sales Manager Head of Marketing and Sales
david.pinheiro@ogma.pt frederico.lemos@ogma.pt renda@ogma.pt Jose.salvada@ogma.pt
M: +351 21 9581000 Ext. 3225 M: +351 21 9581000 Ext. 3955 M: +351 91 28 999 07 M: +351 91 28 999 14

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Tues 1400 Ogma

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Hercules Technical

David Pinheiro Frederico Lemos

• Complete WorkPackage Buildup and engineering

Support Specific Programs

Analisys of the damage Replacement of the Repair & replacement of

Cargo Door Repair

Damage of the cargo door Cargo door repair

Components Propeller Engine and QEC

〉 Fatigue and Damage Tolerance Analysis

OGMA Excelence Criteria – emphasys in Quality and flow:

 Develop well oriented minds and a tottaly commited

 Use visual communication and a simple approach to

 Listen to the customer, provide feedback, present improvement actions plans;

| F-16 UPGRADE PROGRAM | PRODUCTION AND EFFICIENCY | CAPABILITIES | CONTACTS

INTEGRATED Tech Pubs

- Bleed Air System

2. OGMA TECHNICAL SURVEYS

3. OGMA FIELD TEAM

• After placing the switch to

• A few seconds after, the

• OGMA removed the bleed valves

• Even on OFF (closed) position

•This leak was verified in all

A "Residual Pressure Check“ table could be developed and

- Bleed Air System

2. OGMA TECHNICAL SURVEYS

3. OGMA FIELD TEAM

During test flight, flight crew

- Two “melted” fittings of the

• Two plausible causes for this damage:

-Aircraft Electrical Surge

• Fittings were replaced and the

In similar discrepancies, this may be a common damage

- Bleed Air System

2. OGMA TECHNICAL SURVEYS

3. OGMA FIELD TEAM

• IAW Hercules SRM replace the chine

• OGMA is using an alternate solution

• REPLACE Chine Angle REPAIR Chine Angle

• Labour: Intensive • Minimum Technician effort

• Parts costs: High • Parts cost: 25% of the replace

- Bleed Air System

2. OGMA TECHNICAL SURVEYS

3. OGMA FIELD TEAM

• IAW Hercules SRM typical repair is

• OGMA is using an alternate solution

• Labour: Intensive • Minimum Technician effort

• Parts cost: High • Parts cost: less than 20% of the

• Aircraft Down Time (2 Weeks)

- Bleed Air System

2. OGMA TECHNICAL SURVEYS

3. OGMA FIELD TEAM

• During accomplishment of SB 82-

• Repair straps were identified with

• Following Lockheed instructions,

• Despite an exhaustive search, without knowing

• OGMA reinstalled the repair per Lockheed

• Other A/C were found with similar repairs; not

- Bleed Air System

2. OGMA TECHNICAL SURVEYS

3. OGMA FIELD TEAM

• Several differences between A/C

• OGMA reported this discrepancies and

Lockheed issued a helpful SK DWG to